Pellet Boilers Instructions for Use and Maintenance - THE PRESENT MANUAL FORMS AN INTEGRAL PART OF THE BOILER AND MUST BE KEPT FOR FUTURE REFERENCE Bmax Technology - a Division of Elmec Group S.r.l. Localition Cà D Oro 36020 - Asigliano Veneto (VICENZA) - ITALY Elmec Group S.r.l. Tax Code and VAT no.: 03725780245 - BEFORE USING THE BOILER IT IS OBLIGATORY TO READ AND UNDERSTAND THIS MANUAL IN ALL ITS PARTS
Declaration Of Conformity NOTES Elmec Group S.r.l. Location: Cà D Oro 36020 - Asigliano Veneto (VICENZA) - ITALY Declares that the BOILER: SPACE FOR MACHINERY IDENTIFICATION PLATE Conforms to the Following European Standards and Directives: Directive UNI EN 303-5:2012 (Heating Boilers for Solid Combustion Up to 500 kw) Directive UNI EN 15270:2008 (Pellet Burners for Small Boilers for Heating) Directive 2004/108/CE (Electro-Magnetic Compatibility) Directive 2006/95/CE (Low Voltage) Regulation EU 305/11(Fixes the Harmonised Conditions for Sale of Manufactured Products) Directive 2006/42/CE (Machinery Directive) ANY MODIFICATION OF THE BOILER WITHOUT THE PRIOR CONSENT OF Elmec Group S.r.l. WILL RENDER THIS DECLARATION NULL AND VOID Date 01/02/2014 Managing Director : Bmax Technology - a Division of Elmec Group S.r.l. Localition Cà D Oro 36020 - Asigliano Veneto (VICENZA) - ITALY Elmec Group S.r.l. Tax Code and VAT no.: 03725780245 Rev. 00 Date 28/05/2014
NOTES PRESENTATION Dear Customer, We thank you for choosing our product. The B-max Pellet Boilers can be connected to any type of heating system: to Radiators - Floor Skirting, etc.. Our boilers have been exclusively studied to operate with wood pellets (DIN quality 6 mm. diameter. Its structure is similar to a traditional wood boiler, but it is far more economical. It is extremely efficient, with an air-cooled steel door, minimal maintenance requirements and a long life cycle. With this manual you can learn to use your boiler correctly. We therefore ask you to read it completely and very carefully before using it. 20 1
INDEX WARRANTY GENERAL INDEX...... 2 1.0 SAFETY..3 1.1 GENERAL WARNINGS. 3 1.2 SAFETY WARNINGS FOR THE USER..4 1.3 PURPOSE OF THE MANUAL... 5 1.4 RESPONSIBILITY OF THE MANUFACTURER.....5 2.0 CHARACTERISTICS and TECHNICAL DATA.........6 2.1 MANUFACTURING CHARACTERISTICS......6 2.2 BRIEF OF THE PARTS AND CONNECTIONS.... 7 2.3 SIZES...8 2.4 TECHNICAL DATA CHART......9 3.0 INSTALLATION..10 3.1 RESPONSIBILITIES OF THE INSTALLER....10 3.2 SMOKE EXHAUST.....11 3.3 LOCATION.. 11 3.4 INSTALLATION...12 3.5 ELECTRICAL CONNECTIONS. 12 3.6 CONNECTION TO HEATING SYSTEM......12 3.7 INSTALLATION OF BURNER ON BOILER....13 4.0 START-UP....14 4.1 PRELIMINARY OPERATIONS...14 4.2 INITIAL START-UP AND SHUT-DOWN...14 5.0 TRANSPORT and MAINTENANCE. 15 5.1 TRANSPORT.. 15 5.2 CLEANING...15 5.3 WEEKLY MAINTENANCE. 16 5.4 SPECIAL MAINTENANCE..17-18 6.0 WARRANTY..19 6.1 WARRANTY CONDITIONS......19 6.2 WARRANTY. 19 6.0 WARRANTY 6.1 WARRANTY CONDITIONS To be able to use the Legal Guarantee, as per EEC directive CEE 1999/44/E (D/Lgs. 42/2002) the CONSUMER must scrupulously observe the requirements indicated in the present Manual, and in particular, must: Never use the system for purposes other than those indicated in this manual. Always carry out constant, diligent Maintenance as indicated in the various chapters. Follow the safety regulations currently in force in the state in which the boiler is installed. Never tamper with the plant Only use genuine spare parts Ensure that the installation of the boiler is carried out by a qualified technician or by someone with experience in compliance with the instructions given in this manual Only and exclusively use Pellets as fuel, of the type indicated previously in this manual. Consistently carry out the necessary maintenance as indicated in the various chapters in a diligent manner; 6.2 GUARANTEE This product is Guaranteed for 2 (Two) YEARS from the date of purchase and the Guarantee covers all the defects and faults that can be attributed to proven production and material problems. During the guarantee period the company BMax will replace and repair free of charge any pieces that are shown to be defective from the moment of purchase. THE FOLLOWING ARE EXCLUDED FROM THE GUARANTEE: All damage caused during transport. We therefore advise customers to check the machine carefully when it arrives and immediately inform the retailer of any damage that may have occurred; Damage caused by atmospheric, chemical and electrochemical agents; All parts that are subject to normal WEAR. No compensation will be awarded for any periods during which the product is not working efficiently. BMax is not liable for any errors that this manual may contain and is free to vary the characteristics of its product without prior warning 2 19
MAINTENANCE SAFETY 5.4 SPECIAL MAINTENANCE Cleaning the Heat Exhangers: 1. Open all 3 doors as shown in the diagram 2. Scrape the exchangers indicated with the arrow (1) using the special brush supplied with the boiler 3. Vacuum out the ask from the ash pan, as shown by the arrow (2) 1.0 SAFETY 1.1 GENERAL WARNINGS!! CHECK THAT THE CHIMNEY FLUE HAS SUFFICIENT DRAW BEFORE CONNECTING IT TO THE SMOKE EXHAUST ON THE BOILER Always use the safety devices and individual protection devices required in accordance with EEC Directive 89/391 Disconnect the power supply before carrying out any operations. Always use suitable tools. Before starting any work, make sure that the combustion chamber is cold and that the ash is cold. Also wait for the opening handles to cool down before touching them No inflammable material should be stored near the Boiler!!!CAUTION No modifications to the Boiler may be made without written consent from the manufacturer Only use original spare parts or parts approved by the manufacturer to avoid possible damage to the Boiler Do not open the Boiler doors while the burner is working Check for the presence of condensation: this is the sign of possible water infiltrations or of exhaust cooling. It is advisable to identify the possible causes to restore correct functioning DO NOT USE the Boiler if even one part is defective or is not working Always clean the combustion brazier of the burner before ignition (See Burner manual) 18 3
SAFETY MAINTENANCE 1.2 SAFETY WARNINGS FOR THE USER 5.4 SPECIAL MAINTENANCE The place where the boiler will be installed, hereby known as the installation location, MUST be installed in accordance with local, national and European regulations. The boiler is for heating and during operation its external surfaces are very hot. During operation, we recommend maximum caution and in particolar: Do not get too close to and do not touch the doors: DANGER OF BURNS By Special Maintenance, we mean all the checking, cleaning and maintenance operations that should be carried out at least twice a year. These operations should be carried out both on the Boiler and on the Burner by qualified technicians with the training required by law. For maintenance of the Burner see the respective manual. CAUTION! Before starting any maintenance work, check that the plant is disconnected from the mains supply. Do not get too close to and do not touch the smoke exhaust: DANGER OF BURNS Do not carry out any cleaning when the boiler is On Do not open the doors of the Boiler with the burner on Do not remove the ash Do not let Children or Animals go near the boiler OBEY ALL THE RULES SET OUT IN THIS MANUAL Plus, to use the Pellet Boiler correctly: Only use the fuel which conforms to the manufacturer s recommendations Observe the maintenance programme Carry out periodic clearing (only with the Boiler off and when the ash is cold) Do not use in the event of malfunctioning and anomalies Do not throw on water, not even to put out the fire in the burner brazier Do not turn off the Boiler by pulling out the plug from the socket (first turn off the burner and let it go through the shut-down cycle, then remove the plug from the main supply) Do not use wood or coal, only Pellets with the following characteristics: diam. 6 mm. - max. length 30 mm. - humidity 8-9 % Do not use the Boiler as an incinerator Carry out all operations with the maximum concern for safety Check the gaskets on the boiler and substitute them if damaged Check the seals on the 3 doors Check the condition of the electric cables and their connections to the burner Check that the safety valve is working correctly (this should be done every 3 months) Analyse the combustion and record the data on the last pages of this manuel in the NOTES tables. Make a note of any components replaced on the same tables. Check the connection between the smoke duct and the chimney Clean out the chimney Remove the external pannelling and clean the body of the boiler Check all the connections of the hydraulic parts Clean out the inside walls of the boiler, both vertically and horizontally, and clean the heat exchangers situated in the upper part of the boiler (See the diagram on Page 18). This should be carried out using the specific brush supplied with the boiler. 4 17
MAINTENANCE SAFETY 5.3 WEEKLY MAINTENANCE Weekly maintenance involves cleaning the ashes and combustion residues from inside the ash pan of the Boiler and in the Burner. This should be done at least every 2/3 days MAX, but can be more or less frequent according to the quality of the Pellets used. Remember also that cleaning frequently inside the combustion chamber positively affects the general yield of the Boiler. During this phase use any ash vacuum cleaner that is equipped with a filter to prevent the dust that is sucked in from returning into the environment. Begin as indicated below: Switch off the machine and disconnect the power supply Check that the machine has stopped and wait for it to cool. Open the door of the Boiler, using the handle indicated below. 1.3 PURPOSE OF THE MANUAL The purpose of this manual is to allow the user to take all possible, necessary measures and to set up all the machinery and materials in such as a way as to ensure the correct and safe use of the equipment. The present manual is in conformity with the latest regulations at the time of release onto the market. It does not consider the machinery already on the market with its relative tecnical documentation, deficient or inadeguate, if eventual modifications or adjustments or are made or new technologies on new machines on the market are applied. The information in this manual must be scrupulously evaluated and observed, and is all necessary for the correct installation, use and maintenance of the boiler. Therefore, this manual must be carefully stored for consultation, any time there are doubts or problems. The use and instructions manual is an integral part of the boiler equipment. If the boiler is sold to another person, it is obligatory to consign the manual to the new purchaser. If it is lost, it is possible to request a new copy from the manufacturer. 1.4 RESPONSIBILITY OF THE MANUFACTURER On consignment of this manual, BMax declines all responsibility, either civil or criminal, direct or indirect, due to: Suck in the dust from the ash space and the brazier of the burner as shown in the figure Accidents caused by the NON OBSERVANCE of the regulations and specifications present in this manual Accidents caused by an IMPROPER AND INCORRECT USE of the machinery on the part of the user Accidents caused by modifications and repairs carried out by technicians that are not authorised by BMax Inadequate MAINTENANCE Exceptional events Accidents caused by the use of non-original spare parts or parts that are not specific to the model in question For installation operations, the installer is, and remains, solely responsibile. 16 5
TECHNICAL MAINTENANCE 2.0 CHARACTERISTICS AND TECHNICAL DATA 2.1 MANUFATURING CHARACTERISTICS 5.0 TRANSPORT and MAINTENANCE 5.1 TRANSPORT The Boiler is delivered on a pallet and protected with bubble wrap, or in a wooden box for larger models. BOILER BODY The internal burning area is constructed in P - 265GH, thickness 3 and 5 millimetres, while the external casing is in S235 JRG2. The heating water flows through the heat exchanger, which is placed in the upper part of the boiler. The boiler is constructed with water tight welding, and the welding is tested twice by our quality control system at a pressure of 4 bars. DOORS The boiler body has 3 doors to aid efficient working aid cleaning. The three doors are air cooled and are built in steel in 3 layers: respectively, 1.5, 3 and 5 millimetres. The sealing of the doors is guaranteed by means of a glass-fibre fire-retardant seal, placed between the boiler body and the doors. The upper door aids cleaning of the heat exchangers, the central door permits the connection of one of our pellet burners to the boiler by means of the special flange. The lower door allows the cleaning of the ashes produced by the combustion in the burner. The 3 doors are fitted with handles in special anti-overheating plastic material. COVER The boiler body is insulated externally with rock wool, thickness 30 millimetres, and the external pannelling is constructed in sheet metal, thickness 0.8 millimetres. This is covered with electrostatic powder and is screwed to the boiler body. CONNECTIONS The supply and return flow connections to the heating plant are built with 1 1/2 BSP threading, while the filling/emptying connection and the safety valve or pressure gauge are built with 1/2 BSP threading. Transport, loading and unloading Transport, loading and unloading must be carried out with care to avoid damaging the machinery and to protect people, animals and things. For loading and unloading the Boiler, a fork lift with sufficient capacity on the basis of the safety co-efficient (see the gross weight of the Boiler in the TECHNICAL DATA TABLE contained in paragraph 2.4 on page 9 of this manual). During these operations the centre of gravity of the machinery must remain in a central position to keep the load balanced and stable, thus avoiding dangerous inclinations. After having removed the packaging, check that the machinery is undamaged. In case of doubt, immediately contact the agent concerned. The Boiler should appear solid and compact. Packaging Material The packing material (wood, cardboard, polystyrene, nails, etc.) must be collected and disposed of according to current legislation in force. CAUTION! Keep this material out of the reach of children; it can be a source of DANGER. Once the packing has been removed, position the Boiler as shown in paragraph 3.3 POSITIONING on page 11 of the present manual. 5.2 CLEANING THE MACHINE Periodically check the efficiency of the hydraulic plant and the correct functioning of the safety valve.. Keep the machinery clean, avoiding the accumulation of dirt on the machine body. Periodically carry out the following operations, making sure the machine is disconnected from the mains, and that it is cold. Clean the external body regularly, using a soft, damp cloth and a non-toxic, solvent-free detergent. Rub gently, being careful not to press excessively. (DO NOT AIM JETS OF WATER OF ANY TYPE, NOT EVEN INDIRECTLY, ON THE BOILER AND BURNER.) DO NOT USE SOLVENTS If there are any unusual sounds or vibrations, check that all the screws and bolts are tight.. 6 15
TECHNICAL TECHNICAL 4.0 START-UP 4.1 PRELIMINARY OPERATIONS 2.2 BRIEF OF THE PARTS AND CONNECTIONS Before starting the Boiler, the installer must carry out the following checks: Make sure that all the electrical connections have been carried out following the instructions given in the Burner Manual. Make sure that the smoke outlet is thermally sealed. Make sure that the intake and delivery parts are free and not obstructed. Make sure that the burner is correctly fixed to the Boiler. Make sure that all 3 doors of the Boiler are closed correctly, so that the flame is only generated inside the combustion chamber. Make sure that the auger and the flaxible hose for connection to the burner have been connected and positioned correctly. Fill the container with Pellets only, and not with any other fuel. Check that the safety valve is connected and working correctly. Inform all users about the relative risks and dangers, and also train them about how the Boiler works. N.B.= the checks indicated above must also be carried out by the User or Maintenance Technician following any type of maintenance operation that caused the systems to be disconnected, or after intervening on the safety devices or on parts of the Boiler or Burner 4.2 FIRST START-UP AND SHUT-DOWN When starting for the first time, some of the oil and grease that coat the combustion chamber will tend to evaporate. The room must be aired to allow these fumes to exit. For the Start-Up, proceed as follows: 1) Make sure that the Boiler is connected to the Hydraulic system 2) Connect the Burner to the mains 3) Ignite the Burner; for ignition, see the BURNER MANUAL and follow the instructions. The burner electronic board ignites the flame and keeps it constantly under control, The board also monitors any problems that may appear on the burner display To SOLVE possible PROBLEMS, consult the BURNER MANUAL. To shut down the Boiler, it is sufficient: first, to turn off the burner, wait for the cooling cycle to be completed, and once it is finished, disconnect the Burner from the mains. 1) Boiler Body 2) External Pannelling 3) Heating Plant Return Outlet 4) Heating Plant Loading/Unloading Pipe 5) Upper Door 6) Ash Deposit Area 7) Central Door 8) Lower Door 9) Burner Support Flange 10) Door Handles 11) Combustion Chamber Area 12) Heat Exchanger 13) Safety Valve or Pressure Gauge 14) Smoke Exhaust Pipe 15) Heating Plant Supply Outlet 14 7
TECHNICAL TECHNICAL 2.3 DIMENSIONS 3.7 INSTALLING THE BURNER ON THE BOILER For questions of size, distance and safety, the Burner is supplied separately from the Boiler. To install the Burner, follow the instructions below: 1. Insert the support collector (2) onto the 4 M8 pins (1) welded onto the Boiler door 2. Fix on the collector (2) using the M8 nuts (3) 3. Completely insert the burner into the collector (2) 4. Fix the M6 nuts (5) 5. Insert the flexible Pellet feeder tube of the auger to the connection tube (6) 6. For the electrical connections of the auger and the Burner SEE THE BURNER MANUAL ONCE THE BURNER IS FIXED ON, IT MUST REMAIN IN A HORIZONTAL POSITION 8 13
TECHNICAL TECHNICAL 3.4 INSTALLATION The user is fully responsible for the work carried out or still to be carried out in the installation area. Before starting assembly operations, the installer must adhere to the safety precautions required by law and, in particular: must ensure that the provisions for the system comply with local, national and European laws Must check if specific authorisation is required because of urban, architectural and fire prevention regulations ; Must scrupulously follow the instructions given in this manual, above all paragraphs (3.1) on page 10 and (3.2-3.3) on page 11 Must always use the personal protective devices and all the protective means required in compliance with current legislation in force. 3.5 ELECTRICAL CONNECTION The BMax boiler does not need any electrical connection, but the burner does (SEE THE BURNER MANUAL). These electrical connections must be carried out by a specialised, qualified technician who is authorised to work, in line with current legislation in force. 3.6 CONNECTION TO THE HEATING PLANT Choice of the correct size of the boiler and the heating plant, as well as the choice of the type of plant to be realised, are the responsibility of the installer and/or the designer. It is advisable to connect the machinery to the heating system by means of a three-piece joint, in order to be able to remove it without causing damage in the event of malfunctioning, in particular, to the return flow connection. In fact, it could be useful to install a T-junction with a stop cock to be able to drain the plant for maintenance work. For correct functioning of the plant it is advisable to use a mixing valve set at 55 C as a way to regulate the temperature both of the plant and the boiler, and to be able to increase the temperature of the return flow into the boiler, in order to protect the parts from dangerous temperature drops caused by condensation in the flues. After having completed the connections to the hydraulic system, the heating plant and the boiler must be filled. Before this operation, it is necessary to check the hardness of the water and of water residue, and if needed, install (for example, if there is water with a fixed residue greater than 300 mg/ l at 180 C) a water softener before the entry point of the water supply pipe. This will ensure optimal conservation of the inside surfaces of the boiler body, but also of the whole heating plant. Briefly, the following operations are necessary for filling: open any sectioning valves on the plant; completely open all the bleeder valves on all the radiators, so that all the air can escape without leaving air bubbles; fill the system very slowly using the Drainage Connection (4) of the boiler (see Pg. 7) keeping the bleeder valves of the radiators open even when a trickle of water starts to run, again to ensure that no air bubbles are created. When the installation is completed, it is a good rule to keep checking the seals of the hydraulic connections for at least 2 or 3 days for any leakage. 2.4 TECHNICAL DATA TABLE MODEL B-MAX 25 B-MAX 50 B-MAX 100 B-MAX 200 B-MAX 300 Nominal Heating Power (kw) Heating Power Class (Class 5) (kw) Max. Heating Surface According to Type of Heating Plant (m³) Fuel Type 25 50 100 200 300 21.4 40,8 80 124.8 250.2 200-350 600-900 1200-1800 2200-2800 3300-4800 Pellet DIN Ø 6 mm l = 5-30 mm Yield (Fuel: Pellet) (%) 90 90.1 95.8 95.1 92.5 Heating Plant Supply Flow Connection (") M 1" 1/2 2 2 2 2 Heating Plant Return Flow Connection (") R 1" 1/2 2 2 2 2 Size of Ash Deposit Area (L¹x h¹-mm) 235x225 235x225 350x300 415x400 415x400 Smoke Exhaust Tube Diameter (Ø) 132 150 200 250 300 Height (h - mm) 1180 1170 1390 1680 1700 Width (L - mm) 400 480 720 840 1085 Depth (p - mm) 500 640 870 1240 1680 Weight (kg) 142 242 463 837 1500 Water Volume (lt) 40 68 156 411 650 Max. Operating Pressure (bar) 2 2 2 2 2 Testing Pressure (bar) 4 4 4 4 4 Max. Operating Temperature ( C) 90 90 90 90 90 Smoke Draw Length (Pa) 20 20 20 20 20 Combustion Area Size 600x235x330 520x355x455 730x560x700 820x640x1000 800x890x1400 (h² x L² x p - mm) N Exchangers 4 5 5 5 5 12 9
TECHNICAL TECHNICAL 3.0 INSTALLATION 3.1 RESPONSIBILITY OF THE INSTALLER The installer is responsible for :,checking the chimney flue, the air vents and all the necessary actions for installing the boiler. The installer is also responsible for: ensuring that all the safety regulations required by the specific legislation in force in the state, region, province and city of installation are respected. The use is subordinated to the instructions contained in the present manual and all the safety regulations required by the specific legislation in force in the state, region, province, city where the boiler is installed must be complied to. The UNI 10683 Directive defines the responsibilities of the installer: the installer must verify: The type of plant to be installed The compatibility of the installation area with the machinery itself in that the minimum distances required by the manufacturer must be respected The manufacturer s requirements for the boiler regarding the smoke exhaust system regulations (smoke channels and chimney flues) The internal section of the chimney, the material in which it is constructed, the homogeneity of the section, the absence of obstructions The possibility of installing external air outlets and the sizes of existing ones The possibility of the co-existence of the boiler to be installed with pre-existing equipment If the checks are positive, the machine can then be installed, so long as the instructions supplied by the manufacturer and the regulations concerning safety and fire prevention are scrupulously observed. When the installation is completed, there must be a test start-up of the plant, for a duration of not less than 30 minutes, to check the general operational state of the equipment. 3.2 SMOKE EXHAUST The smoke duct and connection to the chimney must be made in compliance with standards and laws in force. The pipes used must be rigid, resistant to temperature and mechanical stress, and watertight The chimney must guarantee the minimum depression indicated by current technical standards, considering a Zero pressure at the connection point with the smoke duct. Unsuitable or badly-sized chimneys or smoke ducts can increase combustion noise and negatively influence the generator combustion parameters. Non-insulated outlet ducts are a potential source of danger. The joints must be sealed using material that is resistant to a minimum temperature of 350 C (e.g. fillers, rubber cement, silicon preparations). N.B.= Refer to the TECHNICAL DATA TABLE (paragraph 2.4) on page 9 for the size of the generator smoke duct. 3.3 POSITION The POSITION in which the boiler is to be placed must be checked/established by the system installer or by a qualified technician, and account must be taken of technical requirements and laws in force. To position the boiler correctly, make sure that : it is placed it on a surface that has been levelled and is able to support the weight; the MINIMUM distances indicated in the figures below are respected to allow correct air flow and to allow normal CLEANING and MAINTENANCE operations to be carried out; When the installation is completed and after the first start-up of the plant, the installer must consign the following documentation to the client: The machine use and maintenance manual (if not present inside the machinery) The necessary documentation in compliance with existing laws 10 11