VIADRUS A0C Manual for boiler operation and installation

Transcription

1 VIADRUS A0C Manual for boiler operation and installation GB_2017_45 LP GB_2016_28

2 Content page 1 Usage and advantages of the boiler Technical data of the boiler Description Boiler structure Placement and installation Regulations and directives Possibility of placement Commissioning instructions for contractual service organizations Delivery and accessories content Mounting procedure Boiler drum installation Mounting of barriers of the combustion space and the baffles Burner mounting Change of direction of ash-pan door opening Mounting of the claddings Mounting of the fuel reservoir Mounting of the fuel reservoir PellasX Reconstruction of the fuel reservoir to the left design Mounting of the fuel feeder Mounting of the fuel feeder to the boiler Hydraulic scheme of the boiler Electric connection scheme Checking activities before actuation Boiler commissioning Handling of the boiler by a user Description of control - S.Control Boiler operation by a user touch-type version S.Control Touch Control, regulating and safety elements Safety thermostat Maintenance Clean-up of the boiler Clean-up of the burner Photo sensor Clean-up of the fuel feeder pipe Clean-up of the burner Mounting of the additional module B (A2) Hydraulic diagram of the additional module B (A2) Hydraulic diagram of the additional module B (A2) IMPORTANT WARNINGS Failure states Instructions for liquidation of the product after the lapse of its service life Warranty and responsibility for defects Product fiche This manual is the original manual for operation and installation. 2

3 Dear customer, We thank you that you have bought a VIADRUS A0C automatic solid fuel boiler, thus having shown your confidence in VIADRUS brand. In order to accustom to correct manipulation with your new product. Before installation and commissioning, please carefully acquaintance with the instruction manual (mainly, chapter 6 Operation with the stove by an user, chapter No. 7 Maintenance, and chapter No. 8 Important warnings). Please observe the below mentioned information, and at the same time observe instructions of the producer, eventually a mounting company, which installed your boiler, in order to ensure a long-term trouble-free operation to your and our satisfaction. 1 Usage and advantages of the boiler Boiler trade name: VIADRUS A0C Boiler trade marking: A0C- X 1 X 2 X 3 -X 4.X 5 X 1 Design: S: standard A: advanced (with an economizer) X 2 Power: 20: 20 kw 28: 28 kw X 3 Fuel: P: pellets X 4 00: regulator S.Control 01: regulator S.Control Touch (touch display) Year of introduction to the market X 5 A hot-water automatic solid fuel boiler VIADRUS A0C is mainly determined for heating of single-family houses, cottages, small production premises, etc. Advantages of the boiler: Automatic operation of the boiler controlled by a room device guaranteed comfort; Possibility of heating of HW; Mechanic supply of fuel from an inbuilt reservoir; Simple, quick manipulation and maintenance; Low operational costs; Low emission; Low effectivity; Possibility of control of up to 1 heating circuits; Cooperation with an accumulating tank (module B is not a part of delivery of the boiler only on request); Possibility of control of up to 2 heating circuits (module B is not a part of delivery of the boiler only on request). 2 Technical data of the boiler Tab.. 1 Dimensions, technical parameters of the boiler Boiler type A0C-S16P-X4.X5 / A0C-A16P-X4.X5 A0C-S20P-X4.X5 / A0C-A20P-X4.X5 A0C-S24P-X4.X5 / A0C-A24P-X4.X5 A0C-S28P-X4.X5 / A0C-A28P-X4.X5 A0C-S32P-X4.X5 / A0C-A32P-X4.X5 Sections number pcs Boiler weight (incl. the reservoir) kg 314 / / / / / 475 Water content l 34 38,5 43,1 47,6 52,2 Chimney throat diameter mm 156 Fuel reservoir dm Boiler dimensions (incl. the reservoir): width x depth x high mm viz. obr. č. 1 Operation water overpressure kpa (bar) 400 (4) Testing water overpressure kpa (bar) 800 (8) Recommended operation heating water temperature C Minimum return water temperature C Boiler hydraulic loss (at T 20 K) mbar 0,425 0,550 0,750 0,825 1,050 Noise level db Nepřesahuje hladinu 65 db (A) Chimney draught mbar 0,17 / 0,15 0,20 / 0,21 0,24 / 0,23 0,25 / 0,25 0,28 / 0,28 Boiler connections heating water Js G 1 ½ (6/4 ) return water Js G 1 ½ (6/4 ) Supply voltage 1/N/PE 230V AC 50 Hz TN - S Electric cover IP 40 Electric energy consumption at the nominal power W Electric energy consumption at the minimum power W Electric energy consumption at the standby state W

4 Tab.. 2 Heating technical parameters of the boiler Boiler type A0C-S16P-X4.X5 / A0C-A16P-X4.X5 A0C-S20P-X4.X5 / A0C-A20P-X4.X5 A0C-S24P-X4.X5 / A0C-A24P-X4.X5 A0C-S28P-X4.X5 / A0C-A28P-X4.X5 A0C-S32P-X4.X5 / A0C-A32P-X4.X5 Sections number pcs Nominal power kw 16 / 16, Fuel consumption at the nominal power kg.h -1 3,87 / 3,88 4,77 / 4,81 5,7 / 6,0 6,72 / 6,62 7,48 / 7,39 Flue gases temperature at the nominal power C 192 / / / / / 130 Combustion time at the nominal power for the filled-up reservoir h Minimum power kw 4,8 / 5 6 7,5 8,4 9,6 Fuel consumption at the minimum power kg/h 1,23 / 1,22 1,4 / 1,38 1,52 / 1,56 1,82 / 1,81 2,1 / 1,99 Flue gases temperature at the minimum power C 119 / / / 79 96/70 82 / 79 Combustion time at the minimum power for the filled-up reservoir h Fuel heating power MJ.kg -1 17,27 Effectiveness % 85,1 / 90 83,3 / 90,5 87 / 88,9 86,9 / 90,4 84,2 / 89,7 Mass flow rate of flue gases on the output side kg.s -1 0,013 / 0,011 0,014 / 0,014 0,021 / 0,017 0,018 / 0,017 0,021 / 0,022 Boiler class according to EN / 5 4 / 5 4 / 5 4 / 5 4 / 5 1. Energy efficiency class A+ A+ A+ A+ A+ 2. Energy efficiency index 104 / / / / / Season energy efficiency % 70 / / / / / 79! Important warning: The above specified heat technical parameters can be varied in dependence on a type, quality and humidity of the assessed fuel. Values specified in table No. 1 and table No. 2 were measured during tests performed with usage of a prescribed fuel. Pellets have to comply at least with one of the following directives and norms: Directive No of the Environmental Ministry of Czech Republic DIN ÖNORM M 7135 Prescribed pellet granulity 6 to 8 mm Heating power MJ.kg -1 Water content in fuel max. 12 %. Ash content max. 1,5 % WARNING! Bad fuel quality can dramatically negatively influence the output and emission parameters of the boiler. Boiler type A0C-S16P-X4.X5 / A0C-S20P-X4.X5 / A0C-S24P-X4.X5 / A0C-S28P-X4.X5 / A0C-S32P-X4.X5 / A0C-A16P-X4.X5 A0C-A20P-X4.X5 A0C-A24P-X4.X5 A0C-A28P-X4.X5 A0C-A32P-X4.X5 L [mm] 1058 / / / / / 1423 Fig.. 1 Boiler main dimensions 4

5 3 Description 3.1 Boiler structure The main part of the boiler is the sectional boiler drum made from grey cast iron according to EN 1561 grade 150. Pressurized parts of the boiler complies with requirements for stiffness according to EN The boiler drum is assembled from sections by means of pressed boiler insertions and is fixed by anchor bolts. The sections create the heating and ash space, the water space and the convection part. The heating water input and output are situated in the rear part of the boiler. The rear section of the boiler has in its upper part a chimney pot and a heating water flange, in its bottom part has a return water flange with a mouthpiece for a filling and draining cock. The cleaning and ash doors with an inbuilt burner are fixed to the front section. The whole boiler drum is isolated by healthy mineral insulation, which decreases losses caused by heat transmission to the surroundings. The steel cladding is painted by quality comaxite paint coat. A pellet burner of PellasX is mounted in the ash door. In the version VIADRUS A0C-X 116P-X 4.X 5, A0C-X 120P-X 4.X 5 it is a burner PellasX Hybrid mini, and in the version VIADRUS A0C-X 124P-X 4.X 5, A0C-X 128P-X 4.X 5, A0C-X 132P-X 4.X 5 it is a burner PellasX Hybrid 35. These burners are equipped with a fan. On the right (on the left) from the boiler it is placed a steel-sheet pellet reservoir with a capacity of 300 l. The reservoir is connected with the burner by means of a feeder and a connecting hose. An electric cabinet, in which the control unit and a display are situated, is mounted on the upper part of the cladding. The unit is supplied in two versions. The S.Control with button control or the S.Control Touch with touch display. 1. Front section 2. Central section 3. Rear section 4. Stocking door (with a rosette of primary air) 5. Ash door 6a. Chimney pot, extended (A0C-AX 2P-X 4.X 5) 6b. Chimney pot (A0C-SX 2P-X 4.X 5) 7. Burner sealing 8. Burner PellasX 9. Connecting hose 10. Feeder 11. Reservoir 12. Cladding (complete) 13. Control cabinet 14. Regulator control elements (S.Control / Touch) 15. Heating water pipe 16. Ash-pan 17. Return water pipe 18. Baffle 19. Burner pipe 20. Bushing Fig.. 2 Boiler main parts 5

6 Fig.. 3 VIADRUS A0C-X 116P-X 4.X 5, A0C-X 120P-X 4.X 5 - burner PellasX Hybrid mini Fig.. 4 VIADRUS A0C-X 124P-X 4.X 5, A0C-X 128P-X 4.X 5, A0C-X 132P-X 4.X 5 - burner PellasX Hybrid 35 4 Placement and installation 4.1 Regulations and directives The boiler complies with requirements of the following norms: EN ISO 12100:2011 EN 953+A1:2009 ČSN ISO 1819:1993 ČSN ISO 11202:2010 EN ISO 3746:2011 EN 303-5:2013 ČSN :1997 EN 62233:2008 EN change A1 EN :2007 Safety of machine equipment General principle for design Assessment of risk and risk decreasing Safety of machine equipment Protective covers General requirements for design and production of firm and movable protective covers Equipment for continuous conveyance of loads. Safety rules. General provisions Acoustics Noise emitted by machines and equipment Determination of levels of emission pressure on the personnel working place and in other specified places with using of approximate corrections for environment Acoustics - Determination of levels of acoustic power and levels of acoustic energy of noise sources by means of acoustic pressure Operation method with a measuring envelope above the reflective plane Boilers for central heating - Part 5: Solid fuel boilers for central heating, with manual and automatic supply, with nominal heat power up to 500 kw - Terminology, requirements, tests and marking Fire safety of heating equipment Measuring methods for electromagnetic fields for household and similar devices from the point of view of exposition of persons Safety of electric consumers for household and similar purposes. Part 1: General requirements Boilers for central heating Testing rules for measurement of noise spread by air emitted by a heat source Part 1: Emission of noise spread by air from heat sources The boiler has to be only installed by a company which has authorization for performance of its installation and maintenance. A project according to valid regulations has to be worked out for installation of the boiler. The heating system has to be filled up by water, which complies with requirements of ČSN , and mainly its hardness mustn t exceed the required parameters. Tab.. 3 Recommended values Hardness mmol/l 1 Ca 2+ mmol/l 0,3 Concentration of total Fe + Mn mg/l (0,3)* *) recommended value ATTENTION!!! The producer doesn t recommend using of antifreezers. a) for the heating system ČSN ČSN ČSN EN b) for the chimney ČSN Heat systems in buildings Design and mounting Heat systems in buildings Securing devices Water and steam for heat energetic equipment with steam operation pressure up to 8 MPa. Boilers for central heating Part 5: Solid fuel boilers for central heating, with manual and automatic supply, with nominal heat power up to 500 kw - Terminology, requirements, tests and marking. Design of chimneys and flue gas ducts. c) regarding to fire-fighting regulations ČSN Fire safety of heat equipment. EN A1 Fire classification of building products and building structures Part 1: Classification according to results of tests for reaction to fire. d) for the hot water heating system ČSN Heat systems in buildings Preparation of hot water Development and design. ČSN Heat systems in buildings Securing devices. ČSN Inside water distributions e) for electric network ČSN ČSN ČSN ed. 2 ČSN ed. 2 ČSN ed. 3 ČSN ed. 2 ČSN ČSN ed. 2 EN EN ed.3 Electric-technical regulations. Marking of conductors by colors or digits. Execution of provisions Electric-technical regulations. Revisions of electric devices. Low voltage electric installation Part 1: Basic aspects, determination of basic characteristics, definitions Low voltage electric installation Part 4-41: Protective measures to ensure safety Protection against electric shock Low voltage electric installation Part 5-51: Selection and construction of electric devices General regulations Low voltage electric installation Inside electric distributions Electric-technical regulations. Connection of electric devices and consumers. Safety requirements for movable power supplies and cords Explosive atmospheres Part 10-1: Determination of dangerous premises Explosive gaseous atmospheres Explosive atmospheres Part 14: Development, selection and performance of electric installations 6

7 EN ed. 2 Capacitors for AC motors Part 1: In general Fulfilment, testing, dimensioning Safety requirements Instructions for mounting and operation. EN ed.2 Electric consumers for household and similar purpose Safety Part 1: General requirements. EN Electric consumers for household and similar purpose Safety Part 2-102: Special requirements for consumers combusting gaseous, oil and solid fuels, containing electric connections. EN ed. 4 Basic and safety principles for the human-machine interface, marking and identification Identification of clamps of subjects, ends of conductors and conductors EN ed. 2 Electromagnetic compatibility (EMC) Part 6-3: Generic norms Emission Residential, trade and light-industry environment. EN ed. 3 Electromagnetic compatibility (EMC) - Part 3-2: Limits Limits for emission of harmonic currents (equipment with input phase current <= 16 A). EN ed. 2 (ed. 3) Electromagnetic compatibility (EMC) Part 3-3: Limits Limitation of changes of voltage, fluctuation of voltage and flickers in low voltage distribution networks with the nominal phase current <= 16 A, which is not a subject of conditional connection. 4.2 Possibility of placement During boiler mounting and operation it is necessary to observe all requirements of ČSN It is prohibited to place the boiler in a residential premise (including corridors)! Placement of the boiler in the view of fire regulations: 1. Placement on the floor from inflammable material Install the boiler on an inflammable, heat-insulated basement exceeding the ground-plan of the boiler with the reservoir on sides by 20 mm. If the boiler is placed in a cellar, we recommend to install it on a supporting brickwork with the high at least 50 mm. The boiler has to stay horizontally, possible unlevelnesses of the supporting brickwork are to be eliminated by means of a regulating screw of the motor seat. 2. Safety distance from flammable materials During installation and at operation of the boiler it is necessary to observe a safety distance 200 mm from flammable materials with the combustibility grade A1, A2, B and C (D); For lightly combustible materials with the combustibility grade E (F), which quickly burn and burn themselves even after removal of the ignition source (for example, paper, paste-board, cardboard, asphalt- and tarboard, wood and fiberboards, plastics, floor cloths) the safety distance is doubled, it means to 400 mm; The safety distance is to be also doubled in case when the grade of reaction to fire is not proven. Tab.. 4 Grade of reaction to fire Grade of reaction to fire Examples of building materials and products included in the reaction of fire (extract from EN A1) A1 incombustible Granite, sandstone, concrete, bricks, ceramic tiles, mortars, fireproof plasters,... A2 hardly combustible acumin, izumin, heraklit, lignos, boards and basalt felt, fibreglass boards,... B heavily combustible Beech and oak wood, hobrex boards, plywood, werzalit, umakart, sirkolit,... C (D) moderately combustible Pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,... E (F) lightly combustible Asphaltboard, fibreboards, cellulose materials, polyurethane, polystyrene, polyethylene, PVC,... Boiler type A0C-S16P-X4.X5 / A0C-S20P-X4.X5 / A0C-S24P-X4.X5 / A0C-S28P-X4.X5 / A0C-S32P-X4.X5 / A0C-A16P-X4.X5 A0C-A20P-X4.X5 A0C-A24P-X4.X5 A0C-A28P-X4.X5 A0C-A32P-X4.X5 L [mm] 1058 / / / / / 1423 Fig.. 5 Sizes of a supporting brickwork 7

8 Placement of the boiler with regard to a needed manipulation space: basic environment AA5/AB5 according to ČSN ed. 2, in front of the boiler it is necessary to have a manipulation space at least 600 mm, the minimum distance between the rear part of the boiler and a wall 400 mm, on the side of the fuel reservoir a gap at least 400 mm for a case of extraction of a feeding auger, the minimum distance from the side wall of the boiler 400 mm, above the boiler at least 450 mm to enable cleaning-up of the convection surface of the heat-exchanger. Placement of the boiler with regard to an electric network: the boiler has to be placed so that the plug in the socket (230 V/50 Hz) was always accessible. Placement of fuel: Fig.. 6 Placement of the boiler in the boiler-room For correct combustion in the boiler it is necessary to use dry fuel. The producer recommends to stock fuel in cellar premises or at least under a penthouse, The producer recommends to observe distance between the boiler and fuel at least mm, or place fuel to the room than the boiler. It is necessary to provide constant supply of air for combustion and possible ventilation into the room where the boiler is installed (air consumption of the boiler VIADRUS A0C-X 116P-X 4.X 5 is about 60 m 3. h -1, VIADRUS A0C-X 120P-X 4.X 5 is about 75 m 3. h -1, VIADRUS A0C-X 124P-X 4.X 5 is about 90 m 3. h -1, VIADRUS A0C-X 128P-X 4.X 5 is about 105 m 3. h -1 and the boiler VIADRUS A0C-X 132P-X 4.X 5 is about 120m 3. h -1 ). Connection of a pipeline of the heating system, as well as an eventual pipeline of the heating insertion of the heater, has to be performed by an authorized person. WARNING: On connection of the boiler to the heating system it is necessary to place a discharging cock in the lowest place and as close as it possible to the boiler. 5 Commissioning instructions for contractual service organizations Only contractual service organization authorized for performance of this activity has the right to perform commissioning of the boiler. 5.1 Delivery and accessories content The boiler VIADRUS A0C is supplied so that the complete boiler drum is situated on one pallet. The boiler cladding is packed separately. Accessories laid inside the boiler drum are accessible after opening the cleaning door. The second pallet includes a burner, a fuel feeder and their accessories. The boiler is packed in a transporting package and mustn t be tripped during transportation; it is only allowed to incline to sides to demount the package from the boiler drum. Standard accessories: 1 pc boiler drum on a pallet with the corresponding number of sections 1 pc combustion space barrier middle part 2 pcs combustion space barrier (4 sec.) 3 pcs combustion space barrier (5 sec.) 4 pcs combustion space barrier (6 sec.) 5 pcs combustion space barrier (7 sec.) 6 pcs combustion space barrier (8 sec.) 1 pc boiler drum cladding cladding insulation ash-pan with appropriate size holder for cleaning tools type 2 turbulators 4 pcs cladding brace 2 pcs 2 pcs heating and return water pipe G 1 1/2" 1 pc cleaning tools - handle 1 pc pack 1 pc production label 1 pc control cabinet with electronics S.Control/SControl Touch 1 pc burner PellasX according to a size 3 pcs burner insulation 1 pc burner sealing 1 pc feeder PellasX 1 pc manual for boiler operation and mounting 1 pc manual for S.Control or S.Control Touch control unit 1 pc warranty certificate 8

9 The pack: 1 pc boiler plug G 1 1/2 - blind 2 pc heating and return water flange for versions of A0C-A X2 P- X4. X5 3 pc plug with outer thread for versions of A0C-A X2 P- X4. X5 1 pc plug sealing Ø 60x48x2 2 pcs flange sealing 90 x 60 x 3 1 pc PVC bag 300 x 500 mm 1 pc filling and discharging cock G 1/2 1 pc manipulating wrench 1 pc brush 1 pc tip for piercer 1 pc capillary spring 1 pc corrugated spring 1 pc thermowell connecting material: 2 pcs nut M8 12 pcs nut M10 4 pc washer 5,3 4 pc washer 6,4 2 pcs washer 8,4 12 pcs washer 10,5 4 pc connecting thorn 8 pc screw M5 x12 8 pc screw ST 4,8 x 13 for versions A0C-A X 2 P- X 4. X 5 6 pc screw ST 4,8 x 13 for versions A0C-S X 2 P- X 4. X 5 8 pc screw M8 x16 8 pc screw M6 x6 4 pc spring clip Obligatory accessories (it is not a part of supply): 1 pc securing valve according to max. operation overpressure of the boiler (see table No. 1) On request: 1 pc outdoor sensor CT4 P 1 pc room regulator ecotouch 1 pc internet module NET CONTROL 1 pc extending module of heating circuits and storage reservoirs module B 1 pc securing valve 1 pc sensor CT4 4 m 1 pc reservoir 1 pc front metal sheet of the reservoir 1 pc rear metal sheet of the reservoir 1 pc right side metal sheet of the reservoir 1 pc left side metal sheet of the reservoir 1 pc upper metal sheet of the reservoir 1 pc reservoir leg 1 pc reservoir leg 2 1 pc reservoir cover 1 pc transversal part of the reservoir 1 pc feeder flange 1 pc hole cover 2 pcs reservoir brace 1 pc blind flange 1 pc transversal part 2 of the reservoir connecting material for the reservoir 2 pcs washer 5,3 2 pcs nut M5 2 pcs washer 9 pc screw ST 4,2 x 9,5 (ISO 7050) 4 pc screw ST 4,8 x pc screw M5 x 12 2 pcs screw M6 x 12 1 pc piano hinge 1 pc handle The boiler equipment ordered on request is not included to the basic boiler price. 9

10 5.2 Mounting procedure Boiler drum installation 1. Place the boiler drum onto the supporting brickwork. 2. Mount to the upper part of the rear boiler section the sealing 90 x 60 x 3 (1) and screw up the heating water flange (2), and connect the other end to the heating system. 1 Backward valve of the manometer 2 Thermostat well Fig.. 7 Thermowells mounting 3. Mount to the bottom flange part of the rear boiler section the sealing 90 x 60 x 3 (5) and screw up the return water flange with a mouthpiece (6) for a filling and discharging cock, and connect the other end to the heating system. 4. After connection the boiler to the heating system, screw up an elbow (9) with the filling and discharging cock into the mouthpiece of the return water flange. 5. Screw up the thermostat well G 1/2 into the hole in the upper part of the rear section (see fig. 10). 6. Blind the hole with the thread Js 6/4" in the front section by a plug Js 6/4". Place sealing 60 x 48 x 2 under the plug. 7. Mount the chimney pipe to the chimney pot and insert it to the chimney hole. 1. Sealing 90 x 60 x 3 2. Heating water flange 3. Washer 10,5 4. Nut M10 5. Sealing 90 x 60 x 3 6. Return water flange 7. Washer 10,5 8. Nut M10 9. Filling and discharging cock Fig.. 8 Boiler drum installation VIADRUS A0C-SX2P-X4.X5 10

11 1. Sealing 90 x 60 x 3 2. Heating water flange 3. Washer 10,5 4. Nut M10 5. Sealing 90 x 60 x 3 6. Return water flange 7. Washer 10,5 8. Nut M10 9. Filling and discharging cock Fig.. 9 Boiler drum installation VIADRUS A0C-AX2P-X4.X Mounting of barriers of the combustion space and the baffles 1. Heating space barrier front part 2. Heating space barrier 2 pcs for A0C-S16P 3 pcs for A0C-S20P 4 pcs for A0C-S24P 5 pcs for A0C-S28P 6 pcs for A0C-S32P 3. Baffle Fig.. 10 Mounting of the heating space barrier in the boiler 1. According to fig. No. 10, insert a heating space barrier into the heating space (1, 2) 4 pcs (for the 5 section size) or 5 pcs (for 7 section size). 2. Insert into the flu gas channel 4 pc of baffles (4) 11

12 5.2.3 Burner mounting 1. Put the burner insulation on the burner. 2. Put the insulation on the welded bolts on the flange and fix it with help of 2 pcs of the nuts M8 and 2 pcs the washers 8,4. 1. Burner insulation sealing 2. Burner PellasX 3. Nut M8 4. Washer 8 Fig.. 11 Bottom door with the burner flange Change of direction of ash-pan door opening 1 Complete ash-pan door 2 Latch assembly 3 Split plug 8x40 4 Closing sheet-metal cover 1 var 1 5 Door pivot 6 Washer 8,4 7 Bolt M8x16 8 Cladding brace 9 Washer 8,4 10 Bolt M8x16 11 Washer 8,4 12 Bolt M8x16 13 Bolt M8x10 14 Latch support 15 Closing sheet-metal cover 2 var 4 Fig.. 12 Change of direction of ash-pan door opening 1. Demount the ash-pan door (1) by withdrawal of 2 pcs of the door pivots (5). 2. Extract the split plug 8 x 40 (3) and the latch (2) from the ash-pan door and mount them to the right side of the door. 3. Demount the closing sheet-metal cover 2 (17) by unscrewing of 2 pcs of the bolts M8 x 16 (19) with the washers 8,4 (18) and mount them specularly to the left side of the door (see fig. 12). 4. Demount the closing sheet-metal cover 1 (4) by unscrewing of 2 pcs of the bolts M8 x 16 (7) with the washers 8,4 (6) and 4 pcs of the bolts M6 x 10 (9) with the washers 6,4 (8).. 12

13 5. Demount the support for the latch (9) by unscrewing of 2 pcs of the bolts M8 x 12 (8) and mount to the right side of the boiler. 6. Demount the upper cladding brace 1 (10) by unscrewing of 1 pc of the bolt M8 x 16 (14) with the washers 8,4 (13) and 2 pcs of the bolts M6 x 10 (12) with the washers 6,4 (11) and mount them to the right side of the boiler. Remount in the same manner the bottom cladding brace. 7. Mount he closing sheet-metal cover 1 (4) specularly to the left side of the boiler. 8. Put on the ash-pan door (4) on the closing sheet-metal cover 1 (4) and fix 2 pcs of the door pivots (5). Fig.. 13 The door for left-hand opening 13

14 5.2.5 Mounting of the claddings 1 Anchoring screw 2 Bracket 1 3 Washer 10,5 4 Nut M10 5 Bracket 2 6 Right side cladding part 7 Insulation of the side cladding part 8 Connecting thorn 9 Washer 6,4 10 Screw M5 x Left side cladding part 12 Serrated lock washer 5,3 13 Upper cladding part 14 Insulation of the upper cladding part 15 Spring clip 16 Bottom part of the control box 17 Cable gland PG Cable gland PG 13,5 19 Upper part of the control box 20 Insulation of the rear cladding 21 Rear part of the cladding 22 Insulation of the rear cladding 23 Rear part of the cladding 24 Rear part of the cladding Fig.. 14 Mounting of the cladding 14

15 1. Take out the claddings from the cardboard package. 2. Perform mounting according to fig. No Mount brackets 1 (2) and 2 (5) to the threads of the right upper anchoring screw (1) and screw up them with help of 2 pcs of nuts M10 (4) and 2 pcs of washers 10,5 (3). 4. Equip the right side cladding part (6) with 2 pcs of connecting thorns (8), afterward insert the insulation (7). Put on the cladding to the bottom anchoring screws and connect the upper part with the brackets 1 and 2 with help of 2 pcs of screws M5 x12 (10) and 2 pcs of washers 5,3 (9). 5. Put on the thread of the left upper anchoring screw the brackets 1 (2) and 2 (5) and screw up them with help of 2 pcs of nuts M10 (4) and 2 pcs of washers 10,5 (3). 6. Equip the left side cladding part (11) with 2 pcs of connecting thorns (8), afterward insert the insulation (7). Put on the cladding to the bottom anchoring screws and connect the upper part with the brackets 1 and 2 with help of 2 pcs of screws M5 x12 (10) and 2 pcs of washers 5,3 (9). 7. Secure the left and rear part of the cladding - For version A0C-S X2 P- X4. X5 equip the rear part of the cladding (21) with insulation of the rear cladding (20) and screw it to the side-wall parts of the cladding with help of 6 pcs of screws ST 4,2 x 9,5. - For version A0C-A X2 P- X4. X5 equip the rear parts of the cladding (23) and (24) with insulation of the rear cladding (22) and screw it to the side-wall parts of the cladding with help of 8 pcs of screws ST 4,2 x 9,5. 8. Unscrew the upper part (13) from the control box. 9. Demount insulation of the upper part of the cladding, install 4 pcs of spring clips and screw the control box (11) with help of 4 pcs of screws M5 x 12 and 4 pcs of serrated lock washers. Pull the boiler temperature sensor, the safety thermostat capillary and the manometer capillary through the bushing. Put the insulation of the upper part on the boiler drum. Screw the manometer capillary into the return valve and insert the boiler temperature sensor together with the safety thermostat capillary into the boiler well and secure with the capillary spring. The electric wiring and the capillaries mustn t be in contact with hot parts of the boiler! 10. Put the upper part of the cladding (3) with the insulation on the side-wall parts of the cladding (1 and 2). Screw the rear upper sheet-metal cover with help of 2 pcs of screws ST 4,8 x 9,5 to the left side-wall part of the cladding. 11. Consequently screw the rear sheet-metal cover with the insulation (6) with help of 5 pcs of screws ST 4,8 x 9,5 to the left and right parts of the cladding. 12. Perform connection of the electric equipment of the heating system according to the electric diagram see chapter The electric wiring and the capillaries mustn t be in contact with hot parts of the heating system. 14. Screw back the upper part of the control box (19) Mounting of the fuel reservoir 1. Rear metal plate 2. Reservoir left leg 3. Reservoir right leg 4. Reservoir brace 5. Right side-wall 6. Left side-wall 7. Front part 8. Upper part 9. Left transversal part 10. Right transversal part 11. Reservoir cover 12. Feeder flange 13. Hinge 14. Cover sealing 15. Reservoir cover 16. Screw M3 x 9 (countersunk) 17. Handle 18. Spring washer Screw M6 x Reservoir blind flange 21. Screw M5 x 12 (cross-head) 22. Washer 5,3 23. Nut M5 Fig.. 15 Fuel reservoir 1. Take out the claddings from the package 2. Mount the reservoir legs to the rear metal plate (1) with help of screws M5 x 12 (21), afterwards mount 2 pcs of braces (4) to the reservoir legs with help of 2 pcs of screws M5 x 12 (21), 2 pcs of nuts M5 (23) and 2 pcs of washers 5,3 (22). 3. Put on the right side-wall (5) and screw up with help of 9 pcs of screws M5 x 12 (21), the same procedure is valid for the left side-wall (6). 4. Put the front part (7) and screw up with help of 13 pcs of screws M5 x 12 (21). 5. Screw up the upper part (8) with help of 13 pcs of screws M5 x 12 (21). 6. Mount the left (9) and the right transversal part of the reservoir (10) with help of 4 pcs of screws M5 x 12 (21). 7. Screw up the reservoir cover (11) with help of 4 pcs of screws M5 x 12 (21). 8. Put on the feeder flange (12) and screw up with help of 4 pcs of screws M5 x 12 (21). 9. Put on the blind flange (21) and screw up with help of 4 pcs of screws M5 x 12 (21). 10. Screw up the hinge (13) with help of 8 pcs of screws M3 x 9 (16), glue the cover sealing (14) to the upper cover (15) and screw up the handle (17) with help of 2 pcs of screws M6 x 12 (19) and 2 pcs of spring washers 6 (18). 15

16 5.2.7 Mounting of the fuel reservoir PellasX 1. Fuel reservoir side-wall 2. Reservoir leg 3. Fuel reservoir bottom 4. Fuel reservoir bottom A 5. Fuel reservoir cover 6. Blind flange 7. Feeder 8. Nut M6 9. Washer 6,4 10. Handle 11. Screw M6 x Screw M6 x 16 Fig.. 16 Fuel reservoir PellasX Reconstruction of the fuel reservoir to the left design 1. Demount the feeder flange (1) and the hole cover (2) and replace their placement. 2. Demount the transversal parts (3, 4) and replace their placement. 3. Connect the feeder see fig. No Feeder flange 2. Cover 3. Transversal part 4. Transversal part Fig.. 17 Mounting of the left-type fuel reservoir Fig.. 18 Left-type fuel reservoiruel 16

17 5.2.9 Mounting of the fuel feeder Fig.. 19 Fuel feeder Fig.. 20 Mounting of the feeder auger 1. Connect the upper (1) and the bottom part (2) of the feeder with help of 1 pc of screw M8 x 30 (3), a nut M8 with a washer 8,4 (4). 2. Place the pin (6) into the hole in the carrier (8), afterwards insert the auger (5) into the pin (6) and tighten with help of a nut (7). 3. Insert the feeder blind flange (10) on the motor pin (9). 4. Put the carrier with the auger (5+8) on the motor pin (9) and fix with help of the pressure screw (11). 5. Insert the auger (4) into the pipe of the fuel feeder (1+2) so that it ends in the middle of the input hole (see fig. No. 19), (in case that the auger overreaches, it is necessary to shorten it according to the fig. 19) and screw up the motor (9) to the pipe flange with help of 4 pcs of screws M5 x 50 (12) and nuts M5 (13) Mounting of the fuel feeder to the boiler Fig.. 21 Mounting of the fuel feeder to the boiler 17

18 1. Pose the fuel reservoir (1) near the boiler. 2. Pull the burner flange (2) on the input hole of the burner PellasX. 3. Slip the fuel feeder (3) into the feeder flange on the reservoir. 4. Pull 2 pcs of sockets (4) onto the feeder hose (5). 5. Fix the feeder against rotation by the screw M8 x 6 (6). 5.3 Hydraulic scheme of the boiler incoming heating water return heating water expansion pipeline cold water (potable) hot technical water ball-valve ball-valve with a discharge valve filter bleeder valve (automatic) drain ball valve pressure meter thermomanometr safety valve backward valve temperature sensor of regulation three-way valve with el. drive three-way thermostatic valve circulating pump 1 Automatic boiler VIADRUS with a reg. S.Control or S.Control Touch 2 Mixed heating circuit 3 Room device ecoster-touch or room thermostat 4 Expansion tank 5 DN of short circuit = min.dn of pipeline, length at least 10xDN 6 Mixing valve SIEMENS with a servo-drive 7 Reservoir heater TV 230 V 3-point. 8 Expansion tank for hot water 9 Electric heating is controlled independently Fig.. 22 Version with a mixing heating circuit and heating of hot water 18

19 5.4 Electric connection scheme LEGEND: A1 REGULATOR PellasX 890 A6 ROOM DEVIDE B1 TEMPERATURE SENSOR T01 B2 BOILER TEMPERATURE SENSOR B3 HOT WATER TEMPERATURE SENSOR B9 OUTSIDE TEMPERATURE SENSOR BT1 SAFETY THERMOSTAT BTr1 ROOM THERMOSTAT D CONTROL PANEL H1 SIGNALIZATION BT1 K1 ALARM RELAY/RESERVE SOURCE CIRCULATING PUMP M20 FUEL FEEDER MOTOR Q1 BOILER PUMP Q2 PUMP T01 Q3 HOT WATER PUMP X1,X2,X3,X4 REGULATOR CLAMPS X10 BOILER CLAMPS X20,X20.1 SOCKET AND PLUG OF MOTOR OF FUEL FEEDER X30 CONNECTOR OF BURNER PellasX Y1 THREE-WAY VALVE T01 PROTECTIVE TERMINAL BOARD CONDUCTORS COLORS bk black bn brown bu blue gnye green-yellow gy grey gn green Fig.. 23 Connection scheme 19

20 capacitor photo sensor fan Hall sensor ignition elektrode burner temperature sensor Fig.. 24 Connection scheme 5.5 Checking activities before actuation Before actuation the boiler into operation it is necessary to check: a) Filling of the heating system by water Water for filling the boiler and the heating system has to be pure and colorless, without suspended matters, oil and chemically aggressive materials. Its hardness has to comply with ČSN , and in case that water hardness doesn t comply, it is necessary to provide its proper preparation. Neither multiple heating of water with higher hardness prevents from exclusion of salts on the heat-exchanger walls. Flocculation of 1 mm limestone in the given place decreases heat-transmission from metal to water by about 10 %. Heating systems with an open expansion tank allow a direct contact of heating water with the atmosphere. During the heating period the expanding water in the tank absorbs oxygen, which increases corrosive effects and at the same time water is significantly evaporated. To refill, you can only use water prepared to the values according to ČSN It is necessary to rinse out the heating system properly in order to ensure washing-away of all impurities. During refilling the heating system by water, it is necessary to be particular about not suction air into the system. Water from the boiler and the heating system never may be discharged or taken off for using, except of cases necessarily needed, such as repairs and so on. By discharging and refilling of new water, you increase a danger of corrosion and creating a scale. If you need to add water into the heating system, add it only to a chilled boiler to avoid a damage of the heat-exchanger. b) Tightness of the heating system; c) Connection to the chimney it has to be approved by a chimney-sweep company; A necessary condition for operation of this boiler is the flue lining from the reason of possible creation of condensate in flue gases due to their low temperature, mainly at the minimum power of the boiler. The flue lining material has to be resistant against chemical effects of condensate. d) Tightness of the burner; e) Connection to the electric power supply network; The boiler has to be connected by a flexible cord by means of a plug into a normalized socket of 230 V/50 Hz/10 A. A protection from electrical injury has to be ensured according to ČSN ed. 2. Completion of mounting and performance of a heat test has to be recorded to the Warranty certificate. 5.6 Boiler commissioning 1. Connect the equipment to the power supply network (insert the plug into the socket). 2. Verify a correct connection and functionality of the connected electric devices. 3. Before commissioning of the burner it is necessary to check all connections and joints of the burner with the feeder. Further check screws fixed the burner to the boiler and sealing between the burner and the boiler. 4. By pressing the rotating button and its subsequent rotation, select a mode Menu/Manual control. 5. Fill-in the fuel reservoir with prescribed fuel. After the reservoir is filled up, close it properly in order to prevent possible suction of air into the burner through the feeder. 6. Pull out the orifice of the transport hose from the filling throat of the burner, and insert the hose, for example, into a tank, a PE pack, etc. Select a mode Menu/Manual control/feeder/on Wait until the fuel feeder is filled up by pellets (pellets are to be spilled into a prepared tank). Switch-off the feeder in Menu/ Manual control/feeder/off. Fix back the orifice of the transport hose to the filling throat of the burner. Perform calibration of fuel supply in menu Service settings (code 1992)/Burner settings/others/fuel calibration (see Instructions Manual for the regulator SControl). 7. Check parameters setting in the control unit 8. Perform boiler kindling. Press the rotating button and subsequently rotate it to select Menu/Switch on regulator. 9. Check repeatedly boiler tightness. 10. Perform a heat test according to corresponding norms (see the Warranty certificate). 11. Acquaint the user with handling. 12. Made a record in the Warranty certificate. Commissioning of the boiler may only perform a professional mounting companies authorized for this activity. 20

21 6 Handling of the boiler by a user An instruction manual of the control unit is supplied separately. 6.1 Description of control - S.Control Rotation selection of Menu, increase/decrease a parameter value. Short press confirmation of a selection/change - ENTER. Activator TOUCH and PLAY Longer press about 2s cancelation of a selection/change - EXIT. Description of the display window OPERATION 1. Working modes of the regulator: FIRING UP, STABILIZATION, OPERATION, EXTINCTION, STANDBY, IDLING, CLEANING, FLAME TEST 2. A value of the required boiler temperature, 3. A value of the measured boiler temperature, 4. A field of functions, which influence the required boiler temperature. Separate symbols signalize: Decreasing of the required boiler temperature after opening of the room thermostat contacts, Decreasing of the required boiler temperature according to active time intervals, Increasing of the required boiler temperature for the period of the hot water (HW) reservoir filling-up, Increasing of the required boiler temperature by the mixer circuit, Switching-on of equithermal control for the boiler circuit, Increasing of the required temperature for the purpose of filling-up of the storage tank. 5. Signalization of the fan operation, 6. Signalization of operation of the fuel feeder, 7. Signalization of operation of the central heating (CH) pump, 8. Signalization of operation of hot technical water (HTW), 9. A value of the measured HTW reservoir temperature, 10. A value of the required HTW reservoir temperature, 11. Hours and a week day, 12. A match symbolized a switched-on heating device, a digit aside means a number of an attempt for ignition, 13. A value of outside temperature (equithermal), 14. A symbol of the auxiliary feeder (a feeder from the reservoir connected to the module B). Setting of the required boiler temperature You can adjust the required boiler temperature and the mixer circuits temperature from the level of menu (values of these temperature values, which can be adjusted, are limited by the range of corresponding with them service parameters of the regulator). 21

22 Boiler settings Required boiler temperature Boiler settings Required boiler temperature Mixer settings 1-5 Required temperature Parameter value: The regulator ignores the required boiler temperature in case that the required boiler temperature is controlled by an outside sensor. Independently on it, the required temperature in the boiler is automatically increased in order to enable to fill-up of the hot technical water reservoir and supply the mixers heating circuits. 6.2 Boiler operation by a user touch-type version S.Control Touch The service instructions for the control unit of the boiler are delivered separately. 1. Boiler operation mode: FLAME TEST, IGNITION, STABILIZATION, OPERATION, EXTINGUISHING, CLEANING, STANDBY, IDLE TIME, ALARM, MANUAL 2. Required boiler temperature 3. Real boiler temperature 4. Input into Menu 5. Information box: fan feeder 1 (in the fuel reservoir) feeder 2 (in boiler burner) central heating and hot water pumps igniter grate mode 6. Real temperature in the HW temperature 7. Required temperature in the HW reservoir 8. Week day and time 9. Outdoor temperature 10. Field of functions, which influence the required boiler temperature decreasing the required temperature by the room thermostat the required temperature in the room was reached decreasing the required temperature according to the time schedules increasing the required temperature of the boiler for a period of heating-up the HW reservoir increasing the required temperature of the boiler from the mixer boiler control according to the outdoor curve increasing the required temperature of the boiler for a period of heating-up the accumulating reservoir The right and left windows on the main display can present different information. Having touched, you may change displayed information between the mixer circuits (1, 2, 3), the information window, the HW window. 22

23 Output boiler temperature setting push up select the option Boiler temperature is set modify temperature with help of the buttons + and - (the range C) confirm by the option return to the main menu with help of or. 6.3 Control, regulating and safety elements Safety thermostat A safety thermostat is placed on the Bottom part of the control box and serves for stopping the boiler course at exceeding the safety temperature. It is necessary to set the safety thermostat to the temperature value of 100 C, i.e. to a higher temperature, than the maximum adjusted boiler temperature (90 C). After opening of the safety thermostat, an indicator lamp of signalization of the safety thermostat is lit up. The fuel feeder and the fan will be stopped. Unblocking of the safety thermostat has to be performed manually to do it, demount the hole cover and press a disk. In case of repeated switching-off of the safety thermostat, it is necessary to switch-off it and find out a cause of repeated boiler overheating. After the safety thermostat opening the primary pump (or the heating circuit pump) continues to work. 7 Maintenance 7.1 Clean-up of the boiler 1.) Remove regularly ash from the heating chamber and the ash-drawer. Ash has to be laid into inflammable tanks with a cover. Use protective equipment and observe personal safety during work. 2.) At least 1 h before clean-up of the boiler it is necessary to switch-off it (including electrical disconnection). Frequency of boiler cleaning depends on fuel quality. In case of pellets with ash content up to 0,5 %, perform cleaning-up with 3 4 weeks intervals. Pellets with ash content 1,5 % and more cause that the boiler has to be checked and cleaned once a week, or more often when necessary. Boiler clean-up means removal of ash or deposits from the boiler drum (the heating chamber, the flue gases channel, etc.). 3.) The burner grate has to be regularly cleaned-up (in dependence on boiler operation). After the heating chamber cooled down, take off the grate, throw out crusted ash by tapping and check the passability of holes for air supply. It is necessary to use protective gloves. 4.) It is necessary to observe timely fuel stocking. If only small quantity remains in the reservoir, it is necessary to refill it immediately to avoid suction of false air. 5.) We recommend cleaning-up regularly the transport hose, because fine particles are deposited during fuel transportation inside the hose, which could finally prevent from passage of fuel through the hose. Beside of that the deposited layer of fine fuel particles could inflame at a backward flame lash-up; 6.) After completion of cleaning-up or after whatever handling with the fuel feeder, check a correct fixation of the transport hose on both its ends with help of hose clips. 7.) For a light overpressure in the heating chamber space during operation of the fan, be particular about excellent tightness of the boiler (the cleaning door, the cleaning cover of the chimney pot, etc.). It is prohibited to uncover the burner or whatever other intervention to these units for the boiler personnel. These operations may only be performed by a service specialist. 7.2 Clean-up of the burner Attention! The equipment can be only maintained after disconnection of the boiler and the burner from power supply network Photo sensor 1. The burner photo sensor has to be cleaned-up each 3 months with a fine clout. 2. After removal of the burner cladding, take off the photo sensor (1), clean it up and put it in again. 3. Install the burner cladding back. 1. Photo sensor Fig

24 7.2.2 Clean-up of the fuel feeder pipe In case that a foreign thing gets in the fuel feeder pipe and blocks its operation, then the feeder motor will start to overheat and the feeder sensor will shut down the boiler. To remove the foreign thing from the feeder pipe, it is necessary: 1. Disconnect the regulator from electric power supply. 2. Demount the feeder motor. 3. Push out the auger. 4. Remove the foreign thing from the pipe of from the auger. 5. Mount the fuel feeder in the opposite order. 6. Check correct operation of the fuel feeder Clean-up of the burner One of the causes of burner failures can be pollution of the burner. Depending on quality of used fuel, it is necessary to clean where necessary the burner furnace from ash. The burner is equipped with a removable furnace, see fig. No. 29. Before extraction of the furnace, it is necessary to clean it up thoroughly so that ash doesn t get during extracting to the air supply chamber; afterwards you can extract the furnace and clean-up holes for air supply. You can use a wire brush or a small rake for cleaning-up. After cleaning-up the furnace, it is necessary to place it back into the burner. The furnace lock has to be precisely placed in the burner, see fig. No. 28. ATTENTION! The furnace after burning-out of the burner can be permanently hot, that s why it is necessary to use proper protective equipment. Fig.. 26 Procedure for burner furnace extracting Fig.. 27 Correct placement of the burner furnace An often cause of pollution of the burner is the burner switching-off on the main switch. Too quick shutting-down of the air supply causes insufficient fuel combustion. On the following burner switching-on without its cleaning-up its tarring can occur, whereas enough air quantity doesn t flow through the holes plugged by impurities. That s why the Boiler Extinction procedure must be performed before its switching-off. 7.3 Mounting of the additional module B (A2) The module is not a part of the boiler standard supply it is only on request. It serves for the extension of the heating system by the next two circuits. It cooperates with the storage reservoir. Mounting of the control box Pull the fork of the supply cable from the 230 V socket. Place the module B on the DIN-rail and secure it with latches (power supply of 230 V has to be directed out of the electric cabinet). Disconnect the conductors of 230 V (No. 71/72, No. 1/2, No. 40/41) from the terminal board (fig. No. 31) and connect it to the terminal board of the module B (A2): (conductor No. 71/72) green-yellow L (conductor No. 1/2) black (brown) N (conductor No. 40/41) blue Disconnect the communication conductors No. 60 and No. 65 from the terminal board (fig. No. 31) and connect it to the terminal board of the module B (A2): G1-RS485:D+ (conductor No. 60) brown (red) D- (conductor No. 65) white Connect the electric outputs of the heating system to the terminal board of the module B (see fig. No. 30). For activation of the function of the mixing valves (MIX 2 and 3) and the storage reservoir, temperature sensors of CT4 type have to be connected. 24