VIADRUS P7C Manual for boiler operation and installation

VIADRUS P7C Manual for boiler operation and installation GB_2016_50 GB_2015_47

Content: p. 1 Boiler Use and Advantages... 3 2 Technical parameters of the boiler... 3 3 Description... 7 3.1 Boiler Construction... 7 4 Location and installation... 8 4.1 Regulations and guidelines... 8 4.2 Placement options... 10 5 Putting into operation instructions for contractual service organization... 11 5.1 Delivery and accessories... 11 5.2 Installation procedure... 12 5.2.1 Installation of boiler drum... 12 5.2.2 Dismantling the boiler shell... 13 5.2.3 Cleaning tools mounting... 13 5.3 Boiler hydraulic diagram... 14 5.4 Electrical wiring diagram... 15 5.5 Verification activities before the boiler commissioning... 17 5.6 Putting into operation... 18 5.7 Control, regulation and safety elements... 18 5.8 Device for removing excess heat... 18 5.9 Equipment for heat exhausting accumulating reservoir... 20 6 Operating Instructions... 20 6.1 Boiler operation by user... 21 6.1.1 Control elements description... 21 6.1.2 Firing... 21 6.1.3 Operation... 22 7 Boiler cleaning - maintenance... 22 8 Fault conditions... 23 9 IMPORTANT NOTICE... 24 10 Instructions for the product disposal after its useful life period... 24 11 Warranty and liability for defects... 25 This manual is the original operating and installation manual. 2

Dear Customer, Thank you for purchasing a pyrolytic solid fuel boiler VIADRUS P7C and thus showing your confidence in the company VIADRUS a.s. For the correct way of handling your new boiler, please read the instructions for its use (especially the Chap. 6 Operating Instructions, Chap. 7 Boiler cleaning Maintenance and Chap. 9 Important warnings). Please follow the current information and take notice of instructions issued by the manufacturer or installation company that installed your boiler so that the long-life trouble-free operation of your boiler can be guaranteed both to your and our satisfaction. 1 Boiler Use and Advantages Boiler trade name: VIADRUS P7C- Boilers type code: P7C-S22D-X 1.X 2; P7C-S30D-X 1.X 2; P7C-S38D-X 1.X 2 S standard 22; 30; 38 boiler output in kw D wood X 1 revision in the current year year of the product launch X 2 The boiler VIADRUS P7C is a pyrolytic low-pressure cast iron boiler for lump wood, designed especially for heating houses. VIADRUS P7C control is solved by automatic regulation, using a lambda sensor for continuous regulation of combustion air supplied to the boiler to make the combustion most efficient. Burning of other materials (e.g. plastic) is forbidden. Boiler Advantages: ecological operation; high efficiency; high lifetime of the Czech cast iron heat exchanger; sophisticated manufacturing technology on the automatic forming lines with consistent and approved quality of the production process (ISO 9001, ISO 14 001). performance grading according to the number of sections; simple operation and maintenance. preheating of the primary and secondary air; use of the lambda sensor for regulating the combustion air. 2 Technical parameters of the boiler Tab.. 1 Dimensions and technical parameters of the boiler Boiler type code S22D S30D S38D Boiler weight kg 500 610 720 Water content l 75 98 121 Flue socket diameter mm 160 Inner smoke pipe diameter mm 156 Stoking chamber volume l 80 100 120 Boiler dimensions: width x height mm 740x1434 depth mm 1050 1251 1453 Stoking chamber depth mm 390 590 795 Maximum water operating pressure kpa (bar) 400 (4) Minimum water operating pressure kpa (bar) 50 (0.5) Test water overpressure kpa (bar) 800 (8) Boiler hydraulic loss (at T 20 K) mbar 0.491 0.687 0.883 Inlet water lowest temperature at the boiler inlet water connection C 50 Cold water temperature C 10 Overpressure for the relief heat exchanger (DBV 1-02) bar 6 Water temperature control range (in the regulator) C 55-87 Noise level db Doesn t exceed level 65 db (A) Chimney draught mbar 0.20 0.25 0.30 Boiler connections heating water DN 50 return water DN 50 Supply voltage 1/N/PE 230V AC 50 Hz TN - S Electric power consumption W 60 Electric power consumption in standby mode W 4 Electrical protection IP40 3

Tab.. 2 Thermal technical parameters of the boiler VIADRUS P7C Boiler type code: S22D S30D S38D Rated power kw 22 30 38 Fuel consumption at rated output kg.h -1 5.5 6.8 9.5 Fuel calorific power MJ.kg -1 15.92 Fuel type Lump wood - hard Burning time h min. 2 Efficiency % 92.1 90.6 89.1 Flue gas temperature at the outlet C 141 145.5 161 Flue gas mass flow at the outlet kg.s -1 Boiler class in accordance with EN 303-5 5 5 5 The values shown in Tab. 1 and Tab. 2 were measured during tests carried out using a prescribed fuel. ATTENTION! Low fuel quality can significantly affect the boiler output and emission parameters. Boiler type code S22D S30D S38D L [mm] 1050 1252 1439 L1 [mm] 851 1051 1256 L2 [mm] 666 868 1070.5 L3 [mm] 764 996.5 1167 Fig.. 1 Main dimensions of the boiler 4

VIADRUS P7C-S22D-00.15 Condensing boiler no Cogeneration solid fuel fired boiler no Combined boiler no Fuel Preferred fuel (only one type): Other suitable fuel: Wood logs, the moisture content 25% yes no Wood chips, moisture content 15-35% no no Wood chips, moisture content > 35 % no no Pressed wood in the form of pellets or briquettes no no Sawdust, moisture content of 50% no no Other wood biomass no no Non-wood biomass no no Hard coal no no Lignite (including briquettes) no no Coke no no Anthracite no no Briquettes from a mixture of fossil fuels no no Other fossil fuels no no Briquettes from a mixture of the biomass (30-70%) and no no fossil fuels Other mixture of biomass and fossil fuels no no Properties when operated on the preferred fuel: Seasonal energy efficiency of the inner space heating ƞ s [%]: 80 Energy Efficiency Index EEI: C Name Designatio n Value Unit Name Designatio n Value Unit Useful heat output Useful efficiency - at rated heat output P n 22 kw - at rated heat output ƞ n 83.9 % - at [30%/50%] rated heat - at [30%/50%] rated heat P output, if applicable p - kw output, if applicable ƞ p - % Cogeneration solid fuel fired boiler: Consumption of auxiliary electrical power: Electrical efficiency at rated - at rated heat output el max 0.038 kw heat output ƞ el, n - % - at [30%/50%] rated heat output, if applicable el min - kw - built-in secondary equipment to reduce kw emissions, if applicable - in standby mode P SB 0.004 kw Contact information VIADRUS a.s. Bezručova 300 Bohumín 735 81 5

VIADRUS P7C-S38D-00.15 Condensing boiler no Cogeneration solid fuel fired boiler no Combined boiler no Fuel Preferred fuel (only one type): Other suitable fuel: Wood logs, the moisture content 25% yes no Wood chips, moisture content 15-35% no no Wood chips, moisture content > 35 % no no Pressed wood in the form of pellets or briquettes no no Sawdust, moisture content of 50% no no Other wood biomass no no Non-wood biomass no no Hard coal no no Lignite (including briquettes) no no Coke no no Anthracite no no Briquettes from a mixture of fossil fuels no no Other fossil fuels no no Briquettes from a mixture of the biomass (30-70%) and no no fossil fuels Other mixture of biomass and fossil fuels no no Properties when operated on the preferred fuel: Seasonal energy efficiency of the inner space heating ƞ s [%]: 80 Energy Efficiency Index EEI: C Name Designatio n Value Unit Name Designatio n Value Unit Useful heat output Useful efficiency - at rated heat output P n 38 kw - at rated heat output ƞ n 81.8 % - at [30%/50%] rated heat - at [30%/50%] rated heat P output, if applicable p - kw output, if applicable ƞ p - % Cogeneration solid fuel fired boiler: Consumption of auxiliary electrical power: Electrical efficiency at rated - at rated heat output el max 0.057 kw heat output ƞ el, n - % - at [30%/50%] rated heat output, if applicable el min - kw - built-in secondary equipment to reduce kw emissions, if applicable - in standby mode P SB 0.004 kw Contact information VIADRUS a.s. Bezručova 300 Bohumín 735 81 6

3 Description 3.1 Boiler Construction 1 Boiler drum 2 Ash door 3 Stoking door 4 Shell with fan 5 Heating water flange 6 Return water flange 7 Sealing 8 Ceramic nozzle 9 Left ceramics 10 Right ceramics 11 Upper ceramics 12 Servomotor flanges 13 Belimo actuators 14 Two-way safety valve DBV 1 02 15 Plug 1/2 16 Connecting hose 17 Discharge valve 18 Spring bracket 19 Spring 20 Lambda sensor 21 Round sealing cord 22 Round sealing cord 23 Left side part of the shell 24 Right side part of the shell 25 Shell rear part 26 Shell rear right part 27 Shell rear left part 28 Shell front lower part 29 Shell front middle part 30 Control box 31 Handle 32 Shell upper part 33 Flap rod Fig.. 2 Main part of the boiler 7

The main part of the boiler VIADRUS P7C is cast iron sectional boiler drum made of grey cast iron according to EN 1561, quality 150. Pressure parts of boiler correspond to strength requirements according to EN 303-5. The boiler drum is assembled of individual sections by means of pressed boiler inserts with 56 mm diameter and secured by anchor bolts. Sections create the feed space, combustion and ash space, water space and convective part of the boiler. Heating water outlet and inlet is located in the rear part of the boiler and is performed through two flanges with the outer thread G 2 for the connection to the heating system. Outlet with the thread G 1/2 is used to install the drain tap. Flue adapter fitted with channels for air preheating is connected to the rear section of the boiler. The lid with interposed insulation is connected to the smoke adapter; the lid prevents cooling of air preheated in the channels. The exhaust fan shell is connected to the smoke adapter. To clean the smoke adapter, three cleaning holes are placed along its perimeter, which ensure easy cleaning of the convection surface of the boiler rear section. The stoking and ash door are mounted to the front section. The air flowing into the boiler is regulated by the Belimo flaps located on the flanges, which are attached to the smoke adapter lid. The whole boiler drum is insulated by using a harmless mineral insulation which reduces losses by sharing heat into the surroundings. The steel shell is coloured by high-quality komaxit coat of paint. 4 Location and installation 4.1 Regulations and guidelines Boiler meets the following standards: EN ISO 12100:2011 Safety of machinery - General principles for design - Risk assessment and risk reduction EN 953+A1:2009 Safety of machinery - Protective covers - General requirements for the design and construction of fixed and movable protective covers CSN ISO 1819:1993 Equipment for continuous transport of cargo. Safety regulations. General provisions CSN ISO 11202:2010 Acoustics - Noise emitted by machinery and equipment - Determination of emission sound pressure levels at work stations and at other specified locations using approximate correction to the environment EN ISO 3746:2011 Acoustics - Determination of sound power levels and sound energy levels of noise sources using sound pressure Survey method using an enveloping measurement surface over a reflecting plane EN 303-5:2013 Boilers for central heating Part 5: Boilers for central heating for solid fuels, manually and automatically stocked, with nominal heat output of up to 500 kw Terminology, requirements, testing and marking. CSN 061008:1997 Fire safety of heat installations EN 62233:2008 Measurement methods for electromagnetic fields of household appliances and similar apparatus with regard to human exposure EN 60335 ed. A1 Safety of electrical appliances for household and similar purposes. Part 1: General requirements EN 15036-1:2007 Heating boilers - Test regulations for airborne noise emissions from heat generators - Part 1: Airborne noise emissions from heat generators. The boiler may be installed by a company holding a valid certification for its installation and maintenance. For the installation, a project must be elaborated in accordance with applicable regulations. The heating system must be filled with water that meets the requirements of CSN 07 7401 and especially its hardness must not exceed the required parameters. Tab.. 3 Recommended values Hardness mmol/l 1 Ca 2+ mmol/l 0.3 Concentration of total Fe + Mn mg/l (0.3)* *) recommended value ATTENTION!!! The manufacturer does not recommend to use antifreeze. 8

a) to the heating system CSN 06 0310 CSN 06 0830 CSN 07 7401 EN 303-5 b) on the chimney CSN 73 4201 c) regarding the fire regulations CSN 06 1008 EN 13501-1+A1 Heating systems in buildings Design and installation Heating systems in buildings Safety devices Water and steam for thermal energy equipments with working pressure up to 8 MPa. Boilers for central heating Part 5: Boilers for central heating for solid fuels, manually and automatically stocked, with nominal heat output of up to 500 kw Terminology, requirements, testing and marking. Chimneys and connecting flue pipes Design. Fire safety of heat installations. Fire classification of construction products and building structures Part 1: Classification using data from reaction to fire tests. d) to the system for the HW heating CSN 06 0320 Heating systems in buildings - Hot water preparation - Design and projection. CSN 06 0830 Heating systems in buildings Safety devices. CSN 75 5409 Internal water piping e) to the power supply network CSN 33 0165 Electrical regulations. Identification of conductors by colours or numerals. Procedure provisions CSN 33 1500 Electrical regulations. Revision of electrical equipments. CSN 33 2000-1 ed. 2 Low-voltage electrical installations Part 1: Fundamental principles, assessment of general characteristics, definitions. CSN 33 2000-4-41 ed. 2 Low voltage electrical installations - Part 4-41: Protection for safety - Protection against electric shock CSN 33 2000-5-51 ed. 3 Electrical installations of buildings Part 5-51: Selection and erection of electrical equipment Common rules CSN 33 2130 ed. 2 Low-voltage electrical installations Internal electric distribution lines CSN 33 2180 Electrical regulations. Connection of electric instruments and appliances. CSN 34 0350 ed. 2 Safety requirements for flexible cords and cables EN 60079-10-1 Explosive atmospheres Part 10-1: Classification of areas Explosive gas atmospheres EN 60079-14 ed.3 Explosive atmospheres - Part 14: Electrical installations design, selection and erection EN 60252-1 ed. 2 Capacitors for AC motors Part 1: In general Design, testing, dimensioning Safety requirements Instructions for installation and operation. EN 60335-1 ed.2 Electric appliances for household and similar purposes Safety Part 1: General requirements EN 60335-2-102 Electric appliances for household and similar purposes Safety Part 2-102: Special demands on appliances containing the electric connections and burning the gas, oil and solid fuels EN 60445 ed. 4 Basic and safety principles for man-machine interface, marking and identification Identification of equipment terminals, conductor terminations and conductors EN 61000-6-3 ed. 2 Electromagnetic compatibility (EMC) - Part 6-3: Generic standards Emission standard for residential, commercial and and light industrial environments. EN 61000-3-2 ed. 3 Electromagnetic compatibility (EMC) - Part 3-2: Limits - Limits for harmonic current emissions (equipment input current 16 A per phase). EN 61000-3-3 ed. 2 (ed. 3 Electromagnetic compatibility (EMC) - Part 3-3: Limits - Limitation of voltage changes, voltage fluctuations and flicker in public low-voltage supply systems, for equipment with rated current 16 A per phase and not subject to conditional connection. 9

4.2 Placement options When installing and using the boiler, all requirements of CSN 06 1008 must be complied with. The boiler positioning in the living space (including corridors) is prohibited! The boiler is approved for the basic environment AA5/AB5 according to CSN 33 2000-1 ed. 2. The boiler is equipped with the movable mains supply and plug. According to EN 60 335 1 ed. 2 p. 7.12.4, the boiler must be located so that the plug is accessible. The boiler positioning with regard to fire regulations: 1. Placement on the floor made of incombustible material place the boiler on a fireproof and heat-insulating base exceeding the boiler dimensions on the sides by 20 mm. if the boiler is installed in a cellar, we recommend to install it on a substructure at least 50 mm high. The boiler must stand horizontally, possible unevenness of the substructure is eliminated by means of adjusting screw of the motor mount. 2. Safe distance from flammable materials when installing and operating the boiler it is necessary to keep the safe distance of 200 mm from flammable materials with combustibility grade A1, A2, B and C (D); for easily flammable materials with combustibility grade E (F), which burn quickly and by themselves also after the ignition source removal (e.g. paper, cardboard, asphalt and tar boards, wood and fibreboards, plastics, flooring materials), the safe distance is doubled, that is 400 mm; the safe distance is to be doubled also when the fire reaction class is not proven. Tab.. 4 Fire reaction class Fire reaction class Examples of building materials and products classified to the fire reaction class (a choice from EN 13501-1+A1) A1 incombustible granite, sandstone, concrete, bricks, ceramic tiles, mortars, fire plasters,... A2 combustible with difficulty acumin, izumin, heraklith, lignos, boards and basalt felt, fibreglass boards,... B hardly combustible beech and oak wood, hobrex boards, plywood, werzalit, gypsum plasterboard, sirkolit,... C (D) medium combustible pinewood, larch, whitewood, chipboard and cork boards, rubber flooring,... E (F) easily combustible asphalt board, fibreboards, cellulose materials, polyurethane, polystyrene, polyethylene, PVC, Boiler positioning with regard to the necessary handling space: basic environment AA5/AB5 according to ČSN 33 2000-1 ed. 2, min. 1000 mm handling space must be left in front of the boiler; of the boiler; minimum distance between the boiler rear side and wall is 400 mm; a gap min. 800 mm is left on the side of fuel tank in case of the feed screw removal; minimum distance from the side wall is 100 mm; at least 450 mm must be left above the boiler for cleaning the convection surface of the heat exchanger. The boiler positioning with regard to electrical network (mains): The boiler must be placed in such a way that the plug in socket (230V/50Hz) is always accessible. Placing of fuel: dry fuel has to be used in order to ensure its proper burning in the boiler. Fuel stored in cellar or at least sheltered is recommended by the manufacturer; it is prohibited to store the fuel behind the boiler or next to the boiler in the distance shorter than 400 mm; the manufacturer recommends to keep the distance between the boiler and the fuel min. 1000 mm or store the fuel in a different room than the boiler is installed. Continuous air supply for burning and eventual ventilation must be provided into the room where the boiler is installed (the air consumption of the boiler VIADRUS P7C is about 75 m 3. h -1 ). Connection of the heating system piping or the heating element heater piping must be performed by authorized personnel. CAUTION: When connecting the boiler to the heating system, drain tap must be placed at the lowest point and as close to the boiler as possible. 10

Fig.. 3 The boiler positioning in boiler room 5 Putting into operation instructions for contractual service organization Putting into operation can be performed only by a contractual service company authorized to carry out this activity. 5.1 Delivery and accessories Standard equipment: boiler on the pallet in the box with the relevant number of sections including shell cleaning tools (cleaner, hook, brush with handle, spike) fan with shell 1pc accessories package 1pc electrical accessories package 1pc two-way safety valve DBV 1-02 1pc fill and drain tap 1/2 1 pc handling key 1pc BELIMO actuators 2 pc Actuators flanges 2 pc Heating water flange 1pc Return water flange 1pc Connecting hose 1pc Sales and technical documentation On request: Safety valve 1 pc Outside sensor CP6-P 1 pc Sensor CT4 length: 4m 1 pc Room controller ecoster 200 1 pc Internet Module econet 300 1 pc Bleeder valve 1 pc The boiler equipment ordered as "on request" is not included in the basic price of the boiler. 11

5.2 Installation procedure 5.2.1 Installation of boiler drum 1. Set the boiler drum on the basement or foundation. 2. Disassemble right rear shell (13), left rear shell (12) and the lower rear shell (15). 3. Mount the return water flange (3). Install fill and drain tap (4) and the connecting hose (4) on the flange. Return water inlet must be connected to the heating system via a demountable joint. 4. Mount the heating water flange. Install the plug (7) and the two-way safety valve DBV 1-02 (6) at the heating water outlet. The valve can be mounted in a horizontal position only. Connect the free end of the connecting hose to the safety valve. Heating water outlet pipe must be connected to the heating system via a demountable joint. 5. Mount flanges for the flap actuator (8) at the cover of smoke adapter with screws M6x12. 6. Adjust the flaps actuators (9) on the flanges so that the labeling of the flaps actuators and the flanges is consistent SAV-SAV, PAV- PAV. 7. Mount the fan with the shell (10) at the smoke adapter, before installing the shell it is necessary to apply mastic on the bearing joint between the shell and the smoke adapter. 8. Mount the rear parts of the boiler shell. 9. Connect the relevant electro. 10. Put the smoke pipe to the exhaust fan and insert into chimney hole. Smoke pipe diameter is given in Table. 1. When the flaps actuator are badly mounted, the boiler with operate incorrectly. 1 Boiler with the shell 2 Heating water flange 3 Return water flange 4 Fill and drain tap 5 Connecting hose 6 Two-way safety valve DBV 1-02 7 Plug G ½ 8 Flaps actuators flange 9 Flaps actuators 10 Shell with fan 11 Sealing 12 Left rear shell 13 Right rear shell 14 Hose bracket 15 Lower rear shell Fig.. 4 Installation of boiler drum 12

5.2.2 Dismantling the boiler shell IMPORTANT NOTICE: Connect the lambda sensor to the module only when the boiler is not connected to the mains. 1. Before removing the shells, wiring of the fan and the flaps actuators must be first disconnected. 2. First, dismantle the connecting hose bracket (1), right rear shell (2), left rear shell (3) and lower rear shell (4). 3. Before removing the upper part of the shell with the control box (5), disconnect the wiring leading to the lambda sensor or unscrew the lambda sensor from the smoke adapter. When handling with the lambda sensor, take extra care to avoid damage. 4. Removing the middle front part of the shell (6). 5. Before dismantling the middle lower part, unscrew the self-tapping screws M5. Then dismantle the middle lower part of the shell (7). 6. Dismount the handle of the stoking flap rod (8). 7. Unscrew the bolts M5x10 (A), which fix the side shells to the boiler drum. 8. Dismounting of the shell side parts (9,10). 1 Hose bracket 2 Right rear shell 3 Left rear shell 4 Lower rear shell 5 Upper part of the shell with the control box Fig.. 5 Dismantling the shell 6 Front middle shell 7 Lower middle shell 8 Handle 9 Right side shell 10 Left side shell 5.2.3 Cleaning tools mounting To mount or dismount the brush, point for the spike and the cleaner (if included), use common assembly tools and leather gloves. 13

5.3 Boiler hydraulic diagram 1 boiler, 2 ecomax regulator, 3 boiler pump, 4 storage vessel (Master), 5 auxiliary storage vessel (Slave), 6 auxiliary storage vessel (Slave), 7 charge pump of the auxiliary storage vessel, 8 discharge pump of the auxiliary storage vessel, 9 boiler temperature sensor type CT4, 10 main storage vessel temperature sensor (top) type CT4 (TBH), 11 main storage vessel temperature sensor (bottom) type CT4 (TBL), 12 heating circuit temperature sensor type CT4, 13 heating circuit temperature sensor type CT4, 14 heating circuit pump TO1, 15 heating circuit servo actuator TO1, 16 heating circuit pump TO2, 18 outdoor temperature sensor CT6-P, 19 ecoster room panel 200 with room thermostat functionality or traditional room thermostat connected to the ECOMAX regulator, 20 room temperature sensor type CT7 connected to ecoster200 (note: usage of the sensor type CT7 is not necessary if the set room temperature is uniform for the entire building), 21 auxiliary storage vessel temperature sensor type CT4, 22 main storage vessel temperature sensor (middle) type CT4 (TBM), 23 switching valve for zoned heating of the main storage vessel, 24 backup source, 25 HW circulating pump. Fig.. 6 Diagram with the storage tank - without additional modules, 14

Fig.. 7 CONTROL BOX CONTROL BOX Boiler circuit diagram 15 ecomax860d1-h CONTROL UNIT ecolambda MODULE 2 HC1 SENSOR HW SENSOR STORAGE TANK UPPER SENSOR STORAGE TANK BOTTOM SENSOR OUTDOOR SENSOR HC1 ROOM THERMOSTAT ZERO BRIDGE LAMBDA SENSOR PRIMARY AIR FLAP HC1 PUMP BOILER PUMP HW PUMP HW CIRCULATION PUMP HC2 PUMP DISCHARGE PUMP OF THE AUXILIARY STORAGE TANK SECONDARY AIR FLAP TERMINAL PLATE HC1 THREE-WAY VALVE HC2 THREE-WAY VALVE SAFETY BRIDGE Conductor colours: bk black bn brown bu blue gnye yellow-green ye yellow gn green gy grey wh white rd red pk pink og orange SAV X1 Y1 Y5 B9 BTr1 N O2 PAV Q1 Q2 Q3 Q4 Q6 Q11 B41 A4 B1 B3 B4 Key: A1 5.4 Electrical wiring diagram

CONTROL BOX COVER CONTROL BOX Fig.. 8 CONTROL BOX COVER Boiler electric diagram 16 Exit 12Vss B21 B40 BT1 BTr2 D MV X1 X5 X6 X7 X8 X10 X11 X12 X13 X14 X15 Key: A1 A6 B2 B6 B8 ecomax860d1-h CONTROL UNIT ecoster200 ROOM DVICE BOILER SENSOR HC2 SENSOR AUXILIARY STORAGE TANK SENSOR SAFETY THERMOSTAT OUTDOOR SENSOR MIDDLE STORAGE TANK SENSOR HC2 ROOM THERMOSTAT BOILER CONTROL PANEL FAN MOTOR TERMINAL PLATE Q1 CONNECTOR Y1 CONNECTOR Q3 CONNECTOR Q2 CONNECTOR BTr1 CONNECTOR B1 CONNECTOR B3 CONNECTOR B4 CONNECTOR B41 CONNECTOR B9 CONNECTOR SAFETY BRIDGE

5.5 Verification activities before the boiler commissioning Before the boiler commissioning it is necessary to check: 1. Filling the heating system with water (check thermomanometer) and tightness of the system. The heating system must be thoroughly flushed in order to wash out all impurities that can be deposited in distribution and heating elements and can cause damage to the pump. Water for filling the boiler and heating system must be clear and colourless, without suspended solids, oil and aggressive chemicals. Its hardness must comply with CSN 07 7401 and in case the hardness does not suit, water must be treated. Even the multiple heating of water with the higher hardness does not exclude salts depositing on the walls of the boiler dram. Settlement of 1 mm calcite reduces the heat transfer at a given point from the metal to water by 10%. Heating systems with the open expansion tank allow direct contact of the heating water with atmosphere. During the heating season the water expanding in the tank absorbs oxygen, which increases the corrosive effects while there is a considerable evaporation of water. To refill, only water treated according to CSN 07 7401 may be used. During the heating season it is necessary to keep a constant volume of water in the heating system. When refilling the heating system with water it must be ensured that no air is sucked into the system. Water from the boiler and the heating system must never be discharged or taken for usage except for the emergency cases like repairs etc. Water discharge and filling with new water increases the danger of corrosion and scale development. If it is necessary to refill water in the heating system, refill water only into the cold boiler in order to prevent damage of the exchanger. 2. Connection to the chimney this connection can be made only with the agreement of a chimney firm (chimney revision). 3. Connection of the two-way safety valve DBV 1-02. 4. Connection to the mains. 5. Tightness of the stoking and ash door: Boiler type code S22D S30D S38D L [mm] 1050 1252 1439 L1 [mm] 851 1051 1256 L2 [mm] 666 868 1070.5 L3 [mm] 764 996.5 1167 Fig.. 9 Connecting dimensions of the boiler 17

5.6 Putting into operation 1. Fire the boiler. 2. Bring the boiler to the necessary operating temperature. The recommended output water temperature is 80 C. 3. Turn on the exhaust fan. 4. Check the two-way safety valve DBV 1-02 function. 5. Operate the boiler in operating condition according to relevant standards. 6. Check again the boiler tightness. 7. Familiarize users with the boiler operation and maintenance. 8. Make a record to the warranty card. 5.7 Control, regulation and safety elements Manometer - is used to detect water pressure in the boiler. Safety thermostat (irreversible) - serves to protect the boiler against overheating. It is set to 95 C. In case of failure, it is necessary to deactivate the safety thermostat manually after cooling of the boiler. Activation of the safety thermostat switches off the exhaust fan, it is signalled by the orange light on the control box panel. 1 Control panel of the ecomax 860 regulator 2 Thermomanometer 3 Fuse 4 Boiler marking Obr. č. 1 The control box with the ecomax 860 regulator 5.8 Device for removing excess heat The two-way safety valve DBV 1-02 serves to remove excess heat in case the water temperature in the boiler exceeds 95 C. If the system is equipped with the two-way safety valve DBV 1-02 and the boiler becomes overheated (outlet water temperature is higher than 95 C), the two-way safety valve creates cold water circuit until the time the temperature drops below the limit temperature. At this moment, the discharge cooling equipment and the cold water inlet for the system refilling are simultaneously closed. A - cold water inlet B - output to the boiler C - output to the drain D - input from the boiler Fig.. 10 Two-way safety valve DBV 1-02 18

Specifications of the two-way safety valve DBV 1-02 (from Regulus) Opening temperature (limit): 100 C (+0-5 C) Maximum temperature: 120 C Maximum pressure on the boiler side: 400 kpa (4 bar) The maximum pressure on the water side: 600 kpa (6 bar) Nominal flow at p 100 kpa (1 bar): 1.9 m 3 /h Use Two-way safety valve DBV 1-02 is designed for central heating boilers protection against overheating. In the valve drum, the discharge and refill valves are controlled by thermostatic element. When achieving the limit temperature the discharge and refill valve open simultaneously, which means that cold water flows into the boiler while hot water is drained from the boiler. When the temperature drops below the limit, the discharge and filling valves are closed simultaneously. ATTENTION! Do not replace the safety valve. In case of reaction of the two-way safety valve, when there could be refilled water that does not conform to CSN 07 7401, it is necessary to adjust water in the system so that it again conforms to this standard. 1 Boiler 2 Two-way safety valve DBV 1-02 3 Safety valve 4 Reducing valve 5 Filter 6 Ball valve Fig.. 11 Installation 19 7 Pump 8 Excess heat removal 9 Fill and drain tap I Cold water inlet II Heating water outlet III Return water inlet Recommended diagram of the two-way safety valve DBV 1-02 connection Installation may only be performed by a qualified person. For proper operation of the thermostatic two-way safety valve it is necessary to comply with the prescribed conditions for its installation and respect the flow directions indicated on its body. The safety valve is always mounted in the outlet pipe of the boiler or directly on the boiler in its upper part where the heated water leaves boiler and is transported into the heating system. When installing the valve, it is necessary to check whether the use of the 3/4 socket, which can be both in the pipeline and on the boiler, ensures complete immersion of the valve thermostatic element after the valve installation. After mounting into the socket, at the point "C" (see Fig. 9), the discharge pipe is connected through which the hot water from the boiler will flow to drain. At the point "A" (see Fig. 9), the supply of cooling water is connected (Fig. 10), which ensures cooling the boiler down after the valve putting into operation. At the cooling water inlet, a filter to remove mechanical impurities must be installed. At the point "B" (see Fig. 9) there is connected the pipeline, which according to Fig. 10 leads to the return line of the heating system near the boiler. Regular maintenance Check 1x per year, turn the safety valve head to remove possible contaminants seated in the valve. Clean the filter at the cooling water inlet. Important It is not possible to reverse flows, so it is necessary to observe the filling and draining indication on the valve.

5.9 Equipment for heat exhausting accumulating reservoir We require connection of the pyrolytic boiler with storage tanks. Benefits: Lower fuel consumption (by 20-30%), the boiler is running at full power until the fuel burnout and optimum efficiency High service life of the boiler and the chimney - minimum production of tars and acids The combination of the heating elements with underfloor heating More comfortable heating Ecological heating Possible combination with other ways of heating Calculation of the smallest capacity of the accumulating heat exchanger, where: V sp Q N T b Q H Q min accumulating reservoir capacity in liters nominal heat power in kw combustion time in hours buildings heat load in kw smallest heat power in kw V sp = 15T b x Q N (1-0,3 x (Q H /Q min )) The sizes of the accumulating reservoir have to be determined on the basis of the boiler power and the used fuel. The biggest capacity has to taken into consideration, whereas the minimum used capacity of the reservoir has to be 300 l. In case that the reservoir is fully charged, it is necessary to shut down the boiler and heat up by heat from the accumulating reservoir. After the heat is spent in the reservoir, put the boiler into operation again. The accumulating reservoir enables provision of heat comfort and at the same time the boiler operation. ATTENTION! Failure of it will cause extreme pollution of the boiler drum. Hydraulic schemes of the boilers with an accumulating reservoir are at disposal in the project materials of Viadrus at www.viadrus.cz. 6 Operating Instructions Incorrect operation and improper combustion of fuel leads to damage to the product. During the first firing of the cold boiler, water condenses therein, which flows down the inner walls. The condensation of water on the boiler stops once the boiler reaches the operating temperature. When operating the boiler at the temperature lower than 60 C, water can condense on the boiler drum, that can lead to the so called low-temperature corrosion, which shortens the life of the boiler exchanger. Therefore we recommend to operate the boiler at 60 C and higher. Guarantee of the clean and good combustion is using only dry natural wood. To achieve the rated output of the boiler, wood moisture content must be max. 20%. If the wood moisture content is higher than 20%, the boiler output declines. Damp wood burning releases water which condenses on the walls of the boiler and the chimney, this leads to an increased formation of tar and water vapour, which reduces the life of the heat exchanger. Additionally, improper combustion leads to occurrence of aggressive agents that cause decrease of the heat-bearing surfaces wall thickness, which may also cause perforation of the exchanger. Fuel must be stored in a dry place. For heating, do not use plastics, household waste, chemically treated wood residues, waste paper, wood chips, brushwood, waste from pressed sheets of bark or chipboard. Follow the instructions for the boiler operation. When operating the boiler follow the recommended operating temperature. When operating the boiler, use only approved fuel. 20

Recommended dimensions of wood blocks Dry split wood logs, diameter from 80 to 150 mm. Length according to Table 5 Tab.. 5 Log length Boiler type code S22D S30D S38D L [mm] 370 570 775 Calorific power 15 17 MJ /kg Moisture 12 20 % Manufacturer's note: The boiler performance and operation is guaranteed at max. moisture up to 20% During the damp wood combustion, the boiler does not operate in the gasification mode, this leads to the performance reduction, emission deterioration and flue gas condensation in the boiler. These factors shorten the life of the boiler and chimney. Fig.. 12 Location of the fuel in the boiler 6.1 Boiler operation by user Operating instructions of the ECOMAX 860 D control unit are supplied separately. 6.1.1 Control elements description 1. "MENU" button 2. Positioning button and "ENTER button 3. "EXIT" button Fig.. 13 Panel view The value of the adjusted parameter can be increased or decreased by turning the positioning button. This is an element for the quick control of the regulator. By pressing this button, select the parameter you wish to correct or confirm the pre-set value. The regulator is activated by pressing the button, then the regulator switches to the STOP working mode. 6.1.2 Firing 1. Check the water volume in the heating system on the manometer. 2. Open the shut-off valves between the boiler and the heating system. 3. Check mechanical function of the shorting flap. 4. Clean the boiler drum, passages between the segments on the nozzle, sweep the ashes out of the ceramics in the bottom door and suck the ashes out of ribbing of the sections. 5. Connect the ecomax 860 D control unit to the mains. The unit is in the Standby mode. By pressing the button, select the function Activate regulator. The regulator is in Stop phase. 6. Put the kindling on the nozzle through the stoking door - small timber and dry smaller chips and paper on it. 7. Ignite the kindling in the funnel. 8. Let the kindling flare. 21

9. Stoke smaller chips to the fire so that to increase the intensity of the flame at a slight opening of the door. If the flame intensity is sufficient, press MENU and put the control unit into operation by selecting MENU FIRING. With the activation of the FIRING mode, the fan turns on, providing sufficient airflow to fire the boiler. After the firing time expiration or reaching the preset temperature of the boiler, the WORK mode is automatically activated. 10. Open the shortening flap, push the positioning button on the regulator and select "STOKING", wait 5-10 s, open the stoking door and refuel to the entire volume of the funnel. 11. Close the door and the shorting flap and select "WORK by pressing the knob. 12. If the outlet water temperature exceeds the set production value of 40 C for 30 min., the boiler firing was successful and the automatic operation of the boiler is switched. If not, repeat the procedure. 6.1.3 Operation 1. Set the desired output temperature of the boiler (55 87 C, the manufacturer recommends 80 C). The preset temperature of the boiler can be adjusted by changing the following parameters: MENU Boiler setting Boiler set temperature Note: The set temperature of the boiler can be automatically adjusted according to the needs of the control unit, if it is too low, it will automatically increase in order to preheat boiler with HW and ensure a constant temperature for all heating circuits of the mixers. 2. According to heat needs and burning intensity, it is necessary to refuel during the boiler operation. At each stoking, it is necessary to select the STOKING function on the control unit, wait 10 seconds to exhaust the flue gas, slowly open the stoking door, add fuel to the entire volume of the funnel, close the door and select the WORK function by pressing the button. 3. After firing, heat the boiler at full power (at 2-4 loadings) at a given volume of the storage tank to 80-85 C, then let the boiler burn out. Then you can take heat from the tank (storage tank) by means of the three-way valve during the time corresponding to the size of the storage tank. 7 Boiler cleaning - maintenance The manufacturer recommends regular annual service inspection, which is necessary to ensure the safe operation of the boiler, maintain sustained high boiler efficiency and durability of its components. ATTENTION! Perform cleaning only before firing and only with the cold furnace. 1. Clean the boiler drum, sweep the ashes out of the nozzle hole and the funnel space, sweep the ashes out of the ceramics in the bottom door and suck the ashes out of ribbing of the sections. It must be done before each firing. Do not pull out the nozzle and the funnel lining. 2. The ash must be put into incombustible containers with lids. During the work, it is necessary to use protective equipment and ensure personal safety. 3. After the heating season, it is necessary to clean the boiler flue gas passages and the fan impeller. 4. After the heating season, treat the pivots of all doors. Cleaning of the boiler drum, the combustion chamber and the smoke adapter: - First, turn on the exhaust fan, open the stoking door and sweep the ashes through the slot into the combustion chamber of the boiler drum. - Remove ashes and unburned pieces of fuel from the combustion chamber by means of the cleaner. - Before cleaning the smoke adapter, it is necessary to remove the rear parts of the shell (1). Then, unscrew two upper cleaning covers (2) and clean the flue gas passage by means of the brush. After cleaning, it is necessary to open the bottom cleaning hole and suck the ashes (2) with the vacuum cleaner (3). - Clean the vents of the boiler drum with the brush. Brush of polyamide cannot be used at higher temperatures (cleaning must be performed only with the cold boiler drum). - Clean (sweep) the inside part of the door from ash and soot. 22

1. Rear shell 2. Cleaning covers 3. Vacuum cleaner Fig.. 14 Cleaning of the boiler drum and combustion chamber 8 Fault conditions Malfunction Cause Correction measure The boiler output is too low Excessive amount of condensate is formed in the stoking area of the boiler. Exhaust fan does not rotate or is too noisy Beware! Non-rotating fan leads to incomplete combustion and the formation of tar deposits The calorific value of fuel is insufficient, fuel moisture is higher than 20% Clogged or deformed fan propeller Reversible fan Clogged nozzle Failure to comply with the operating conditions Incorrect or too wet fuel Low boiler water temperature Only when the fan does not rotate: The maximum boiler temperature is reached The fan motor or starting capacitor are defective The fan propelled is sintered Use prescribed fuel with the prescribed moisture value Clean the fan propeller or replace it Checking the direction of the fan rotation Clean the nozzle hole by the fire poker Check transport pressure, return line temperature Use prescribed or dry fuel At the control unit, check / raise the minimum boiler water temperature and ensure the minimum return line temperature of 60 C by appropriate adjusting of the the mixing valve Fault did not occur! The boiler is working properly. Exhaust fan starts when opening the stoking door. Too much fuel loaded Fan or capacitor have to be replaced by a specialist company. Clean the fan propeller from the tar and deposits, when damage is detected, replace the fan propeller 23

9 IMPORTANT NOTICE he boiler may only be used for the intended purposes. The boiler can be operated only by adults familiar with this instruction manual. Do not leave unattended children near the operated boiler. The boiler is not intended for use by persons (including children) whose physical, sensory or mental disability or lack of experience and knowledge prevents them from using the appliance safely, if they are not supervised or were not instructed to use the appliance by a person responsible for their safety. Children should be supervised to ensure that they do not play with the appliance. If there is a danger of development and penetration of combustible vapours or gases into the boiler room or at works with temporarily developed fire or explosion danger (gluing the floorings, painting with flammable paints etc.), the boiler must be put out of operation before such works. It is forbidden to use flammable liquids for the boiler firing. Flame control is done by opening the upper door. However it must be borne in mind that in this state there is an increased danger of sparks flying into the boiler room space. After performing the flame visual check, the door must be closed. During the boiler operation it is forbidden to overheat it in any way. Do not put any objects made of flammable materials on the boiler and within a distance smaller than the safe distance from the boiler. When removing the ash from the boiler, no flammable substances must be at the minimum distance of 1500 mm from the boiler. The ash must be put into incombustible containers with lids. After the heating season, it is necessary to clean the boiler including the flue pipe. The boiler room must be kept clean and dry. It is forbidden to interfere with construction and electrical installation of the boiler. ATTENTION! Low fuel quality can significantly affect the boiler output and emission parameters. When mounting, installation and operation of the appliance it is necessary to meet the standards valid in the relevant destination country. Connect the lambda sensor to the module only when the boiler is not connected to the mains. In case of failure to comply with these conditions, warranty repairs cannot be claimed. The list of contractual service organizations is attached separately. 10 Instructions for the product disposal after its useful life period VIADRUS a.s. is the contract partner of the company EKO-KOM a.s. with the client number F00120649. The packaging complies with EN 13427. The packaging should be disposed of as follows: - plastic foil, cardboard package - use the special waste collection point - metal tightening tape - use the special waste collection point - wooden base is intended for single use and cannot be further used as a product. Its disposal is subject to the law 477/2001 Sb. and 185/2001 Coll. as amended. Individual parts of the boiler should be disposed of as follows: - exchanger (grey cast iron) - use the special waste collection point - piping, shell - use the special waste collection point - other metal parts - use the special waste collection point - insulation material ROTAFLEX - through a firm dealing with waste collection and disposal In case of loosing the use properties of the product, back collection service can be used (if applicable), in case the manufacturer states it is waste, the waste should be disposed according to the valid legislation of the country. 24

11 Warranty and liability for defects For its boilers, VIADRUS a.s. provides basic warranty for the period of 24 months from the date of purchase, max. 30 months from date of shipment from the factory. Condition for the warranty is compliance with the instructions for installation, mainly: Connection according to the manufacturer's wiring diagrams performed by a mounting or installation company with a valid installation certificate. Putting into operation by a service company with a valid service certificate. Compliance with the instructions included in the boiler operation and installation manual. Performance of periodic inspections set by the manufacturer by a service company with a valid service certificate. Usage of the original spare parts supplied by the manufacturer. Sending information on the boiler putting into operation (sent by the end user - the consumer) to the manufacturer. In particular, it is necessary to specify when and by whom the boiler was put into operation and the precise address of the boiler operation. VIADRUS a.s. provides an extended warranty on the boiler drum for a period of 60 months from the date of purchase, max. 66 months from date of shipment from the factory. Condition for recognition of the extended warranty period is: Fulfilment of conditions for recognition of the basic warranty period. Sending information on the boiler putting into operation (sent by a service company - the consumer) to the manufacturer. Performance of the regular service inspections to the extent prescribed by the manufacturer, by the service company with a valid service certificate. For any claim regarding the shell the customer is obliged to submit the packaging label of the boiler shell. It is located on the cardboard in which the shell is dispatched. User is obliged to entrust fault rectification to a contractual service accredited by VIADRUS, otherwise the guarantee for boiler proper function is not valid. If the boiler is operated in accordance with the instructions provided in the "Boiler operation and installation manual", the boiler does not require any special service interventions. "Certificate of quality and completeness of the boiler VIADRUS P7C" serves as the "Warranty card after its filling. The user is obliged to perform regular maintenance of the boiler. Each notice of defect must be made immediately after its finding always in writing and by a telephone agreement. In case of failure to comply with these guidelines, the warranty will not be recognized by the manufacturer. The manufacturer reserves the right to make changes within the product innovations that need not be included in this manual. The guarantee does not apply to: - defects caused by improper mounting and improper operation of the product and faults caused by improper maintenance see Chap. 8 - product damage during transport or other mechanical damage; - defects caused by failure to observe water quality in the heating system see Chapter 4.1 and 5.3 or by using antifreeze; - defects caused by improper storage; - defects caused by the boiler operation with the non-prescribed fuel (see Tab. 3 and 4). - defects caused by failure to follow instructions provided in this manual; - defects caused by natural disaster or force majeure. 25

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