PELMAX HEATING BOILER FOR SOLID FUEL

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1 PELMAX HEATING BOILER FOR SOLID FUEL INSTALLATION, SERVICE AND MAINTENANCE MANUAL OF THE BOILER Member of the NIBE Group Issue Changes reserved

2 Installation, service and maintenance manual of Pelmax boiler 5 Generally Security Comments with regard to instructions Application and installation of a heating boiler Information on the boiler room Information on safe use STB temperature limiter of the boiler Overcurrent switch Burner protection Information on ventilation Information on the chimney Product description PELMAX heating boiler Structure of PELMAX boiler PBMAX burner Adjustment of burner operation Burner structure scheme Technical specifications Installation of the device Placement of the boiler Distances from walls Levelling the heating boiler Equipment of the boiler Assembly and connection of the system Connection to the flue gas discharge system Connection to the heating system Electric connection Installation of the burner Fuel container and wormwheel feeder Feeding pellet Start-up and operation of the boiler Basic fuel Starting the burner Extinguishing Alternative fuel Adaptation of PELMAX boiler for combustion of alternative fuel Burning on the additional grate Reviews and maintenance activities PELMAX boiler Cleaning from soot PBMAX burner Cleaning /removal of ash Annual maintenance or when needed (performed by the installer) CE marking

3 Operating instruction of the Pelmax boiler regulator Generally Introduction Advantages Safety precautions Proceeding with worn equipment Connection to the system Electrical installation Connection Direct connection of devices Review of basic functions Control panel Status LED Buttons Graphic display Furnace statuses Handling Navigation in the menu Start-up of the regulator - ON Turning off the regulator - OF Time programs Service password Simple menu Simple menu screens Main menu Heating Selection of the circuit Status Settings Time program Service Utility water Selection of the circuit Status Settings Time program Service Buffer Status Settings Time program Service Boiler Status Settings Service Settings Date and time Language General settings

4 Alarm buzzer Service Configuration of modules System configuration Restore factory settings Burner Status Settings Service Alarms Alarm codes Solar collectors Status Settings Service Info Expansion of the system - CAN bus Sample hydraulic schemes Lambda probe Solar collectors Specification

5 Generally Thank you for trust and for choosing our heating boiler and, at the same time, we congratulate on the choice of the model. It is a high-quality universal heating boiler with long life span, prepared and manufactured by NIBE- BIAWAR Sp. z o.o., Al. Jana Pawła II 57, Białystok, phone no In order to obtain the highest efficiency of the boiler of PELMAX type read carefully the instruction, service and maintenance manual and follow recommendations and comments concerning correct and safe service and operation of the device. PELMAX boiler is adapted to operation in open or closed systems. Remember to protect the system in accordance with valid regulations. In the case of boiler operation in an open system, protection of the system should be performed according to standard PN - 91/B-02413, whereas, in the case of work in a closed system-according to standard PN-B PELMAX boiler is applied in residential, one and multi-family buildings, guesthouses, sales pavilions etc. PELMAX boiler, along with PBMAX burner, is a device with high power efficiency up to 92%, a considerable functionality and modern design. The structure of the device refers to many years of tradition and experience of the Swedish concern NIBE in manufacturing solid fuel boilers. The basic fuel of the boiler is modern, ecological fuel in the form of granulated timber product - pellet. The burner applied in the device provides minimum consumption of pellet in relation to received heat power, which is reflected in economics of work and comfort of use of the boiler. A clear asset of PELMAX boiler is the possibility to use additional grate for combustion of alternative fuel in the form of wood logs. When necessary, (e.g. if there is no fuel), you can use alternative fuel, preserving, at the same time, high efficiency of the boiler. PELMAX boiler is characterized by small structure and the applied operation solution that facilitate its functioning. With our expanded electronic control, we can control many parameters of the device's operation, adapting it to different installation conditions and individual needs. The manual applies to PELMAX boiler with PBMAX burner Applied symbols The manual uses the following graphic symbols: TIP - the symbol means useful information and tips. - The symbol means important information on which destruction of property, hazards to health or life of people and domestic animals can depend. Note: the symbols have been used to mark important information in order to facilitate familiarizing with the manual. This does not exempt the user and the installer from compliance with the requirements not labelled by means of graphic symbols! The product is not intended for use by people with reduced physical /mental fitness or without experience and knowledge, if these people are not supervised or instructed by the person responsible for their safety. It is not allowed to let children operate the device. The possibility of introducing structural changes and changes in the manual is reserved. NIBE-BIAWAR

6 1. Security 1.1. Comments with regard to instructions PELMAX boiler has been built according to the latest technology and on the basis of the valid regulations on technical safety. However, inappropriate use of the device resulting from non-observance of this manual can lead to damage of the boiler, as well as the danger for the user or other people. Before beginning installation and service of the device, please become acquainted with the present manual. The manual presents information on safe and proper installation, first start-up, operation and proper maintenance of the heating boiler. PELMAX heating boilers for solid fuel, below in the manual, will be generally called the heating boiler or the boiler Application and installation of a heating boiler The heating boiler is intended for heating one and multi-family houses, public buildings, guesthouses etc. The boiler is adapted to combustion of solid fuels in the form of timber pellet and, in emergency situations, alternative fuel in the form of pieces of wood of appropriate humidity (see item 6.2. Alternative fuel). The boiler should be connected to a chimney with proper dimensions, ensuring appropriate line adapted to the efficiency of the boiler. Correct operation depends on professionally performed installation, an appropriate chimney draught, but also on correct operation and maintenance of the device. Installation of the boiler in an open system must be protected in accordance with valid regulations: PN - 91/B "Heating and heat engineering. Protection of the installation of water heating of an open system. Requirements." While installing the boiler in a closed system, it should be equipped with devices discharging the excess of heat, and protected in accordance with valid regulations: Journal of Laws of 2009, No. 56 item 461, Polish Standard PN-B "Heating and heat engineering. Protection of water heating systems of closed system with diaphragm collecting vessels. Requirements." Connection, protection operation of the boiler and of the heating system must correspond to national regulations and this manual. As a result of improper connection, damages may arise, for which the manufacturer is not responsible. Before connecting the boiler to the heating system, flush it with water in order to remove dirt that could damage the system. TIP Use only original spare parts. NIBE-BIAWAR bears no responsibility for any damages arising as a result of using spare parts of other manufacturers. Do not touch, with a bare hand, door and other elements which have a direct contact with a flame, as there is a risk of burn. The boiler should be operated using suitable protective clothing. The device is powered with electric current 230V/50Hz. Incorrect installation or improper repair may result in hazard to life through electrocution. Electric connection may be performed only by a person with proper qualifications and licenses Information on the boiler room The boiler room should be made according to the binding standard: PN-/B "Heating. Boiler rooms for solid fuel. Requirements." There is a risk of asphyxiation with carbon monoxide when the boiler is located in the room with insufficient supply of fresh air. It is not allowed to diminish or close inlet or exhaust holes. It is not allowed to store flammable materials in the immediate vicinity of the boiler. 6

7 1.4. Information on safe use During operation, observe fire safety regulations. The heating boiler may be operated only by adults, and after having read the operation manual. Near the operating boiler, there can be no children without the supervision of adults. Us only the indicated fuel. It is not allowed to use liquid fuels (gasolines, solvents etc.). It is not allowed to spray, inject or pour liquid fuel to heat or fire. Do not open the door of the combustion chamber during operation of the device. The door of the boiler can be open only after extinguishing and cooling the boiler. Even after longer time of waiting for cooling, the temperature inside the boiler may be very high. When delivering the heating boiler, carefully check compliance and completeness of the delivery. Maximum temperature, with which the heating boiler may operate is 85 C, temperature should be controlled periodically. Ash should be removed to a container made of non-flammable materials. In the case when the boiler is not used for a longer period, at its restarting, increased caution is necessary. To cleaning the boiler's heating surfaces, use only non-flammable substances. On the boiler and in its close environment, there can be no flammable materials STB temperature limiter of the boiler Boiler automation protects the boiler in case of overheating, with non-automatic STB protection. It is a mechanical protection, which do not require power supply. STB actuation temperature is 89 C-99 C. After exceeding the acceptable operation temperature, STB will cause total deactivation of the burner and interruption of the boiler operation (until manual activation of STB). After actuation of STB, its second activation can be performed only after cooling the boiler to the temperature below 80 C-the current temperature of the boiler operation is signalled on the display. In order to activate STB, (see Fig. 1): 1. Disconnect the boiler from electrical supply. 2. Open the doors of the boiler and unscrew two screws (torx 20) fixing the front panel of the boiler. 3. The panel of the boiler, apart form screws, is fastened with latches. Carefully pull out the panel, paying attention to connection wires of the controller. 4. Press the button of STB limiter of the boiler's temperature. The button is located on the left side of the thermostat, looking from the front part of the front panel of the boiler. After switching on STB, reassemble the panel of the boiler, and then switch on the boiler in the power supply network. After starting the controller, approve STB alert (see item: Alarms). When removing fastening screws of the front panel of the boiler, extra caution should be maintained, because elements of the furnace chamber and the burner may have high temperature. In the case of firing with alternative fuel on the additional grate, remember that actuation of STB limiter does not guarantee protection against further increase in the boiler's temperature. TIP After actuation of STB temperature limiter, analyze and determine the cause of overheating of the device and only after it has been removed, once again turn on STB. If a situation of STB disconnection is repeated, report this to an authorized service point. The boiler is equipped in sensor of boiler door opening that turns off the boiler when you open the door of the boiler and the boiler can not start if the door unclosed (Fig. 1). Opening the door during operation of the boiler may damage boiler elements placed over the doors by the operation of flame and high temperature. Opening the door of the combustion chamber is possible only after extinguishing and cooling the boiler at that time. Prior to the commencement of works both on the STB safety thermostat and the burner temperature limiter, power supply should be disconnected. 7

8 Burner protection The burner has been equipped with two systems protecting against flame withdrawal, i.e. with a temperature limiter and with a self-extinguishing, flexible goffered pipe. If the temperature limiter on the charging channel detects heat (> 90 C), the limiter cuts off power supply to the burner and the pellet feeder. Before restarting the burner, it should be reset. This activity is made by disconnection of power source, unscrewing the casing and pressing a small "resetting plate" placed on the casing of STB limiter. Before restarting the, screw the casing again and then switch on the regulator and remove (by approving it by pressing "Enter") the alarm "Burner safety" (see item Alarms). Fig. 2. Burner temperature limiter PBMAX. The burner is also equipped with a switch placed on burner installation frame. This switch prevents startup of the burner removed from the boiler doors, it also prevents start-up of the burner in the case when it is improperly tightened (too lightly). Fig. 1. Switching on STB limiter of the boiler's temperature Overcurrent switch The boiler is internally protected with 10A overcurrent switch, located under the front panel of the device (Fig. 3 item 9), that protects the device against the effects of overloads and short-circuits. Access to the overcurrent switch can be obtained after dismantling the front panel of the boiler (disassembly of the front panel is described in item STB limiter of the boiler's temperature) Information on ventilation. The boiler room should have non-closed inlet channel with the total area of at least 200 cm 2. The exhaust channel should have a section not smaller than 14x14 cm, with an inlet opening under the ceiling of the room, introduced over the roof and placed next to the chimney. The inlet opening to the exhaust channel should have free section equal to the section of the channel. The exhaust channel and the inlet opening to it must not have devices for closing. Ventilation ducts should be made of nonflammable materials. 8

9 1.6. Information on the chimney. PELMAX boiler is equipped with a pin, external diameter: 140 mm. The lowest recommended height of the chimney with the diameter of 160 mm at the heating power of the boiler kw is 7 m. The draught in the chimney is important and should be at least 18 Pa. In order to obtain the highest combustion capacity and the lowest possible degree of harmfulness for the environment, it is recommended to install a chimney draught regulator. Before installation, the smoke duct should undergo the technical inspection and acceptance by a chimney sweeper. 2. Product description 2.1. PELMAX heating boiler PELMAX type boiler has been prepared specially for combustion of solid fuels in the form of pellets. The burner for burning pellets is assembled directly in the installation hole of the burner with the aid of supplied M8 star knobs. The boiler enables combustion of alternative fuels in the form of wood logs (see item 6.2. Alternative fuel). The vertical convection system, as well as a system for automatic removal of soot from smoke tubes in the structure of the boiler, they facilitate its cleaning (see item 6.2. Alternative fuel). As a result, high and equal degree of power efficiency is ensured. Large ash drawer facilitates daily maintenance of cleanliness and prolongs the time between the next removal of ash. The burner mounted on PELMAX boiler is equipped with automatic fuel feeding system. The process of feeding fuel as well as operation of the burner is the responsibility of the boiler regulator. Owing to his modular structure, it is possible to expand the control system. The maximum expansion is: 16 heating circuits, including 2 circuits for preparation of hot tap water, control of heating system in connection with heat accumulation tank - buffer, control of solar system cooperating with the boiler. 9

10 Structure of PELMAX boiler Fig. 3. Construction scheme of PELMAX boiler 1. Pin ø140 external 2. Soot cleaning mechanism 3. Convection channels (smoke tubes), 4. Flue gas turbulators 5. Furnace chamber 6. Soot container 7. Ceramic insert 8. Ash container 9. 10A overcurrent switch 10. Cleanout cover 11. Stub pipe for heating water supply CH 1''GW 12. Boiler regulator 13. Master switch 14. Gland for running supplying ducts of burner 15. Control pane to the burner's flame 16. Installation hole of the burner 17. Boiler doors 18. Additional stub pipes of heating water supply heating CH 1" GW 19. Pipe for conducting ducts Ø26, internal 20. Stub pipe for return of heating water CH 1''GW 21. Drain stub pipe ½" GW 10

11 2.2. PBMAX burner Burner structure scheme PBMAX burner is designed for combustion of granulated timber product (pellet), after installing it in the boiler. As fuel for combustion in PBMAX burner, use only granulated timber product with the diameter of Ø6 10 mm and the humidity of 12%. Using other fuels is forbidden Adjustment of burner operation The power of the burner strictly depends on the amount of pellet and on the volume air blown-in through the fan embedded in the burner. PBMAX burner is controlled by the boiler regulator which has two kinds of the burner operation regulation. Method I - modulated regulation Fuzzy Logic II. After the end of the process of ignition and kindling, the regulator controls operation of the burner in a modulated manner, adapting the power of the boiler to the demands in the facility (according to power characteristics of the boiler). The regulator smoothly regulates the dose of pellet and the blow-in power of the fan, maintaining stable temperature of the boiler, as well as optimum combustion process. Method II - stroke regulation After the end of the process of ignition and kindling, the regulator controls operation of the burner in a stroke manner. This means that the burner operates with two-stage power, depending on the demand, it operates at the 1st or the 2nd degree of power. The 1st degree corresponds to the minimum power, while the 2nd degree corresponds to the maximum power. Both values are adjusted by the user. The burner passes from 2nd degree to the 1st degree of power at the time of reaching the set temperature (determined by the user), ± hysteresis. Fig. 4. PBMAX burner structure. Description: 1. The furnace 2. Breaker (protecting against activation in the case of the burner removed from the door or improperly fastened), 3. Burner temperature limiter 4. Flame sensor 5. Fan 6. Burner casing 7. Power supply socket for connecting the pellet feeder 8. Low voltage socket (burner control), 9. High voltage socket (burner power supply), 11

12 3. Technical specifications Size Unit Value Size Unit Value A mm 120 K mm 526 B mm 140 L mm 342 C mm 645 M mm 133 D mm 801 N mm 232 E mm 350 O mm 150 F mm 263 P mm 210 G mm 12 R mm 24+15/-0 H mm 296 S mm 65 I mm 942 T mm 876 J mm

13 Table 1. Technical data of PELMAX boiler No. Parameter Unit Value 1. Type - K-PAA20 2. Rated power kw Alternative fuel - Wood logs 4. Boiler efficiency % Water capacity L Net weight kg Maximum working temperature o C Minimum return temperature (at the inlet of the boiler), o C Flue gas temperature o C Pin diameter mm 140 external 11. Maximum pressure bar 2,5 12. Required waste gas thrust Pa Capacity of the loading chamber (at assembled grate), L Combustion chamber length mm Degree of protection - IP Chimney section (square/circle), mm 160x160/Ø Minimum height of the chimney m Power supply voltage V Power consumption by the controller W 11 Table 2. Technical data of PBMAX20 burner No. Parameter Unit Value 1. Type - PBMAX20 2. Power of the burner kw Fuel, wood pellet mm Voltage V 230V NAC 50 Hz 5. Electric power W Electric startup power kw 1,2 7. Degree of protection - IP21 8. Net weight kg 14,5 13

14 4. Installation of the device At the installation of the heating boiler, binding legal regulations must be observed. The boiler room should be made according to PN-87/B The heating system of the open system must meet the requirements of PN-91/B The heating system of the closed system must meet the requirements of: PN-99/B and be equipped with devices protecting the system, consisting of: safety valve along with inlet and oulet duct, membrane collecting vessel, collecting pipe, protection of heat source against exceeding the acceptable temperature of the system's water, devices discharging excess of heat as required by Journal of Laws of No. 56 ITEM 461, of fittings: control and measurement devices, indicating at least the temperature of the system's water at the supply and the pressure in the system; fittings automatically deaerating the collecting pipe; discharge fittings which allows to empty the water space of the collecting vessel. TIP The door of the boiler can be installed on both sides, which enables their opening to the left or to the right Distances from walls The boiler should be set maintaining minimum distances from the walls (Fig. 5). While installing the device, pay special attention to provide convenient access to the boiler, the burner, the chimney during maintenance, cleaning and operation. TIP If possible, the boiler should be transported to the place of placement in the packaging on the pallet Placement of the boiler The boiler should be installed according to the standard at the place designed for it with the height of min. 2.5m. In this room, the floor should be made of non-flammable materials. In the case of floors of flammable materials, it should be it covered with steel sheet with the thickness of 0.7 mm, at a distance of at least 0.5 m from the edge of the boiler. It is preferred to set the boiler and the pellet container on an even, levelled concrete foundation with the height of min. 5cm, with the edges of the foundation secured with steel curbs. The boiler room should have proper air exchange. It should have inlet channels situated near the floor with the min. total area of 200cm 2 and the exhaust channel placed under a ceiling with the dimensions of at least 14x14cm. Ventilation channels should be made of nonflammable materials. It is required to provide appropriate lighting, to the possibly greatest extent covered by the natural light, but there should be also a system with artificial lighting. Fig. 5. Distance of the boiler from the walls. Table 3. Minimum distances from the walls of the building Size Value [m] A 1 B 0,7 C Levelling the heating boiler To set and level the boiler, use regulatory legs (Fig. 6) Fig. 6. Levelling the heating boiler. 14

15 4.4. Equipment of the boiler At the time of delivery of the boiler, check whether the boiler has no mechanical damage. Check the delivered equipment and compare it with the table below. Item. Part Quantity 1 Temperature sensor hot tap water 1 2 Temperature sensor primary circulation 3 Smoke tube cleaning brush 1 4 Pipe cleaner holder 1 5 Operation manual with the guarantee card 5. Assembly and connection of the system 5.1. Connection to the flue gas discharge system A chimney with a sufficient draught and proper dimensions is the main condition for correct functioning of the heating boiler. To a great extent, it determins efficiency and economy of operation. The heating boiler can be connected to the chimney, but with a sufficient draught (technical data). It is important that the smoke duct had such a diameter (section) and height so that in the boiler and in the smoke channel, there could be not excessive pressure. Pelmax boiler has a pin (round section), external diameter ø140 mm. The pin should be tightly connected (e.g. by means of a connection made of accordingly thick steel sheet) to the chimney duct. Connection should be done with inclination towards the boiler (recommended) or in a straight line: boilerchimney. Do not reduce the diameter of connection. Every bend, application of elbows increases flow resistance of flue gas, which may cause improper operation of the boiler. 1 1 TIP Owing to the possibility of operation of the boiler with low temperature of flue gas (particularly at firing on the additional grate), the boiler should be connected to the flue gas discharge system with embedded insert e.g. acid-proof, ceramic etc., with condensate discharge in the bottom part of the chimney. Before installation, the smoke duct should undergo the technical inspection and acceptance by a chimney sweeper Connection to the heating system The boiler should be connected to the heating system with binding standards and regulations. The diameter of connection pipes of the central heating system should be selected in accordance with valid regulations and standards, it should not be decreased on the way from the output from the boiler to the distributor of the CH system, both at the supply and at the return to the boiler. TIP Before connecting the boiler to the heating system, the boiler and the system should be rinsed with water in order to remove dirt that could lead to damage. Conducting power cord of heating system should be performed in such a way so that a free access to the boiler cleanout (Fig. 3 item 10). In connection with the possibility of alternative fuel combustion on the additional grate, it is necessary to embed, in the heating system, a thermometer that enables to control the temperature of the heating medium Electric connection The boiler has been equipped with the regulator controlling operation of the burner and circulating pumps. Electric connections of external devices should be made by a person with appropriate licenses and qualifications. External supplying outputs of the device should be connected in accordance with the symbols. Fig. 7. Connection of the boiler to the chimney duct Power supply: 230V NAC 50Hz Outputs to external equipment 230V/50Hz 15

16 The boiler should be connected to a separately led supply line protected with 16A fast fuse and a differential current switch. No other electrical devices can be connected to the boiler power supply line. Electric installation and possible servicing may be performed by a person having appropriate licenses and qualifications. The electrical system and conducting cables must proceed in accordance with valid regulations Fuel container and wormwheel feeder The pellet feeder supplies the burner with fuel from the external container. It is recommended to use the following set: pellet container ZP 300 and pellet feeder of series PP by NIBE-BIAWAR, specially adapted for cooperation with Pelmax boiler. The container should be placed in the vicinity of the boiler, so as to enable problem-free assembly of a wormwheel feeder, and connection of a goffered protective pipe between the feeder and the burner, ensuring free transport of pellet - without any unnecessary bends that could cause stopping of pellet Installation of the burner Fig. 8. Installation of pellet burner. The burner of PBMAX type is installed in the installation hole of the burner, made in the boiler door. The burner should be mounted using knobs supplied with the burner. After assembly of the burner, make sure whether the burner tightly adheres to the door of the boiler. After assembly of the burner: 1. Install the goffered pipe on the chute pipe of the burner and protect it with a trim. 2. Connect electrical ducts from the boiler to the burner and from the pellet feeder to the burner. 3. Switch on the boiler regulator check whether the display does not show the alarm "burner safety circuit". In the event of indication of an alarm, check correctness of connections and confirm the alarm in accordance with item: Alarms. To connect the burner with the pellet feeder, use a self-extinguishing goffered pipe, included in the equipment of the boiler. Using other chute ducts is not permitted. Fig. 9. Correct connection of the charging duct. Fig. 10. Incorrect connection of the charging duct. TIP The burner - feeder connection should be made in such a way so that it was possible to open the door of the boiler within the full range (e.g. for cleaning and maintenance of the boiler). 16

17 Use of container of a different type. It is accepted to use containers of a different type (e.g. with greater capacity), however, the container should be designed in such a manner so that the wormwheel feeder was fitted at the angle of 45 ± 5 in relation to the base. The container should have a cover protecting pellets against humidity and mechanical elements of the feeder against possible physical damages (e.g. as a result of penetration of hard object, which is likely to damage the feeder). TIP Filling the feeder with pellet may be executed also from the controller level. This is the responsibility of the function "feed fuel" in the simple menu or the function "feeder container test" in the servicing menu of the burner. These functions eliminate the need to connect a wormwheel feeder to the network socket. 6. Start-up and operation of the boiler 6.1. Basic fuel PBMAX burner installed in the boiler is adapted to combustion of high-quality timber pellet, with the granulation of 6 10 mm and the maximum humidity of 12%. Using other fuels for combustion in the burner is forbidden. Fig. 11. Sample setting of a container of a different type Feeding pellet The below way of filling the feeder is applicable in the case of feeders by NIBE-BIAWAR, (dedicated to Pelmax boiler, type PP 15) with the length of 1.5 m, inclined at the angle of ca. 45. Before the first start-up of the burner (or if the fuel has ran out), the wormwheel feeder must be filled with pellet. It is performed by filling the container with pellet and then switching on a wormwheel feeder to the network socket. Total filling of the feeder pipe takes approximately minutes. When the pellets reach the outlet of the feeder, leave the feeder activated for ca. 2 minutes for the purpose of optimum filling of the feeder pipe and provide steady fuel feeding. During filling, let the pellets fall to the container (e.g. the bucket) so as to ensure that they could be put back to the container. Then, relocate the plug to the burner socket and install the goffered pipe between the feeder and the burner (fastening it with a trim). If there is a need for transport of pellet to a greater distance, it is possible to purchase a feeder with the length of 2.5 m (type PP25, available in retail outlets). It is recommended to use high-quality fuels coming from certain sources. Fuels should have appropriate humidity and they must not contain mechanical contamination (sand, stones etc.), which can worsen the combustion process and cause device failure. NIBE-BIAWAR is not responsible for device failure and improper combustion process resulting from use of improper fuel Starting the burner The burner is fully automatic, i.e. it ignites and extinguishes automatically, does not require manual start-up and regulation during operation. The process of pellet ignition in PBMAX burner is activated by the regulator of the boiler. For this purpose, press and hold (for approximately 3 s) the red ON/OFF button on the boiler regulator. Each ignition process is preceded by two cycles cleaning the burner grate - factory setting (possibility of selection of 2 5 cycles). The display of the regulator shows the text: CLEANING. At the same time, the process of cleaning convection ducts (smoke tubes) from soot is conducted (see item 7. Reviews and maintenance activities). TIP The process of cleaning the smoke tubes will start along with cleaning the burner grate only at the first ignition. In a later period, this process is executed automatically, once a day (in the adjustable time range) and may not proceed at each start-up of the burner. After completion of cleaning, the proper ignition process commences, in which there are the consecutive processes: 17

18 The regulator display shows the text: IGNITION A dose of pellet (determined in time - factory setting: 50 seconds) is fed on the burner grate The igniter and the fan of the burner are started The flame sensor monitors the presence of the flame and it detects it at the sensitivity threshold of 50 units (factory setting). When the flame sensor detects the flame, the igniter is switched off and the process of kindling begins The display shows the text: KINDLING Kindling takes approximately 3 minutes, additional portion of fuel is fed, and the fan gradually increases its power After 3 minutes, kindling ends, and the regulator moves to the proper operation mode displayed on the regulator. TIP Time for single process of pellet ignition lasts for 9 minutes. If during this time flame sensor does not register the flame in the combustion chamber, the process is repeated firing. Maximum quantity of firing cycles is 5. When complete there will be no lighting of within 5 cycles, the controller of the boiler will generate an alarm. TIP The factory settings of burner PBMAX are given for 8mm pellets of grain size and moisture max 12% Extinguishing The process of extinguishing is activated by pressing and holding (for approximately 3 s) the red ON/OFF button on the boiler regulator. This results in activation of consecutive processes: The display shows the text: EXTINGUISHING Fuel feeding is interrupted The fan operates until a complete fading of the flame Boiler controller does not control the operation of pumps in this extinguishing method The process of burner operation can be interrupted also from the level of the simple menu in BURNER OPERATION options. After finding the menu of BURNER OPERATION options, press ENTER, then, with a down or up arrow, change the displayed option to NO. This will cause immediate start of the extinguishing process (controler of the boiler will continue to control the operation of pumps). TIP If the option in the "BURNER OPERATION" will be approved and recorded as "NO", the burner can not be restarted. To be able to restart the burner, change the options "BURNER OPERATION" to "YES". EMERGENCY STOP Set main switch to "0". This will stop operation of the controller, the burner and feeder but pellet burning on the grill burner not extinguishing immediately Alternative fuel TIP The use of alternative fuel is recommended only in emergency situations such as lack of basic fuel, maintaining the temperature in the case of long interruptions in the supply of electricity. When burning alternative fuel, the controller can control the boiler circulation pumps. As alternative fuel (for burning on the additional grate), use fuel wood from any deciduous trees with high hardness, such as: oak, beech, acacia, ash or hornbeam. You can also use softer wood: birch, poplar. The length of the combustion chambers is 320 mm. TIP Shoul be use dry wood with a moisture content of 20% (corresponding to approximately 18 months of storage timber under the covers). When using additional grid should anticipate a change in boiler efficiency and the inability to control the combustion process from the control of the boiler. In extreme cases this can lead to overheating of the boiler, for which responsibility lies entirely with the user. Use of the alternative fuel requires prior preparation of the boiler (see item Adaptation of Pelmax boiler for combustion of alternative fuel) Adaptation of PELMAX boiler for combustion of alternative fuel Preparation of the boiler for alternative fuel combustion consists in dismantling PBMAX burner, installation the primary air door, installation of the additional grate and taking out flue gas turbulators. 18

19 Removal of flue gas turbulators is an obligatory activity in the case of firing the boiler with alternative fuel. To install the additional grate: Disable the controller and disconnect the boiler from electrical supply, Disconnect electrical ducts of the burner and the pellet feeder, Unscrew the knobs fixing the burner and remove the burner from the boiler door, Instead of the burner, install the primary air door, tightening it with fixing knobs. In the combustion chamber, install the additional grate, basing it on supports intended for this. After dismantling the burner and installation of the additional grate, remove flue gas turbulators. For this purpose: Disassemble the cleanout cover (Fig. 3 item 10), by unscrewing external knobs (use internal knobs as holders), Remove flue gas turbulators, pulling them up by connectors, After removing the turbulators reassemble the cleanout cover. Fig. 12. Installation of the additional grate After conducting the above activities, re-start the boiler regulator. In in the regulator, in "FUEL" options, enable "WOOD" operation mode. In the case of lack of electric energy, or with the activated boiler regulato, burning on the additional grate it is acceptable only in gravity central heating system (with non-forced circulation of the heating medium). TIP The primary air door and the additional grate do not constitute standard equipment of the boiler. To enable adaptation of the boiler for alternative fuel combustion, obtain necessary elements at the device manufacturer's. Fig. 13. Installation of the primary air door Burning on the additional grate During burning on the additional grate, controling temperature in the boiler takes place manually, by regulation of air supply with a control flap of the primary air door, installed in the boiler door. Ignition should proceed gradually, first with small pieces of wood and after obtaining a suitable amount 19

20 of heat and the temperature of approximately 50 C, larger logs can be put in. Burning in the boiler will proceed automatically with the efficiency dependent on the quantity of supplied air through accordingly open control flap. Through the door of the boiler, control the burning process and supplement the fuel. During burning on the additional grate, constantly control the conditions and the correctness of the boiler operation and, when necessary, supplement fuel. After the end of burning on the additional grate, the grate and the whole boiler should be carefully cleaned (see item Cleaning from soot). At the time of return to the basic fuel (pellet), it is necessary to previously clean the boiler, then disassemble the additional grate and again install the pellet PBMAX burner, install the flue gas turbulators and, in the regulator of the boiler in the "FUEL" options, change the parameter to Pellets. After conducting the above mentioned activities, the regulator of the boiler will automatically supervise the combustion process. 7. Reviews and maintenance activities In order to avoid risk of soot ignition, follow fire regulations with regard to frequency of soot removal. Soot removal covers all smoke channels from the furnace to the peak of the chimney PELMAX boiler Cleaning the boiler and the chimney connected to it should proceed according to valid regulations. During servicing or maintenance of the boiler and the burner, electrical power supply should be disconnected. The boiler is equipped with and automatic system for soot removal from flue gas ducts (smoke tubes). This is to facilitate maintenance of cleanliness and efficiency of the boiler during the period of its work. In order to obtain optimum degree of power efficiency of operation of a modern and well-adjusted burner for pellets, other boiler surface exposed to contact with flame should be regularly cleaned from soot (recommended every 7 days). At least once a month, clean the boiler combustion chamber, flue gas turbulators and boiler flues (see Section Cleaning from soot). Performance of activity is the responsibility of the user of the boiler and is not included in guarantee activities Cleaning from soot Cleaning can be performed only after extinguishing the furnace and the decrease in temperature of the boiler to the ambient temperature. During cleaning, use personal protection equipment. If chimney draught regulator has been mounted, before cleaning, it should be closed. This is to prevent soot from getting to the boiler room during cleaning. After cleaning, the regulator should be opened again. PELMAX boiler is cleaned automatically but also requires regular manual cleaning. Automatic cleaning is executed through movement of the turbulators in the convection part, this movement is forced by the driving engine of the soot removal assembly. The layer of soot accumulated on the walls of convection channels is scrubbed from them to the soot container. Automatic cleaning takes place once a day, in a time interval specified by the user. Manual cleaning is done by pulling the soot brush through convection channels of the boiler (smoke tubes), after prior removal of the turbulators. First of all, make sure that the power supply to the boiler is disabled. Before cleaning convection channels (smoke tubes), remove the flue gas turbulators; for that purpose: open the cleanout (by unscrewing external knobs, use the internal ones as holders), pull away the mobile arm under the pair of turbulators to place them in their highest position, remove flue gas turbulators, pulling them up by the connectors, after removing the turbulators from combustion channels of the boiler, they should be cleaned from dirt. The soot removed from convection channels of the boiler accumulates in the soot container, which is in the lower part of the boiler, behind the ash container. To empty the soot container, in the first place, open the door, remove and empty the ash container, then pull out and empty the soot container. After the end of cleaning, slide ash and soot containers to their place and close the door. Flue gas 20

21 turbulators should be again put to their place and the cleanout should be closed. The ash can contain long-term smoldering particles. For this reason, when you empty the ash pan and soot cleaning, should use protective gloves and ash tray made of inflammable materials. Do not touch, with a hand, door and other elements which have a direct contact with a flame, as there is a risk of burn. Fig. 14. Dismantling the flue gas turbulators Description: 1. Turbulator 2. Connectors 3. Mobile arm 7.2. PBMAX burner PBMAX burner requires maintenance to a minimum extent. It mainly comes down to controlling the quality and the size of used pellets. The burner is cleaned automatically but also requires regular manual cleaning. Automatic cleaning takes place before the ignition process. Additionally, cleaning takes place in certain time intervals, programmed by the user ( min), it takes place in the case when the burner operates continuously for a long period. Automatic cleaning consists in pulling out the grate of the burner into the interior of the combustion chamber so as to ensure that the collected ash falls down to the ash container and then the grate of the burner is inserted to its place. Each automatic cleaning of the grate takes place twice - factory setting (2 pull out-insert cycles). The user has the opportunity to adjust this setting in the scope of 2 5 cycles. There is also a possibility of setting time interval in which PBMAX burner will have permit for execution of automatic grate cleaning. This function has a higher priority than the function of automatic cleaning, which activates after expiration of maximum time of continuous burner operation ( min). To carry out the process of manual burner cleaning, perform the following activities: start the process of flame extinguishing and wait for its end, until the regulator displays "OFF", disable power supply and wait until the burner cools down, which will allow to avoid burns, clean the goffered pipe clean the chute pipe (1), Scrape the board of the lighter (2) and the grate (3) and clean the openings in the grate, remove ash from the burner and the boiler. Before beginning servicing and maintenance works, disconnect the device from the main power supply Cleaning /removal of ash A remnant of combustion of granulated timber product (pellet) is ash in the quantity of 0.5% %. The frequency of cleaning the burner is determined by the contamination, type of used fuel and the size of consumption. Ash should be stored in a closed container. The burner grate should be cleaned each time after combustion of 200 kg of pellet or once a week. Depending on the pellet, pauses between cleaning processes can be extended to two weeks. Fig. 15. PBMAX burner Even after a long time the ash may contain heat. Therefore, the removal of ash and soot should be used with non-combustible container. 21

22 Annual maintenance or when needed (performed by the installer) For safety of users and proper operation of the burner, the device should be subjected to annual maintenance. Extinguish the flame and when the grate is in the external position (pulling the grate out), disable the master switch of the boiler. Then: 1. Remove the casing and clean the flame sensor with a cloth and a soft grinding agent (e.g.: toothpaste). 2. Clean the fan blades. It is good to clean them carefully with compressed air. 3. Unscrew the sides of the grate and the board of the lighter, loosen the ducts of the heating element of the lighter. 4. Clean the space behind the lighter board, clean the grate. 5. Re-install all parts. 6. Clean the pellet container and the feeder from fine particles. 7. Check the condition of the goffered pipe. 8. Activate the pellet feeder, by putting the plug to the network socket. Total filling of the feeder pipe takes approximately minutes. 9. Adjust the burner. 8. CE marking It is hereby declared that this product has been manufactured in accordance with: Low-voltage Directive 2006/95/EC Electromagnetic Compatibility Directive 2004/108/EC Pressure Directive 97/23/EC Machine Directive 98/37/EC This symbol, placed on devices certifies that this product has been made in accordance with the above directives. This symbol placed on devices and/or the attached documentation, means that worn out electric and electronic devices cannot be thrown out together with other waste. 22

23 OPERATION MANUAL PELMAX BOILER REGULATOR 23

24 1. Generally 1.1. Introduction IGNEO Slim boiler operation regulator is a modern microprocessor system that controls not only the boiler, but also the central heating and hot tap water system. The device controls the combustion process by supplying a suitable amount of air and fuel. As a result of applying semiconductive relays, the power of the blower is regulated smoothly. Thanks to the advanced algorithm of operation as well as the possibility to adjust many parameters, the system can be very flexibly adjusted to the needs of the heating system Advantages Graphic display - thanks to the application of a large FSTN graphic display, operation of the device is intuitive. Large font and icons - increase ease in operation of the device for the elderly. Two types of menu - simple menu and advanced menu. During daily operation of the device, operation is possible from the level of easily available simple menu. Info button - the regulator has been equipped with a smart help function. Each parameter has been described, calling out the description takes place through pushing the Info button. Modular structure of CAN regulator - thanks to the application of industrial data exchange bus CAN (used mostly in the demanding automotive industry), expansion of the control system is possible. The maximum expansion is: 16 heating circuits, 2 circuits for preparation of hot tap water, energy buffer, solar collectors. Buffer - controlling the heating system in connection with heat accumulation reservoir (buffer). Solar collectors - the regulator controls the solar system cooperating with the boiler control. Efficient modern 32-bit ARM processor (ARM family is commonly used in mobile phones) - enables advanced control of 2nd generation Fuzzy Logic algorithm. Alarms and errors history - the regulator stores the history of 20 last errors and alarms along with the description, the date of arising and the date of confirmation. Timer along with a calendar - the timer enables programming, in a weekly cycle, the required temperatures of the room and hot tap water system which contributes to reduction in expenses incurred for fuel. Statistics - the regulator stores, in the memory, statistical data on the system operation, thanks to which it is possible to observe operation and reduce fuel consumption. For instance, observation of the boiler's temperature and the burner's power.fuel feeder operation time. Sound signalling of alarms - embedded piezo-electric speaker signals the occurrence of an alert situation in the boiler, which increases the safety of device operation. Restoring factory settings - the function enables restoring factory settings of the regulator. 24

25 1.3. Safety precautions Electric shock hazard! Prior to using the device, read the whole attached manual. Keep the operation manual and refer to it in the case of any operation with the device in the future. All principles and warnings included in the device operation manual must be observed. Make sure the device is not damaged in any way. In the event of doubts, do not use the device and contact its supplier. In case of any doubts applying to safe operation of the device, contact the supplier. Special consideration should be given to any warning signs shown on the casing and the package of the device. The device should be use in accordance with its designated use. The device is not a toy, children should be prevented from playing with it. Prevent children from access to small parts for instance, fixing screws, pegs. These elements can be included in the equipment of the delivered device and in the case of their swallowing, they may cause suffocation of a child. Do not perform any mechanical or electrical changes in the device. Such changes may result in improper operation of the device, inconsistent with the standards, and negatively affect operation of the device. Do not insert, through gaps (e.g. ventilation gaps), any objects inside the device, it may cause a short circuit, electrocution, fire or destruction of the device. Do not let water, humidity and dust get inside the device, it may cause a short circuit, electrocution, fire or destruction of the device. Ensure proper ventilation of the device, do not cover ventilation openings and provide free air flow around it. The device should be installed inside rooms. Do not allow the device to be exposed to impact and vibrations. When connecting the device, make sure electrical parameters of power supply network correspond to the scope of the device's operation. Any made connections must be consistent with the electrical assembly diagram of the system as well as with national or local regulations with regard to electrical connections. In this device there are no parts which the user may replace on his/her own. All servicing activities, apart from cleaning, setting functions, should be performed by an authorized service. Before beginning any maintenance activities, the device should be absolutely disconnected from the supplying network. To clean the device, it is not allowed to use gasolines, solvents or other chemicals which may damage the casing of the device. It is recommended to use a delicate cloth Proceeding with worn equipment An electronic device has been made of made that are partially suitable for recycling. For this reason after they have been worn out, they must be sent to the point for recovery and recycling of electrical and electronic equipment. The device cannot be disposed of together with other household waste. 25

26 2. Connection to the system 2.1. Electrical installation Prior to using the device, thoroughly read the whole attached manual. Person undertaking installation should show technical experience. Connections made with a copper cable should be adapted to work in the temperature not lower than + 75 o C. All executed connections must be consistent with the electrical assembly diagram of the system as well as national or local regulations with regard to electrical connections. The device should be connected to a separate electrical circuit, equipped with a properly selected overcurrent circuit breaker and a differential-current circuit breaker Connection Controller should be accompanied by all sensors and executive elements needed for boiler operation, as necessary. The figures present the diagram of connection of devices. The tables show the description of inputs and outputs. Under no circumstances connect the protective conductor (PE) with the zero conductor (N). Connections must be performed with the device disconnected from the electrical network. Connections should be performed by a person having appropriate licenses in this respect. Remember to connect the operator's panel to the executive module. The method of connection is described by the figure below. 26

27 Direct connection of devices INPUTS Input description Explanation Number of input Tk Boiler temperature sensor IN1, GND STB, burner cir. Safety circuit IN2, GND Tcwu Hot utility water temperature sensor IN3, GND Tco Central heating temperature sensor IN4, GND CTP Room temperature sensor IN5, GND CTZ External temperature sensor IN11, GND Photo Brightness sensor in the burner IN12, GND GDN Electronic mass for connecting sensors DO1, N CH pump 1 Central heating circulating pump DO2, N CH mixer opening 1 Central heating mixer opening DO3, N Grate cleaning L1 Controlling cleaning the grate for the module DO4, N Igniter Burner igniter DO5, N Grate cleaning L2 Controlling cleaning the grate for the module DO6, N Blow-in fan Burner blow-in fan AO1, N1 Exchanger cleaning Exchanger cleaning AO2, N Container feeder Container feeder AO3, N1 HTW pump 1 Hot tap water circulating pump AO4, N STB STB temperature limiter of the boiler N Neutral constant N1 Neutral separable, e.g. through STB PE Ochronny 27

28 3. Review of basic functions 3.1. Control panel Buttons Button ON / OFF CH Hot Utility Water INFO Function Long pressing on the main screen (>3 seconds) changes the condition of regulator status ON/OFF (enabled/disabled). Quick access to the full configuration of central heating settings. Quick access to the full configuration of hot tap water settings. It shows navigation information and descriptions of parameters. regulated Status LED Light description Green is on continuously Green pulsates Orange is on continuously Orange pulsates Red is on continuously Red pulsates Graphic display Importance Regulator disabled Regulator on, burner off Regulator on, burner on Burner operates There is an alarm to confirm Alarm active ESC Arrow up Arrow down ENTER Return a level up in the menu, resignation from parameter change. Moving in the menu, increasing the value of the edited parameter. On the main screen, entering the simple menu. Moving in the menu, reduction in the value of the edited parameter. On the main screen, entering the simple menu. Entering the menu. Acceptance of change in the value of the edited parameter. Alarm confirmation Furnace statuses Status Description The burner does not operate. Consent for Off operation disabled. Cleaning the burner with a strong stream of Cleaning air. Fuel ignition. Specification of the initial fuel Lighting off dose, start-up of the igniter and the blowers. After detection of flame in the ignition phase, feeding additional portion of fuel Kindling and increase in the power of the blower for kindling the furnace. Power 1 The burner operates with the first power. The burner operates with the second Power 2 power. The burner operates with modulated Modulation power. Extinguishing the furnace. Operation of the Extinguishing blower until the total fading of the flame. The burner does not operate but there is a Stop consent for its operation. Required boiler temperature achieved. 28

29 4. Handling 4.1. Navigation in the menu The device has two types of menu: simple menu and main menu. Simple menu - allows fast access to basic functions of the controller. Entering the simple menu takes place through pressing the "up arrow" or "down arrow" button on the main screen. Description of a simple menu in Chapter 5. Main menu - allows access to all functionalities of the controller (condition monitoring, change of settings and maintenance settings,). Entering the main menu takes place through pushing the "Enter" button on the main screen. Description of the main menu in Chapter 6. Back to the main screen is possible from any screen by pressing several times "Esc" button. The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system Start-up of the regulator - ON To start the regulator (ON mode), press for 3 the "ON /OFF" button on the main screen, when it is in the OFF mode Turning off the regulator - OF To disable the regulator (OFF mode), press for 3 the "ON /OFF" button on the main screen, when it is in the ON mode Time programs The regulator is equipped with a timer and a calendar. Thanks to that it is possible to program operation of particular elements of the heating circuit, depending on the current time and week. Date and time are not subject to deleting during voltage failure, as the regulator is equipped with a battery which should be replaced every 2 years. Programming takes place in the menu of a given circuit (e.g. hot tap water, heating, buffer) and for each element, it is done in the same manner. Selecting the day of the week. After entering the "Time program" menu, the day of the week pulsates. Using arrow buttons, select the day which you want to set or only check program settings. Programming. After selecting the day of the week and accepting with "ENTER" button, the indicator of the currently programmed time starts pulsating, and at the same time, this time is displayed, and next to it, an icon is displayed, showing the currently selected time zone (the symbol of sun means comfortable temperature, the symbol of moon means the economical temperature). To go to the next time, press the down arrow (economical temperature) or the up arrow (comfortable temperature). If the whole day is already programmed as you wish, press "ENTER" button. After approving changes (or cancelling), the day of the week starts pulsating. The figure shows an example of a programmed day of the week. Temp. economic 00: 00 to 6:00 Temp. comfortable 6:00 to 9: 00 Temp. economic from 9: 00 to 18: 00 Temp. comfortable from 18: 00 to 24: 00 CAUTION! After turning off the controller according to the earlier time, the burner can still work (extinguishing) of this condition should not be interrupted. If the device is to be excluded from the mains, wait for the process of extinction until the burner status will be "off". CAUTION! The value of comfortable and economy temperatures are set in the SETTINGS menu and may be different for each of the circuits. In order for a time program work should also include time in the SETTINGS menu 29

30 4.5. Service password Access to servicing parameters is protected with a password. After entering the correct password, access is unblocked. Access to servicing parameters is blocked after the period of 10 minutes without pressing the buttons. Servicing password is the set temperature of the boiler in the BOILER/SETTINGS menu and 3 letters: "EST". Example: If the set temperature of the boiler in the BOILER/SETTINGS menu is 60 C, the password is: 60EST. The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system 5. Simple menu 5.1. Simple menu screens Barrier Description It presents the current temperature of the boiler (big font) and the set temperature (small font). After pressing the "ENTER" button proceed to adjusting the set boiler temperature. It presents the current temperature of hot water (big font) and the set temperature (small font). After pressing the "ENTER" button, proceed to setting the set hot utility water temperature. The menu applies to circuit no. 1. It heats hot water once to the comfortable temperature, regardless of the program. The menu applies to circuit no. 1. Hot tap water program no. 1: a) temporary - in accordance with the programmed time intervals b) constant - regardless of time intervals, the comfortable temperature is maintained c) disabled - disables heating. 30

31 The menu applies to circuit no. 1. It presents the current temperature in room no. 1 (big font) and the set point (small font). After pressing the "ENTER" button, proceed to set the set temperature in the room. The menu applies to circuit no. 1. Heating program for circuit no. 1: a) temporary - in accordance with the programmed time intervals b) constant - regardless of time intervals, the comfortable temperature is maintained c) disabled - disables heating. The menu applies to circuit no. 1. Consent for burner operation. At disabled consent for burner operation, the regulator controls the heating system, but does not activate the burner. 6. Main menu Manual start-up of the fuel feeder from the container. Function useful after exhausting fuel from the container. After re-filling the container with fuel, activate the function of fuel feeding until fuel feeding starts sifting to the feeding pipe to the burner. 6.1 Heating 6.2. Utility water 6.3. Buffer 6.4 Boiler 6.5 Settings 6.6. Burner 6.7 Alarms 6.8 Solar collectors 6.9 Info 31

32 6.1. Heating Time program It is used to configure the time program controlling central heating. Description of setting the time program is included in Chapter Service Selection of the circuit It allows to choose the central heating circuit number. The selection of the circuit is done using the arrows. The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system Status It allows to monitor the condition of the central heating system Settings Function Temp. comfortable Program: Temp. economic analysis Settings Description Set temperature in the room in the heating period Programs: a) temporary - in accordance with the programmed time intervals b) constant - regardless of time intervals, the comfortable temperature is maintained c) disabled - disables heating. d) economic - at all times economic temperature is maintained in rooms Set temperature in the room beyond the heating period. Function MAX Tzew pump comf. MAX Tzew pump econ. MIN Tco pump Source Temp. maximum Mixer time HTW priority Pump test Mixer test Circuit name Temp. CH for -20 o C Temp. CH for 0 o C Temp. CH for 10 o C Correction coefficient Service Description Maximum external temperature at which circulation pump may operate in the comfortable range. Maximum external temperature at which circulation pump may operate in the economic range. Minimum calculated central heating temperature at which central heating circulation pump may operate. It defines the energy source for the central heating circuit. Maximum calculation temperature for central heating Full opening time of the mixer. Hot tap water priority for a given central heating circuit During heating hot tap water, the central heating pump does not operate. It activates circulating pump regardless of other conditions. It activates the mixer's servomotor independently of other conditions. It gives the name for the central heating circuit Heating curve point for -20 o C Heating curve point for 0 o C Heating curve point for 10 o C Correction of the central heating set temperature in relation to the set temperature in the room for each 1 C. 32

33 Operation mode TCH set manually Room sensor CH sensor Constant pump 6.2. Utility water It defines the manual mode of setting central heating temperature - central heating temperature set manually weather - central heating temperature calculated from the heating curve Set CH temperature when manual operation mode is set. It defines whether the system uses a room sensor. It defines whether the system uses a CH sensor. Yes - the pump works after reaching the set temperature in the room, calculated central heating temperature is reduced (only at the application of the central heating sensor and the room sensor) No - after reaching the set temperature in the room, the pump is switched off Settings Function Temp. comfortable Program: Heat now Hysteresis Temp. economic analysis Settings Description Set temperature of hot tap water in the heating period. Programs: a) temporary - in accordance with the programmed time intervals b) constant - regardless of time intervals, the comfortable temperature is maintained c) disabled - disables heating. It heats hot water once to the comfortable temperature, regardless of the program. Value by which the temperature of hot tap water may reduce. Set temperature of hot tap water beyond the heating period Time program It is used to configure the time program controlling preparation of hot tap water. Description of setting the time program is included in Chapter 4.4. Time programs Selection of the circuit It allows to choose the hot tap water circuit number Service The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system Status It allows to monitor condition of the hot tap water system. Function Source delta Source Temp. maximum MIN temp. delta Pump test Circuit name Service Description Increase in source temperature in respect of the set temperature of hot tap water during heating. It defines the energy source for hot tap water Maximum temperature of hot tap water. Minimum difference of temperatures between the source, and the hot tap water at which pumps can operate. It activates circulating pump regardless of other conditions. It gives the name for the hot tap water circuit 33

34 6.3. Buffer 6.4. Boiler Status Settings Function Temp. set top Temp. set temperature bottom Program: Time program Settings Description Below this temperature, at the top part of the buffer, the loading process starts. Above this temperature in the lower part of the buffer, the loading process ends. Constant - the buffer is loaded regardless of the time, temporary - the buffer is loaded only in specified time intervals. Time intervals are agreed in the menu "time program" disabled - buffer loading disabled It is used to configure time program controlling buffer loading. Description of setting the time program is included in Chapter 4.4. Time programs Service The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system. Function Minimum temp. the pump Automatic temp. top Service Description Minimum buffer temperature at the top part at which circuit central heating pumps can operate It determines whether the upper buffer temperature (minimum) is set manually or automatically. Automatically on the basis of the demand of other energy receivers from the buffer Status Statistics of the boiler operation over the past 24 hours. The chart presents the temperature of the boiler and the power of the burner. "Number of hours" determines for how many hours ago since the present moment boiler kept given working parameters. On the whole screen, statistics from 2 hours are displayed. Screens are switched using"up" and "down" buttons Settings Function Temp. boiler's set temperature Service Settings Description Heating agent temperature in the boiler, which will be maintained by the regulator. The menu is active only in continuous operating mode. The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system. Function Temp. MIN pump Operation mode Hysteresis MIN temp. return Return mixer time Service Description Temperature above which the regulator may activate the pumps. Boiler operation mode: a) auto - temperature determined automatically b) continuous - temperature is maintained constantly Temperature of the boiler must decrease by this value so that burner start-up took place. It determines time of full opening of the return mixer. 34

35 Boiler pump test Return mixer test Exchanger cleaning from Exchanger cleaning to Exchanger cleaning test 6.5. Settings It activates the boiler pump regardless of other conditions. It activates the servomotor of the return mixer, regardless of other conditions. It defines the scope of hours at which automatic exchanger cleaning may be conducted. Testing the mechanism of exchanger cleaning. SHORTENED DESCRIPTION OF EXPANSION MODULES Module Description Module no. 0 3 heating circuits with nos. 2,3,4. External temperature sensor. Module no. 1 3 heating circuits with nos. 5,6,7. Module no. 2 3 heating circuits with nos. 8,9,10. Module no. 3 3 heating circuits with nos. 11,12,13. Module no. 4 3 heating circuits with nos. 14,15,16. Buffer. Module no. 5 Solar collectors. HTW no. 2. Return temperature sensor. Module no. 6 Main module of the boiler. Module no. 7 Additional boiler module. Lambda Module Lambda probe module System configuration Date and time By means of this menu, the date and the time of the controller are set Language By means of this menu, the language of the controller menu is selected General settings Alarm buzzer We define here whether the controller is supposed to notify on alert states with a sound signal Service The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system Configuration of modules The menu is used to configure the system of the CAN network. In the menu, mark the modules that are connected to the network. A detailed description of the modules and their purpose are described in the instructions of expansion modules. The menu is used to configure the (hydraulic) heating system. Possibility of settings depends upon the number of set expansion modules. First, you should configure the modules. Function No. of CH circuits No. of HTW circuits Number of buffers Temperature sensor external temperature sensor Temperature sensor return Solar collectors SYSTEM CONFIGURATION Description It determines the number of central heating circuits in the heating system. It determines the number of hot tap water circuits in the heating system. It determines the number of buffers in the heating system. It determines whether the system has an external temperature sensor installed (module 0). It determines whether the system has a return temperature sensor installed (module 5). It determines whether the system is equipped with solar collectors Restore factory settings Function enabling to restore factory settings of the regulator. All factory settings will be restored, which may cause improper operation of the system. After restoration of factory settings, re-configuration of the regulator may be necessary. 35

36 6.6. Burner Status Settings Function Feed fuel Burner operation Fuel type Service Settings Description Is activates the fuel feeder regardless of other functions. Consent for burner operation. It determines the type of combusted fuel. The servicing menu is intended only for qualified technical staff. Changes may result in improper operation of the system. Function Air MIN (power 30%) Air MAX (power 100%) Feeding MAX (power 100%) Power MIN Power MAX Service Description Minimum quantity of air at modulation, when the power of the burner is 30% or at the power of 1. Maximum quantity of air at modulation, when the power of the burner is 100% or at the power of 2. Maximum fuel feeding time at modulation, when the power is 100% or at the power of 2, every 20 seconds. Minimum power of the burner during modulation or at the power of 1. Maximum power of the burner during modulation or at the power of 2. Type of modulation Photo threshold Test igniter* Test feeder burner* Test feeder container* Test blower* Fuel quantity test Value calorific fuel value Lambda Control Oxygen MIN (30%) Oxygen MAX (100%) Starting fuel dose Cleaning interval Cleaning cycles Exhaust fan** Grate cleaning test Silent mode of the grate Method of work of the burner, modulated power (Fuzzy Logic 2) or two degrees of power (stroke). Brightness in the burner above which the regulator recognizes the flame. Switches on the igniters for testing. Switches on the burner feeder for testing. Switches on the container feeder for testing. Switches on the blower for testing. The quantity of fuel fed by the container feeder during continuous operation, for 1 hour. Calorific value of used fuel (kwh/kg). It determines whether the regulator is to take account, in the control process, of the value of oxygen from the Lambda probe. Set point of the oxygen at minimum burner power of 30%. Set point of the oxygen at the maximum burner power of 100%. Fuel feeding time in the ignition process. Time between the cycles of burner cleaning. Number of movements in each grate cleaning cycle. Set power of the exhaust fan. Testing the mechanism of grate cleaning. Grate cleaning takes place only in the scope of hours for exchanger cleaning (BOILER/SERVICE) * Testing of devices in the menu BURNER is only possible when the controller is in OFF mode. ** Exhaust fan must be connected to an additional expansion module No Alarms This menu contains the history of maximum twenty alarms, which occurred during controller operation. The meaning of alarm codes has been presented in the table below. 36

37 When you point alarm, determine the cause of the alarm and remove it. After removing the alarm, the alarm can be approved. If this action has no effect, please contact an authorized servicer Alarm codes COD E 1 ALARM CODES AND THEIR MEANING Shortened Explanation description Overheating CPU 2 No fire/fuel Burner safety circuit Short circuit in the boiler sensor Break in the boiler sensor Short circuit of the burner sensor Break of the burner sensor Overheating of the boiler Processor reset 10 STB 11 Communicati The processor of the controller is overheated. A reason for this can be frequent overheating of the boiler or opening the door during boiler operation. The controller has sensed lack of flame in the burner. The reason could be running out of fuel or extinguishing the flame. Burner temperature has reached the maximum value and thermal protection of the burner was activated /opening of the boiler door took place /the burner has not been accordingly pressed The controller has sensed a short circuit of the boiler temperature sensor. The reason may be damage to the sensor or the jumper. The controller has sensed opening of the boiler temperature sensor. The reason may be damage to the sensor or the jumper. The controller has sensed short circuit of the burner temperature sensor. The reason may be damage to the sensor or the jumper. The controller has sensed opening of the burner temperature sensor. The reason may be damage to the sensor or the jumper. The boiler temperature has exceeded the maximum value. Probable damage to the controller! Possible power supply failure. on with module 0 Communicati 12 on with module 1 Communicati 13 on with module 2 Communicati 14 on with module 3 Communicati 15 on with module 4 Communicati 16 on with module 5 Communicati 17 on with module 6 Communicati 18 on with module 7 HTW sensor 19 short circuit HTW sensor 20 break Short circuit 21 of the room sensor Break of the 22 room sensor Extinguishing 23 error Communicati on with 24 module Lambda Overheating 25 solar collectors Freezing solar 26 collectors Codes from modules Short circuit IN1 33 Module 0 Short circuit IN2 34 Module 0 Short circuit IN3 35 Module 0 Short circuit IN4 36 Module 0 Short circuit IN5 37 Module 0 Short circuit IN6 38 Module

38 Short circuit IN11 Module Opening IN1 Module 0 46 Opening IN2 Module 0 47 Opening IN3 Module 0 48 Opening IN4 Module 0 49 Opening IN5 Module 0 50 Opening IN6 Module Opening IN11 Module Overheating of module 0 65 Short circuit IN1 module 1 66 Short circuit IN2 module 1 67 Short circuit IN3 Module 1 68 Short circuit IN4 Module 1 69 Short circuit IN5 Module 1 70 Short circuit IN6 Module Opening IN1 Module 1 78 Opening IN2 Module 1 79 Opening IN3 Module 1 80 Opening IN4 Module 1 81 Opening IN5 Module 1 82 Opening IN6 Module Overheating of module 1 97 Short circuit IN1 module 2 98 Short circuit IN2 module 2 99 Short circuit IN3 module Short circuit IN4 module Short circuit IN5 module Short circuit IN6 module Opening IN1 module Opening IN2 module Opening IN3 module Opening IN4 module Opening IN5 module Opening IN6 module Overheating of module Short circuit IN1 module Short circuit IN2 module Short circuit IN3 module Short circuit IN4 module Short circuit IN5 module Short circuit IN6 module Opening IN1 Module Opening IN2 module Opening IN3 module Opening IN4 module Opening IN5 module Opening IN6 module 3 38

39 Overheating of module Short circuit IN1 module Short circuit IN2 module Short circuit IN3 module Short circuit IN4 module Short circuit IN5 module Short circuit IN6 module Opening IN1 module Opening IN2 module Opening IN3 module Opening IN4 module Opening IN5 module Opening IN6 module Overheating of module Short circuit IN8 module Short circuit IN9 module Overheating of module Solar collectors Status Settings Function Activation delta Deactivation Delta Settings Description Difference in temperatures between the collector and the heated water needed for start-up of the solar pump. Difference in temperatures between the collector and the heated water needed for deactivation of the solar pump. 193 Short circuit IN1 module Short circuit IN2 module Short circuit IN3 module Short circuit IN4 module Short circuit IN6 module Short circuit IN7 module 5 39

40 Service Function Scheme of organization Flow [l/min] Liquid heat Temp. max. water temp. T. alarm of collectors MAX T. alarm of collectors MIN Solar pump test Service Description It determines the type of solar system. Flow of the agent through the solar system during pump operation. Parameter necessary to calculate the power of collectors. Proper heat of applied solar liquid given in kj/(kg C) Maximum temperature of heated water. Maximum temperature of collectors, above which the protective procedure is activated and an alarm is generated. Minimum temperature of collectors, below which the protective procedure is activated and an alarm is generated. Is activates the solar pump regardless of other settings Info Here, you can find information on the device, useful for the user, among others, the version of the controller software. 7. Expansion of the system - CAN bus The regulator is equipped with a broadband CAN bus for communication with the modules. Thanks to the bus, known for its reliability, used commonly in car industry, the possibility of system expansion is at the highest level. Using CAN bus involves a number of advantages. First for all, we have the possibility of application of a broadband Lambda probe, and using additional expansion modules I/O, we can install, throughout the entire system: - up to 16 heating circuits, - 2 circuits for hot tap water preparation, - heat accumulation reservoir (buffer), - solar collectors systems (solar collectors). - additional boiler module (e.g. the exhaust fan) The jumper of the CAN bus should be connected in accordance with the above marking. Description of the connection: L Line LOW (white) H Line HIGH (brown) GND ground (gray) For connections on CAN bus, use duct LiYCY 2x0.25. Only this type of duct ensures correct operation of the devices. Connections it is done in a serial manner, presented in the figure below. When connecting expansion modules, remember to correctly set the terminator, which should be activated only on the last module in the whole system, even if there is only one module. After making all connections, it is required to configure the settings of modules. This is done by marking the modules that are connected to the network. More information on configuration of particular modules can be found in chapter and I/O expansion module manual. After the end of modules configuration, you only have to change the system settings. The menu is used to configure the heating system, and the possibility of settings depends upon the quantity of set expansion modules. The table with a description of functions is included in Chapter On the next page, there is a a sample diagram of the system. Remember that this is only a demonstration drawing, not containing all elements of the system. 40

41 7.1. Sample hydraulic schemes 41

42 42

43 43

44 7.2. Lambda probe The Lambda probe can be connected to the system in two ways: directly to the regulator, if the CAN bus in the whole system will be used only by the Lambda probe module, - through a I/O expansion module with number 5, if the system also has other expansion modules. After connecting the module, you must configure the regulator. For this purpose, you should act according to the following instructions. On the list, find the item: Lambda Control and switch it to YES. It is also possible to operate at disabled Lambda control mode. Then, the Lambda probe module will be responsible only for displaying measurements. From the rotary menu, select SETTINGS 7.3. Solar collectors Then, in the SERVICE mode, enter the access code Solar collectors are operated only by I/O expansion module with number 5. After making all connections, configure the regulator to work with solar collectors in accordance with the description provided below. In the first place, enable module number 5. From the rotary menu, select SETTINGS After entering a correct code, we activate MODULES CONFIGURATION code Then, in the SERVICE mode, enter the access Find Lambda Module and switch it on, changing the option to YES After entering a correct code, we activate MODULES CONFIGURATION Now you have activated the Lambda Module. The second stage of configuration is the change of burner settings. From the rotary menu, by selecting BURNER, you enter the settings Here, again, switch on the SERVICE mode and, if required, enter the access code 44

45 Find Module 5 and activate it by changing the setting to YES After entering the code, we activatesystem CONFIGURATION Now we will enable solar collectors operation. Being in the rotary menu, select SETTINGS Find item Solar collectors and switch them on by changing the setting to YES code Then, in the SERVICE mode, enter the access After the end of configuration of the regulator, you can begin change of settings of solar collectors. Description of configuration of these elements can be found in chapter Specification Technical specifications Module power supply voltage ~230V/50Hz ±10% Module power consumption <6VA Accuracy of temperature measurement ±4 o C NTC 10kΩ Sensors B25/85=3877K±0,75% VISHAY BC components Ambient temperature 0-60 o C Humidity 5-95%, without condensation Software class A Module outputs current carrying capacity CH pump 100W HTW pump 100W Igniter 1000W Blower 150W Burner feeder 150W Container feeder 150W 45

46 46

47 47

48 NIBE BIAWAR sp. z o. o. Al. Jana Pawła II Białystok serwis@biawar.com.pl phone no fax

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