[INSTRUCTIONS FOR INSTALLATION, USE AND MAINTENANCE] This user manual is an integral part of the product

Transcription

1 [INSTRUCTIONS FOR INSTALLATION, USE AND MAINTENANCE] This user manual is an integral part of the product

2 INDEX SECTION TITLE PAGE Introduction 3 Purpose 3 1 Important recommendations 3 2 Safety 3 3 Installation Responsibility of the installer Permitted installations Non permitted installations Chimney Chimney end Insulation, finishes, coatings and recommendations for safety Hydraulic connections National, regional, provincial and municipal regulations 8 4 Pellet and pellet loading Pellet quality Pellet storage Pellet loading 10 5 Operation Control Board The Menu Functioning States Other Functions 21 6 Connections Installation of external thermostat Check of thermostat proper connection Supply connection Components connection diagram 23 7 Technical data 24 8 Maintenance Firebox Ash pan Flame chamber Exhaust system Flue gas fan Non operation period 26 2

3 INTRODUCTION MEGATRON 25 & 35 Please read thoroughly this manual before installing and using this product. The pellets heaters are manufactured and tested in accordance with the safety standards of the applicable European Directives. This manual intends to give instructions for the use and maintenance of the products to their owners and the installation technicians. If you have any doubts as to the contents or for any other question, please contact an authorized service center. PURPOSE The purpose of this manual is to allow the user to take all possible measures and prepare all equipment and materials to ensure the safe and correct use of the product. 1. IMPORTANT RECOMMENDATIONS The installation should be performed by trained personnel or by the technical support of the manufacturer, taking full responsibility for the final installation and subsequent smooth operation of the installed product. It is also necessary to consider all national, regional, provincial and municipal laws and regulations of the country where the device is installed. There will be no liability of the manufacturer for failure to comply with these precautions. 1. Electrical connections: it is therefore recommended to the authorized personnel after every operation conducted on the product, to pay particular attention to electronic connections, notably to the point of bare conductors which must not exit the terminal, thus avoiding possible contact with live parts of the conductor. 2. Correct use: the boiler is to be used for the purposes for which it is built. 3. Responsibility of the manufacturer: The manufacturer assumes no contractual or non contractual liability for damage caused to persons, animals or things, from installation errors, improper use and maintenance. 4. Verify the integrity of the product: After removing the packing, check the integrity and completeness of the contents. In case of discrepancies, please contact the dealer where you purchased the device. 5. Electrical components: All electrical components that make up the product to be able to guarantee the correct operation and should be replaced with genuine parts only from authorized service provider. 6. Maintenance: Daily and monthly maintenance of the product should be made by the buyer and at least once a year, planning it in advance, by specialized staff or the technical support of the manufacturer. 2. SA FETY For safety reasons, remember that: The use the boiler by people (including children) with no experience or with reduced physical and mental capacity, if not supervised and are not guided in the use of the appliance by a person responsible for their safety, is not permitted. You should check and make sure children do not play with the appliance. Do not touch the boiler when barefoot or with wet and moist areas of the body. Do not modify safety equipment or settings without the permission or the manufacturer's instructions. Do not pull, do not turn and cut off the electrical wires protruding from the boiler even if it is disconnected from the network. We recommend that you put the power supply cable in place not in contact with the hot parts of the appliance. The supply plug must be accessible after installation. Avoid closing or reducing the size of ventilation openings at the installation site, the vents are necessary for proper combustion. Do not let the elements of the package near children. During the normal operation of the product all doors and lids should always remain tightly closed. When the device works it is warm to the touch, especially the external surfaces. We advise you to use in caution. 3

4 Check for obstructions before turning on the device if it has been out of operation for a long time. In case of particularly adverse weather conditions (strong wind, frost) it is likely that safety systems intervene and turn off the boiler. If this happens please contact technical support and NEVER disable safety devices. In case of fire in the flue way obtain the means to suppress the flames or seek the intervention of the fire service. This device should not be used for burning wastes. Do not use flammable liquids for ignition. When filling, do not bring your pellet sack in contact with the product. 3. INSTALLATION 3.1 RES PONS I BI LIT Y OF T HE INST ALLE R Responsibility of the installer is to perform inspections of fluepipes, air inlet and all the electrical and hydraulic solutions required for your pellet boiler. Responsibility of the installer is also to ensure compliance with current special local laws where the boiler is installed. The use of the pellet boiler should take place in compliance with the directions given by this document and by all maintenance and safety standards in line with current special legislation, valid where the boiler is installed. According to the standards that define the obligations of installer, the installer should confirm: The type of the installed unit The compatibility of the installation space with the unit, expressed as minimum volume installation according to the manufacturer's instructions. The instructions of the boiler manufacturer regarding the conditions of smoke removal system (fluepipes or flueways). The internal cross section of the stack, the material of which it has been constructed, equal crosssectional dimensions, lack of obstructions. The height and vertical extension of the chimney. The height above sea level at the site. The existence and adequacy of watertight closure. The capacity of external air inlets and the sizes of existing ones. The possibility of parallel use of the generator system with pre existing other equipment. If the results of all tests are positive, the installation can proceed. Carefully observe the instructions provided by the manufacturer and current safety and fire safety standards. Once installation is complete, the system should be tested for no less than 60 minutes for all functions to be checked. Once the installation and trial operation are completed, the installer should provide the customer with the following: The use and maintenance form of the unit as supplied by the manufacturer (if not already provided with the unit) The required documentation for compliance with the current standards. 3.2 PERMITTED INSTA LL ATIONS At the location where the boiler is installed, may already exist, or may be established only devices that pose no recession in space in relation to the external environment. 4

5 3.3 NO N- PERM ITTED INSTA LLA TIONS MEGATRON 25 & 35 In the area where you need to install the boiler must not already exist or be installed: Hood with gas suction. Ventilation ducts with gas suction. If these devices exist in areas adjacent to the installation site, the simultaneous use of the boiler is permitted because of the risk that one of the two areas falls into recession. 3.4 C HI MNEY To assemble the stack non flammable materials must be used suitable to withstand the combustion products and any condensation. The use of flexible metal tubes and fiber cement to connect the flue of the boiler is prohibited. The chimney must not cross areas where installation of combustion appliances is prohibited. The placement of the chimney should be done in such a way as to ensure the operating conditions of the device, to reduce the formation of condensate and avoid their transfer to the device. the placement of horizontal sections should be avoided as much as possible (allowable limit 3m). Fig. 1 For devices that must reach the top or the wall the direction changes must be made with open elbows no more than 45 or angled 90 (no more than 3 in total). The use of reverse inclination components is prohibited. It is recommended that the chimney has a collection chamber for solid materials and any condensate, located below the inlet of smoke pipe, so that it can easily be opened and inspected (Fig. 2). It is forbidden for other air ducts and piping to pass inside the smoke pipe, even if it is of large size. It must be properly spaced from combustible materials through am insulating layer of air or proper insulation (Fig. 3, 4, Table 1). The chimney must accept the discharge from a single boiler. The direct indoors discharge is prohibited even in rooms with open ceiling. Fig. 2 Fig. 3 Fig. 4 5

6 SYMBOL Flammable Nonmaterials Flammable materials A 200 mm 100 mm B mm 750 mm C 200 mm 100 mm Table 1 The smoke discharge system SHOULD NOT be connected: In flue ways used by other generators (boilers, furnaces, fireplaces, etc.) Air exhausts systems (hoods, air ports etc.) even if enclosed in pipes. The draught of the chimney must be Pa!!! Fig. 5 Fig C HI MNEY EN D The chimney end must meet the following requirements: have inner section equal to that of the stack. have useful outlet section not less than twice that of the interior of the chimney. be constructed in such a way as to prevent the penetration of rain, snow, foreign bodies in the chimney, and to guarantee the discharge of combustion products even in case of winds of any direction and inclination. be positioned in such a way as to ensure proper dispersion and dissolution of the combustion products and certainly outside the regression area where the formation of opposite pressures is favored, such area has different sizes and configurations depending on the tilt angle of the cover. The end of the stack must have no mechanical suction. 6

7 3.6 INS U LATION, FINISH, COATING AND SAFETY RECOMMENDATIONS MEGATRON 25 & 35 The coatings regardless of the material they are made must be a self supporting structure with respect to the heated system and should not be in contact with it. Beams and finishes of wood or flammable sufficiently insulated. materials must be placed outside the radiation area of the boiler or be If covers made of flammable or heat sensitive material exist in the space above the boiler, a protective barrier of insulating or non combustible material should be placed. Components made of combustible or flammable material such as wooden furniture, curtains, etc. that are directly exposed to the radiation of the fire should be placed at a safe distance. The device installation must guarantee easy access for cleaning the device itself, pipelines and gas discharge pipes H YDRA U LIC CONN ECTION This appliance has been designed to heat water for a hot water type heating system. When the appliance is operating regularly it produces hot water at a temperature that is necessarily below boiling point and a heating system must therefore be designed that is suited to the characteristics of the appliance. A qualified heating plumber must be called in to: check an existing heating installation. design, install and check a new heating installation. The water heating system must be sized in relation to the average power of the appliance and the heating requirements of the building (see TECHNICAL DATA ). The fittings for connecting the appliance to the plumbing system are to be found at the rear. Connections: Connect the appliance to the heating plumbing system (supply return) using pipe unions and stop valves facilitate any future maintenance or draining of the heating system. Should the temperature/pressure relief valve activate, the water must be free to flow away without causing injury to person, damage to property or to the electrical parts of the boiler. Installing shut-off valves on the inlet and the outlet enable maintenance to be carried out without having to drain the system. Drain taps inserted in the lowest points of the system make it easier to drain the system if necessary. Air valves installed at all the highest points of the system make it easier to bleed the heating system. Do not install thermostats on all the heaters (radiators) of the heating system so that at least the minimum output of the appliance can be dissipated. Use sections of hose to connect the boiler so that it can be moved slightly (check that any kinks in the hose do not allow air pockets to form). Install a manometer near the appliance delivery or return fittings to check the working pressure of the system. Connect the appliance pressure/temperature relief valve to a suitable drip funnel to take away water at high pressure and temperature. Avoid any narrowing in the diameter of the pipe work. Avoid using elbows or bends with a small radius. Provide adequate supports for the water pipes so that they do not weigh on the fittings of the unit. Before connecting the appliance, flush the heating system through to eliminate any residues (oil, swarm, drops of weld material, hemp, rust) inside the pipe work, which could otherwise damage the boiler or cause malfunction. Insulate the connecting pipe work adequately to prevent heat loss and the formation of condensation. Under no circumstances light the appliance unless the water circuit is completely filled with water. to 7

8 HYDRAULIC DIAGRAM MEGATRON 25 & NATI ONA L, REGIONA L, PRO VI NSIONA L AND LOCAL REGULATIONS It is also necessary to keep in mind all national, regional, provincial and municipal laws and regulations of the country in which the device is installed. 4. PELLET AN D PE LL ET LOA DING ATTENTION!!! THE USE OF PELLETS NOT IN ACCORDANCE WITH THE STANDARDS, AND THE USE OF OTHER COMBUSTIBLE MATERIAL, HARMS THE PROPER FUNCTION OF YOUR PRODUCT AND MAY VOID THE WARRANTEE AND THE ATTACHED MANUFACTURER S RESPONSIBILITY. 4.1 PELLET Q UA LIT Y The pellet boiler is designed to use compressed wood pellets. Since the market has many products of this type, it is important to choose pellet with high standards. The link to the burning compressed wood has established a model for that fuel product. Be sure to use quality pellet that is compact and has low concentration of dust. Ask your dealer for the appropriate pellet, the diameter of which should be 6mm and its length about 30mm. The proper functioning of the pellet boiler depends on the type and quality of the pellet used, and the heat generated by the different types of products can have varying degrees of efficiency. We recommend pellet with specifications according to ÖNORM M1735, DIN plus EN The manufacturer shall not be liable for the use of low quality pellet and for the resulting improper function of the boiler. To ensure smooth operation, you must: Avoid using pellets with dimensions different from those provided by the manufacturer. Avoid using pellets, containing saw dust, bark, corn, resins or chemicals (additives, adhesives) Avoid using wet pellets. Avoid using pellets that produce other residuals except ashes after burning. 8

9 Using unsuitable pellets causes: Obstructions of the burner and flue way. Reduction in efficiency. Excessive dirt on the protective glass Unburned grains and heavy ash. MEGATRON 25 & 35 Specifications Units Austria Sweden Germany Italy EU ÖNORM M1735 SS DIN DIN plus CTI EN Diameter mm 4-10 To be referenced Length mm 5* 4* 50 5*D -4*D 3,15-40 Density Kg/m smithereens % of mass Moisture content % of mass Ash content % of mass 0,5 0,7 1,5 0,5 0,7 0,7 Calorific value MJ/kg 18 16,9 17,5-19, ,9 16,5-19 Sulfur % of mass 0,04 0,08 0,08 0,04 0,05 0,03 Nitrogen % of mass 0,3-0,3 0,3 0,3 0,3 Chlorine % of mass 0,02 0,03 0,03 0,02 0,03 0,02 Arsenic mg/kg - - 0, Cadmium mg/kg - - 0, ,5 Chromium mg/kg Copper mg/kg Mercury mg/kg - - 0, ,1 Lead mg/kg Zinc mg/kg Nickel mg/kg Additives % 2 To be referenced - 2 To be referenced 2 9

10 4. 2 PELL ET STORAGE The pellets should be stored in a dry place that is not too cold. Essentially, cold and moist pellet (of temperature below 10 º C) reduce the thermal energy of the fuel and require extra cleaning of the pellet boiler. THE PELLET SHOULD NOT be kept near the boiler. Keep at least 0,5 m 1 m away PELL ET L OADING Caution when loading the pellet to prevent snapping. Avoid bringing the pack of pellets in contact to the boiler chassis. Do not load dust and sawdust because it can block the supply system. The pellets reservoir cover must always remain closed and only be opened during loading of fuel. 5. O PE RATION TURNING ON PROCEDURE 1. Load the silo with pellet 2. Check and clean the combustion container 3. Close the doors tightly 4. Choose the combustion power (1 to 6 or Auto if you wish the power to be set automatically) according to the following steps: a. Press P3 (set) b. Choose Combustion Management (set) c. Choose Pellet (set) d. Set the desired power (set) e. Press P1 (Esc) twice 5. Choose the desired water temperature of the stove: a. Press P3 (set) b. Choose Heating Management (set) c. Choose Boiler Thermostat (set) d. Set the desired water temperature (set) e. Press P1 (Esc) twice 6. Press the P2 button for 3 seconds in order to turn on the stove For half a minute the stove performs a check and cleaninig For 1 1,5 minute the stove performs ignition and resistance preheat After that, it fills the combustion container with pellet The flame is lit (if it doesn t after 25 minutes the error message er12 is shown on the LCD display) When the exhaust temperature exceeds 45 o C the stove goes to Stabilization state After 7 10 minutes the stove goes to Run Mode 10

11 Combustion chamber vacuum The system operates maintaining a vacuum in the combustion chamber within a certain range. Therefore, the combustion chamber door must be tightly closed. If it remains open, the er34 message will be displayed on the screen after sec. 5.1 C ONT RO L PANEL Buttons Function Descrip Button On/Off Ignition and Extinguishing of the boiler/stove pushing the button for 3 seconds until the acoustic signal Unblock Unblock the system pushing the button for 3 seconds until the acoustic signal P2 Modify Menu Values Run on Menu and Submenu Visualizations In modify mode change parameter s value Run Menu and Submenu Enter visualization menu P4 P6 Esc Function exit P1 Menu Enter a menu or submenu Modify Set Enable modify mode in a menu Save data Reset System Maintenance 2 Function Reset cleaning timer P5 Leds Function Description Button Heating Resistance Led On: Heating Resistance On D1 Auger Led On: Auger On in intervals D2 Circulator Led On: Circulator On D3 Valve Led On: Valve On (Not Used) D4 Output V2 Led On: Output V2 On (Not Used) D5 Output Aux2 Led On: Output Aux2 On (Not Used) D6 11 P3

12 Output Aux3 Led On: Output Aux3 On (Not Used) D7 Pellet Level Led On: Lack of pellet (Not Used) D10 External Thermostat Led On: Contact Open Thermostat Off D11 Flow switch Led On: Domestic water demand (Not Used) D12 Display Main Frame Display Visualizations on Main Fraime Date and time, chrono modality (D Daily, W Weekly, We Week End), system power, recipe, system state, error code, Boiler Thermostat, water temperature System states Check Up, Ignition, Stabilization, Run Mode, Modulation, Standby, Safety, Extinguishing, Recover Ignition, Block, Off REMOVE AN ERROR MESSAGE ON THE SCREEN Perform the correcting actions according to the cause of the error Wait until the Block message is displayed on the screen Press P2 for some seconds until the error message disappears Restart the appliance pressing P2 Errors All errors result in Block system state, except the Er04 and Er05 errors, that in Wood modality result in Safety state Overeating Wait until the water temperature drops Hugh water temperature. Over 100 ο C safety and the system goes to Block Er01 thermostat is enabled. Unblock the water safety thermostat Press P2 and hold Restart the system Er02 Chimney without draught. Depressurize switch is enabled. Low draught. The draught of the chimney is not adequate or the depressurize switch is broken. Clean the chimney or replace the depressurize switch 12

13 Er03 Extinguishing when the exhaust temperature drops below the set value (70 ο C) MEGATRON 25 & 35 Low exhaust temperature The system ran out of fuel. Load more fuel The fuel is not transferred correctly in the combustion chamber (blocked auger due to dust or other obstructions). Clean the auger Er04 Er05 Er07 Er08 Extinguishing when the water temperature exceeds the set value (90 ο C) Extinguishing when the exhaust temperature exceeds the set value (280 ο C) Encoder error. Occurs in case of lack of encoder signal. Encoder error. Occurs in case of fan rounds per minute adjustment problem Water overheating Wait until the system goes to Block Press P2 and hold Restart the system High exhaust temperature Wait until the system goes to Block Perform the monthly maintenancecleaning Press P2 and hold Restart the system Encoder problem The control board does not communicate with the exhaust fan encoder The encoder needs cleaning The encoder is broken The exhaust fan is broken Fan rotation problem The encoder needs cleaning The encoder is broken The exhaust fan is broken Er09 Low water pressure Er10 High water pressure Er11 Real time clock error Wait until the system goes to Block Press P2 and hold Restart the system Er12 Extinguishing due to Ignition failure Ignition failure The combustion container needs cleaning The combustion container is not positioned correctly The ignition resistance power is low The ignition resistance is broken High moisture content in pellet The pellet hopper is empty Pellet temperature too low The ignition resistance tube is blocked by ash Clean the combustion container, press P2 and hold, restart the system Er15 Lack of voltage Power supply outage Clean the combustion container Wait until the system goes to Block Press P2 and hold Restart the system Er17 Air Flow Regulator Error Er18 Run out of pellet 13

14 Er34 Vacuum below the minimum threshold MEGATRON 25 & 35 Low vacuum in the combustion chamber The combustion chamber door is open The combustion chamber door does not close tightly The system and the chimney need cleaning (monthly maintenance) Low chimney draught (below 10 Pa) The exhaust fan is broken The combustion fan power is to high Call service Er35 Vacuum over the minimum threshold High vacuum in the combustion chamber. Call service Er39 Air Flow Regulator Sensor broken Vacuum sensor broken. Call service Er41 Minimum air flow in Check Up not reached - Er42 Maximum air flow reached - Other messages Visualization of the state of temperature probes. The message displayed in Check-Up indicates - Check the water, room, exhaust sensors Sound that the red temperature of one or more probes is equal to the minimum value (0 C) or maximum (it depends on probe considered). Checks that the probes aren t open (0 C) or in short-circuit (maximum value of the temperature scale). Service Clean Ignition Block Er20 This message notifies that the planned hours of operation until service (parameter T66) is reached. Service is necessary. This message notifies that the planned hours of operation until cleaning (parameter T67) is reached. Cleaning of the stove/boiler is necessary. The message appears if the system is turned off during Ignition (after Preload) by an external device: the system will stop only when it goes in Run Mode. Grid Sensor open with the system in Pellet modality The system needs annually service (cleaning) - Perform the annually service - Reset the timers (system menu -> Timers - > Reset all timers) - Press P2 and hold until the service message disappears Clean the combustion chamber Press P5 and hold until the cleaning message disappears - Restart the system - Port High fuel temperature. Fuel thermostat is enabled Fuel overheating Perform the monthly cleaning Unblock the fuel safety thermostat by pressing its button Restart the system If this error persists call the authorized dealer Er06 Pellet thermostat open Link Error Lack of communication between motherboard and keyboard Visualizations. Pressing the button Ρ4 or Ρ6 Check if the connection cable is disconnected from the LCD display or the control board L3 On Pump P1 L4 Off Valve/Pump P2 L5 Off Out not pres L6 Off Safety Valve L7 Off Pellet Engine Led number and pump state Led number and valve state Led number and Output V2 state Led number and Output Aux2 state Led number and Output Aux3 state 14

15 Exhaust Temp: 103 Boiler Temp: 55 Buffer Temp: 52 Room Temp: 21 Pressure: 1548 Air flow: 580 Vacuum: 280 Fan speed: 1850 Auger: 30 Product Code FSYSD PSYSF Exhaust temperature Boiler temperature [ C] Buffer temperature [C] (Not used) Room temperature [ C] (Only for stoves) Pressure [mbar] (Not used) Air Flow [cm/s] (Not used) Vacuum [Pa] Combustion Fan Speed [RPM] Auger Speed [%] or Auger work time [s] Product Code Control board firmware, code and version Keyboard firmware, code and version MEGATRON 25 & THE MEN U The Menu of the control panel consists of a User Menu and a System Menu in which the manufacturer can modify the operating parameters, test the outputs, check the history of the system. Browsing the menu: Push P3 button to enter the User Menu. Using P4 and P6 buttons it is possible to select the desired Menu or Submenu. Push P3 button to enter the desired Menu or Submenu. To decrease or increase a value, push the buttons P4 or P6. To save the new value push the button P3. To cancel any changes and restore the old parameter s value push the button P1. If a parameter value is changed, the new value is sent to the control board. If the transmission fails the following message is displayed: 15

16 Transfer not successful In this case modify again the parameter s value. MENU Functioning Pellet Power DESC Menu to choose between Wood/Pellet/Combi functions. Menu to modify the combustion power in Pellet function. Combustion Management Wood Power Pellet Recipe Auger Calibration Fan Calibration Menu to modify the combustion power in Wood function. Menu to set the pellet combustion recipe. Menu to modify the speed or working time of the Auger. Menu to modify the Combustion Fan speed. Heating Management Boiler Thermostat Buffer Thermostat Room Thermostat Summer Winter Heating Power Menu to modify the boiler thermostat value. Menu to modify the Buffer thermostat (Not used) Menu to modify the room thermostat value (If a probe is used) (Only for stoves) Menu to select between Summer and Winter function. Menu to modify the heating power. Chrono Load Time and Date Language Keyboard Menu System Mennu Remote Keyboard Menu to enable the Room Thermostat of the remote keyboard (Not used) Menu to select the Chrono s program and the timers for Ignition/Extinguishing of the boiler/stove Menu for auger loading Menu to set the time and date Menu to change the language of the LCD display Menu to set the contrast and light of the LCD display Menu to enter the system menu C O MB USTION MA NAGEMENT MEN U This menu is used to change the combustion parameters. It includes the following submenus. 16

17 FUNCTIONING MEGATRON 25 & 35 This menu is used for changing the function of the appliance between WOOD/PELLET/COMBI functions. Only the pellet option is available. PELLET POWER This Menu allows the setting of the system s combustion in automatic or manual mode. If the manual mode is set, the user can choose the combustion power between values P1 and P6. If the automatic mode is chosen the system sets the combustion power automatically. Combustion Description 1 6 Power manually from 1 to 6 Auto Power set automatically COMBUSTION RECIPE This Menu allows to select the combustion recipe in Pellet modality. The maximum value is the number of recipes visible to the user. AUGER CALIBRATION Menu to change the Auger s work time or speed. The system has 10 calibration s steps (0 value is set by the factory). The calibration s effect is valid only in Run Mode and Modulation for the current recipe. For each step the value is increased or decreased by 1% set in the Default Settings Menu of the System Menu. FAN CALIBRATION Menu to change the Combustion Fan speed. The system has 10 calibration s steps (the 0 value is set by the factory). The calibration s effect is valid only in Run Mode and Modulation for the current recipe. For each step the value is increased or decreased 5% set in the Combustion Fan Menu of the System Menu HEATING MANAGEMENT Menu to change the system s heating parameters. It includes the following submenus. 17

18 BOILER THERMOSTAT (DESIRED WATER TEMPERATURE) Menu which allows to modify the Boiler Thermostat s value. It is possible to program the minimum and the maximum value of the Boiler Thermostat. ROOM THERMOSTAT (ROOM TEMPERATURE) Menu which allows to modify the Room Thermostat s value (only for stoves). SUMMER WINTER Menu which allows to modify the plumbing plant functioning according to the season. One of these symbols: or is shown on the display. HEATING POWER This Menu allows to set the system s heating function in automatic or manual mode (in this case it is possible for the user to select the heating power). Heating Description 0 Heating Fan Off 1 Power set by user Heating power manually from 1 to user selection Automatic Heating power automatically set by the system If the user chooses the automatic mode, the heating is proportional to the exhaust temperature. REMOTE KEYBOARD Menu which allows to enable the Room Thermostat of the Remote Keyboard C H RON O MENU Menu which allows the programming of turning on/off the system. CHRONO FUNCTION DESCRIPTION BUTTONS DISPLAY The current setting blinks Enter in modification mode Select favorite function Cancel any adjustment and restore the previous setting Save the new setting Exit the menu P3 P4 and P6 P1 P3 P1 Disable Daily Weekly Week End CHRONO PROGRAM 18

19 PROGRAM SELECTION BUTTONS DISPLAY The current setting blinks Enter the submenu Select favorite program Exit the menu P3 P4 and P6 P1 Daily Weekly Week End The three types of programming are stored separately: if for example the Daily program is set, the other programs aren t changed. After making the programming it is necessary to select the desired mode to turn on/off the system by Chrono. Choose the program type: Daily: select the day of week and program the times to switch on and off the system. For each day there are 3 time slots. Program across midnight: set the time of extinguishing of a day at 23:59 and the time of ignition for the next day at 00:00. Weekly: program the times to switch on and off the system (there are 3 time slots). Week-End: choose between 'Monday-Friday' and 'Saturday-Sunday'. There are 3 time slots for each period. CHRONO PROGRAMMING After choosing the favorite program, select the programming time. Enter in modification mode (the selected time blinks) Modify the timers. Save the program Enable a program (a V appears) or disable a program (a V disappears) Exit ΠΛΗΚΤΡΑ P4 ή P6 P3 P4 ή P6 P3 P5 P1 19

20 LOAD MEN U This menu allows to manually loading the Auger. The system has to be in off state to do the loading. When the Auger is manually started the Exhaust Fan switches on T IME AND DATE M EN U This Menu allows to set the time and date. Push the button P4 and P6 to select hours, minutes, year, month and day. Push P3 to enter editing, P4 and P6 button to change the value. Push P3 to save and P1 to exit LANG UAGE SELE CTION This Menu allows changing the language of LCD panel. The highlighted language is currently set LCD MENU Set Contrast Set minimum Light ME DESCRIPTION Menu to set the contrast of the LCD panel Menu to set the light of the LCD panel SET CONTRAST This Menu allows to set the display contrast. Push the buttons P4 and P6 to increase or decrease the contrast; P3 to save and exit, P1 to exit without saving. SET MINIMUM LIGHT This Menu allows setting the display light when any button is pushed. Push the buttons P4 and P6 to increase or decrease the light, P3 to save and exit, P1 to exit without saving. 20

21 S Y STEM MENU This menu allows entering System Menu. The access is protected by password. Push P3 to enter in editing mode, P4 and P6 to increase or decrease the selected digit. Push P3 to save the digit and pass to the next. Push P1 to cancel the digit or exit the Menu. If the password is correct, the first menu screen appears. Auger Auger Speed Exhaust Fan Exhaust Fan 2 Heating Fan Thermostat Extinguishing Thermostats Timer Default Settings Enables Air Flow Sensor Vacuum Sensor Delta Pressure Sensor Counters Output s Test Restore Default Values MENU 5. 3 F UNCT IONIN G STATES The operation of the controller is managed with functioning states; each one is characterized by the control of the system s main functioning parameters. The system guarantees the safety and alarms in each state. Functioning States: Off, Check Up, Ignition, Stabilization, Recover Ignition, Run Mode, Modulation, Standby (Extinguishing or Maintenance), Safety, Extinguishing, Block 5. 4 OT HER F UN CTION S SYSTEM MAINTENANCE 1 FUNCTION BOILER SERVICE When the system exceeds the working hours set by the parameter T66 it notifies the user to contact the service to verify the proper functioning of the system. The display shows the message 'Service' and the system goes in Block. To unblock the system it is necessary to reset the counters.. SYSTEM MAINTENANCE 2 FUNCTION BOILER CLEANING When the system exceeds the working hours set by the parameter T67 it notifies the user to clean the boiler or the stove. The display shows the message 'Clean' and the system gives out an acoustic signal periodically. To stop the signal push the button P5. 21

22 EXTINGUISHING IN IGNITION PHASE When the system is turned off during the Ignition phase (after Preheating phase) by an external device or by internal chrono, it really goes in Extinguishing when it enters the Run Mode at the end of Ignition. On the display appears the message "Block Ignition". If an error occurs the system goes immediately in Extinguishing. If the P2 button is pressed it is possible to get immediately the system in Extinguishing or in Ignition. LACK OF SYPPLY VOLTAGE MANAGEMENT In case of supply voltage outage, the system saves the most important functioning data. With the return of the supply voltage, the system evaluates the saved data and: If the outage is less than 60 s the system returns to the state in which it was previously If the system was in a On state and the outage of voltage is less than 50 min and greater than 60 s, the system goes in Recover Ignition In case of prolonged absence of Supply Voltage the system goes in Block with error message Er CONNECTIONS 6.1 T HERMOSTAT CONNECTION The room thermostat is connected to two pink wires on the back of the boiler. This connection should serve as a simple switch on / off (cold junction). It gives neither requires power. (If the thermostat you want to use gives power, drive it through an external relay and get cold touch on / off from the relay). Attention: The inlet of the thermostat is a clean contact, with zero potential. For this reason, it should connected to any voltage element. not be Function of the room thermostat The system is set so that when the room temperature reaches the thermostat set value, the boiler goes to the Modulation operation state. 6.2 C HECKING T HE CO RR ECT CONNECTIONS OF T HE T HERMOSTAT To check the correct connection and operation of the thermostat it is enough to turn it off and then observe a black line next to the thermostat symbol on the control display. Instead, the black line turns off when the thermostat is on. 6.3 S UPP LY CON NECTION There is a power cable provided with the boiler. Plug the power cord into the slots on the back of the boiler and the other side in an earthed socket. DO NOT CONNECT THE BOILER WITH A POWER CABLE WITHOUT USING GROUND. IMPORTANT Use uninterruptible power supply system (U.P.S. uninterruptible pure sine wave power supplies 500W minimum) to avoid problems in case of power outage. Damage due to power outages or large fluctuations in voltage is not covered by warranty. 22

23 6.4 C ONNECTION OF COMPON ENTS TO THE CONTROLLER DIAGRAM 23

24 7. TECHNICA L D ATA OF 25 and 35 BO ILER 25 KW 35 KW WIDTH (mm) mm DEPTH (mm) mm HEIGHT (mm) mm SILO CAPACITY (Lt) Lt SILO CAPACITY (kgr) Kgr HEATING OUTPUT RANGE (kw) kw EFFICIENCY (%) 91 91,5 % WATER HEATING OUTPUT EFFICIENCY (%) 87 87,5 % PELLET CONSUMPTION (Kgr/h) 1,2 to 5,6 1,2 to 7,8 Kg/h AUTONOMY MAINTAINED (h) 6,5 to 30 6,5 to 42 Hours FLUEGAS OUTLET (Φ mm) mm TOTAL WEIGHT (kgr) Kg TOTAL POWER CONSUMPTION (W) W POWER CONSUMPTION DURING W OPERATION (W) SUPPLY (Volts) V FREQUENCY (Hz) Hz WORKING PRESSURE min/max (Bar) 1,5/2,5 1,5/2,5 Bar WATER CAPACITY (Lt) Lt MEAN FLUEGAS TEMPERATURE (C ) C HEATING VOLUME COVERAGE (DEPENDING m3 ON THE INSULATION OF THE ROOM) m3 HEATING SURFACE (DEPENDING ON THE INSULATION OF THE ROOM) m m2 8. MAINTENANCE Under current legislation on safety of electrical appliances for all installation operations, maintenance or repairs that require access to the interior of the boiler or gas chamber should be directed to a service center or qualified service personnel. The required actions of regular maintenance considered mandatory to ensure the smooth and efficient operation. If these actions do not run with the expected frequency, the device performance can drop significantly. The manufacturer assumes no responsibility for reducing performance or malfunctions due to poor maintenance. All maintenance activities (cleaning, replacements, etc.) must be performed after the device is switched off, cooled down and unplugged from the power supply. Do not use materials that could scratch or corrode glass. The scratches could be converted into cracks or breaks. A damp cloth is sufficient. Furthermore, do not use any abrasive cleaners. The instructions provided below are purely indicative. The frequency of these operations depends on how hard the boiler is used and the quality of the pellet used. Any cleaning or maintenance work must be carried out with the appliance disconnected from the power supply. 24

25 8.1 C O MB USTION CONTAINER Every day before every start, the chamber should be cleaned: Detach the container out of the slot. Clean the ash and any accumulated tartar. Thoroughly clean the holes of the container with a sharp object. Check the reception of the container and remove any ash Before turning on the device, make sure the container is properly positioned into the slot and shifted backwards to touch the resistance tube. Fig AS HP AN Every 2 3 days before the start, you should clean the ash pan: Open the lower ash pan door of the boiler. Empty the ash pan into a metal trash can. Tightly close the lower ash pan door of the boiler Fig COMBUSTION CHAMBER AND TUBES Every month or so (or after burning 2 tons of pellets) the combustion chamber and the tubes present therein should be cleaned. The clean tubes favour the better operation of the device and maximize performance. For the above mentioned cleaning process you may have to obtain a vacuum cleaner specific for ash as well as a brush for cleaning the pipes. Proceed as follows: Fig. 22 Unclip the upper boiler cover (Fig. 22). Unscrew the top cover of the boiler (Fig. 23). Remove the cleaning lever and the flue gas retarder. Remove with a vacuum cleaner the ash that has accumulated Scrape the tubes with the brush (Fig. 24). Fig. 23 Clean the removed parts and assemble them again in the reverse order. Open the front flame inspection door (the one with the window) (Fig. 25). Fig

26 With the vacuum suck (or scrape with a spatula) the ashes and debris accumulated in the side walls and the upper side of the hearth MEGATRON 25 & 35 Close tightly the door. Unscrew the side cover. Unscrew the two screws and remove the door (Fig. 25a). Use a brush to clean the accumulated ash (Fig. 25b). Fig. 25 Fig. 25a Assemble the removed parts again in the reverse order Attention: For the 25 / 35 kw model move up and down 4 5 times the lever for cleaning the pipes every 2 3 days and when the boiler is off. (Fig. 26). g Fig. 25 b Fig C LE A NING OF T HE F LUEGAS E XHA UST SYSTEM Every month we recommend you to perform this maintenance at least once. Remove the cap of the T fitting and clean the fluepipes. Clean the removed parts and assemble them again, In the reverse order. Fig C LE A NING OF FLUEGAS FAN The boiler has an exhaust fan at the rear side. The excessive accumulation of ash or dust on the impeller of the fan causes loss of balance and therefore excessive noise during the operation. For this reason, you should clean the fan at least once a year. In order to perform the cleaning some parts of the device must be dismantled, we recommend that you call technical support or a qualified technician. 8.6 C LE A NING FOR NON- OPERATION PE RI O D At the end of the usage period of the boiler, you must do the following: Remove all pellets from the container and the auger. Thoroughly clean the burner, the burner slot and the ash drawer. Clean with a wire the interior of the combustion chamber. Thoroughly clean the fluepipes. We recommend that you assign the cleaning to a professional chimney sweep. Clean once a year (dust, spiders, etc.) the gap between covers. Unplug the power cord from the power supply. 26

27 EVERY TIME the scheduled maintenance must be performed and before the turning on of the device, after a long period of inactivity. The following actions are necessary for the smooth and safe operation of the device. Thorough cleaning of exhaust chamber (see section "CLEANING EXHAUST CHAMBER AND BOILER"). Check and clean the exhaust system. Clean dust and spiders that may exist in the internal side of the covers. Cleaning of moving parts and mechanisms. Checking of electrical, electronic and hydraulic parts. Check the water level and pressure of hydraulic system. Possibly restore normal values and bleed radiators. Check that the impeller of the pump is in good condition. If it is blocked, unscrew the cap of the pump with a screwdriver and unblock it. Check the seals of the glass for leaks and damage, the hydraulic circuit and all items that may be worn, and replace any worn items. Check the tightness of unions and piping connections. Check the condition of the thermal protection and safety valve (relief), if activated. Make sure they are operating properly. Otherwise, replace them. Perform all maintenance actions and control measures required for the proper operation and compliance with safety rules. Turn on the boiler once, according to the instructions under "TURNING ON THE BOILER". Any cleaning and / or maintenance should be done with the device disconnected from the power supply. 27

28 MODEL SERIAL NUMBER INSTALLATION DATE INSTALLATION TECHNICIAN Nr. DATE MAINTENANCE AND REPAIRE WORKS DESCRIPTION OF WORK DETAILS TECHNICIAN 28