POWER. Installation, user and maintenance manual. Cast-iron wood gasification boiler. The section for the user is at the end of the manual

Transcription

1 Cast-iron wood gasification boiler POWER Installation, user and maintenance manual The section for the user is at the end of the manual

2 The appliance must be installed by qualified personnel in compliance with the technical standards and national and local legislation in force. In addition, the instructions on safety, installation, maintenance and operation provided in this manual must be observed. Instructions for disposing of the appliance (European Directive 00/96/EC) The appliance, at the end of its working life, MUST BE DISPOSED OF SEPARATELY, as required by the legislation in force. It MUST NOT be disposed of as municipal waste. It can be delivered to separate waste collection centres, if such exist, or to the resellers that provide this service. Separate waste disposal avoids potential hazards to the environment and human health. It also allows many recyclable materials to be recovered, with significant economic and energy savings. The appliance shows the following symbol signifying separate waste disposal as required by the European Directive. - -

3 - - GENERAL

4 Dear Customer, Thank you for having chosen our appliance, a simple, high quality and high efficiency product that will certainly satisfy your comfort requirements. PRESENTATION Please carefully read this manual before use, and in particular observe the WARNINGS AND SAFETY RULES. Furthermore, the appliance should be maintained by personnel from the EDILKAMIN Technical Service, who are specifically trained to perform the maintenance operations, using original spare parts where required. This manual is an integral part of the appliance and consequently must be carefully kept for all future reference or to be passed on to other owners or users. Best regards. The Management WARRANTY The POWER appliances come with a SPECIFIC WARRANTY starting from the date this is validated by the Technical Service. The warranty does not cover the components subject to normal wear and tear, such as the refractory burner, the stainless steel duct and the ash container. CONFORMITY The POWER appliances are compliant with: PED directive 97//EEC Low Voltage Directive 7//EEC Standard EN 0.5 For the appliance serial number see the rating plate. The Management - 4 -

5 CONTENTS SAFETY WARNINGS AND SAFETY RULES Pag. 6 PROHIBITED ACTIONS 6 GENERAL INFORMATION ON USING WOOD FUEL Pag. 7 DESCRIPTION 7 IDENTIFICATION 8 LAYOUT OF THE MAIN COMPONENTS 9 TECHNICAL SPECIFICATIONS 0 probes CONTROL PANEL WIRING DIAGRAMS CONTENTS INSTALLATION RECEIVING THE PRODUCT Pag. 4 DIMENSIONS AND WEIGHT 4 HANDLING 5 BOILER ROOM 5 NEW INSTALLATION OR INSTALLATION REPLACING ANOTHER APPLIANCE 6 WATER CONNECTIONS 6 PRINCIPLE DIAGRAM 7 FLUE GAS OUTLET AND COMBUSTION AIR INTAKE 9 HANDLE ON THE LOADING DOOR 9 CHANGING THE DIRECTION OF OPENING 0 ASSEMBLING THE MICROSWITCH INITIAL AIR REGISTER SETTINGS ASSEMBLING THE FAN ASSEMBLING THE CASING AND THE CONTROL PANEL ELECTRICAL CONNECTIONS 5 FILLING AND EMPTYING THE SYSTEM 7 COMMISSIONING 8 REACHING STEADY STATE 0 TOPPING UP THE WOOD 0 SETTING THE TIMER ADJUSTING THE COMBUSTION AIR CONTROL DEVICES ON THE APPLIANCE CHECKS MAINTENANCE MAINTENANCE AND CLEANING Pag. TROUBLESHOOTING 5 OPERATION (FOR THE USER) IGNITING THE APPLIANCE AND FIRST LOAD Pag. 6 SUBSEQUENT LOADS 8 SHUTDOWN 40 MAINTENANCE 4 ordinary CLEANING 4 TROUBLESHOOTING 4 USEFUL REFERENCES 44 NOTES

6 WARNINGS AND SAFETY RULES After having removed the packaging, check that the material supplied is intact and complete; if this is not the case, contact the reseller that sold the appliance. The appliance must be installed by professionally qualified personnel in compliance with the national and local legislation in force and the instructions provided in the manual supplied with the appliance. SAFETY The appliance must be used for the intended purpose. EDILKAMIN is not liable for any damage caused to people, animals or things due to errors in installation, control, maintenance and improper use of the appliance. In the event of water leaks, disconnect the appliance from the mains power supply, close the water supply and promptly notify the Technical Service or other professionally qualified personnel. If the appliance is not used for an extended period, at least one of the following operations must be performed: - Place the main switch on the appliance and the main system switch in the "off" position - Close the cocks on the water circuit - Empty the central heating and domestic hot water systems if there is the danger of frost. The manual is an integral part of the appliance and consequently must ALWAYS be kept with the appliance when transferred to another owner or user, or installed in another system. The manual must be kept carefully and if damaged or lost a replacement can be ordered form the Technical Service. The appliance must be serviced at least once a year. PROHIBITED ACTIONS DO NOT allow the appliance to be controlled by children or incapable persons without supervision. DO NOT touch the appliance when barefoot or with wet parts of the body. DO NOT perform any service or cleaning operations without having first disconnected the appliance from the mains power supply, placing the main system switch and the main switch on the appliance in the off position. DO NOT perform any cleaning operations when the boiler is hot or when there are coals inside the boiler. DO NOT use fuel containers to dispose of the combustion residues. DO NOT adjust the safety or control devices without the authorisation and instructions of the manufacturer of the appliance. DO NOT pull, remove or twist the electrical cables coming out of the appliance, even if these are disconnected from the mains power supply. DO NOT plug or reduce the size of the ventilation openings in the room where the appliance is installed and on the appliance (if present). The ventilation openings are essential for correct combustion. DO NOT leave containers with flammable substances in the room where the appliance is installed. DO NOT dispose of the packaging material in the environment, as this may be a potential source of danger. It must be disposed of according to the legislation in force

7 INFORMATION ON USING WOOD FUEL Firewood is a solid fuel and is a precious source of energy. It readily absorbs moisture and consequently when burnt leaves evident traces. Storing the fuel in sheltered, dry and slightly ventilated areas reduces the moisture level and consequently the fouling of the boiler, improving heat output. The best combustion techniques (gasification and pyrolysis) are improved by frequent cleaning and correct fuel storage. Cleaning the inside of the boiler ensures maximum efficiency and limits atmospheric emissions. GENERAL Desiccation and gasification chamber Primary air Secondary air Combustion chamber Flue gas path DESCRIPTION The POWER boilers are hot water generators that operate by gasification of wood, with the combustion chamber kept at negative pressure and fan-assisted combustion with reverse flame. They feature a high quality and extremely thick EN GJL 00 cast-iron body. The large heat exchange surface, the fins in the flue gas path and the burner made from refractory material ensure exceptional resistance to corrosion and very high efficiency that remains constant over time (self-cleaning effect). The appliances can independently serve central heating systems or combined central heating and domestic hot water circuits, when connected to a storage cylinder. On their own or combined with another heat generator they can supply an energy accumulator. The control panel includes all the safety and control devices, in compliance with the legislation and standards in force, and has been designed expressly to guide the user in the operation of the boiler. The doors can be opened in either direction, and leave the factory with opening to the right, however, if required, the direction can be changed

8 IDENTIFICATION The appliance is identified by: - the Technical rating plate that MUST be applied by the installer, after assembling the casing, so that it is legible when the appliance is installed (for example, on one of the side panels as shown on page 6). GENERAL - the Body rating plate applied to the front of the body NAME CODE MAXIMUM AVERAGE HEAT OUTPUT MAX OPERATING PRESSURE BOILER WATER CAPACITY POWER SUPPLY SERIAL NUMBER YEAR OF CONSTRUCTION MINIMUM AVERAGE HEAT OUTPUT MAX OPERATING TEMPERATURE CLASS INDEX OF PROTECTION YEAR OF CONSTRUCTION SERIAL NUMBER MAX POWER INPUT WARNING If the rating plates or any other means of clearly identifying the product are defaced, removed or lost, proper installation and maintenance may be rendered difficult

9 LAYOUT OF THE MAIN COMPONENTS 4 GENERAL Control panel Loading door Door handle/knob 4 Combustion air distributor 5 Primary air register 6 Combustion air intake 7 Secondary air register 8 Combustion chamber door 9 Flame inspection window 0 Ash container Combustion chamber Wood desiccation and gasification chamber Mobile smoke plate 4 Casing 5 Probe socket 6 By-pass 7 Flue attachment 8 Fan 9 Insulation 0 Smokebox Cleanout door - 9 -

10 TECHNICAL SPECIFICATIONS The data shown in the table were measured by an accredited organisation in compliance with European standard EN0.5, which applies specifically to this type of appliance. The performance data refer to the average value over hours of operation and with a complete load of wood. GENERAL DESCRIPTION POWER 4 POWER Fuel Only logs of wood ( to 0% RH) Destination country/countries CEE Rated max average heat output (Pn Max) 4,,9 kw Rated min average heat output (Pn Min) 7 5 kw Useful efficiency at Pn Max 78,4 77, % Average flue gas temperature (ΔT) > 0 ( Max) C Negative pressure at the stack (Min/Max) 0,5 / 0,5 mbar Maximum temperature allowed 0 C Operating temperature (range) C Minimum return temperature allowed 50 C Max operating pressure "PMS" 4 bar Power supply 0 ~ 50 V ~ Hz Max power input 0 W Index of protection X0D IP Class of the appliance (**) n CO < 400 (*) < 400 (*) mg/m Flue gas mass flow-rate,4, g/sec Duration of one load > h Diameter of the stack fitting 50 mm Water-side pressure drop (ΔT=5 C) 0 50 mbar Water-side pressure drop (ΔT=0 C) 8 0 mbar Water content in the boiler l Sections 5 7 No. (*) At 0% O referring to dry flue gas at 0 C, 0 mbar. (**) Based on the efficiency and the emissions. Wood desiccation and gasification chamber Size of the pieces of fuel H Ø H A Average W P Model 4 Average W 4 cm H 45 cm H 5 cm P 40 cm Volume 78 6 l Model 4 A (max) 50 cm Ø ~ 5 cm Max loadable weight (typical) 0 0 Kg - 0 -

11 probes Probe sheath - Boiler and heat removal thermostat probe (TC) - Minimum thermostat probe (TM) - Safety thermostat probe (TST) - Boiler thermometer probe (TMC) Flue gas thermostat probe (TF) GENERAL CONTROL PANEL Ip SAE TMC APC SF FU TST TC AV E/I SCL SV Ip Main switch SAE Power indicator TMC Boiler thermometer APC Activate loading procedure SF Minimum flue gas temperature indicator light FU Fuse TST Thermal safety thermostat with manual reset TC Boiler thermostat with heat removal function AV Fan shutdown E/I Summer/winter selector switch SCL Load wood indicator light SV Fan indicator light Functional notes - Constant operation at steady temperature: the appliance always operates at the set temperature so as to effectively supply the system connected and any storage cylinder. Total shutdown logic is not adopted. - Activate loading procedure (APC): pressing APC starts the fan, thus preventing gas and smoke from being released into the room when opening the loading door. - Load wood indicator light (local and remote): the SCL signal warns that the appliance has run out of wood and that a new load is required. This is featured on the control panel and can also be available as a remote control signal. - -

12 WIRING DIAGRAMS CR. CR. CR. CR.4 CR GENERAL TM TC TF CR R R AV T APC Ip TST SAE SF SV SCL R E/I FU JP JP IG L N 0V~50Hz SCL MP TA TB CB CI V Responsibility of the installer IG Main system switch Ip Main switch FU Fuse (6, A - 50V T) SAE Power indicator light MP Loading door microswitch R Loading door relay CR Relay contact R Minimum temperature relay CR.-CR.4 Relay contacts TM Minimum thermostat (50 C) TB Storage cylinder thermostat (optional) CB Storage cylinder pump (optional) TA Room thermostat E/I Summer/winter selector switch CI TC AV T TST V SV SCL TF SF APC R CR System pump Boiler thermostat (70-85 C) Fan shutdown Timer(40 minutes) Thermal safety thermostat (0 C) Thermal safety thermostat Fan indicator light Load wood indicator light Flue gas thermostat (85 C) Flue gas thermostat indicator light Activate loading procedure Flue gas thermostat relay Relay contact - -

13 FU Ip CR. CR. CR. CR.4 CR GENERAL MP TM TB JP TC TF CR TA JP SAE AV E/I APC T R R TST CB CI SCL R V SV SF Ip Main switch FU Fuse (6, A - 50V T) SAE Power indicator light MP Loading door microswitch R Loading door relay CR Relay contact R Minimum temperature relay CR.-CR.4 Relay contacts TM Minimum thermostat (50 C) TB Storage cylinder thermostat (optional) CB Storage cylinder pump (optional) TA Room thermostat E/I Summer/winter selector switch CI TC AV T TST V SV SCL TF SF APC R CR System pump Boiler thermostat (70-85 C) Fan shutdown Timer(40 minutes) Thermal safety thermostat (0 C) Thermal safety thermostat Fan indicator light Load wood indicator light Flue gas thermostat (85 C) Flue gas thermostat indicator light Activate loading procedure Flue gas thermostat relay Relay contact - -

14 RECEIVING THE PRODUCT The POWER appliances are supplied in four boxes on a wooden pallet, protected by nylon wrapping and a cardboard box - Boiler body with outlet counterflange. Inside the desiccation/gasification chamber are the outlet and return stubs, the stainless steel duct. installation Attached to the boiler body is the document envelope (A), containing: - Technical rating plate - Installation, user and maintenance manual - Water pressure test certificate - Spare parts catalogue. - Boiler body casing and insulation, and bag with fastening screws. - Control panel and door microswitch, complete with cable and bag with fastening screws. 4 - Fan. 4 WARNINGS Use suitable safety and protection equipment when both removing the packaging and handling the appliance. This manual is an integral part of the appliance and consequently must be read before installing and commissioning the appliance and carefully kept for all future reference or to be passed on to other Owners or Users. A DIMENSIONS AND WEIGHT H H Dimensions and Weight POWER 4 POWER L 700 mm P mm H 00 mm H 80 mm Net weight (body only) Kg Overall weight Kg L P - 4 -

15 HANDLING Once the packaging has been removed: - Remove the boxes so that they are not damaged. - Remove the four screws () fastening the boiler to the pallet. - If hoisting equipment is available, suitable for the weight of the boiler (net weight), use the eyebolts () provided on the body and lift it. - If no suitable hoisting equipment is available, handle the boiler manually, as follows: - Position the pallet near the point of installation - Use a suitable lever to push the boiler towards the rear of the pallet, sliding it along the two slides (). The front of the pallet will lift up, making it easier to unload the body. - When the body is on the floor, the slides can be left underneath the appliance, or can be removed by tilting the body to each side. WARNINGS Use suitable safety equipment and observe the maximum liftable weights per person. DO NOT dispose of the packaging material in the environment, as this may be a potential source of danger. It must be disposed of according to the legislation in force. installation BOILER ROOM The room where the appliance is installed must only be used for this purpose and must always comply with the technical standards and the legislation in force and have suitably sized ventilation openings. WARNINGS Check that the index of protection of the appliance is suitable for the characteristics of the room where the appliance is installed. INDICATIVE CLEARANCES Allow for the space required to access the safety/ control devices and to perform the maintenance and loading operations. DO NOT install the POWER appliances: - in inhabited rooms such as kitchens or living rooms, as special care is required and because, in some circumstances, smoke and odours may be released; - outdoors, as they are not designed for this type of installation. m,5 m 0,6 m 0,6 m - 5 -

16 NEW INSTALLATION OR INSTALLATION REPLACING ANOTHER APPLIANCE When the appliance is installed, check that: - The flue, if reused, - ensures the negative pressure required for the new appliance (see the table of technical specifications on page 0); 0); - is suitable for the temperature of the products of combustion, and has been calculated and constructed according to the reference standards; - is as straight as possible, airtight, insulated and is not blocked or choked; - is fitted with a condensate drain. - When the appliance is in standby, with the stack hot and the fan off, the primary air damper must remain closed. - The electrical system has been developed in compliance with the specific standards and by qualified personnel. installation - The system has been washed, cleaned of any slime and deposits, vented and tested for water tightness. - A water treatment system is used when the supply/top-up water requires. Two reference parameters for normal water are: - ph=6 8 - Total hardness 5 F. EDILKAMIN is not liable for any damage caused by the incorrect development of the flues. WATER CONNECTIONS The characteristics of the water fittings are shown in the figure: MI Central heating flow outlet (counterflange and threaded stub, Ø "/ M) = = MI RI Central heating return inlet (threaded stub, Ø "/ M) NOTE The threaded outlet and return stubs are located inside the packaging placed in the desiccation/gasification chamber. Remove them and fit them on the appliance. 6 RI - 6 -

17 PRINCIPLE DIAGRAM Diagram : POWER boiler connected directly to the systems CENTRAL HEATING FLOW OUTLET 0 MI RI CENTRAL HEATING RETURN INLET 0 5 Disconnect valve Pumps Non-return valves 4 Outlet manifold 5 Return manifold 6 Open expansion vessel 7 Pressure reducer 8 Filter/softener 9 Pump to prevent condensation 0 Drains Probe for pump to prevent condensation MI Central heating flow outlet RI Central heating return inlet IAF Cold water inlet installation IAF Diagram : POWER boiler with energy accumulator to supply the systems CENTRAL HEATING FLOW OUTLET 9 MI CENTRAL HEATING RETURN INLET 9 Disconnect valve Pumps Non-return valves 4 Outlet manifold 5 Return manifold 6 Open expansion vessel 7 Pressure reducer 8 Filter/softener 9 Drains 0 Energy accumulator Vent valve MI Central heating flow outlet RI Central heating return inlet IAF Cold water inlet RI 5 IAF

18 Diagram : POWER boiler, combined with another boiler, with energy accumulator to supply the systems 9 MI 6 0 CENTRAL HEATING FLOW OUTLET 4 9 Disconnect valve Pumps Non-return valves 4 Outlet manifold 5 Return manifold 6 Open expansion vessel 7 Pressure reducer 8 Filter/softener 9 Drains 0 Energy accumulator Vent valve installation RI IAF CENTRAL HEATING RETURN INLET 9 5 MI Central heating flow outlet RI Central heating return inlet IAF Cold water inlet Diagram 4: POWER boiler, combined with a DHW storage cylinder, with energy accumulator to supply the systems 9 MI 6 ACS CENTRAL HEATING FLOW OUTLET CENTRAL HEATING RETURN INLET RI 5 IAF Disconnect valve Pumps Non-return valves 4 Outlet manifold 5 Return manifold 6 Open expansion vessel 7 Pressure reducer 8 Filter/softener 9 Drains 0 Energy accumulator Vent valve MI Central heating flow outlet RI Central heating return inlet IAF Cold water inlet ACS (DHW) Domestic hot water WARNINGS The choice and installation of the components making up the system is left to the expertise of the installer, who must operate in a workmanlike manner and according to the legislation in force. The system must feature an open vessel and ensure a minimum head of 0 metres. The boiler can be used for the production of domestic hot water when combined with a storage cylinder. DO NOT install on-off devices on the safety discharge

19 FLUE GAS OUTLET AND COMBUSTION AIR INTAKE The flues must be made in compliance with the standards and the legislation in force, using pipes that are rigid, resistant to high temperature, condensate and mechanical stress, and that are airtight. 90 Ø WARNINGS The appliance takes in the combustion air from the room where the appliance is installed, which MUST FEATURE ventilation openings as required by the relevant technical standards. The smokebox, during operation, may reach very high temperatures. Non-insulated flues are potential sources of danger. The flue () must ensure the minimum negative pressure envisaged by the technical standards in force (see the table of technical specifications on page 0). When the appliance is in standby, with the stack hot and the fan off, the primary air damper must remain closed. Unsuitable or incorrectly sized flues () and stacks () may cause problems of condensation, negatively affect the combustion parameters and generate noise. The joints should be sealed using materials that can resist temperatures of at least 00 C (for example, putty, mastic or silicone products). installation HANDLE ON THE LOADING DOOR To avoid accidentally opening the loading door the handle has been specifically designed to act in two phases: - first, partial opening of the door - then, complete opening. F Door CLOSED Position To partially open the door, lift the handle completely (position ); it will remain hooked to the catch (F). To completely open the door, partially lower the handle (position ), to release the catch (F), and then lower it completely. To close the door, hold the handle down (position ) and push the door against the catch (F). Then lift the handle, so as to hook onto the catch (F) and then lower it fully. F F Position Position - 9 -

20 CHANGING THE DIRECTION OF OPENING The doors on the desiccation and gasification chamber and on the combustion chamber can be opened in either direction. In the factory they are fitted to open to the right, however, when required, this can be changed, as follows: Combustion air distributor - Unscrew the three nuts () and remove the distributor (), handling it with care so as to avoid damaging the components installed. Door on the wood desiccation and gasification chamber installation - Open the door () and remove the pins () that fasten it to the hinge (). A - Remove the hinge () and the handle catch (4) and fit them on the other side. B 5 IMPORTANT: - The hinge () must always have the stop (A) at the top - The handle catch (4) must be turned over so that the shaped edge (B) is always facing the outside Thoroughly tighten the locking screws (5). - Remove the stop ring (6) using a suitable screwdriver and remove the pin. - Move the handle to the other side, insert the pin in the opening provided and secure it with the previously removed catch

21 - Insert the pins () in the holes to secure the door () to the hinge (). 8 Door on the combustion chamber 7 - Unscrew the locking knob (7) and open the door (8) installation - Remove the pins (9) that fasten the door to the hinge (0). A - Remove the hinge (0) and the knob catch () and fit them on the other side. B 0 IMPORTANT: - The hinge (0) must always have the stop (A) at the top - The handle catch () must be turned over so that the shaped edge (B) is always facing the outside. - Thoroughly tighten the locking screws (). - Insert the pins (9) in the holes to secure the door to the hinge (0). - Replace the combustion air distributor () and fasten it with the three nuts (). - -

22 ASSEMBLING THE MICROSWITCH - Remove the microswitch (), complete with cable, from the control panel packaging and fit it to the combustion air distributor, on the side with the handle for opening the desiccation and gasification chamber door. - Close the door and make sure that the microswitch contact is activated. If this is not the case, adjust the lever () with a screwdriver accordingly. installation INITIAL AIR REGISTER SETTINGS - Set the primary air () and secondary air () registers on the intermediate notch (second) to prepare the appliance for first startup. ASSEMBLING THE FAN Once having removed the fan from the packaging, proceed as follows: - Unscrew the fastening screws (), remove the cable gland () and separate the protective casing () from the fan assembly (4). - Unscrew the screws (5) from the smokebox, and use them to fasten the fan assembly (4), complete with gasket, to the smokebox - Apply the protective casing () to the fan assembly (4), secure it with the screws () and fasten the cable gland () to the casing ()

23 ASSEMBLING THE CASING AND THE CONTROL PANEL - Remove the panels making up the casing, the fastening brackets and the insulation for the boiler body from the packaging - Apply the insulation () around the boiler body - Prepare the microswitch cable for connection to the control panel installation - Fasten the support brackets () to the side panels () - Insert the boiler body studs in the front holes on the side panels () - Fasten together the brackets () on the side panels and the brackets (4) on the smokebox, using the screws (5) - Fit the front crossbar (6) to the side panels ()

24 - Fasten the front panel (5) to the side panels () using the 6 screws supplied with the casing - Open the control panel by unscrewing the locking screws (6). - Fasten the bottom part (7) of the control panel to the front panel (5) using the 4 screws supplied - Insert the thermal safety (TST), minimum (TM) and boiler (TC) thermostat and the boiler thermometer (TMC) bulbs in the probe socket (8), inserting them through the guide rings located on the side panels - Insert the flue gas thermostat bulb in the socket (9) fitted on the smokebox. - Insert the fan connector and fasten it to the slot (0) on the side panel. installation - Fasten the rear panel () to the side panels (), using just the three screws supplied, as the screw (V) must be used to connect the earth wire V 0 - Complete the electrical connections as described in the corresponding chapter

25 M ELECTRICAL CONNECTIONS The POWER appliances require connection to the terminal block (M), as illustrated in the figures below; these connections must be made by the installer or other professionally qualified personnel. To access the terminal block, remove the front panel () from its housing. The external connection cables must be threaded through the cable glands on the side panels. NOTE - Connect the door microswitch (MP) cable. - Insert the fan cable plug () in the connector () fitted to the side panel. - Connect the panel earth wire, using the screw (V) that also fastens the rear panel (4). 4 V installation Diagram : central heating only M IG Main switch MP Desiccation and gasification chamber door microswitch TA Room thermostat CI System pump SCL Load wood indicator light (remote) SCL IG MP TA CI L N 0V~50Hz Diagram : central heating and DHW IG Main switch MP Desiccation and gasification chamber door microswitch TA Room thermostat CI System pump SCL Load wood indicator light (remote) TB Cylinder thermostat CB Water cylinder pump JP-JP Jumpers JP JP IG MP SCL TA CB CI L N 0V~50Hz TB NOTE: jumpers JP and JP must be removed

26 WARNINGS The following measures are compulsory: The use of an omnipolar thermal overload switch, mains disconnect switch, compliant with the EN standards. The power cable must be housed in a rubber sheath, H05RR-F or equivalent, with a minimum cross-section of,5 mm. Observe the connection L (Live) - N (Neutral). Leave the earth wire at least cm longer than the L (Live) - N (Neutral) wires. Refer to the wiring diagrams in this manual for any operations on the electrical system. Connect the appliance to an effective earth system (*). DO NOT use the water pipes to earth the appliance. (*) EDILKAMIN is not liable for any damage due to the failure to earth the appliance and to observe the information provided on the wiring diagrams. installation Once the electrical connections are complete: - Fit the front panel and cover on the control panel and lock it with the screws that were removed previously. 9 - Fasten the rear panel (8) to the side panels (), using the screws supplied. - Fit the top panel (9). IMPORTANT: When assembly has been completed, the installer must apply the TECHNICAL RATING PLATE supplied to the casing, so that it is legible when the appliance is installed. For example, on one of the side panels as shown in the figure

27 FILLING AND EMPTYING THE SYSTEM Before starting the system filling and emptying operations, move the main system switch (IG) and the main switch (Ip) on the control panel to the off position. IG Ip FILLING - Check that any system drain cocks () are closed. - Open the on-off devices () of the system water and in the water circuit and slowly fill until activating the valve/float () installed on the open expansion vessel. CENTRAL HEATING FLOW OUTLET installation WARNINGS To assist the removal of air from the system, open the vent valves, if featured, with the due precautions. The on-off devices () in the water circuit must remain open to allow the circuit to be topped up. To avoid the risk of frost when the system is not used, add suitable antifreeze fluid to the water. CENTRAL HEATING RETURN INLET EMPTYING - Check that the on-off devices () in the water circuit are closed. - Connect the drain cock () and open it. IAF - 7 -

28 COMMISSIONING PRELIMINARY CHECKS Before commissioning the appliance, check that: - The on-off devices in the water circuit are open - The water circuit has been vented. - The electrical connections have been completed correctly - The flues and combustion air intake openings have been developed correctly. - The primary air and secondary air registers are both set to notch. - The thermostat probes are correctly fitted in the corresponding sockets. IG Ip To ignite and load the appliance for the first time: installation - Move the main system switch (IG) and the main switch (Ip) on the control panel to the ON position - Set the room thermostat TA so that it is activated (around 0 C) Open the loading door (), and insert the stainless steel duct () in the special housing on the burner - Place small pieces of paper and dry wood (4) on the bottom of the chamber () and ignite them - Wait for them to ignite and then close the loading door () 4 - Press the button (APC), make sure the green indicator light (SV) comes on and hold it until the red light (SF) goes off APC SF SV

29 Wait a few minutes, open the loading door and load the appliance. - Close the loading door (). - Make sure the flame is visible through the window (5). - Set the boiler thermostat (TC) between Tmax and Tmin. The appliance will remain on until the set temperature is reached. POSSIBLE FAILED IGNITION If the red light (SF) is still on a couple of minutes after having pressed the button (APC), the ignition procedure has FAILED. Open the loading door and repeat that above operations. 6 Make sure: - that the level of wood does not exceed the smoke plate (6), and the wood is placed depth-wise in the chamber, in an orderly fashion and without being jammed in. - use complete loads of wood to both maximise operating autonomy and reduce the formation of dirt. Complete loads means the loading door is opened less frequently and the level of comfort is maintained. 5 installation WARNINGS Wear protection garments to avoid possible burns or problems when handling the wood. DO NOT open the loading door before have pressed the button (APC), to avoid the possible leakage of smoke from the desiccation and gasification chamber. TST TC TMC IMPORTANT The activation of the safety thermostat (TST) is not signalled by indicator lights, but rather by the boiler thermometer (TMC) (T>0 C). To reset normal operation: - Wait for the temperature in the boiler to fall below 00 C. - Remove the cap () from the thermal safety thermostat (TST). - Press the manual reset rod ()

30 REACHING STEADY STATE When the boiler has started, the "reaching steady state" phase commences, during which the water temperature must reach the value set using TC within 40 minutes TC SCL If this is not the case, the indicator light (SCL) comes on. The probable causes are: - insufficient fuel - insufficient timer setting - heat required higher than the output delivered APC SV installation To restore normal operating conditions and the 40 minute time limit, press the button (APC) and make sure the indicator light (SV) comes on TOPPING UP THE WOOD To top-up the load: APC SV - Press the button (APC) and make sure the fan operating indicator light (SV) comes on Slowly open the loading door () (see page 9) and place the wood neatly on the existing fuel - Close the loading door ()

31 SETTING THE TIMER The time limit is set using the timer (T): IG Ip - Move the main system switch (IG) and the main switch (Ip) on the control panel to the "OFF" position Open the control panel by unscrewing the locking screws. - Set the desired time by adjusting the setting screw (). he position of the screw is determined by multiplying the value shown on the timer by 6. E.g.: position 0 = minutes (0x6). When the setting has been made, replace and secure the cover on the control panel. T installation ADJUSTING THE COMBUSTION AIR The air required for combustion is taken in by the fan through the damper () and is divided into primary air and secondary air flows. ADJUSTING THE PRIMARY AIR The primary air is used to assist the gasification process and produce the combustible mixture. It affects the boiler output, the duration of the load of wood and is adjusted using the register (). THIRD notch FIRST notch ADJUSTING THE SECONDARY AIR The secondary air is used to optimise the quality of the flame. It affects the efficiency of combustion and is adjusted using the register (). SECOND notch Both registers () and () are normally set to the same notch. However, depending on the type of wood used and the moisture content, the registers may have different settings. Setting on the FIRST notch: Minimum output of the appliance and longer duration of the load. Positioning on the THIRD notch: Maximum output of the appliance and shorter duration of the load. WARNINGS To assess the results of the adjustments made, first wait 5-0 minutes. Best performance is achieved after two - three days of operation. - -

32 CONTROL DEVICES ON THE APPLIANCE The appliance is fitted with the following control devices: - Thermal safety thermostat with manual reset (0 C; 0/-6 C). - Boiler thermostat with heat removal function. This has two functions: - Control the water temperature in the boiler from 70 C (min.) to 85 C (Max). - Start the system pump or the storage cylinder pump, where featured, when the temperature in the boiler exceeds the set temperature by 0 C. - Timer set to 40 minutes (range of settings from 6 to 0 minutes). - Minimum thermostat (0-90 C), set to 50 C. - Flue gas thermostat (0-00 C), set to 85 C. installation NOTE: The minimum and flue gas thermostats can be accessed after having removed the cover () on the control panel. The factory settings should not be modified. AVVERTENZA DO NOT tamper with the safety thermostat. Minimum thermostat Flue gas thermostat CHECKS After the appliance has been commissioned, make sure that the fan stops and starts again, with the light (SV) on, when: TC SV Changing the setting of the boiler thermostat (TC) IG - Moving the main system switch (IG) and the main switch (Ip) on the control panel, to the "on" and/or off position. - -

33 MAINTENANCE AND CLEANING Periodical maintenance is a legal requirement and is essential for the safety, efficiency and life of the appliance. This ensures the condition of the components subject to normal wear can be checked and the deposits removed from the areas that are inaccessible to the user. It must be performed by qualified personnel at least once a year so as to clean the entire flue gas path: desiccation/ gasification chamber, combustion chamber, smokebox and flues. IG Ip - Before starting the maintenance and/or cleaning operations, move the main system switch (IG) and the main switch (Ip) on the control panel to the off position and wait for the boiler to cool down To access the inside of the appliance: - Unscrew the three nuts () and remove the distributor (), handling it with care so as to avoid damaging the components installed. - Open the loading door () and remove the smoke door (4) for better access. - Make sure there are no hot coals underneath the ash. - Lift and remove the duct (5) from its housing, checking for wear. Replace it if necessary. - Clean the walls of the desiccation/gasification chamber, using suitable equipment and remove/vacuum up the residues. 4 5 MAINTENANCE - Open the combustion chamber door (6). - Make sure there are no hot coals underneath the ash. 6 - Remove and empty the ash container (7). - Clean the inside parts using suitable equipment. - Remove/vacuum up the residues

34 - Disconnect the fan connection cable (8) and remove the fan (9), in the reverse order to that described on page - Remove the rear panel (0) 8 - Remove the cleanout door () - Clean the fan and the walls of the boiler and the smokebox. - Remove the residues. Clean all removed components, then follow the above steps in the reverse order to refit them. The gaskets removed when dismantling should be replaced. 9 0 WARNINGS DO NOT use equipment that may damage the refractory burner. MAINTENANCE The flue and stack must be checked and cleaned so as to avoid possible malfunctions and/or dangers due to the creosote that forms along the flue gas path. DO NOT use fuel containers to dispose of the combustion residues

35 TROUBLESHOOTING There is a smell of fumes. Problem Cause Corrective Action The boiler does not reach the set temperature Boiler thermal safety shutdown The boiler has reached the set temperature but the radiators are still cold - Flue gases are escaping into the air - Fan - Ignition and/or loading of the boiler - Wood poorly loaded in the desiccation chamber or insufficient load - The capacity required by the system is higher than the output supplied by the appliance - Clean and check the tightness of the flue gas path - Check that the loading and combustion chamber doors close correctly - Check the wiring - Check the correct position of the AV switch - Replace the fan - Follow the procedure described in this manual - Rearrange the wood in the desiccation chamber - Top-up the load - Set the primary air and secondary air registers on the top notch (e.g.: from Notch to Notch ) - The setting of Timer T is too short - Set a longer time - Check the position of the bulb - Boiler thermostat - Check the electrical connection - Replace the thermostat - Check the position of the bulb - Boiler thermostat - Check the electrical connection - Replace the thermostat - Open all the on-off devices in the water system - No water - Check the correct operation of the automatic valve on the open expansion vessel - Air in the circuit - Bleed the circuit - Pump malfunctioning - No signal from the room thermostat - Reset the pump - Replace the pump - Check the room thermostat and the connections - Flue blocked - Clean the flue gas path MAINTENANCE Flue gas emissions dark in colour - Air setting - Check and change the position of the registers - Unsuitable wood used (unseasoned) - Use seasoned wood (-0% RH) - 5 -

36 IGNITING THE APPLIANCE AND FIRST LOAD The user of a wood-fired boiler must be aware that the igniting and loading the boiler for the first time is a normal procedure whose frequency depends on the way the appliance is operated. IG Ip - Move the main system switch (IG) and the main switch (Ip) on the control panel to the ON position. - Set the room thermostat TA so that it is activated (around 0 C) Open the loading door (), place small pieces of paper and dry wood () on the bottom of the chamber () and ignite them. - Wait for them to ignite and then close the loading door (). 4 OPERATION USER - Press the button (APC), make sure the green indicator light (SV) comes on and hold it until the red light (SF) goes off APC SF SV

37 Wait a few minutes, open the loading door and load the appliance. - Close the loading door (). - Make sure the flame is visible through the window (6). - Set the boiler thermostat (TC) between Tmax and Tmin. 7 The appliance will remain on until the set temperature is reached. POSSIBLE FAILED IGNITION If the red light (SF) is still on a couple of minutes after having pressed the button (APC), the ignition procedure has FAILED. Open the loading door and repeat that above operations. Make sure: - that the level of wood does not exceed the smoke plate (7), and the wood is placed depth-wise in the chamber, in an orderly fashion and without being jammed in. - use complete loads of wood to both maximise operating autonomy and reduce the formation of dirt. Complete loads means the loading door is opened less frequently and the level of comfort is maintained. 6 WARNINGS Wear protection garments to avoid possible burns or problems when handling the wood. DO NOT open the loading door before pressing the button (APC), to avoid the possible leakage of flue gas from the desiccation and gasification chamber. IMPORTANT The activation of the thermal safety thermostat (TST) is not signalled by indicator lights, but rather by the boiler thermometer (TMC) (T>0 C). To reset normal operation: - Wait for the temperature in the boiler to fall below 00 C. - Remove the cap () from the thermal safety thermostat (TST). - Press the manual reset rod (). TST TC TMC OPERATION USER - 7 -

38 SUBSEQUENT LOADS The wood can be loaded before it runs out or alternatively when the load wood indicator light (SCL) comes on. APC SCL WARNINGS Before loading the wood wear protection garments to avoid possible burns or problems when handling the wood. DO NOT open the loading door before pressing the button (APC), to avoid the possible leakage of flue gas from the desiccation and gasification chamber GENERAL LOADING AND LOADING WHEN THE INDICATOR LIGHT "SCL" HAS JUST COME ON To top-up the load: APC SV - Press the button (APC) and make sure the indicator light (SV) comes on. - Carefully open the loading door () (see page 9), and place the wood neatly on the existing fuel. - Close the loading door () LOADING WHEN THE INDICATOR LIGHT "SCL" HAS BEEN ON FOR SOME TIME OPERATION USER When the load wood indicator light (SCL) has been on for some time: - Press the button (APC) and make sure the fan operating indicator light (SV) comes on. - Carefully open the loading door () (see page 9), and check whether or not there are hot coals on the bottom of the chamber. If there are hot coals: - Spread them out across the bottom of the desiccation and gasification chamber - Neatly place new wood on top - Close the loading door ()

39 If the coals are extinguished: AV SV - Press the fan shutdown switch (AV) and check that the green indicator light (SV) goes off Place small pieces of paper and dry wood () on the bottom of the chamber () and ignite them. - Wait for them to ignite and then close the loading door () 4 - Press the fan shutdown switch (AV) and check that the green indicator light (SV) comes on. APC SF SV Press the button (APC), make sure the green indicator light (SV) comes on and hold it until the red light (SF) goes off, if on. - Wait a few minutes, open the loading door and load the appliance OPERATION USER - 9 -

40 SHUTDOWN TEMPORARY SHUTDOWN IG Ip In the event of temporary absence over the weekend, brief trips, etc. and when the outside temperature is above ZERO, proceed as follows: Move the main system switch (IG) and the main switch (Ip) on the control panel to the "OFF" position. - Remove the ash from the combustion chamber. EXTENDED SHUTDOWN If the appliance is not used for an extended period, at least one of the following operations must be performed: IG Ip - Move the main system switch (IG) and the main switch (Ip) on the control panel to the "OFF" position. - Close the on-off cocks in the water system. - Remove the ash and carefully clean the desiccation/ gasification and combustion chambers. - Assess whether the Technical Service needs to be contacted for more thorough cleaning WARNINGS OPERATION USER Empty the system or add suitable antifreeze fluids if there is the danger of frost. A container with powdered lime should be placed inside the boiler to absorb the humidity

41 MAINTENANCE Periodical maintenance is a legal requirement and is essential for the safety, efficiency and life of the appliance. This ensures the condition of the components subject to normal wear can be checked and the deposits removed from the areas that are inaccessible to the user. It must be performed by qualified personnel at least once a year so as to clean the entire flue gas path: desiccation/ gasification chamber, combustion chamber, smokebox and flues. ordinary CLEANING - Before starting the cleaning operations, move the main system switch (IG) and the main switch (Ip) on the control panel to the off position and wait for the boiler to cool down. IG Ip EXTERNAL CLEANING The casing can be cleaned using cloths dipped in soap and water. For hard-to-remove stains, dip the cloth in mixture of 50% water and denatured alcohol or other specific products. Once finished cleaning, carefully dry the appliance. WARNINGS Do not use abrasive products, petrol or trichloroethylene. Always make sure there are NO hot coals underneath the ash. Use suitable safety equipment. The boiler is supplied without accessories, as cleaning can be performed using normal household utensils that can be purchased at shops that sell products for stoves and fireplaces. OPERATION USER - 4 -

42 INTERNAL CLEANING - Open the loading door (). - Make sure there are no hot coals underneath the ash - Clean the walls of the desiccation/gasification chamber, using suitable equipment and remove/vacuum up the residues - Open the combustion chamber door () - Make sure there are no hot coals underneath the ash - Remove and empty the ash container () - Clean the inside parts and remove/vacuum up the residues - Close the doors () and (). WARNINGS DO NOT use equipment that may damage the refractory burner. DO NOT use fuel containers to dispose of the combustion residues. OPERATION USER - 4 -

43 TROUBLESHOOTING There is a smell of fumes Problem Cause Corrective Action The boiler does not reach the set temperature Boiler thermal safety shutdown The boiler has reached the set temperature but the radiators are still cold - Fumes are escaping into the air - Fan always off - Ignition and/or loading of the boiler - Wood poorly loaded in the desiccation chamber or insufficient load - The thermal safety thermostat is activated - No water - No signal from the room thermostat - Check that the loading and combustion chamber doors close correctly - Check the correct position of the AV switch - Follow the procedure described in this manual - Rearrange the wood in the desiccation chamber - Top-up the load - Do not reset more than two times - Contact the Technical Service or other professionally qualified personnel - Set the room thermostat so that it is activated - Flue blocked - Clean the flue gas path Flue gas emissions dark in colour - Air setting - See the chapter on "ADJUSTING THE COMBUSTION AIR" - Unsuitable wood used (unseasoned) - Use seasoned wood (-0% RH) In the boiler does not start operating normally, contact the Technical Service or other professionally qualified personnel. OPERATION USER - 4 -

44 USEFUL REFERENCES APPLIANCE Reseller:... Name... Address... Phone... Installer:... Name... Address... Phone... CHIMNEY SWEEP Name... Address... Phone... Name... Address... Phone... Date Type of service OPERATION USER

45 FUEL Supplier:... Name... Address... Phone... Supplier:... Name... Address... Phone... Date Quantity supplied Date Quantity supplied Date Quantity supplied Date Quantity supplied NOTES OPERATION USER

46 NOTES OPERATION USER

47

48 EDILKAMIN S.p.A. 000 Lainate (MI) via Mascagni, 7 tel fax mail@edilkamin.com EDILKAMIN is dedicated to the continuous improvement of all its products. The appearance, dimensions and technical specifications of equipment, accessories and appliances may therefore be subject change.