abc COMBO 25 User manual

INSTRUCTIONS FOR USE OF COMBINED BOILER INTENDED
FOR COMBUSTION OF BOTH PELLETS AND SOLID FUEL
ABC COMBO

1.Technical specifications
DESCRIPTION
Frequency
Width
Height
Debth
- Pellet
- Wood
UNIT
Boiler power
Water content in a boiler
Required draft
Supply electrical power:
- Ignition stage
- Operation stage
Supply voltage
Boiler weight
Maximum operating pressure
Maximum operating temperature
Flue pipe diameter
Boiler dimensions
Boiler
connectors
Supply line
Return line
Charging
and discharging
Fuel dimensions:
Pellet storage capacity
1
kw 25 40
lit 80 100
Pa 12 14
W 370 480
W 70 180
V 230 230
Hz 50 50
kg 280 360
bar 2,5 2,5
°C 85 85
mm 100 120
mm 827 986
mm 1371 1539
mm 988 1052
Col 1 5/4
Col 1 5/4
Col 1/2 1/2
mm 30x6 30x6
mm 100x100x350 100x100x400
L 170 250
COMBO 25 COMBO 40 COMBO 60
60
120
16
480
180
230
50
410
2,5
85
120
986
1524
1202
5/4
5/4
1/2
30x6
100x100x500
340

2. Display: Functions and use
Figure 1
ON/OFF and resetting alarm
Visualization/Increasing values
Locking the keypad
Visualization/Decreasing values
Buttons
P1 Exit from the menu or sub-menu
P2
P3
P4
P5
P6
Short press Long press (3-5 seconds)
Activating Chrono function within the
Chrono menu
Entering the main menu, saving setup,
activating time setup Entering the system menu,
setting up the keypad
-
-
-
-
LED lights
L1 Heater turned on
L2 Motor – reduction gear turned on
L3 V2 output active - Pump
L4 AUX 1 output active
L5 AUX 2 output active
L10 Pellet level sensor turned on
L11 Auxiliary input active
L12 Micro-switch turned on
2
P1
P2
P3
P4
P5
P6

3.Alarms
4.Visualization
- Exhaust gas temperature
- The water temperature in the boiler
- The water temperature in the ,,Buffer,,
- Fan speed
- illumination
- Number of admissions
- Software serial number
Exhaust Temp: 103
Boiler Temp: 25
Buffer Temp: 25
Fan Speed : 1000
Flame Light: 0
Recipe [nr]: 1
Product Code: 488: 1234
5.User menu
This menu is accessed by short pressing the button P3
3
DESCRIPTION STATUS NUMBER
Blocked Er1
Er2
Er3
Er4
Er5
Er7
Er8
Er11
Er12
Er15
Er16
Er18
Er52
Prob
Safety thermostat HV1
Boiler door opened
Turning off due to lack of fire
Turning off due to excessive temperature in the boiler
Turning off due to excessive temperature of exhaust
Error in encoder: no signal
Error in encoder: failed fan control
Error in real time
Failed ignition
Failure of main power supply
RS 485 connecting error
Lack of pellet in the storage
Micro-switch error
Failure in probe control during the “Check Up” stage
Resetting of all alarms is performed by long pressing the button P2
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked
Blocked

5.1 Combustion power settings
Combustion power can be set via this menu. Setting mode may be manual or
automatic. In the first case the user sets the power by himself, while in the other the
system sets the combustion power in relation to the defined temperature.
Pellet: 1-2-3-4-5-Auto
Wood: 0-1-2-3-4-5-Auto
5.2 Thermostats
These are used to adjust the set temperature in the boiler and/or “Buffer”, if installed.
“Buffer”-thermostat is visible only if P26=1 and P42=1
5.3 Operation mode
This menu enables the user to choose the boiler operation mode: pellet or solid fuel.
Changing the operation mode is possible only when the boiler is turned off.
5.4 Recipe
This menu is visible only when the boiler operation mode is “pellets” and the recipe
change is not allowed.
Only “Pellet recipe” 1 is available.
5.5 Chrono
It is used to set the time of ignition and shutdown of the boiler. Press the button P3
to enter the menu.
4

5.5.1 Modality
It is used to activate and deactivate the program settings.
Press button P3
5
Press button P3 and choose Daily, Weekly or Week End program using the buttons
P4 or P6. Activation of Chrono program is done by pressing the button P3 (selected
field flashes) and then the button P2 (Disabled changes to Enabled)

5.5.2 Chrono Program
Press the button P1 to return one step back and select the field Chrono Program.
Press button P3 to enter the menu
Choose Daily, Weekly or Week End program using the buttons
P4 or P6 and press the button P3 to confirm
Select the day of the week using the buttons P4 or P6 and press
the button P3 to confirm.
6

Within each day there are three programs that can be used. Press the button P3
(selected field flashes) and set the time of ignition of the boiler (ON)
using the buttons P4 or P6. After setting the time press the button P3 to confirm.
Press the button P6 to move to the field for boiler shutdown. Press the button
P3 (selected field flashes) and using the buttons P4 or P6
set the boiler shutdown time.
7

Press the button P5 (symbol “√” appears) and setting of time for a specific day of a
week is now activated.
Press button P1 until the display shows the initial screen. The symbol indicating that
the Chrono program is active now appears in top left corner of the screen.
Programming for operation around midnight
Set the clock to ON for the previous day at a specified time: for example, at 20:30
Set the clock to OFF for the previous day at 23:59
Set the clock to ON for the next day at 00:00
Set the clock to OFF for the next day at a specified time: for example, at 6:30
Thy system turns on on Tuesday at 20:30 and turns off on Wednesday at 6:30.
8

5.5.3 Manual charging with pellets / Load
This option activates manual charging with pellets, while the motor-reducer works
non-stop. Charging stops automatically after 600 seconds or by manual deactivation
at any time by pressing OFF via the button P3.
Activating this function is only possible when the boiler is switched off.
Manual charging with pellets is only used during start-up of the boiler or when there
are on pellets in the storage.
5.5.4 Correction of charging with pellets / Calibration
This function is used to fine-tune the selected combustion power. The range of
correction is from -7 to +7
Example:
1. If the set combustion power level 3 is not sufficient and power level 4 is too much
power in such a case a correction of power level 3 can be made by +1 or 2 or power
level 4 by -1 or 2.
2. The correction can be made even when the pellet is of poor quality and there is a
large ash residue.
6. User Menu 2
This menu is accessed by long pressing the button P3.
6.1 Keyboard settings
6.1.1 Date and Time
In this menu you can adjust the day, month, year and hour.
6.1.2 Language
This menu is used to load data from the motherboard.
9

6.2.2. Setting the contrast
Display contrast setting menu.
6.3 System menu
This menu is protected by a security password and can be used only by authorized
service technician.
6.4 Connection diagram
Figure 2
10
6.2 Keyboard Menu
6.2.1 Loading Menu (Learn Menu)
This menu is used to load data from the motherboard.

Pin
1
2
3
4
5
6
7
8
9
10
N
L
N
L
N
L
N
L
N
L
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
RED
GREEN
FUNKCIJE CHARACTERISTICS
Main line
Fan
Configurable output V2 – Pump
Heater
Motor-reducer
Safety thermostat, input Hv1
Safety thermostat, input Hv2
Exhaust probe
Buffer temperature probe
Boiler temperature probe
Encoder signal
Auxiliary input: Chrono/Room thermostat
Configurable input
+5V
GND
S4
GND
S6
GND
S7
+5V
+12V
F
COM
NC
NO
RS 485
RS 232
Photo-cell
Phase
Configurable auxiliary output
Display
Conector Rs232
230Vac± 10% 50/60Hz
F1= fuse T5,0A
Triac regulation max 1A
Triac ON-Off max 1A
Relay 3A max
Triac ON-Off 1A max
Contact ON-Off, Default valueclosed;
Bypass of not used
Contact ON-Off, Default valueclosed;
Bypass of not used
Thermocouple K: 500°C Max
NTC 10K @25°C 120°C Max
NTC 10K @25°C 120°C Max
Signal TTL 0 / 5V
Contact ON-Off
Signal 0 / 5V
Analogue input
Max voltage 5A
Relay 3A max;
Connecting modem/computer
11

7. Instructions for use
Combined pellet and wood boiler ABC COMBO is designed for pellet combustion,
and the addition of a grid into the combustion chamber of the boiler creates the
possibility for the combustion of solid fuels. The boiler is designed using the most
modern production technology and high-quality and certified materials, welded with
modern robotic technology and tested in accordance with EN 303-5: 2012 standard,
in order to meet all the requirements for connecting to the central heating system as
well as European norms in terms of the efficiency and emissions of harmful
particles.
7.1 Important information
§When installing the boiler all national, European as well as local regulations must
be observed.
§It is allowed to use only original spare parts which are available through
authorized dealers, service technician or directly from the factory.
§Combo boiler can be connected to the open and closed central heating system.
Installation must be made in accordance with the technical standards by a
professional who will be responsible for the correct operation of the boiler.
§If the boiler is installed to an open central heating system, it is necessary to place
an open expansion tank minimum 0.5m above the level of the highest radiator. If
the tank is installed in a room that is not heated it must be carefully insulated.
§If the boiler is mounted to a closed central heating system the installation of a
certified safety valve and membrane expansion tank is required. Safety valve and
expansion tank must be installed according to the professional requirements.
§The boiler must not be operated in flammable and explosive environment. The
product should not be used by children or persons with reduced mental or
physical abilities, 7 Instructions for use 16 as well as people without knowledge or
experience, unless they are supervised or trained by a person responsible for their
safety. Children must be supervised near the product.
7.1.1 Connecting the boiler to the chimney
Properly sized and configured chimney is a prerequisite for the safe operation of
boiler and heating efficiency. The chimney must be highly insulated. On the lower
part of the chimney a door for cleaning must be fitted. The chimney must be
resistant to condensation of flue gases.
12

7.1.2 Fuel
ABC Combo Boiler is designed for burning wood pellets as well as solid fuel (wood
and coal). Pellets used should meet the following standards: EN Plus, DIN Plus,
Önorm-M-7135 or DIN 51731. It is recommended that the humidity of the wood does
not exceed 25%.
* Pellets characteristics:
ŸHumidity ----- 6 – 8%
ŸRadius ------ 6mm
ŸLength ------- 10 – 30mm
ŸAsh residue -------- 1%
8. Boiler installation
8.1 The safety distance of the boiler from the wall and other
facilities
A – 1000mm
B – 300mm
C – 500mm
D – 200mm
Figure 3
13
Pellets
storage Boiler
A
B
C
D

8.1.2 The opening for fresh air supply
Each boiler has to contain an opening for the supply of fresh air that is dimensioned
in accordance with the power of the boiler. This opening must be protected with
protective net or grate. All installation work must be performed in accordance with
applicable national and European standards. The boiler must not operate in
flammable or explosive environments.
8.1.3 Connections dimensions
14
ABC COMBO 25kW
A – 1353mm – supply line
B – 150mm – return line
C – 130mm – charging and discharging
D – 799mm – heat exchanger
E – 566mm – cold water inlet
F – 1371mm – flue pipe / boiler height
G – 827mm – boiler width
H – 988mm – boiler depth
ABC COMBO 40kW - 60kW
A – 1504mm – supply line
B – 150mm – return line
C – 130mm – charging and discharging
D – 899mm – heat exchanger
E – 665mm – cold water inlet
F – 1539mm - flue pipe / boiler height
F – 1524mm - flue pipe / boiler height 60kW
G – 986 mm - boiler width
H – 1052mm - boiler depth
H – 1202mm – boiler depth 60kw

8.2 First commissioning of the boiler
§Check whether the burner is properly set
§Check whether all spirals of the turbulator are in place
§Connect the power supply cable to the 220V outlet
§Turn the main switch to position 1
§Select the boiler operation mode: pellets or solid fuel (the boiler is by default
preset to pellets)
§Charge the storage with pellets
§Activate the option “Load” (manual charging 5.5.3) and wait until pellets start to
fall into the combustion chamber. Wait 10 – 15 seconds and stop charging by
pressing the OFF. Pellets in the combustion chamber should be emptied and
the burner should be returned to its place making sure that the opening on the
left side of the burner fits over the heater pipe.
§Close the lower door of the boiler and start the boiler by long pressing the
button P2
§Set the power of the boiler (section 5.1)
§Set the set temperature of water (section 5.2)
8.3. Boiler operation using the solid fuel
In order to switch to the “solid fuel” operation mode, it is required to proceed as
follows:
§press the button P3 and using the button P6 select the “Operation Mode”, then
press the button P3 and using the button P6 select “Wood” and press the
button P3 to confirm
§press the button P1 until the initial screen appears with message “Wood”
instead of “Pellet” in the lower left corner
§open the lower door of the boiler and remove the burner from the combustion
chamber and set a cast grid (to be ordered separately) on mounts that are
designed for this purpose.
Figure 4
15

§a protective cover supplied with the boiler should be mounted to the pipe
leading the pellet into the combustion chamber
§light a fire in the boiler and start the boiler by pressing the button P2
§it is necessary to close the upper and lower boiler door
§set the boiler power (section 5.1)
§set the water temperature (section 5.2)
Note: In case of power failure an overheating of the system may occur when
the boiler is in “solid fuel” operation mode, so it is recommended to 21 install
an “UPS device” that will allow the operation of the pump in case of power
failure or connect the boiler to an open central heating system.
9. Cleaning and maintaining the boiler
Every millimeter of soot and dust on the heat exchangers and the flue pipes means
5% higher consumption of pellets. A clean boiler saves fuel and protects the
environment.
USE OF PROTECTIVE
GLOVES IS NECESSARY!
Daily cleaning:
§Depending on the intensity of firing it is necessary to empty the ashtray at least
once a day
§The rest of the ash in the combustion chamber should be collected in the
ashtray
§Remove the burner from its tray and clean the pellets residuals and ash
deposits
§Clean the ash from the inside of the burner carrier
§Pull spirals of the turbulator back and forth
Weekly cleaning:
§Open the upper door of the boiler and clean the ash deposits in the turbulators
and from the sides of the boiler
§Remove the turbulators (spirals) and clean the pipes
Monthly cleaning:
§Remove the flue pipes and clean them
§Separate the cable from the fan
16

Press the connector in the middle and pull back
Figure 5
Figure 6
Pull out the exhaust temperature probe from its port. Open the door of the opening
for cleaning (from the back of the boiler Fig. 7) and clean the soot and ash deposits
Figure 7
After the cleaning is completed the mounting procedure is performed
in reverse order
17
Unscrew
Unscrew

At the end of the heating season:
§Remove the fan housing and clean the dust with a vacuum cleaner taking care
not to damage the fan propellers
§Clean the flue pipes and check if the chimney is congested
§Clean the storage for pellets from dust and tiny debris of pellets
§Scrape the layers of ash and soot from all metal parts in the combustion
chamber of the boiler as well as the tube heat exchangers in the zone of the
upper door
Note: If the boiler uses solid fuel cleaning dynamics is tripled. At the end of
the heating season it is necessary to thoroughly clean the boiler from soot
and grime and it is obligatory that the boiler always be filled with water,
whether it is connected to a closed or open system of central heating.
Dismantling the pellets storage
1. Disconnect the cables from the main switch
2.Unscrew 4 screws from the cover
of the display and then pull the cable out
from the housing.
3. Disconnect the cables from
the safety thermostat
18

1.
2.
3.
4.
5.
6.
7.
Remove the boiler cover.
Before removing the cover, disconnect the electrical
installations:
- main switch
- display
- safety thermostat
Unscrew the screws.
Unscrew the three screws from the figure, from the internal
side of the storage.
Remove the side cover.
Place hand under the sheeting and press lower corners
of theside cover.
Unscrew the screws.
Unscrew the two indicated on the figure, from the inside,
under the storage.
Removing the storage.
Lift the storage 20mm and then remove it to the side,
in the direction of the arrow.
Unscrew the screws.
Unscrew the three screws from the figure, from the funnel of
the storage.
Removing the funnel of the storage together with pellets
conveyor.
Lift the funnel of the storage together with the pellets
conveyorin the direction of the arrow (at an angle of 45°).
19