BURNiT CombiBurn DC-A v2 series User manual

TECHNICAL PASSPORT
INSTALLATION and OPERATION MANUAL
DUAL-CHAMBER BOILER
CombiBurn DC-A v2 series
EN
Version p0.1.2
Model:
Serial No:

2
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TABLE OF CONTENTS
1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS .................................... 3
1.1. Explanaonofsymbols .......................................................................................... 3
1.2. Requirementstodual-chamberboilerinstallaonroom...................................... 3
1.2.1.Instruconstoboierinstaller................................................................................. 3
1.2.2.Instruconstoinstallaonuser ............................................................................ 4
1.2.3. Minimumclearancesforinstallaonandammabilityofconstruconmaterials 5
2. PRODUCT DESCRIPTION ........................................................................................ 5
2.1. DesignstructureofDual-chamberboilerCombiBurnDC-Av2.............................. 6
2.2. Automacashremovalsystem.Ashdepositcontainer ........................................ 6
2.3. Designofpelletsburner......................................................................................... 7
2.4. Designofaugermechanismandfuelhopper ....................................................... 7
2.5. Boilersafetydevices ............................................................................................. 8
3. FUELS .................................................................................................................... 8
4. TRANSPORTATION OF THE BOILER....................................................................... 11
5. DELIVERY PACKAGE ............................................................................................. 11
6. INSTALLATION OF THE HEATING BOILER ............................................................. 12
7. SETUP OF THE HEATING BOILER .......................................................................... 12
7.1. Connecngtheboilertoachimney.................................................................... 12
7.2. Connecngtheboilertothemainspowersupply.............................................. 13
7.3. Connecngthesafetyheatexchanger................................................................ 14
7.4. Connecngtheboilertotheheanginstallaon ............................................... 20
7.5. Connecngdiagrams .......................................................................................... 22
8. FILLING THE HEATING INSTALLATION .................................................................. 26
9. OPERATION OF BOILER ........................................................................................ 26
9.1. OperaonofDualchamberCombiBurnDC-A .................................................... 26
9.2. Importantrecommendaonsforlong-lasngandcorrectoperaonoftheboiler .... 27
10. CONTROLLER UNIT .............................................................................................. 27
10.1. Controllerview.Explanaonofbuonsandindicators ....................................... 27
10.2. Usermenu........................................................................................................... 29
11. WARRANTY TERMS .............................................................................................. 32
12. TECHNICAL FEATURES ......................................................................................... 32
12.1. TechnicalparametersofDualChamberboilerDC-Av2 ........................................32
12.2. ElementsofDualChamberboilerDC-Av2 .......................................................... 33
13. RECYCLING .......................................................................................................... 34

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1. EXPLANATION OF SYMBOLS AND
SAFETY INSTRUCTIONS
1.1. Explanaon of symbols
CAUTION! - Important
recommendaon or warning
concerning safety condions during
installaon and operaon of the pellet
burner
DANGER! - fault or improper use
may cause injury or be hazardous
to life of humans or animals.
FIRE HAZARD! - fault or improper
installaon and operaon may
cause re.
INFORMATION – Important
informaon on the proper operaon
of the product.
1.2. Requirements to Dual-chamber
boiler installaon room
This manual contains important
informaon for the safe and correct
installaon, start-up and trouble-free
operaonandmaintenanceoftheboiler.
The Dual-chamber boiler can be used
for heang rooms only in the manner
describedinthismanual.
The applicaon and any other was the
areaofoperaonisnotrecommendedby
the manufacturer and is not responsible
fortheoccurrenceofdefectsorfailures.
Notetheboilertypedataon thefactory
rang label and the technical data
providedinchapter12inordertoensure
properoperaonoftheproduct.
1.2.1. Instrucons to boiler installer
During installaon and operaon, the
country-specic requirements and
regulaonsmustbeobserved:
• Local construcon regulaons on
installaon, air supply and exhaust
gas extracon as well as chimney
connecon.
• Regulaons andnorms concerning the
ng of the heang installaon with
safetydevices.
• Requiredinstallaonofasmoke
detectorintheboilerroom.
Use only original BURNiT parts

WARNING! Installation and
setup of pellet burner should be
done by an authorized specialist
/ service shop and must follow
the safety instructions and rules
of operation.

DANGER of intoxicaon,
suocaon.
Inadequate inow of fresh air
to the boiler room may result in
dangerous leak of exhaust gases
during boiler operaon.
- Make sure the air inlets and
exhaust gas outlets are not
clogged or closed.
- If faults are not remedied
immediately, the boiler must not
be operated.
- The user must be provided with
wrien instrucons on the fault
and the hazard it entails.

DANGER of re when burning
ammable materials or liquids.
- Flammable materials/liquids
must not be le in close proximity
of the burner and heang boiler.
- Instruct system user of the
allowed minimum clearances
from surrounding objects.
It is mandatory to assure a backup
power generator of corresponding
rated power! (see 12.1)

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1.2.2. Instrucons to installaon user

DANGER of intoxicaon or
explosion
Toxic gases may be discharged
when burning waste, plascs,
liquids.
- Use only the fuels indicated in this
manual.
- In case of danger of explosion,
ignion or discharge of exhaust
gases in the room, stop the pellet
burner from operaon.

CAUTION! Danger of injury
/ damage of system due to
incompetent operaon.
- The boiler must be serviced only
by persons familiar with the
operaon manual.
- As user, you are only allowed to
start the boiler up, adjust the
temperature of the boiler, shut
the boiler down and clean it.
- Unaended children must not be
allowed access to premises with
running boiler inside.
It is mandatory to assure a backup
power generator of corresponding
rated power! (see 12.1)
Safety rules for user operaon:
-Operate the pellet burner on
recommendedfuelonly,andtothatend
you must regularly inspect the boiler
room.
-Do not use both cameras for burning
fuel at the same me. Before starng
theboiler,makesurethereisnoresidual
fuelinoneofthetwocamerasand/or
burner.
-Donotuseammableliquidsforignion
orincreaseofburneroutput.
-Collect ash in lid-covered reproof
containers.
-Clean the burner surface using non-
ammableagentsonly.
-Do not place ammable objects onto
the burner housing and heang boiler
cabinet or in their proximity. (see
diagram1fortheminimumclearances)
-Donotstoreammablematerialsinthe
boilerroom.
-Boilers,chimneysandotherconnecons
ofmountedburnermustmeetstandards
for re and emergency safety of the
country.
-It is mandatory to strictly observe
instructions for connecting the burner
to power network as well as to all
peripherals.
-Structural changes to Dual-chamber
boiler by user can cause damage to
equipmentorinjury.
-Do not allow contact transmission of
electricalwireortouchanypart of the
boiler, where the surface temperature
canexceed70°C.
-Thismanualshouldbekeptthroughout
thelifemeoftheboiler.

CAUTION! Hot surface!
Risk of burns if you touch the
running system. Burner housing,
body and ange are hot surfaces
during burner operaon.
-It is strictly prohibited to open
boiler inspecon doors with the
burner running.
-Close and buckle-lock the hopper
hatch cover after filling the boiler
with fuel. The hopper hatch cover
is not allowed to remain open for
longer periods of time.
-Also, exercise cauon when
touching the observaon port for
monitoring the burning process.
It may be hot.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1.2.3. Minimum clearances for
installation and flammability of
construction materials
The applicable minimum clearances in
your country may dier from the ones
specied below. Please, consult your
installer.
The minimum distance from the burner,
heang boiler or exhaust gas pipe to
objectsorwallsmustbeatleast200mm.
Table 1. Flammability of construcon
materials
Class А–non-
ammable
Stone, bricks, ceramic les,
bakedclay,soluons,plaster
freeoforganicaddives.
Class B –
hardly
ammable
Gypsum board panels,
basalt ber needled felt,
berglass board, AKUMIN,
Izomin,Rajolit,Lignos,Velox,
Heraklit.
Class С1/С2 -
Medium
ammable
Wood beech, oak. Wood
sowood,layeredwood
Class C3–easy
ammable
Asphalt,cardboard,cellulose,
tar, berboard, cork,
polyurethane,polyethylene.
Diagram 1. Recommended clearances
between boiler and walls.
For general safety consideraons, we
recommendthattheboilerbeplacedon
afoundaonmadeofclassAmaterial,see
table1.
2. PRODUCT DESCRIPTION
The CombiBurn high-efficiency dual
chamber boiler is designated for central
heating of premises through burning of
woodpellets.

Alternative fuels:
wood chips, dry stones of
cherries, plums, apricots, crushed
stones of peach and olive stones.
Use different types of alternative
fuels separately!
The combustion of these fuels is
performed in the lower combustion
chamberbymeansofanintegratedintoit
high-performance burner. As alternative
(backup fuel) for it can be used wood
logs,woodbriquettesandcoal,whichare
loadedtotheupperboilerchamber.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
CAUTION! Do not use both
chambers for burning fuel at the
same me.
The specially designed water jacket
completely covers the combuson
chamber in order to increase the
eecvenessandeciencyofupto89%.
Designed in conformity with EN 303-5,
class5.
Set includes Dual-chamber boiler DC-A
v2, pellet/chips burner, fuel hopper,
removable ash-and-soot container and
cleaningtools.
2.1. Design structure of Dual-chamber
boiler CombiBurn DC-A v2
Boiler body is with two combustion
chambers. The wood pellet/chips and
fruitstonesburnerisinstalledinthelower
chamber.Ametalgratedividestheupper
from the lower combustion chamber.
On this grate the backup fuel (firewood,
wood briquettes or coal) is loaded. The
boilerbodyismadeofboilergradesteel
of thickness 6 mm for the  combustion
chamberand3mmforthewaterjacket.
• Ecological. Wood pellets, wood chips
and fruit stones and rewood used in
thecombusonprocessarerenewable
energy sources with minimum
emissions.
• Automated. The main control unit,
integrated in the burner, manages
the entire heating process. Controller
functions:
1)Fully automated ignition and pellet
feed;
2)Fan ensuring stable operation of
burner;
3)Self-cleaning function (adjustable 1-4
timesover24hoursatequalintervals),
programmablestartme;
4)Built-in discharge mechanism drives
the ash and soot into a removable
container;
5)Controlstheoperationofthecirculation
pumpofthe centralheating;
6)Controlstheoperationofthepumpof
thedomestic hotwater;
7)Optionforcontrolbyroomthermostat;
8)Oponalformanualmodewhenusing
theupperchamberandburnedwood
and/orcoal.
9) Temperature control of the burner in
buffertank;
10)Exhaustsensor;
•Ecient. On their way to the chimney
uegasesmakeathree-passrunaround
three water-lled barriers inside the
combuson chamber. Thus ue gas is
cooleddownunlexitfromboiler,having
all its heat energy transferred to the
waterinsidethejacket.Thewaterjacket
embraces the combuson chamber
in full to ulize the emied heat most
eciently. To prevent heat losses into
theambience,theboilerisinsulatedon
the outside by high-temperature rock
wool.Eciency–rate89%.
2.2. Automatic ash removal system. Ash
deposit container
The specially designed ash-and-soot
disposalsystemallowstheashandsootto
subsideatthelowestpointoftheboiler
body (1) and be disposed inside the ash
and soot container (2) using a transport
screw (3). Ash-and-soot container is
removable. It is equipped with a handle
(4)andwheels(5)forconvenientdisposal.
Onceyouhaveemptiedthecontainerof
ashes, please make sure you close the
container covertightly(6),buckle-lockit

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
tothecontainerbuckles (7),thenbuckle-
lock the container to the boiler buckles
(8).
Diagram 2. Removabe container elements
2.3. Design of pellets burner
Theburnerismadeofhigh-qualitystainless
steel able to withstand temperatures of
up to 1150°С. The burner is installed on
side-flangeofheatingboiler.
2
4
5
8
9
6
7
Diagram 3. Burner elements
1 - Burner;
2 - Air mantle;
3 - Screw mechanism;
4 - Air feed fan, step-regulated;
5 - Screw (inner auger) motor;
6 - Cleaning system;
7 - Secondary screw mechanism;
8 - Stirring mechanism;
9 - Support with adjustable leg.
2.4. Design of auger mechanism and fuel
hopper (pellets)
Itconsistsofaspiralconveyormountedto
theaxle,drivenbymotorreducer,which
is attached to the body of the auger.
Augerandfuelhopperareconnectedby
medialflange.
Temperaturesafetyvalve(3)isconnected
toawatertank(2)andincaseofreverce
flameinauger,releacethewaterintothe
medialflange(4),locatedbetweenauger
(5)preventingself-immolationofthefuel
tothehopper(1)
Convinient maintenance openings are
provided on auger mechanism and on
medialflange.
The hopper hatch-cover remains to be
closedduringoperationofboiler.
The water tank (2) must be filled when
boilerisoperating.
3
1
2
5
7
6
4
Diagram 4. Auger and Fuel hopper elements

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1 - Fuel hopper
2 - Water tank
3 - Safety valve
4 - Medial flange
5 - Auger
6 - Lighter for solid fuel operating on
hot air
7 - Sensor safety valve of reverce fire
temperature
2.5. Boiler safety devices
Safe operation of boiler is ensured via
a set of safety devices. Combustion
process is electronically regulated via
step modulation of burner performance
according to power needs, and also
maintained in optimum working mode.
Two independent thermostats – that on
theboiler(STB type)andtheoneonthe
augermechanism(bimetallic thermostat
set at 105°С) would stop the fuel
feedingintotheburnerincaseofexcess
temperatureload.
Inaddition,theburnerhasasupplementary
heat safety valve (with sensor mounted
on auger housing)connectedtoanextra
watertankofvolume10litres(mounted
on the back side of hopper housing and
pipe-connected to auger mechanism)
capabletoputoutabackfireflameshould
oneemergeinsideaugertubeorhopper.
• Fuse. In case of electrical fault in the
system of the burner (short circuit,
currentoverload,etc.),theoverloadis
borne by the electrical fuse fitted on
the main control panel of the burner
(10А).
• Power interruption. In case of power
interruption,allparametersettingsare
storedinthememoryofthecontroller.
Upon the subsequent restart of the
burner, the controller resumes the
execution of the program from the
point when the power interruption
occurred.
3. FUELS
3.1. The main fuel for the boiler is pellets.
All pellets are biomass manufactured
from common low-growing plants and
trees.Themostcommonhouseholdtype
pellets are made of sawdust and milled
woodchippingswhicharewastematerial
fromwoodusedintheproduconoflogs,
furnitureandotherproducts.Woodisthe
richestrawmaterialwhichdoesnothave
any impact on the producon costs of
foodproductsorethylalcohol(ethanol).
Therawmaterialisprocessedunderhigh-
pressureandtemperatureandispressed
to produce small-size cylindrical pellets.
The producon process may ulize so
wood material (such as sowood, pine),
hardwood(oak)aswellasrecycledwaste
wood. Wood pellets are produced in
hammermillsorwoodpelletplants.
Advantages of wood pellets:
•Convenient storage. Pellet bags canbe
stored on a small area in a dry garage,
basement,serviceroomorshed.
•Easy loading. In most cases the boiler

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
hopperneedsloadingonlyonceaweek
–thisdependsonthehoppercapacity.
•Beer control of fuel quanty.Thesmall
sizeofthepelletsallowsforprecisefuel
feeding.Ontheotherhand,the supply
of air for reaching opmal combuson
eciency is easier to adjust since the
fuelquantyinthecombusonchamber
remainsconstantandpredictable.
•Fuel eciency. High combuson
eciency is also determined by
consistently low moister content of
pellets (consistently under 10% as
opposedto20%to60%moisturecontent
of the logs). Low moisture content,
controlled fuel porons and precise
air seng means high combuson
eciencyandverylowcarbonoxidesin
theuegases.
i
When purchasing pellets, ask
for conformity declaraon and
cercate issued by an accredited
laboratory and make sure the
fuel meets the requirements
indicated in the manual. If
you purchase large amount of
pellets (bulk supply for the enre
heang season for example), ask
your supplier to provde accurate
and true informaon about the
storage condions.
Werecommendtousepelletwithsizeof
6-8mm.Density600-750kg/m3 heang
value4.7-5.5kWh/kg.Ashcontent–less
than1%andmoisturecontentupto8%.,
EN14961-2:2011.
Theopmaldensity of the pelletswhich
guarantees their quality is 605 - 700 kg
percubicmeter.
Pelletmoisturecontentmustnotexceed
10%.Make sureyou storeyourfuel in a
dryandwell-venlatedplace.
The opmal pellet ash content is ≤ 1%.
This also provides for less frequent
cleaningintervalsfortheburner.
Thetablebelowcontainstheparameters
whichwerecommendthatyoutakeinto
consideraonwhenchoosingfuelforyour
burner.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Table 2. European Certification of Wood Pellets for Heating Purposes
Parameters Units ENplus-A1 ENplus-A2 EN-B
Diameter mm 6(±1)
8(±1)
6(±1)
8(±1)
6(±1)
8(±1)
Length mm 15≤L≤401) 15≤L≤401) 15≤L≤401)
Bulkdensity kg/m2≥600 ≥600 ≥600
Caloric/heangvalue MJ/kg ≥16,5-19 ≥16,3-19 ≥16,0-19
Humidity/moisture Ма.-% ≤10 ≤10 ≤10
Dust Ма.-% ≤13) ≤13) ≤13)
Mechanicaldurability Ма.-% ≥97,54) ≥97,54) ≥96,54)
Ash Ма.-%2) ≤0,7 ≤1,5 ≤3,5
Melngpointofash °C ≥1200 ≥1100 -
Chlorinecontent Ма.-%2) ≤0,02 ≤0,02 ≤0,03
Sulfurcontent Ма.-%2) ≤0,03 ≤0,03 ≤0,04
Nitrogencontent Ма.-%2) ≤0,3 ≤0,3 ≤1,0
Coppercontent mg/kg2) ≤10 ≤10 ≤10
Chromiumcontent mg/kg2) ≤10 ≤10 ≤10
Arseniccontent mg/kg2) ≤1,0 ≤1,0 ≤1,0
Cadmiumcontent mg/kg2) ≤0,5 ≤0,5 ≤0,5
Mercurycontent mg/kg2) ≤0,1 ≤0,1 ≤0,1
Leadcontent mg/kg2) ≤10 ≤10 ≤10
Nickelcontent mg/kg2) ≤10 ≤10 ≤10
Zinccontent mg/kg2) ≤100 ≤100 ≤100
1) not more than 1% of the pellets may be longer than 40 mm, max. length 45 mm;
2) dry weight;
3) parcles <3.15 mm, parculate maer, before handing over the goods;
4) measurements with Lignotester limit value ≥ 97,7% by weight.
3.2. (Table 3.) Alternative fuels - Wood chips corresponding to EN 14961-1 P16A
Class Main fraction, at
least 75-w%, mm**
Fine particles, w-%
(<3,15 mm) All - main and fine particles, w-%
P16A* 3,15≤P ≤16mm ≤12% ≤3%>16mmandall<31,5mm*
** Cross-seconal area of the oversized parcles is as follows: P16 <1 cm²;
** The numerical values for size (class P) refer to the amount of parcles which pass through the
circular opening with sieve plates in accordance with standard EN 15149-1;
See Tables 8, 9, 10, 11 and 12 for the controller parameters

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
4. TRANSPORTATION OF THE BOILER
Werecommendtotransporttheheang
boiler to the installaon site in its
packaging placed on the pallet. During
transport and installaon, depending on
theweight,suitablesafetydevicesshould
be used in accordance with Direcve
2006/42/EC.
Whentransporngitemsweighingmore
than30kg,theuseofpalletjack,fork
truckorotherhoisngdevicesisamust.
Product must be in original packaging
following the instrucons on the label -
to be protected from adverse weather
condions (snow, rain and dust) from
the shocks, and other acvies likely to
causedamage.In caseofmalfunconof
thefanorthemotordrive(noise,fricon)
or failure of high-tech elements such as
brokenLCDscreen,contactyournearest
authorizedservicecenterforrepairsand
maintenance.
The boiler is securely fastened with
fastenerstoawoodenpallet.

Important: When installing the
boiler, the wooden pallet onto
which the boiler is placed must
be removed by unscrewing the
bolted connecons using at ring
wrench S13.
Table 4.
Overal dimensions of Set CombiBurn DC-A
v2, including: Dual-chamber boiler, Burner,
Auger, Fuel hopper, ash-and soot container
(packed and placed into Fuel Hopper).
Set
CombiBurn
A,
mm
B,
mm
C,
mm
D,
mm
Weight,
kg
DC 35 A v2 1200 1600 125 1925 645
Diagram 5.
Indicaons dimensions
5. DELIVERY OF THE BOILER
• Inspect the integrity of the packaging
upondelivery.
• Check whether all components
have been delivered to you. Boiler
consignmentpackageincludes:
1)SetCombiBurnDC-Av2:boiler,burner,
ash-and-sootcontainer.
2)Safetyvalve3bar.
3)Fireirons.
4)Cleaningbrushforuepipes.
5)Technical passport. Installaon and
operaonmanual.
6)ServicebookletandWarrantycard.
If any of the above items are missing,
contactyoursupplier.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
6. INSTALLATION OF THE HEATING
BOILER

The assembly, installaon and
set-up of the boiler must be
performed by a technician
authorized for such operaons.
Installer must indicate to the
user of the installaon the
minimum clearances from
ammable materials and liquids.
Requirements:
-Boilerroommustbefrost-proof;
-Boiler room must allow for connuous
access of air necessary to maintain
combuson;
-Boilersmustnotbeplacedininhabitable
rooms;
-All boiler rooms must have correctly
calculatedventdependingontheboiler
output.Theventmustbeprotectedby
meansofanetorgrate.
Thesizeoftheventiscalculatedaccording
totheformula:
А = 6,02*Q -where:
А–areaoftheventincm2,
Q –boileroutputinkW
-Removethepackagingwithoutpollung
theenvironment
-Observe building supervision
instrucons, in parcular the exisng
Ordinance on combuson devices and
storage of combuson materials, on
building requirements applicable to
installaonsitesandonvenlaon;
-The boiler must be placed on a
foundaonwhosesurfaceareaislarger
than the base of the heang boiler
accordingtodiagram1;
-Theboilermustbeplacedinaposion
which allows for the easiest possible
cleaningandservicing;
-Installaon must be carried out
according to installaon diagram 1
whichshowstheboilerhousing;
-Noobjectsmadeofammablematerials
or liquids may be placed on/near the
boiler;
7. SETUP OF THE HEATING BOILER
7.1. Connecng the boiler to a chimney
Boiler-to-chimney connecon must
alwayscomplywiththeexisngstandards
and rules. The chimney must provide
sucient draught for evacuaon of the
smokeunderanycondions.
The proper funconing of the chimney
requires adequate sizing of the chimney
itselfsincethedraughtitproducesaects
combuson,boiler’soutputandlifespan.
The draught created by the chimney
is in funconal relaon to its cross-
secon, height and the roughness of its
interior walls. No other appliance may
beconnectedtothechimneyservingthe
boiler. Chimney diameter must not be
smallerthantheueoutletoftheboiler.
Flue outlet must be connected to the
chimneyopening.Intermsofmechanical
properes,theueoutletmustbesturdy
and properly sealed (to avoid gas leak)
and allow for easy access for cleaning
on the inside. The inner secon of the
ueoutletmustnotbegreaterthanthe
eecveseconofthechimneyandmust
notnarrow.Avoidusingelbowjoints.

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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
135 0
Diagram 6. Boiler size and chimney
parameters
Table 5. Recommended minimum sizes and
chimney dra
Boiler
output
Chimney
diameter, mm
Chimney
draft, Pа
35-40 kW
Ø 180 mm
Ø 200 mm
Ø 220 mm
15 - 30
15 - 30
15 - 30
Thechimneycleaningopening has tobe
initslowestpart.Thechimney’swallhas
tobethreepliedwherethemediumlayer
isfrommineralwool.Thethicknessofthe
insulation is not less than 30 mm when
thechimneyissettingupinsidethehouse
and the thickness is 50 mm, when the
settingupisoutside.
The inner diameter of the chimney
dependsonitsrealheightandthepower
capacityoftheboiler(seediagram6).

Data in the tables are for
indicave purposes.
Draught depends on the
diameter, height, uneven secons
along the chimney surface and
dierences in temperature
of combuson products and
outside air. We recommend that
you use chimney ed with ue
terminal. Heang specialist must
calculate the precise sizing of the
chimney.
7.2. Connecting the boiler to the mains
power supply

Such connecon must be
performed by a technician /
service shop authorized for such
operaons.

Caution! ELECTRIC SHOCK
HAZARD!
- Before opening the unit: switch
off the voltage and secure the
unit against accidental restart.
- Observe installation
instructions.
Theboilermustbeconnectedtoa220V/
50Hzmainsusingpowercord.
Createghtconnectionwiththeelectrical
mains which complies with the local
regulations(seediagram8,9).

14
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
7.3. Connecng the safety heat exchanger
Such connecon must be
performed by a technician /
service shop authorized for such
operaons.
The Dual Chamber boiler DC-A v2 is
equipped with safety heat exchanger
(coolingcircuit).Itconnectstothewater
system through a thermostac valve. In
case of overheang, the thermostac
valvefeedsincoldwaterfromthewater
mains which passes through the heat
exchanger and absorbs the heat in the
boiler. The wateristhen dischargedinto
the sewage system. This arrangement
ensures safe evacuaon of the excess
heat without the need for addional
energy.Thisguaranteesthatthewaterin
the boiler will not exceed the maximum
safelevelof95°C.
The minimum operang pressure of the
coolingwaterinthesafetyheatexchanger
mustbewithintherange2÷8bar.
Aowrateofatleast12l/minisrequired.
Connect the safety heat exchanger
accordingtothehydraulicdiagramusing
thermostac valve. Install a lter on the
inletbeforethethermostacvalve.

15
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1. Water supply network (pressure 6-10 bar)
2. Drainage (sewerage)
3. Boiler DC-A v2
4. Safety heat exchanger inlet
5. BVTS valve sensor
6. Safety heat exchanger outlet
Diagram 7. Connecng the safety heat exchanger

16
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Diagram
8. Wiring diagram for connection of peripherals and controller terminals.
LN
LNLN
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
El. motor for
cleaning of ash
3IK15GN-C/150K
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
PE
NL
+__+
_+YU
NL
_+YU
NL
Exhaust gas
temperature
sensor PT1000
RGTFA-100MM
220V
001 002 004 005 006 007 008 009 010 011 012 013 014 015 018 019
I01 I02 I03 I04 I05 I06 I07 I08 I09 I10 I11 I12 I13 I14 I15 I16
I18
016 017
PE
003
021
020
NL
+__+
heater signal
_+YU
NL
_+YU
NL
L
N
I17
Boiler temperature
sensor NTC
with a silicone
insulation L-2m.
H05VV-F 3G0,75
H05VV-F 3G0,75
H05VV-F 3G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
NTC
sensor
L-0.5M
NTC
sensor
L-0.5M
NTC
sensor
L-0.5M
Inputs
Designaon Group 1
I02 Room Thermostat
I03 Boiler temp
I04 STB KSD
I05 DHW Sensor
I06 Smoke gases tem-
perature
I08 Buer top sensor
I17 Buer boom sensor
Outputs
Designaon Group 2
002 Main Fan
003 Heater
004 Cleaning Fan
005 Screw burner
007 CH pump
008 DHW pump
011 Clean ash
018 Heater Fan
019 Rotary actuators

17
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Diagram 8. Wiring diagram for connection of peripherals and controller terminals.
LN
LNLN
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
El. motor for
cleaning of ash
3IK15GN-C/150K
ПВ-А2 0,5 yellow-green + cable shoe
М5 - 1 pc.
PE
NL
+__+
_+YU
NL
_+YU
NL
Exhaust gas
temperature
sensor PT1000
RGTFA-100MM
220V
001 002 004 005 006 007 008 009 010 011 012 013 014 015 018 019
I01 I02 I03 I04 I05 I06 I07 I08 I09 I10 I11 I12 I13 I14 I15 I16
I18
016 017
PE
003
021
020
NL
+__+
heater signal
_+YU
NL
_+YU
NL
L
N
I17
Boiler temperature
sensor NTC
with a silicone
insulation L-2m.
H05VV-F 3G0,75
H05VV-F 3G0,75
H05VV-F 3G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
H05VV-F 2G0,75
NTC
sensor
L-0.5M
NTC
sensor
L-0.5M
NTC
sensor
L-0.5M
Inputs
Designaon Group 1
I02 Room Thermostat
I03 Boiler temp
I04 STB KSD
I05 DHW Sensor
I06 Smoke gases tem-
perature
I08 Buer top sensor
I17 Buer boom sensor
Outputs
Designaon Group 2
002 Main Fan
003 Heater
004 Cleaning Fan
005 Screw burner
007 CH pump
008 DHW pump
011 Clean ash
018 Heater Fan
019 Rotary actuators

18
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Diagram
9. Wiring diagram for connection of the components of the burner to the controller and to the connecting socket.
N
L
N
L
N
L
N
L
1
2
3
4
5
6
7
8
9
10
1
2
4
5
67
10 11
89
LN
STB
KSD301105DEG0
11
L
3
L
8
9
1
2
10
11
7
6
3
4
5
LN
12
13
12
13
12
13
heater signal
2х0,75m 0,4m + 2 pc.
cable shoe 6,3mm insulated
STB
yellow-green
3х1,5mm мм 0,2m + cable shoe М5
Connective box IP 54 +
luster terminal 13pc.
Cable 14х0,75mm 1,5m
LIGTHER FOR
SOLID FUEL
LIESTER
blue
brown
black
Heater
Heater
Fan
INPUT
Connector
OUTPUT
Connector
Main Fan
2pc. cable connector sleeve
red
black
blue
brown
Rotary
actua tors
FAN
CY 100
blue
blue
brown
brown
H05VV-F 2G 0,75
FM
2pc. cable shoe
6,3mm insulated
ACTUATOR
GRUNER
304-230-05 5N
H05VV-F 2G 0,75
blue
brown
blue
brown
ELECTRIC MOTOR
0326002D130
1200W
Cleaning
Fan
Screw
Burner
blue
brown
yellow-green yellow-green
brown
blue
H05VV-F 3G 0,75
SB
H05VV-F 2G 0,75
KSD
blue
brown
blue
brown
MOTOR-REDUCER
40/63 with an
EL. MOTOR
ММ 71B4 370W
STB KSD
301 A NC 105DEG
yellow-green
3х1,5mm 0,2m + cable shoe М5
to body of a hopper
Inputs
Designaon Group 1
I02 Room Thermostat
I03 Boiler temp
I04 STB KSD
I05 DHW Sensor
I06 Smoke gases tem-
perature
I08 Buer top sensor
I17 Buer boom sensor
Outputs
Designaon Group 2
002 Main Fan
003 Heater
004 Cleaning Fan
005 Screw burner
007 CH pump
008 DHW pump
011 Clean ash
018 Heater Fan
019 Rotary actuators

19
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Diagram 9. Wiring diagram for connection of the components of the burner to the controller and to the connecting socket.
N
L
N
L
N
L
N
L
1
2
3
4
5
6
7
8
9
10
1
2
4
5
67
10 11
89
LN
STB
KSD301105DEG0
11
L
3
L
8
9
1
2
10
11
7
6
3
4
5
LN
12
13
12
13
12
13
heater signal
2х0,75m 0,4m + 2 pc.
cable shoe 6,3mm insulated
STB
yellow-green
3х1,5mm мм 0,2m + cable shoe М5
Connective box IP 54 +
luster terminal 13pc.
Cable 14х0,75mm 1,5m
LIGTHER FOR
SOLID FUEL
LIESTER
blue
brown
black
Heater
Heater
Fan
INPUT
Connector
OUTPUT
Connector
Main Fan
2pc. cable connector sleeve
red
black
blue
brown
Rotar y
actua tors
FAN
CY 100
blue
blue
brown
brown
H05VV-F 2G 0,75
FM
2pc. cable shoe
6,3mm insulated
ACTUATOR
GRUNER
304-230-05 5N
H05VV-F 2G 0,75
blue
brown
blue
brown
ELECTRIC MOTOR
0326002D130
1200W
Cleaning
Fan
Screw
Burner
blue
brown
yellow-green yellow-green
brown
blue
H05VV-F 3G 0,75
SB
H05VV-F 2G 0,75
KSD
blue
brown
blue
brown
MOTOR-REDUCER
40/63 with an
EL. MOTOR
ММ 71B4 370W
STB KSD
301 A NC 105DEG
yellow-green
3х1,5mm 0,2m + cable shoe М5
to body of a hopper
Inputs
Designaon Group 1
I02 Room Thermostat
I03 Boiler temp
I04 STB KSD
I05 DHW Sensor
I06 Smoke gases tem-
perature
I08 Buer top sensor
I17 Buer boom sensor
Outputs
Designaon Group 2
002 Main Fan
003 Heater
004 Cleaning Fan
005 Screw burner
007 CH pump
008 DHW pump
011 Clean ash
018 Heater Fan
019 Rotary actuators

20
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
7.4. Connecng the boiler to the heang
installaon.
Such connecons must be
performed by a technician /
service shop authorized for such
operaons.
Whentheboilerisconnectedtoaheang
system,itismandatorytoinstalla3bar
reliefvalveandexpansionvessel.Noshut-
ongsmaybeinstalledbetweenthe
reliefvalve,expansionvesselandboiler.

It is mandatory to install a three-
way valve (Laddomat or similar)
or a four-way mixing valve which
to ensure that the temperature
of the heang medium fed into
the boiler from the heang
installaon is at least 65°С.
Table 6. TROUBLE-SHOOTING TABLE
Installaon damage
Cause Solution
1. Due to unsealed connecons
1. Install the connecting piping strain-free to the boiler
connections. Connect the heating installation outlet to
connection B. Connect the heating installation inlet to
connection A. Mount the cock Y included in the set item.
11.4. at the drainage outlet.
2. Due to freezing
2. If the heang installaon, including the piping network,
has not been built frost-proof, we recommend that you
ll the heang installaon with a liquid which has low
freezing point and corrosion protecon and anfreeze
agent.
Boiler water too hot, heang bodies too cold
1. Hydraulic resistance is too high.
2. Air in the system
3. Inoperable circulaon pump
Make sure the circulaon pump has been properly selected
and the heang installaon is of the proper dimensions.
(You must contact your installer.)
The STB safety thermostat has
been triggered.
Upon reaching a temperature of 95°С, the thermostac
safety protecon device is triggered and the fan is turned
o. To resume protecon, remove the black cap on the
front panel of the boiler and press the buon on the STB-
thermostat.
Contact your installer to determine the cause of protecon
triggering.
Low temperature in the boiler on which the burner is installed. Unable to reach normal
temperature mode of 65°-85°С
Inadequate sizing and/or
combinaon of heang appliances
Immediately consult your installer about the problem.
Mount the supplied lling and drainage cock on the
drainage outlet Y.