Centrometal PelTec 12 Owner's manual

TECHNICAL INSTRUCTIONS
TUPLTC-09-2013-ENG
PelTec 12-48
HEATING TECHNIQUE
Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: [phone], fax: [phone]
for installation, use and maintenance
of hot water boiler
and installation of additional equipment
THE FIRST START-UP MUST BE DONE BY AUTHORIZED PERSON
OTHERWISE PRODUCT WARRANTY IS NOT VALID

2Technical instructions PelTec
Technical data
TECHNICAL INFORMATION
Boiler body
dimensions
Boiler
connections
Dimensions of the boiler to enter the room PelTec 12 PelTec 18 PelTec 24 PelTec 48PelTec 36
Width (G)
Depth (H)
Height (I)
Type
PelTec 12 PelTec 18 PelTec 24 PelTec 48PelTec 36
Nominal heat output
Heat output range
Boiler class
Required chimney underpressure
Water amount in boiler
Exhaust gas temperature at nominal heat output
Exhaust gas temperature at minimal heat output
Exhaust mass flow at nominal heat output
Exhaust mass flow at minimal heat output
Combustion period
Min. inlet water tem. at the boiler supply water connection
Setting range for temperature controller
Minimal return temp.at boiler return tapping
Standby heat losses
Boiler resistance on water side at nominal output
Fuel type
Fuel moisture content
Fuel size
Firebox volume
Combustion chamber dimensions
Combustion chamber volume
Combustion chamber type
Pellet tank volume
Volume of ash boxes (left / right)
Required minimum accumulation next to boiler
Auxiliray power requirements at QN
Auxiliray power requirements at Qmin
Supply voltage
Frequency
Total mass - (boiler with tank and feeder screw)
Max. operating overpressure
Test pressure
Max. operating temperature
Flue gas tube - external diameter
Dimension D
Dimension E
Dimension F
Heating appliance running
Heating applieance running
(kW)
(kW)
(mbar)
(lit.)
(°C)
(°C)
(kg/s)
(kg/s)
(h)
(°C)
(°C)
(°C)
(W)
(mbar)
(%)
(mm)
(lit.)
(mm)
(lit.)
(lit.)
(lit.)
(W)
(W)
(V~)
(Hz)
(mm)
(mm)
(mm)
(kg)
(bar)
(bar)
(°C)
(mm)
(mm)
(mm)
(mm)
(A)
(B)
(C)
Lenght
Width
Height
Flow and return pipe (male thread)
Charge/discharge (female thread)
12
3,6-12
5
0,12
78
120
100
0,0131
0,0005
-
-
65-90
5
0,942
465x300x300
41,85
single 8,7
1050
1105
1200
1560
328
150
1515
135
555
1"
1/2"
18
5,4-18
5
0,12
120
100
0,0164
0,0029
-
-
65-90
9
1,59
650x300x300
58,5
7 / 8,7
1050
1105
1420
1560
150
1040
125
510
1"
1/2"
24
7,2-24
5
0,12
100
120
100
0,0197
0,0052
-
-
65-90
> 0°C
13
wood pellets
max. 12 %
fi 6x50
1.59
650x300x300
58.5
underpressure
340
8,7 / 8,7
by EN 303-5, point 4.2.5
1050
220
50
1080
1400
1560
402
2.5
5
90
150
1140
130
495
5/4"
1/2"
with fan
under non-condensing conditions
36
10,8-36
5
0,12
108
120
100
0,031
0,0092
-
-
65-90
10
2,56
620x385x385
91,90
13 / 19,6
1100
1160
1485
1560
455
160
1160
120
555
5/4"
1/2"
48
14,4-48
5
0,12
120
100
0,041
0,0131
-
-
65-90
14
2,56
770x385x385
114,13
13 / 19,6
1100
1175
1485
1560
478
160
1310
115
555
5/4"
1/2"
650
765
1565
880
765
1275
880
735
1345
965
795
1345
965
795
1495
PelTec 18
PelTec 12 PelTec 24-48 PelTec 12-48
H
PelTec
G
I
G
I
PelTec
G
I

SG *
SP
VE DP
PLV
MV
PVV
PP
E
FD
PLV
MV
PVV
VE
PT
SP
SG *
PP
E
F
D
RPRP
3
PelTec 12 PelTec 18-48
PLV
PVV
PP
DP
VE
SP
PT
RE
MV
RP
SG
VC
PE
FC
CP
-
-
-
-
-
-
-
-
-
-
-
-
-
-
-
PelTec
C
PelTec 18
C
PelTec 12
PelTec
B
C
PelTec 24-48
RE RE
VC VC
PE PE
PT
FCFC
Technical instructions PelTec
Dimensions and basic parts of the boiler
Boiler flow
Boiler return
Charge / Discharge
Flue gas tube
Fan (fan output can be mounted in any directions)
Pellet tank
Pellet feeder
Boiler control unit
4-way motor mixing valve
Pellet level sensor
Safety ventilation group (not included in delivery)
Connecting tubes
Connection for expansion vessel
Flexible PVC tube
Circulation pump (mandatory set on the speed 3)
CP CP
BB
A
PelTec 12-48
RE

4
Basic parts and sensors
1 - Boiler sensor (NTC 5k)
1
2 - DHW sensor (NTC 5k)
3 - Presostat
4 - Photocell
5 - Electric heater
6 - Flue gas sensor (Pt 1000)
7 - Fan speed sensor
8 - PVC tube bimetal sensor
9 - Pellet level in the tank
1
10 - Flow sensor (NTC 5k)
11 - Return sensor (NTC 5k)
12 - Elbow with socket for
2
sensor
1 Depending on the configuration can be used as: PTV sensor, flow sensor, the sensor
accumulation tank (CAS), hydraulic crossover (HS)
2 Obligatory installation
Technical instructions PelTec
PelTec 18
PelTec 12 PelTec 24-48
PelTec PelTec
11
1
11
2
4
3
5
4
3
5
4
3
5
1
PelTec 12 PelTec 18-48
7
9
11
810
6
7
6
910
11
8
12 12
2 2
1
1

1.0. INTRODUCTION
The PelTec has a modern construction and design and is made out of the controlled materials of high
quality, welded with most modern technology and is approved and tested under EN 303 - 5 norm and
fulfil all special request for the connection on the installation of a central heating system.
1.1. BOILER DESCRIPTION
All local regulations, including those referring to national and European standards need to be
complied with when installing the appliance.
The boiler must not be modified unless using the tested original accessories we provide or if the
work is undertaken by our Customer Service.
Only fit original spare parts. These can be obtained from your customer service partner or directly
from ourselves. European standards need to be complied with when installing the appliance.
Regular care and cleaning of the appliance, flue gas outlets, connecting piece and flue.
CAUTION:
The flue may block if the boiler is heated again after a long period of it not being used. Before
starting the boiler, have the flue checked by a specialist (chimney sweep).
Ensure sufficient supply of fresh air in the installation room when heating. The air must be replaced
at least 0.8 times an hour through constant and reliable room venting. Fresh air may have to be
provided from outside if the windows and doors in the room where the boiler is installed are well
sealed or if this room contains other equipment, such as extractor hoods, clothes dryer, fan etc.
1.2. SAFETY PRECAUTIONS
1.3. IMPORTANT INFORMATIONS
This symbol indicates measures for protection against
accidents and warning for the user and / or exposed
persons.
Steel hot water boiler are engineered for wood pellet firing. In the boiler is installed the burner for wood
pellet firing with the automatic firing and automatic self-cleaning function which enables the reliable
operation also with the low quality wood pellets. The function of the automatic cleaning flue gas tubes
provides the unifying exchange of the heat and high and unifying level of boiler efficiency. Digital boiler
controller in a basic construction offers also the possibility of control with the additional equipment likes
lambda probe or level control of the wood pellets in the pellet tank. The pellet tank is the integral part of
the boiler. The boiler is delivered in pieces due to the easier transport into the boiler room.
The boiler and related accessories are state of the art and meet all applicable safety regulations.
The control unit, wiring chamber, el. heater, safety cut-out STB thermostat, fan, grid cleaning
mechanism, flue gas tubes cleaning mechanism and pellet supply mechanism are integrated into the
PelTec. They are operate at a voltage of 230 V AC. Improper installation or repair can pose the danger of
life-threatening electric shock. Installation may beperformed only by appropriately qualified technicians.
Caution symbols:
Please take careful note of the following symbols in this Operating Manual.
Introduction, boiler description, safety precautions, important informations
Technical instructions PelTec 5

1.4. STATUS OF DELIVERY
Equipment is delivered seperately:
1. Boiler with planking and thermal insulation
2. Pellet tank in a cardboard box (the parts need to be mounted, see instructions for mounting
the pellet tank)
3. Feeder screw with a flexible PVC tube (should be placed in the pellet tank)
4. Grating cleaning mechanism (requires installation on the boiler)
5. Fan (requires installation on the boiler)
6. Connection tubes with holenders, 4-way mixing valve and circulation pump (need to be mounted on
boiler, Mandatory set the pump on the speed 3.)
7. Motor device (requires installation on the 4-way mixing valve)
Figure 1. Status of delivery
PelTec 12 Pellet tank
Boiler
Feeder screw
PelTec 18-48
Boiler
Status of delivery
Fan
Cleaning
mechanism grillee
PelTec 18-48PelTec 12
Connection
tubes
T-piece
Motor device
6
Feeder screw
Pellet tank
Technical instructions PelTec

Positioning and mounting the boiler
For ease of handling, transport and import of boiler, PelTec is delivered in parts that need be mounted on
the boiler when the boiler is in the boiler room. These parts need to be installed on the boiler:
- Fan - mount on the back of boiler, is obligatory to use the flange gaskets fan, fastened using M8 bolts
and nuts. Plug-connector for power supply fan and the fan tachometer in the back of the control box. Fan
output can be mounted in any directions.
- Mechanism for grating cleaning - mount on the right side of the boiler ( in this side is pellet tank), must
be fastened using M8 bolts and nuts. After assembly, it is necessary to attach the lever burner grid with
gear motor trail. Plug-in two cables with connectors (motor and microswitches).
- Connection tubes - mount connecting tube with 4-way mixing valve to the boiler so that the T-piece is
in the upper side. On the upper connector of the T-piece incorporate safety ventilation group. On the
back of boiler were prepared two holenders for mounting connection tubes (connection tubes with 4-
way mixing valve). Be sure to use the seal for holenders. Set return temperature sensor in the elbow
with a socket for the sensor between the 4-way mixing valve and the boiler. It is obligatory using the
included thermal paste. Plug-in return flow sensor on the back of the box control. Connect the pump
cable with connector to the back of the control box. Mandatory set the pump on the speed 3.
- Elbow with socket for the flow sensor -must necessarily be installed after 4-way mixing valve on the
flow of the installation. Set flow sensor in the socket for sensor. It is obligatory using the included
thermal paste. Plug-in return flow sensor on the back of the box control.
- Motor device - set the motor device to the 4-way mixing valve. Plug-in the power connector on the
back of the control box.
- Pellet level in the tank sensor - mount this sensor on the back side inside of the pellet tank (see page
9). First set the plastic glass distance for sensor. After that, put the sensor on this glass. Attach the
sensor and the plastic distance with 4 screws supplied. Attach protective cover. Plug-in the cable with
connector of the pellet level sensor on the back of the box control.
- Pellet tank - mount pellet tank according installation manual for mounting pellet tank. Set up pellet
transporter in the pellet tank. Place the pellet tank to the boiler and set PVC tube to conveyor and tube
supply on the boiler. Set up the PVC tube so as to allow the smooth falling pellet into the burner. If
necessary, cut the PVC tube to the required length. Plug-in the power connector on the back of the
control box.
NOTE: check the tightness of connection tubes. Fasten connections binding tubes if necessary, so that
a good seal.
7
Technical instructions PelTec

Status of delivery, mounting parts
1.5. MOUNTING COMPONENTS
Slika 2. Mounting components
Fan
(Fan output can be mounted in
any directions)
Mechanism for grating cleaning
Flange for mounting
on the boiler
Flange for mounting on the boiler
Connection tube
PelTec 12
4-way mixing valve
Motor device for 4-way
mixing valve
Connection tube
PelTec 18-48
Technical instructions PelTec
8

9
Technical instructions PelTec
Positions of mounted components
Flange for mounting fan Flange for mounting mechanism
for self-cleaning
Position of pellet tank
Position of mechanism for
grating cleaning
Protection cover
Pellet level sensor
Plastic pad
Mounted position (be
sure to attach the cable
with cable ties
The main switch
Display
The main electronic board
Electronic board inputs
Connectors for pump /
diverter valve
Elbow with socket for
sensor
Socket

10 Technical instructions PelTec
1. Set valve clapper so that it is
horizontal position
(designation must be on the right side ’’A’’)
A B
2. Put clutch of motor device
(designation must be on the right side ’’B’’)
3. Set motor device on the valve as shown in
figure (moving part of motor device
must be in a horizontal position; Green
delimiter'' C'' must be in the center of the
handle slot'' D'')
4. Set screw for fastening motor device ’’E’’
DC
E
5. Tighten the screw to secure the motor device
(when the screw is tightened, the movable
part of the device is rotated to the right down
to the end position)
6. Set lever ''F'' to drive 7. Set the designation of openness "G" on
device as shown in figure
F G
1.5.2. Installation of motor device (THE FIRST ASSEMBLY)
Installation of motor device

8. Handle position ’’H’’
Position UP - Manual operation
9. Turning the handle'' G'' so that it can be set in
the DOWN position - automatic operation
HG
1
2
Installation of motor device
1.5.3. INSTALLATION OF MOTOR DEVICE (IF THE BOILER IS WORKED)
If the boiler is worked motor device may be removed only when the boiler is switched off. When the
boiler is switched off motor-driven closes 4-way mixing valve and is in the position as shown in Figure 1
below.
1. Device position when the boiler is not
working (valve is closed)
2. Valve position when the boiler is not working
(valve is closed); designation on the axle'' A''
is the top right corner (45 °)
A
3. Designation position on clutch of motor device
before assembly, designation on the clutch
''B'' is at the top right (45 °)
B
4. Set the motor device as shown below
(the movable part of the devicemust be turned
so that green delimiter'' C'' is aligned with the
groove of the handle'' D'' and is in the top right
corner (45 °)
C
D
11
Technical instructions PelTec

12
Installation of motor device
6. Set the device handle, rotate the
left until it reaches the beneficial position,
so that can be set in position DOWN -
- Automatic operation
5. Tighten the screw to secure the motor device
(when the screw is tightened, the movable
part of the device is rotated to the right down
to the end position)
7.Device position in the DOWN position - automatically
work; boiler ready for operation
flow from the boiler
Return from installation
flow in the installation
return to the boiler
Technical instructions PelTec

13
1. Remove the two screws (A), cover (B) of the grate cleaning mechanism and remove cover
carefully not to damage cables.
B
2. Remove the two screws (C) and the stop nut (D). Carefully set the grate cleaning mechanism to
the boiler, fasten with screws (C) and set the screw (E) into the jagged track, set the stop nut on
the screw (F) (tighten the stop nut so that there is 1-2 mm space (G).
E
F
C
D
B
A
G
D
1-2mm
Technical instructions PelTec
Installation of a mechanism for grate cleaning

Installation of a mechanism for grate cleaning
3. Press and hold the motor clutch (A) and slide the jagged track (F) in the boiler and release
the motor clutch
H
F
4. Before lowering the cover, place cable so that cable doesn’t disturbing the microswitch and
jagged track. Carefully set the cover and tighten with the screws (A). Connect the connectors (I)
so they have a good contact.
WRONG CORRECT
A
14
I
Technical instructions PelTec

1.6. SAFETY ELEMENTS
1.6. FUEL
Safety elements, fuel
Boiler have a few safety elements:
- Bimetal thermostat built on the burner pellet feeding tube. If the bimetal set temperature (80°C)
is exceeded, pellet feeding is stopped, the burner shuts down and the error E3 appears on the
control unit (LED diode switches on).
- If there is no flame (the built in photo-cell does not detect the flame within set time), control
stops the burner operation and error E2 is displayed or it goes to blowing off and error E6 is
- Displayed (LED diode switched on).Control unit has a built in protective function which protects the
boiler against overheating. If temperature in the boiler exceeds 93°C, regardless heating or
sanitary water is needed the boiler pump and/or the sanitary water turns on and works until
temperature in the boiler falls below 93°C.
- The fan has a built-in RPM counter and, if regulation is informed that the fan does not operate in
accordance with the requirement interrupts the process display fan error
- Drive for grate linear move have in-built two switches by wich control unit monitor position of grate.
If grate at given moment is not on provided place, control unit recieve information that grate is not
on provided place and interrupt proces and display information about grate error.
- Flue gas connection have in-built sensor for flue gas temperature meassuring. If flue gas tube
temperature is over 250°C, control unit interrupt proces and display information about too high flue
gas temperature.
When temperature in the boiler exceeds 110°C (+0°C / - 9°C), power supply is turned off by the
safety thermostat (via control unit).
Thermal protection built in coils of the fan electric motor at the burner and the screw feeder motor,
protects them against overheating caused by failure or locking.
A flexible tube connecting the pellet burner and pellet tank is made of plastic material reinforced with
metal wire which, in case of back flame from the burner to the tank, melts and prevents flame to
penetrate to the pellet tank.
Wood pellets are used as fuel in boilers with built-in pellet burner. Wooden pellets are bio-fuel made of
wooden wastes. Pellets can be packed in different packaging: in bags (15 kg or 1000 kg), or as bulk in
3
large (underground) tanks ( 4 - 15 m ) or in basement spaces. Recommended properties of pellets for
firing in PelTec boilers are the following:
- heating value >= 5 kWh/kg (18 MJ/kg)
-diameter <= 6 mm
-max. moisture content <= 12 %
-max. dust content <= 1,5 %.
15
Tehničke upute PelTec

2.0. BOILER POSITIONING AND ASSEMBLY
2.1. MINIMUM DISTANCE FROM THE ROOM WALLS
Figure 3. Minimum distance from the room walls for PelTec
1
Boiler PelTec
Chimney
Flue (Chimney connection; must be insulated)
-
-
2
A = 6,02 x Q
Each boiler room must be equipped with an opening for supply of fresh air which is dimensioned in
accordance with boiler output (minimum opening area according to the below shown equation). Such
opening must be protected with a net or grate. All installation works have to be performed in accordance
with valid national and European standards. Boiler must not operate in flammable and explosive
environment.
2.2. OPENING FOR FRESH AIR (FRESH AIR SUPPLY)
3
-
Boiler positioning, assembly and building in must be performed by a qualified person. We recommend that
boiler is placed on a concrete base with height of 50 to 100 mm above the floor. Boiler room must be frost-
proof and well ventilated. Boiler has to be positioned so that it can be properly connected to the chimney (see
Figure 2) and simultaneously, enabling tending of boiler and additional equipment, control during operation,
cleaning and maintenance.
WARNING!
Flammable items must not be placed on the boiler and within the minimum distances shown in
Figure 1.
Q - boiler output in kW
2
A - opening area in cm
1
-
-
2
3
-
min. 550 mm
min. 1500 mm
min. 450 mm
2
3
1
min. 300 mm max 1500 mm
16 Technical instructions PelTec

Figure 4. Dimensioning of the chimney for PelTec
3.0. CONNECTION TO THE CHIMNEY
10
15
20
25
30
35
40
45
50
5 10 15
Wood pellets
16
18
20
23
6 7 8 9
The chimney must be resistant against flue condensate!
IProperly dimensioned and built chimney is the main condition for safe and economical
functioning of the boiler. The thermal insulation of the chimney has to be done properly, it has
to be absolutely gas-proof and smooth. On its lower part there has to be built in the opening for
cleaning with the door. An brick-layed chimney has to have three layers with an insulation of 30 mm
in the middle, if the chimney is built inside the house (i.e. inside the heated area), or an insulation of
50 mm if it is built outside the house (i.e. outside the heated area). The flue gas temperature has to
be at least 30°C higher then the temprerature of their consdensation point. The choice and the
construction of the chimney has to be performed by the authorized person. Inside dimensions of the
chimney intersection selected in accordance with diagram for chimney selection, they depend of its
height and of the capacity of the boiler.
Chimney must be dimenensioned by "diagram for chimney selection" and maximum permetted
lenght of connection flue gas tube between connection on fan and chimney is 2000 mm and
minimum light diameter xx0 mm with maximum two 90° bends. Connection flue gas tube can be
mounted horizontally or at any angle which allows to gas, on his way to chimney, a constant
increase of height with condidering of exit point from fan. Connection flue gas tube must have
openings for cleaning through which is possible to clean entire lenght of flue gas tube or must
ensure easy removal part of flue gas tube which allow complete cleaning of connection flue gas
tube. To prevent entry of condensate form chimney into the boiler, flue gas tube must be mounted
10 mm deeper into the chimney. Connection flue gas tube between fan and chimney must be
insulated with 30-50 mm mineral wool.
Connection to the chimney
Useful height of the chimney (m)
Rated thermal output of the boiler (kW)
Chimney light diameter (cm)
Chimney dimensioning example:
for boiler Pel - Tec 36
Boiler heat output: 36 kW
Fuel: wood pellets
Required usable chimney height: 7 m
Required chimney light
diameter: 20 cm
17
Tehničke upute PelTec

In open system it is necessary to put an open expansion vessel min. 0,5 m above the height of the
highest heating body. If expansion vessel is located in a room without heating, it should be insulated.
The system pump could be connected on the inline or back line of the boiler.
4.1.1. CONNECTION TO OPEN HEATING SYSTEM
4.1. CONNECTION TO CENTRAL HEATING SYSTEM
All installation work must be made in accordance with valid national and European standards.
Boiler PelTec can be built in closed and open central heating systems. In both cases boiler can be fired
with wood chips. Installation has to be made, in according to technical standards, by a professional who
will be responsible for proper boiler operation. Before connecting boiler to central heating system, the
system has to be flushed to remove impurities remaining after system installation. It prevents boiler
overheating, noise within the system, disturbances at a pump and mixing valve. Boiler should always be
connected to central heating system by connectors, never by welding. Figure 1. shows safe distances
required for boiler cleaning and maintenance.
4.0. INSTALLATION
All local regulations, including those referring to national and European standards need to be complied
with when installing the appliance.
Installation, connection to central heating system
4.1.2. CONNECTION TO CLOSED HEATING SYSTEM
In closed heating system it is obligatory to build in certified safety valve with opening pressure of 2,5 bar
and a membrane expansion vessel. Safety valve and expansion vessel must be built in accordance with
professional rules and between safety valve and expansion vessel and boiler must not be any valve.
Schemes for possible configurations are on following pages.
18 Technical instructions PelTec

Configuration PTV, DKG
Scheme 2. Configuration DKG
36
bar
2
4
5
1 - Boiler PelTec
2 - Air self-venting group 2,5 bar
3 - Motor 4-ways mixing valve
4 - Closed type expansion vessel
5 - Return flow sensor
6 - Flow sensor
7 - Heating circuit
8 - Room thermostat
P1
Scheme 1. Configuration PTV
1 - Boiler PelTec
2 - Air self-venting group 2,5 bar
3 - Motor 4-ways mixing valve
4 - Closed type expansion vessel
5 - Return flow sensor
6 - DHW tank
7 - DHW sensor
3
M
bar
2
4
5
HV
P1
6
1
1
M
P2
7
7
8
19
Tehničke upute PelTec

Scheme 3. Configuration DKG || PTV
1 - Boiler PelTec
2 - Air self-venting group 2,5 bar
3 - Motor 4-ways mixing valve
4 - Closed type expansion vessel
5 - Return flow sensor
6 - Flow sensor
7 - DHW tank
8 - DHW tank sensor
9 - Heating circuit
10 - 3-way diverter valve
11 - Room thermostat
3
M
6
bar
2
4
5
HV
P2
P1
7
1
9
P
Scheme 4. Configuration AKU
1 - Boiler PelTec
2 - Air self-venting group 2,5 bar
3 - Motor 4-ways mixing valve
4 - Closed type expansion vessel
5 - Back flow sensor
6 - Accumulation tank CAS
7 - Accumulation tank sensor CAS 1 (upper)
8 - Accumulation tank sensor CAS (lower)
3
bar
2
4
5P1
6
7
8
1
M
P3
10
8
11
Configuration PTV || DKG, AKU
20 Technical instructions PelTec