STAR 18 PELLET BOILER STOVE

Transcription

1 STAR 18 PELLET BOILER STOVE INSTALLATION, USE AND MAINTENANCE, USEFUL TIPS S.R.L. ENGLISH Rev. 1.2

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3 DICHIARAZIONE DI CONFORMITÀ DECLARATION OF CONFORMITY In accordo con la Direttiva 89/106/CEE (Prodotti da Costruzione), la Direttiva 2006/95/CEE (Bassa Tensione) e la Direttiva 2004/108/CEE (Compatibilità Elettromagnetica). According to the Directive 89/106/EEC (Construction Products ), the Directive 2006/95/EEC (Low Voltage) and the Directive 89/336/EEC (Electromagnetic Compatibility). N di identificazione - Identification No. : ST18-01 Emesso da - Issued by : KLOVER s.r.l. Via A. Volta, San Bonifacio (VR) Tipo di apparecchio - Type of equipment : Marchio commerciale -Trademark Wood pellet domestic heating device : KLOVER Modello o tipo - Model or type : STAR 18 Uso - Use : Domestic heating Costruttore - Manufacturer : KLOVER s.r.l. Via A. Volta, San Bonifacio (VR) Ente notificato - Notified body : NB 1880 ACTECO s.r.l. I Cordenons (PN) Via Amman, 41 Le norme armonizzate o le specifiche tecniche (designazioni) che sono state applicate in accordo con le regole della buona arte in materia di sicurezza in vigore nella CEE sono: The following harmonised standards or technical specifications (designations) that comply with good engineering practices concerning safety matters in force within the EEC have been applied: Norme o altri riferimenti normative Standards or other regulatory references EN EN EN EN EN EN EN Rapporto di Prova ITT Initial Type Test Report NB In qualità di costruttore e/o rappresentante autorizzato della società all interno della CEE, si dichiara sotto la propria responsabilità che gli apparecchi sono conformi alle esigenze essenziali previste dalle Direttive su menzionate. As the manufacturer s authorised representative within the EEC, we hereby declare under our sole responsibility that the equipment complies with the provisions of the Directives stated above. San Bonifacio (VR), 10/04/2013 Mario Muraro Chairman of the Board

4 CONTENTS INTRODUCTION... 2 IMPORTANT SAFETY INSTRUCTIONS... 2 A FEW PRECAUTIONS... 2 INTENDED USE... 2 THE MACHINE AND THE PELLETS... 4 CONNECTIONS DATA SHEET... 4 BOILER STOVE COMPONENTS... 5 TECHNICAL SPECIFICATIONS... 7 PELLET FEATURES... 8 REQUIREMENTS OF THE PLACE OF INSTALLATION... 9 POSITIONING... 9 SPACES AROUND AND ABOVE THE BOILER STOVE... 9 EXTERNAL AIR VENT... 9 FLUE AND CONNECTION TO THE LATTER - STACK ELECTRICAL CONNECTION...13 CONTROL OF ANY COUPLED BOILER CONNECTION TO THE ROOM THERMOSTAT PLUMBING CONNECTION...15 CLEANING AND MAINTENANCE...16 PRECAUTIONS BEFORE CLEANING ROUTINE CLEANING EXTRAORDINARY CLEANING CLEANING THE CERAMIC GLASS CLEANING THE FLUE MAINTENANCE THE DISPLAY...22 THE MENU...25 INITIAL START-UP...28 FILLING THE SYSTEM FOR THE FIRST TIME PELLET LOADING AND CONNECTION TO THE ELECTRICITY NETWORK BOILER STOVE IGNITION CYCLE BOILER STOVE WORKING MODE SWITCHING OFF THE BOILER STOVE CHANGING THE ROOM AND WATER TEMPERATURE SETTINGS ALARM SIGNALS USEFUL INFO WHAT HAPPENS IF PCB PARAMETERS...33 WIRING DIAGRAM...35 NOTES...36 WARRANTY...38

5 Dear Customer, innanzitutto la ringraziamo per aver scelto un prodotto KLOVER e ci auguriamo che possa trarre dal suo recente acquisto ogni soddisfazione. Please read the warranty certificate carefully. This is found on the last page of this User Guide. Please contact the authorised Technical Assistance Centre (TAC) for the initial start-up of your stove and to validate the warranty. We would like to thank you again for trusting KLOVER products, and we would also like inform you that these models are the result of forty years of experience in the manufacture of solid fuel products using water as heat transfer fluid. Every single detail of the boiler stove is manufactured by qualified staff, using the most advanced equipment. This manual contains a detailed description of the boiler stove and its operation, alongside instructions for proper installation, basic maintenance and inspection points, which must be performed regularly; furthermore, it contains practical advice for obtaining maximum performance from the boiler stove with minimum fuel consumption. The boiler stove's heat output may vary depending on the type of pellets used. Stay warm with KLOVER! Technical Support Klover pellet stoves are imported and distributed by FirePower Heating, Unit 11/12 Quadrant Distribution Center, Quedgeley, Gloucester, GL2 2RN. UK technical and product support is provided by FirePower Heating who can be reached on Smoke Control Areas The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been "authorised" in Regulations and that appliances used to burn solid fuel in those areas (other than "authorised" fuels) have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved administrations. PELLET FIREPLACE 22 Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and you can contact them for details of Clean Air Act requirements Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if located in a designated smoke control area. It is also an offence to acquire an "unauthorised fuel" for use within a smoke control area unless it is used in an "exempt" appliance ("exempted" from the controls which generally apply in the smoke control area). The Klover Star 18 (model - ST 18) has been recommended as suitable for use in smoke control areas when burning wood pellets. Copyright All rights reserved. The reproduction of any part of this manual, in any form, without the explicit written permission of KLOVER Srl. is forbidden. The content of this manual may be modified without notice. Although the documentation contained in this manual has been carefully compiled and checked, KLOVER srl cannot be held liable for any damages arising from the use of the same. Copyright 2013 KLOVER srl Latest revision: 1.2 May

6 INTRODUCTION Important safety instructions Please read these instructions before installing and using the product. The installation and initial start-up of the boiler stove must be performed by skilled personnel trained in the relevant safety standards. They will be responsible for the definitive installation of the appliance and its proper operation. KLOVER srl shall not be held liable if these precautions are not observed. During installation of the appliance, all local regulations - including those referring to national and European Standards - must be observed. Connect the flue gas outlet to a flue having the features described in the Connections section of this User Guide. The device is not suitable for installation on a shared flue system. If the flue should catch fire, use appropriate fire extinguishing equipment or call the fire brigade. Connect the product to an earthed power socket. Avoid using sockets controlled by switches or automatic timers. Do not use damaged or worn power supply cables. If a multiple socket is used, make sure that the total voltage of the connected devices does not exceed the rated voltage for the socket. Also make sure that the total voltage of all the devices connected to the socket does not exceed the maximum permitted level. Do not use flammable substances to clean the appliance or its parts. Do not leave flammable containers and substances in the room where the boiler stove is installed. Do not use the appliance as an incinerator or for any use other than that for which it was designed. Do not use different fuels to those recommended. Do not use liquid fuels. The appliance, and its outer surfaces in particular, become very hot to the touch during operation; handle with caution in order to avoid burns. Only use original spare parts recommended by the manufacturer. Do not make any unauthorised modification to the device. The use of poor quality pellets or any other material can damage the boiler stove's operation, voiding the warranty and exempting the manufacturer from all responsibility. A few precautions Do not touch any hot parts of the product (ceramic glass, flue pipe) during normal operation. Use the appropriate button to switch the electrical panel off. Do not disconnect the power supply cable while the boiler stove is running. Keep children away from the boiler stove when it is running since they could get burnt by touching the hot parts. Children and inexperienced people must not be allowed to use the appliance. NEVER open the door of the boiler stove while it is running. Intended use The automatic operation STAR 18 boiler stove by Klover is designed to heat your entire home. The boiler stove works exclusively with wood pellets and only with the hearth door shut. Never open the door while the device is operating. The boiler stove features a DOUBLE COMBUSTION system guaranteeing clean flue gas emissions with among the lowest CO2 values in Europe, alongside excellent average performance values. Do not use the boiler stove in ways other than those indicated in this user guide. The boiler stove is an indoor product. This user guide is an integral part of the boiler stove. If the product is sold to another user, this manual must be handed down to the new owner. 2

7 KLOVER S.R.L. DECLINES ALL LIABILITY IN CASE OF ACCIDENTS DUE TO FAILURE TO COMPLY WITH THE SPECIFICATIONS OF THIS MANUAL. KLOVER S.R.L. DECLINES ALL LIABILITY DUE TO INCORRECT USE OF THE PRODUCT BY THE USER, UNAUTHORISED MODIFICATION AND/OR REPAIRS, AND USE OF NON-ORIGINAL SPARE PARTS OR SPARE PARTS NOT SPECIFICALLY DESIGNED FOR USE ON THIS PRODUCT MODEL. KLOVER S.R.L. SHALL NOT BE HELD LIABLE FOR THE STOVE'S INSTALLATION. THE INSTALLER IS THE SOLE PARTY RESPONSIBLE FOR THIS OPERATION AND IS ALSO ENTRUSTED WITH CHECKING THE FLUE, EXTERNAL AIR VENT AND THE CORRECTNESS OF THE PROPOSED INSTALLATION SOLUTIONS. ALL THE SAFETY REGULATIONS CONTAINED IN THE SPECIFIC LAWS IN FORCE IN THE COUNTRY OF THE STOVE'S INSTALLATION MUST BE OBSERVED. EXTRAORDINARY MAINTENANCE MUST ONLY BE PERFORMED BY AUTHORISED AND QUALIFIED STAFF. To ensure the validity of the warranty, the user must comply with the indications contained in this guide and, in particular, must: Use the boiler stove within its operational limits; Regularly perform all maintenance activities; Only authorise experienced and competent people to use the boiler stove. Failure to comply with the requirements of this guide shall automatically void the warranty. 3

8 THE MACHINE AND THE PELLETS Connections data sheet REAR VIEW M = Ø ¾ F GAS SYSTEM FLOW R = Ø ¾ M GAS SYSTEM RETURN S = Ø 100 mm M FLUE GAS OUTLET A = Ø 43 mm AIR EXTRACTION DEVICE E = SWITCH WITH ELECTRIC CABLE CONNECTION 4

9 Boiler stove components MAIN SWITCH, CONNECTION FOR POWER SUPPLY CABLE WITH 2 BUILT-IN FUSES (4A 250V) SYSTEM FEEDER CONNECTION WITH PLUG AIR INTAKE PIPE SAFETY THERMOSTAT MANUAL RESET FLUE GAS OUTLET TERMINAL FOR ROOM THERMOSTAT CONNECTION REAR VIEW SYSTEM RETURN CONNECTION SAFETY VALVE CALIBRATED AT 2.5 BAR 8 LITRE EXPANSION VESSEL FLOW CONNECTION WITH CHECK VALVE 5

10 SYSTEM PRESSURE GAUGE FRONT FLUE GAS PASS SCRAPER AIR VENT VALVE WITH RUBBER KEY AND PIPE FRONT VIEW The boiler stove is delivered with the following equipment: 1 - USER, INSTALLATION AND MAINTENANCE GUIDE; 1 - POWER SUPPLY CABLE; 1 - SWAB FOR CLEANING FLUE GAS PASS; 1 - METAL KEY FOR AIR VENT VALVE; 1 - INFRARED REMOTE CONTROL (which should be fitted with a type MN21 12Volt battery - i.e. remote control for automatic gates). This manual is an integral part of the machine: if the stove is sold, it must be passed on to the new owner. 6

11 Technical Specifications Nominal heat capacity (reduced) kw 19.9 (6.2) Nominal heat output (reduced) kw 17.8 (5.6) Nominal thermal power released to heating water (reduced) kw 12.7 (3.3) Nominal thermal power released into the room (reduced) kw 5.2 (2.3) (Reduced) nominal heat performance % 89.8 (90) CO at 13% oxygen at nominal thermal power (reduced) % (0.041) Volume that can be heated at nominal power with a demand of 35 Kcal/m3 (45 Kcal/m3) m (340) Nominal voltage V 220 Nominal frequency Hz 50 Expansion vessel litres/preloading bar 8 / 1 Maximum/recommended working pressure bar 2.5 / 1.5 Chimney draught at nominal power Pa 12.3 Combustion gas flow at nominal power (reduced) g/s 9.0 (7.6) Exhaust flue gas temperature at nominal power (reduced) C (87.5) Hourly pellet consumption at nominal power (reduced) Kg/h 4.12 (1.29) Boiler body capacity litres 12 Minimum safety distance from flammable materials mm 200 Weight Kg 165 The manufacturer reserves the right to effect any modifications to the product in order to improve its performance. The heat output may vary according to the type of pellet used. 7

12 Pellet features The boiler stove has been tested with all types of pellets available on the market. The pellets used must have the following properties: Diameter 6 mm; Maximum length 35 mm; Maximum humidity content 10 %; 100% wood. Total absence of additives. Maximum ash residue 1.1 % For a good boiler stove performance, we recommend using good quality pellets. Pellets should be poured into the tank using a shovel, and not directly from the bag. To identify good-quality pellets, it is necessary that: They are manufactured from constant diameter cylinders and have a smooth, shiny surface; There is not a lot of sawdust inside the packaging; After grabbing a bunch of pellets and placing them into a container filled with water, good-quality pellets will sink and poor-quality will tend to float; The quality certification data, in particular conformity to international standards such as EN Wood pellet class A1-A2 (maximum moisture level of 10%), are indicated on the packaging; The packages are intact, since pellets tend to absorb humidity. Humidity not only reduces the calorific value and increases the amount of flue gases expelled, but may also create problems with the boiler stove. International Standards must be respected during the manufacture of pellets as in France, Austria, Germany and recently in some Eastern countries, also complying with the DIN and the O- NORM M7135 Standards in the production phase. These Standards establish the minimum values in order to check pellet quality. In Italy there is no official Standard, but we recommended the use of pellets that comply with the above Standards. The use of poor quality pellets or any other material can damage the boiler stove's operation, voiding the warranty and exempting the manufacturer from all responsibility. In order to guarantee trouble-free combustion, the pellets must be stored in a humidity-free place. 8

13 REQUIREMENTS OF THE PLACE OF INSTALLATION Positioning The initial phase for good boiler stove installation is to determine the best location; the following elements need to be considered: The possibility of including an external air vent; The possibility of creating a straight flue pipe, preferably coaxial to the boiler stove outlet; Proximity to the main water drain and/or the boiler (if one already exists); Proximity or ease of connection to the water system; Ease of access for cleaning the boiler stove, the exhaust gas ducts and the flue pipe. The stove must be installed on a floor with an adequate load-bearing capacity. If the existing building does not fulfil this requirement, appropriate measures (e.g. load distribution plate) must be taken. Once you have found the best location for the boiler stove, position it following the instructions given below. The minimum safety distance from flammable materials must be at least 200 mm from the sides and back of the boiler stove. Spaces around and above the boiler stove The diagram below indicates the minimum distances to be observed when positioning the boiler stove in relation to the walls. At least 85 cm of free space must be maintained above the boiler stove. It is therefore essential that any shelves and/or false ceilings must be at least this distance from the top of the boiler stove, also to allow the flue gas pass to be properly cleaned. Furniture and mobile objects must be positioned at least 10 cm away from the sides of the appliance; these items should be easily removable in the event of maintenance work and in any case they should be moved before any operation is carried out by the authorised Technical Assistance Centre in order to provide easy access to the sides of the appliance. Protect all structures that can catch fire from heat radiation. External air vent While it is running the boiler stove draws air from the room in which it is installed; It is therefore essential that this air is restored through an external air vent. 9

14 An air vent must be made behind the appliance (15 cm diameter hole), at a height of 20 cm from the ground, near the boiler stove air intake pipe (see figure A and the Connections data sheet). If the rear external air vent does not draw air directly from outside the home, a further hole in an adjacent room must be made, provided this room communicates with the outside of the home (minimum diameter 15 cm). If an air vent cannot be made in the wall behind the boiler stove, the boiler stove should be placed at least 10 cm away from the rear wall and a hole should be made (diameter as above) in a perimeter wall of the room where the boiler stove is installed. The hole must be protected externally with a fixed grille. Periodically check that the grid is not obstructed by leaves or similar, as this may block the passage of air. The UNI Standard FORBIDS the withdrawal of combustion air from garages, combustible material warehouses, or from businesses with a fire hazard. Do not connect the external air vent to the boiler stove via a pipe. If there are other heating or extraction devices inside the room, the air vents must guarantee a sufficient amount of air for properly operating all the devices. Only sealed equipment (e.g. C-type gas devices, as defined by the UNI 7129 C standard) or equipment that does not lower the pressure in the room compared to the outside environment can be housed in the room where the boiler stove is installed. Extractor fans can cause operating problems in the boiler stove when they are installed in the same room or space as the appliance. Fig. A 20 Flue and connection to the latter - Stack The flue pipe is an essential element for the efficient operation of the boiler stove. The minimum crosssection of the flue pipe should be that indicated in the boiler stove specifications (100 mm). Each boiler stove must be equipped with its own flue pipe, without other adjoining elements (boilers, chimneys, stoves etc.). The dimensions of the flue pipe are closely related to its height, which should be measured from the boiler stove flue gas outlet to the base of the chimney stack. In order to guarantee draught, the stack flue outlet surface must be twice as big as the flue cross-section. The discharge pipe for combustion products, generated by the forced draught device, must comply with the following requirements: It must seal off the combustion gases, besides being waterproof and suitably isolated and insulated in relation to the conditions of use (refer to UNI 9615); 10

15 It must be made of suitable materials capable of withstanding normal mechanical stress, heat, and the effects of combustion gases and condensate, if any; It must go upwards after the vertical section, for the entire remaining part, with 5% minimum gradient; The sub-horizontal section must not have a length greater than ¼ of the actual height of the flue or chimney, and must not be longer than 2,000 mm; It must preferably have a round internal cross-section: square or rectangular cross-sections must have rounded corners with radius not inferior to 20 mm; It must have a constant, free and independent internal cross section; Rectangular cross-sections must have a maximum ratio of 1.5 between the sides; If the flue is installed outdoors or in a cold room (e.g. boiler room) it is absolutely necessary that it is insulated to prevent cooling of the fumes and the formation of condensate; Parts made from non-combustible materials - capable of withstanding combustion gases and potential condensation - must be used for mounting the flue gas pipes (for the section from the appliance to the flue inlet); It is forbidden to use fibre cement pipes to connect the appliance to the flue; Flue pipes must not pass through rooms in which the installation of combustion devices is prohibited; The flue pipes must be assembled in such a way as to guarantee adequate sealing of flue gases during low pressure operation of the appliance; The assembly of horizontal sections is forbidden; It is prohibited to use counter sloping elements; The flue gas pipe must allow for the recovery of soot or be cleanable, and must have a constant crosssection; It is forbidden to allow other air intake conduits and system pipes to transit inside the flue gas pipes, even if over-sized. The stack is the end section of the flue, and is used to facilitate dispersion of combustion by-products. It must satisfy the following requirements: It must have a usable outlet cross-section no less than double that of the flue onto which it is inserted; In must be shaped in such a way as to prevent rainwater or snow from seeping into the flue; It must be built in such a way as to ensure the discharge of combustion by-products even in case of winds from every direction and with any inclination. The outlet height (where height refers to the top of the flue, regardless of any chimney stacks), must be outside of the so-called reflux zone, in order to prevent the formation of counter-pressures preventing the free discharge of combustion by-products into the atmosphere. It is therefore necessary that the minimum heights - indicated in the following diagrams - are observed: 11

16 FURTHER SPECIFICATIONS TO BE CONSIDERED The stove functions with the combustion chamber in depression; it is fundamental that the exhaust is hermetically sealed. We recommend using rigid stainless steel pipes having a minimum diameter of 100 mm, with sealing gaskets. The pipes must have a double wall or be suitably insulated with rock wool. The maximum temperature of the pipe must not exceed 70 C. IT IS MANDATORY TO HAVE A FIRST VERTICAL SECTION OF AT LEAST 1.5 METRES IN ORDER TO GUARANTEE CORRECT FLUE GAS DISCHARGE. Every direction change must be carried out with T-shaped fitting and inspection cap. The pipes must guarantee sealing against flue gas via suitable gaskets capable of resisting 250 C. Fix the pipes to the wall with the relevant metal collars in order to prevent any vibrations. ATTENTION: IT IS FORBIDDEN TO INSTALL DRAUGHT REGULATION VALVES (BUTTERFLY VALVES). If a traditional flue is used for discharging flue gas, make sure that it is in good working order and that it complies with the applicable standards. If the flue is too large (internal diameter greater than 14 cm), duct the flue using an appropriately insulated stainless steel pipe (using rock wool or vermiculite) sized according to the relevant route. The connection to the flue must be appropriately sealed. When assembling the flue, there must be no more than 4 direction changes, including the initial T- shaped fitting. The maximum allowed length of the horizontal section is 2 metres. Before effecting horizontal movements, there must be a vertical section of at least 1.5 metres. 12

17 ELECTRICAL CONNECTION The electric connection must be performed by qualified staff only, in conformity to all general and local safety standards in force. Check that the power supply voltage and frequency correspond to 220V 50 Hz. The appliance's safety is ensured when it is properly connected to an efficient earthing system. In the electric connection to the mains power supply, include a 6 A Id 30 ma differential trip-switch with suitable breaking load. The electric connections, including earthing, must be made after shutting off the electrical system. When completing the system, bear in mind that the cables must be laid in an unmovable manner and far from parts subject to high temperatures. During the final wiring of the circuit, only use components with a suitable electrical protection rating. KLOVER srl declines all responsibility for injury to persons and animals or damage to objects due to failure to connect the boiler stove to earth or failure to comply with IEC specifications. The electronic control unit manages and controls all the boiler stove functions, and ensures optimal operation of the appliance at all times. Control of any coupled boiler If the STAR 18 boiler stove is to be coupled with a previously installed boiler in the system (e.g. wall-hung gas boiler), it must be ensured that the standard boiler stops when the pellet-fired boiler stove takes over doing the heating. This is to make sure that you do not have to add up the heat output of the two appliances installed on the system. This is why our set-up intervenes on the coupled boiler when the pellet-fired boiler stove heating pump starts. In this way, there will never be two boilers functioning simultaneously on the same system. The coupled boiler is however always available for the production of domestic hot water. The two wires prepared on the back of the boiler stove (blue and brown wires) will have an output voltage of 220 V when the pellet-fired boiler stove pump is working, and no voltage when the pump stops. It is therefore easy to connect the 2 wires to a relay that will control the Room Thermostat input of the coupled boiler. 13

18 Connection to the room thermostat A bridge clamp is installed on the rear of the boiler stove (free contact), which is useful to connect any room thermostat. In this way, connecting an external thermostat with the function to open or close the contact depending on the heat demand will be easier. OPERATING PRINCIPLE Open contact: 1. The boiler stove switches directly to economy mode operation T-OFF ECONOMY, reducing the working power to a minimum. 2. The boiler stove pump is switched off. 3. The temperature in the boiler stove increases due to thermal inertia until reaching the SET H2O temperature, showing T-H2O ECONOMY on the display 4. At this point, the stove will switch off automatically if at least one of the following conditions occurs: it remains in economy mode operation T-H2O ECONOMY for a time set on Pr44 (30 minutes default setting); the temperature differential set on Pr43 (factory set value 5 C) or H2O Temperature > ( SET H2O + Pr43 ) is exceeded. N.B.: table). The pump is calibrated to start at temperatures 83 C in all conditions (see parameter The boiler stove will switch on automatically if both the following conditions arise: The contact of the room thermostat is closed. It goes below the temperature differential set on Pr43 (5 C default setting) or H2O Temperature < ( SET H2O Pr43 ). If the above-mentioned condition occurs when the boiler stove is still carrying out the switch-off cycle, please wait until the cycle is complete. 14

19 PLUMBING CONNECTION The plumbing connections must be made in a rational way using the connections on the boiler stove template. To facilitate the connection of the pipes, we have provided all plumbing connections on the rear left side, leaving space to make the appropriate connections. Remove the side panels on the boiler stove to facilitate connection to the plumbing system. The boiler stove can be coupled with any other boiler already installed on the system. In this case it is essential to fit all the necessary safety devices and shut-off valves based on the system and intended use. N.B.: The boiler stove can be installed with the expansion vessel closed because it is equipped with a device for stopping fuel loading, a safety manual reset thermostat and an audible alarm, which are activated if temperature becomes too high. The boiler stove may be installed in the same room as another boiler only if this boiler is a sealedchamber device. THE STOVE MUST BE FITTED EXCLUSIVELY BY QUALIFIED PERSONNEL. STRICTLY COMPLY WITH THE INSTRUCTIONS GIVEN IN THIS GUIDE; IN THE EVENT OF ANY DOUBT CONTACT THE TECHNICAL ASSISTANCE CENTRE. THE MANUFACTURER DECLINES ANY RESPONSIBILITY FOR DAMAGES CAUSED BY INCORRECT ASSEMBLY. THE MAXIMUM MAINS WATER PRESSURE SHOULD NEVER EXCEED 3 BAR; RECOMMENDED OPERATING PRESSURE: 1.2 BAR. DO NOT PASS ELECTRIC CABLES IN THE IMMEDIATE VICINITY OF THE FLUE GAS PIPE, UNLESS THEY ARE INSULATED WITH APPROPRIATE MATERIALS IN THE EVENT OF WATER WITH HARDNESS EXCEEDING 28 f, AN ANTI-LIMESCALE DEVICE MUST BE INSTALLED. THIS MUST BE SELECTED ON THE BASIS OF THE SPECIFIC PROPERTIES OF THE WATER. 15

20 CLEANING AND MAINTENANCE Precautions before cleaning Before carrying out any cleaning or maintenance operations, make sure that: The boiler stove is off and has cooled down completely; The ash is completely cold; Before re-starting the boiler stove, re-install all previously disassembled parts. For cleaning operations, personal protective equipment should be worn.i.e. gloves, goggles and dust masks, as directed in eu 89/391/EEC. The cleaning frequency depends on the type and quality of the pellets used. The schedule indicated below may therefore vary. Any problem affecting the boiler stove due to a lack of cleaning will not be covered by the warranty. Routine cleaning The boiler stove requires regular cleaning at least every 20 hours of operation or after 3-4 ignitions, so as to always guarantee efficient performance and optimal operation. Carefully clean any combustion residues from the brazier, by removing it from its housing. Use a vacuum cleaner to remove the ash deposited under the brazier. 16

21 Empty the ash drawer. After having removed the upper top, repeatedly operate the side rods in order to clean the side flue gas pass. ATTENTION: use suitable bin type vacuum cleaners equipped with a fine mesh filter, in order to prevent part of the ash from being spilled and thus damaging the cleaner itself. 17

22 Extraordinary cleaning To be performed at least every 15 days. Perform routine cleaning; Repeatedly operate the front rod in order to clean the front flue gas pass. Use the swab provided to clean the elements above the combustion chamber. 18

23 After having removed the ash drawer, extract the underlying base. Do not force the flue gas intake device flaps with the ash vacuum cleaner hose. Use a suitable ash vacuum cleaner to remove the internal residues then re-position the base and ash drawer. 19

24 After having opened the door, unscrew the hand wheels and remove the side plates underneath the combustion chamber. Vacuum the deposit inside using a suitable vacuum cleaner and then close the ducts; make sure the plates have been securely fastened. 20

25 To ensure correct operation, it is necessary to remove the sawdust deposited on the base of the tank at least once every 15 days. The pellet tank must be emptied at the end of every season. Cleaning the ceramic glass Always clean the glass when the boiler stove is off and completely cold. Use a damp cloth or a detergent specifically formulated for ceramic glass. Do not use abrasive sponges. Cleaning the flue This operation must be performed at least twice a year, at the beginning and half-way through the winter season, and - at all events - whenever necessary. It is important to check for any obstructions in the flue pipe before switching the boiler stove on following long periods of disuse. If cleaning is not performed, the operation of the boiler stove and its components may be jeopardised. The cleaning frequency of the boiler stove and flue pipe depends on the quality of the pellets used. USE TOP QUALITY PELLETS TO OBTAIN THE BEST RESULTS. Maintenance Timely and systematic maintenance is essential for guaranteeing correct operation, optimal heat performance and durability of the appliance. Therefore, qualified technicians should check the stove at least once a year at the beginning of the season. It is advisable to stipulate an annual contract for product maintenance with the Authorised Technical Assistance Centre (TAC). 21

26 THE DISPLAY The device's operating mode is displayed on the console. After turning on the menu, it is possible to choose many types of visualisations and perform the available settings according to the selected menu. The diagram below shows the display when the unit is in on or off mode. CLOCK ROOM TEMPERATURE (optional) 1 Set ! 17: C OFF 6 DIALOGUE WATER TEMPERATURE 1st LED SERIES 2nd LED SERIES 1 6 Set ! The diagram below shows the meanings of the status signals shown on the left side of the display (1st LED SERIES). ROOM THERMOSTAT: the LED lights up when the room thermostat contact is open. PROGRAMMABLE THERMOSTAT: the LED lights up when at least one start-up and switch-off program is active. IGNITION HEATING ELEMENT: the LED is on when ignition heating element is active. SCREW FEED: the LED lights up when the pellet loading gear motor is started. FLUE GAS EXTRACTOR: the LED lights up when the flue gas extractor is active. DHW FLOW SWITCH: the LED lights up when the DHW flow switch contact is closed (which means there is demand for hot water). NOT USED ON THIS PRODUCT PUMP: the LED lights up when the system circulation pump is active.! ALARM: the LED lights up when the boiler is in a state of alarm. 22

27 The diagram below shows the meanings of the status signals appearing on the top right side of the display (2nd SERIES LEDs) the LED lights up when the programmable thermostat daily program is active. 2 the LED lights up when the programmable thermostat weekly program is active. 3 the LED lights up when the programmable thermostat week-end program is active. 4 the LED lights up (flashing) when the operating parameters are being edited. 5 the LED lights up when the summer function is active (NOT USED ON THIS PRODUCT). 6 the LED lights up when the winter function is active. 7 the LED is not currently used. The following diagram shows the display when setting or programming operating parameters. INPUT 1 Set ! On M TIMER DAY 6 DIALOGUE MENU LEVEL The INPUT area shows the entered programming values. The MENU LEVEL area shows the current parameter/menu level. The DIALOGUE area displays the meaning of the current parameter/menu. BUTTON DESCRIPTION MODE ACTION 1 Increase temperature (1) 2 Decrease temperature Programming mode.. Working/off.. Programming mode.. Working/off.. Changes/increases the value of the selected menu item. Increases the DHW thermostat temperature value. Changes/decreases the value of the selected menu item. Decreases the DHW thermostat temperature value. 3 Set - Accesses the selected menu. Menu mode.. Accesses the next level of submenus. 23

28 Working.. Switches the boiler stove on and/or off when pressed for 2 seconds. 4 ON/OFF Outlet In alarm block.. Releases alarm Menu/programming mode.. Moves you to the next menu level up, storing the changes made. Working/off.. Decreases the boiler stove working power. 5 Decrease power 6 Increase power (2) Menu mode.. Programming mode.. Working/off.. Menu mode.. Programming mode.. Moves you to the next menu item. Moves you to the next submenu item, storing the changes made. Increases the boiler stove working power. Moves you to the previous menu item. Moves you to the previous submenu item, storing the changes made. (1) One press selects SET WATER TEMPERATURE SET H2O. (2) One press selects WORKING POWER SET POWER. 24

29 THE MENU Access the Menu by pressing key 3 (Set). The latter is divided into different entries and levels accessing the PCB programming and setting options. Buttons 5 and 6 allow for scrolling the menus to be modified. Individual menus can be modified using keys 1 and 2. The menu options that provide access to technical programming features (parameters reserved for the Technical Assistance Centre) are protected by a password. Listed below are the menus present on the PCB, with the different explanations. 1. Menu 01 Set clock Sets current date and time. 2. Menu 02 Set timer Sub-menu enable timer Allows for globally enabling and disabling all programmable thermostat functions. Submenu daily program Allows for enabling, disabling and setting the daily programmable thermostat functions. Two operating time slots can be set according to the following table, where OFF signals the clock to ignore the command: MENU LEVEL SELECTION MEANING POSSIBLE VALUES START 1 Start time Time OFF STOP 1 Switch-off time Time OFF START 2 Start time Time OFF STOP 2 Switch-off time Time OFF Sub-menu weekly program Allows for enabling, disabling and setting the weekly programmable thermostat functions. The weekly programmer has 4 independent programmes, the end effect of which combines the 4 individual settings. The weekly programmer can be enabled or disabled. In addition, by setting OFF in the time field, the clock ignores the corresponding command. PROGRAM 1 MENU LEVEL SELECTION MEANING POSSIBLE VALUES START PROG 1 Start time Time OFF STOP PROG 1 Switch-off time Time OFF MONDAY PROG 1 On/off TUESDAY PROG 1 On/off WEDNESDAY PROG 1 On/off THURSDAY PROG 1 Days of reference On/off FRIDAY PROG 1 On/off SATURDAY PROG 1 On/off SUNDAY PROG 1 On/off 25

30 PROGRAM 2 MENU LEVEL SELECTION MEANING POSSIBLE VALUES START PROG 2 Start time Time OFF STOP PROG 2 Switch-off time Time OFF MONDAY PROG 2 On/off TUESDAY PROG 2 On/off WEDNESDAY PROG 2 On/off THURSDAY PROG 2 Days of reference On/off FRIDAY PROG 2 On/off SATURDAY PROG 2 On/off SUNDAY PROG 2 On/off PROGRAM 3 MENU LEVEL SELECTION MEANING POSSIBLE VALUES START PROG 3 Start time Time OFF STOP PROG 3 Switch-off time Time OFF MONDAY PROG 3 On/off TUESDAY PROG 3 On/off WEDNESDAY PROG 3 On/off THURSDAY PROG 3 Days of reference On/off FRIDAY PROG 3 On/off SATURDAY PROG 3 On/off SUNDAY PROG 3 On/off PROGRAM 4 MENU LEVEL SELECTION MEANING POSSIBLE VALUES START PROG 4 Start time Time OFF STOP PROG 4 Switch-off time Time OFF MONDAY PROG 4 On/off TUESDAY PROG 4 On/off WEDNESDAY PROG 4 On/off THURSDAY PROG 4 Days of reference On/off FRIDAY PROG 4 On/off SATURDAY PROG 4 On/off SUNDAY PROG 4 On/off Sub-menu week-end program Allows for enabling, disabling and setting the weekend (Saturdays and Sundays) programmable thermostat functions. TIP: in order to avoid confusion and any undesired switching on/off operations, only activate a single programme at a time if you do not know exactly what you desire obtaining. Deactivate the daily programme if you wish to use the weekly programme instead. If you use the weekly program in programs 1, 2, 3 and 4, always keep the week-end program disabled. Only enable week-end programming after disabling the weekly program. 3. Menu 03 Choose language Allows you to select the dialogue language from the available choices (Italian, English, French, German and Spanish). 4. Menu 04 Enables T.A. contact (NOT USED ON THIS PRODUCT) 26

31 5. Menu 05 3-Way Valve Threshold (NOT USED ON THIS PRODUCT) 6. Menu 06 Acoustic alarm Allows for enabling or disabling acoustic signal in case of alarm. The acoustic alarm is only available on the boiler stove PCB, and not on the external remote control. 7. Menu 07 Initial load Allows pellet pre-loading to take place for 90 seconds with the boiler stove off and cold. Start the function with button 1 and stop with button 4. Useful if the boiler stove is ignited once the tank has been fully emptied or the first time it is filled. 8. Menu 08 Stove status It displays the instantaneous status of the boiler stove, by showing the status of the various devices connected to it. Several pages are displayed in succession. As the reported data is reserved for the Technical Assistance Centre, we recommend not accessing this menu. 9. Menu 09 Technical calibration Allows for accessing all data reserved for the Technical Assistance Centre. Access is protected by a password. Unauthorised access can cause serious damage to the equipment and the environment as well as personal injuries. 27

32 INITIAL START-UP Filling the system for the first time After connecting the boiler stove, fill the system as follows: Check the seal of all piping, the expansion vessel, and the circulation pump; Open the manual air release valve on the boiler stove; Load the system very slowly to allow any air to escape from the boiler stove through the manual air release valve ; the optimum operating pressure is 1.2 bar; If necessary, very slowly loosen the pump vent plug, draining the fluid for a few seconds; Vent all radiators and any other de-aeration systems to ensure that there are no air bubbles in the system. After installation, check the seal of all hydraulic joints for the first few days of operation. The boiler stove system can be emptied using the boiler body and system drain cock. In intensely cold periods it is good practice to leave the heating system running. In the event of a prolonged absence, anti-freeze must be added to the heating water or the system must be completely emptied. In a system subject to being emptied frequently, it is essential that filling is performed with water suitably treated to remove hardness which can give rise to scaling. Pellet loading and connection to the electricity network Perform the following operations: Connect the boiler stove to the electrical system using the cable supplied; Set the main ON/OFF switch situated behind the boiler stove to (on); Fill the pellet tank; for the first ever ignition, to avoid wasting the time required for filling the entire screw feed channel (this should be done every time the boiler stove runs out of pellets), we recommend using what is mentioned in MENU 07 INITIAL LOAD; Switch on the boiler stove using the dedicated ignition button on the control panel. See the instructions below. We recommend using high-quality pellets so as to avoid jeopardising the boiler stove's functions. Damages caused by poor-quality pellets shall not be covered by the warranty. Boiler stove ignition cycle Pressing button 4 (ON/OFF) for a few seconds starts the boiler stove ignition cycle. After a while, the display shows START, and the flue gas extractor and ignition heater element are switched on. After 40 seconds, the boiler stove switches to a pre-loading phase ( PELLET P-LOAD ) useful to quickly fill the brazier with pellets. The boiler stove goes into FLAME STAND-BY after the pre-loading phase. When the flame is lit, the display shows the message FIRE. This step allows the fire to spread evenly across the brazier. After these steps, the boiler stove enters work mode at the pre-set power output. In the event of no pellet ignition, the boiler stove goes into NO IGNIT- alarm. This alarm may also occur if the brazier is dirty; in this case, clean the brazier and re-start the boiler stove. 28

33 Summary: The ignition cycle can last 25 minutes max. and is divided into four steps: 1 - START: Flue gas extractor start up duration - 40 seconds 2 PELLET PRE-LOAD: Pellet pre-load (initial continuous load) and heater element start up Pr40 = ignition pre-load time 3 - FLAME STAND-BY: pellet load (intermittent load) and heater element in operation Pr01 - Pr40 = ignition cycle maximum time ignition pre-load time 4 - FIRE PRESENT : Heater element switches off and flame stabilization Pr02 = start time The boiler stove switches into working mode at the power output set during ignition via buttons 1 and 2. Boiler stove working mode During the working phase, you can set SET H20 (water working temperature in the boiler stove) by pressing button 1. When this temperature is reached, the boiler stove enters economy mode operation T- H2O ECONOMY. Before reaching the temperature set for SET H20 the boiler stove starts modulating output by decreasing the pellet intake and reducing the flue gas suction speed. Example: SET H2O set at 75 C Working power set at 5 - Working power automatically changes to 4 when the temperature reaches Working power automatically changes to 3 when the temperature reaches 72 C. - Working power automatically changes to 2 when the temperature reaches 73 C. - Working power automatically changes to 1 when the temperature reaches 74 C. - Working power automatically changes to economy mode operation when the temperature reaches 75 C. T-H2O ECONOMY. At this point, the stove will switch off automatically if at least one of the following conditions occurs: it remains in economy mode operation T-H2O ECONOMY for a time set on Pr44 (30 minutes default setting); the temperature differential set on Pr43 (factory set value 5 C) or H2O Temperature > ( SET H2O + Pr43 ) is exceeded. The boiler stove will automatically switch on if: It goes below the temperature differential set on Pr43 (5 C default setting) or H2O Temperature < ( SET H2O Pr43 ). If the above-mentioned condition occurs when the boiler stove is still carrying out the switch-off cycle, please wait until the cycle is complete. The brazier is cleaned at pre-set time intervals (indicated on the display with BRAZIER CLEANING ) for an established duration (see parameters table). 29

34 Switching off the boiler stove Pressing button 4 (ON/OFF) switches off the boiler stove. The display will show FINAL CLEANING. Pellet loading is stopped, turning off the gear motor. The flue gas extractor speed is increased to maximum and switched off after the appliance has cooled, displaying "OFF. Changing the room and water temperature settings. - Water Temperature Press key 1 and select SET H2O to change the water temperature. Then press keys 1 and 2. During this operation, the display appears as shown in the figure C 6 Set ! SET H2O After setting the desired value, press button 4 or wait a few seconds. The stove will enter economy mode upon reaching this temperature. At this point, the stove will switch off automatically if at least one of the following conditions occurs: it remains in economy mode operation T-H2O ECONOMY for a time set on Pr44 (30 minutes default setting); the temperature differential set on Pr43 (factory set value 5 C) or H2O Temperature > ( SET H2O + Pr43 ) is exceeded. Alarm signals In case of operating anomalies, the PCB intervenes and signals the malfunction by operating in different modes depending on type of alarm. The following alarms are signalled on the PCB. DISPLAY VISUALISATION AL 1 BLACK OUT ALARM ORIGIN OF ALARM Black-out alarm. When power is cut off under determined conditions(see What happens if ) AL 2 FLUE GAS PROBE ACTIVE ALARM Faulty or disconnected flue gas temperature sensor. AL 3 HOT TEMP ACTIVE ALARM Flue gas over-temperature. When the flue gas temperature exceeds 260 C. The display shows the wording HOT FLUE GAS before displaying the alarm, or when flue gas maximum temperature is reached (Pr14). AL 4 FAULTY INTAKE DEV- ACTIVE ALARM Faulty flue gas extractor. When the encoder (tachometer) in the extractor detects an extractor speed equal to 0. AL 5 NO IGNIT- ACTIVE ALARM No ignition. When the flue gas minimum temperature (Pr13) is not reached within the maximum ignition cycle time (Pr01). 30

35 AL 6 NO PELLET ACTIVE ALARM Sudden switch-off during the work phase. When, during the work phase, the flue gas temperature drops below the minimum threshold (Pr13). AL 7 SAFETY-TEMP. ACTIVE ALARM Temperature safety device. When the safety thermostat (water over temperature) or fire door micro switch (contact interrupted) cuts in. If the safety thermostat cuts in the boiler stove must be manually rearmed. AL 8 DEPRESS.-FAILURE ACTIVE ALARM Poor depression. When the flue gas pressure switch cuts in (contact interrupted) due to poor draught in the flue pipe. AL 9 WATER PROBE ACTIVE ALARM Faulty or disconnected water temperature probe. AL c SF TRIAC ERROR ACTIVE ALARM Screw feed TRIAC error. When the screw feed gear motor does not stop for at least 0.2 seconds during the maximum work interval of 8.0 seconds. Before the alarm is activated a safety relay cuts in and forcibly cuts off the power supply to the gear motor. Every alarm causes the device to switch-off immediately. After the time set on Pr11 (alarm delay) the alarm state is reached; press key 4 to reset it. Useful info. Listed below is some important information regarding the equipment: It is normal for the device to emit a smell of paint during its first few days of operation. The first time the boiler stove is ignited, we recommend keeping the installation room ventilated. For the first few days its operation, we also recommend running the device at maximum power. The boiler body is treated with an anti-rust paint to protect it against oxidation during long periods of disuse. After initial start-up, the paint no longer preserves these features and any wearing of the paint inside the combustion chamber must not be regarded as a product defect. Any perceived noise may be due to the boiler body's settlement expansion and must not be regarded as a manufacturing defect. This noise is perceived especially when igniting and switching off the device. In the event of an air ventilation system failure, the boiler stove should not be used under any circumstances in order to avoid overheating. 31