Cerbos QUAD 10 Troubleshooting guide

USER AND SERVICE MANUAL
MODEL COMFORT /PLUS/PREMIUM
QUAD
10,
QUAD
15,
QUAD
20,
Q
UAD
25,
QUAD
30
BTI Gumkowski
Obornicka 71
62-002 Suchy las, Poland

Table of Contents
1 Introduction
1.1 General description of the boiler
1.2 Description of the intended use
1.3 Standards met by the boiler
2 Construction
2.1 Division into variants
2.2 The principle of operation of individual modules
2.3 Division into power series of types
3 Technical Specifications
3.1 Summary of overall dimensions
3.2 Technical parameters
4 Transport of the boiler
4.1 Delivery of the boiler
4.2 Unloading from the pallet
5 Installing the boiler
5.1 Positioning the boiler
5.2 Fitting the burner to the boiler
5.3 Change of door assembly sides
5.4 Connection to the chimney system
5.5 Connecting to the CH and / or HUW installation
5.6 Connecting to the electrical installation
6 Using the boiler
6.1 Filling and draining the boiler with water
6.2 Fuel requirements
6.3 Filling the hopper and feeder (WZ, WZO, WZ + gp, WZO + gp)
6.4 Boiler start-up and shutdown
6.5 Modes of operation
6.6 Cleaning the boiler
7 Inspection and service activities and maintenance recommendations
8 Security systems
8.1 Safety systems in the boiler
8.2 Procedure in the event of a failure
9 List of spare parts
Nameplate

1 Introduction
WARNING!
 Please read this manual before using the boiler! The
heating device may only be used in accordance with this
manual,
 Any other use of the device requires the written consent of
the manufacturer ,
 The manufacturer of the device is not responsible for the
consequences of improper use of the device, contrary to the
instructions!
This manual covers the description, construction, technical data, rules of installation and operation,
as well as other necessary information enabling safe and trouble-free operation of
the Compact pellet boiler . The following instructions / documents are enclosed with the boiler
operating and installation manual:
 ROTARY (ROT-POWER) burner instruction manual by KIPI,
 controller a touch panel brand PLUM,
1.1 General description of the boiler
The compact boiler is a water boiler for solid fuel - pellets . Possible heating media are glycol and
water. It is available in various construction and range of this power (for a detailed description
available in Chapter 2 ). The following drawings show the main parts of the boiler:
Figure 1 - Main parts of the boiler ( on the example of WZO + GP )

Figure 2 - Main parts of the boiler ( example W)
Table I - List of the main parts of the boiler
No. component function / application / description
w
EXCHANGER
w1 burner Conversion of fuel into thermal
energy
w2 Exhaust fan Providing thrust
w3 Exhaust outlet (flue) Flue gas discharge to the chimney
system
w4 Door Cleaning the boiler
w5 Back cover Cleaning the boiler
w6 Rear cover opening Cleaning the boiler
w7 Power socket strip and electrical components Electric power supply to the boiler
W8 Top exchanger cover (W, WO)
w9 Supply and return ( WZO + GP and WZ + GP ) Connection to central heating and
hot water installations
w10 Supply and return connectors (W, WZ, WO,
WZO)
Connection to central heating and
hot water installations
w11 Water drain connection Draining the boiler water block
z HOPPER
z1 Front cover
z2 Fuel feeder (with gear motor) Automatic fuel feeding.
z3 Fuel feeder spiro pipe Feeding fuel from the container to
the burner
z4 Fuel hopper hatch Filling the tank with fuel
z5 Tray handles Removing the tray from the
exchanger
o DUST REMOVAL SYSTEM
o 1 Ash container Collecting the resulting ash during
boiler operation
o 2 Ash removal system gear motor Discharge of ash into the ash pan
S. Controller Automatic regulation and control of
the combustion process
In addition, the following items are attached to the boiler:
 Brush for cleaning the boiler ( ramrod )
 DHW temperature sensor

1.2 Description of the intended use
The purpose of the device is to supply the central heating (CH) and central utility water
(DHW) installations .
Examples of application objects:
 single-family house
 Small commercial premises
1.3 Standards met by the boiler
This manual and the compakt boiler meet the following standards and / or directives :
 PN-EN 303-5 2012 - Solid fuel heating boilers with manual and automatic fuel
charging with a nominal power up to 500 kW
 MACHINERY DIRECTIVE 2006_42_EC
2 Building
2.1 Division into variants
The compact water boiler is a device with a modular structure. It consists of an exchanger, a
container and an automatic ash removal system . Figure 3 shows the division of the boiler into
individual modules.

Figure 3 - Modular structure of the boiler
The modular structure of the boiler enables its availability in several different
variants. Table II describes all the possible options available.

Table II - Boiler variants
QUAD QUAD PLUS Quad COMFORT QUAD PREMIUM
Variant
Exchanger Exchanger + ash
removal
Exchanger + tank Exchanger + ash
removal + tank
Without
pump
group
With
pump
group
Without
pump group
With pump
group
marking
W
WO WZ WZ+gp WZO WZO+gp
controller ecoMAX920 ecoTOUCH 860-P3-C
NOTE: The chapters in these instructions contain the designations of the boiler variants (eg WO,
WZO + gp). This means that a given chapter applies only to selected variants. All other unmarked
sections apply to all variants .
The pump group assembly, replacing some of the boiler installation elements, is available only for
variants containing an integrated pellet container (WZ and WZO). Figure 4 and Figure 5 show a
fragment of the boiler with or without a pump group installed.
Figure 4 - Boiler in the option without a pump
group
Figure 5 - Boiler with pump group option

2.2 The principle of operation of individual modules
1. Tray (WZ, WZ + GP , WZO, WZO + GP )
Pellet fuel in the hopper (1) goes by gravity to the feeder (2) . The feeder consists of
a pellet feeding spiral (3) and a supply motor (geared motor) (4) . Pellet is forced by a spiral from
which the flexible tube ± spiro by ( 5 ) goes to the burner, which is an integral part of the heat
exchanger.
Figure 6 - Hopper principle of operation
2. Exchanger
Compact boiler exchanger converts fuel ( pellets ) into thermal energy. The thermal energy is
transferred to the water circuit through the exchanger. The exchanger has the following features:
 Exhaust fan - creates negative pressure of exhaust gases in the exchanger This
prevents unwanted smoke escaping through burner or boiler leaks , and ensures a
constant thrust value
 Three-pass system - the combustion chamber is the first line (1). Then the
exhaust gases pass through the smoke tubes of the 2nd line (2) to the return chamber
(3). The third line consists of smoke tubes with a simple shape (4), which lead the flue
gases to the flue chamber (5), from where they are discharged by means of an
exhaust fan (6) through the flue (7) to the chimney system.
The filled (colored) areas in Figure 7 show that the boiler waterblock is in direct contact
with the water.

Figure 7 - The principle of operation of the exchanger
 Ash chute - The ash generated during the combustion process is discharged
into a special drawer inside the combustion chamber or into the automatic ash
removal system - depending on the boiler variant.
 No condensation in the exchanger. Water vapor condenses in the chimney
system - see details in chapter 5.4
3. Ash removal ( WO, WZO, WZO + gp )
Most of the ash generated during the combustion process goes directly from the combustion
chamber (1) to the ash removal spiral (2) . This spiral is driven by a motor (gear motor) (3) . The ash is
forced through the ash removal pipe to the ash container (4) .
Figure 8 - Ash removal principle
2.3 Division into power series
The compact boiler is available for several different powers (series of types) . Depending on the
power of the boiler, different burners of the appropriate series are used. The boiler uses ROTARY (ROT-

POWER) type pellet burners from Kipi. Table III shows the division of the boiler into power series with
the burner used.
Table III - Boiler power types
Boiler series of types
Nominal
capacity of the boiler
Burner used
10-15 kW
10,5 kW
3
-
10 kW
15 kW
4
-
16 kW
20-25 kW
20 kW
5
-
20 kW
25 kW
6
-
26 kW
30 kW
30 kW
8
-
36 kW
3 Technical Specifications
3.1 Summary of overall dimensions

Table IV - List of dimensions of the boiler series of types
Name
Dimensi
on 10-15 kW
20-25 kW 30 kW unit
A1 254 mm
A2 705 780 855 mm
A3.1 1055 1130 1205 mm
A3.2 1119 1194 1269 mm
A4 1022 1097 1172 mm
B 595 650 705 mm
H1.1 637 692 747 mm
H1.2 922 977 1032 mm
H1.3 1324 1414 1504 mm
H1.4 1609 1699 1789 mm
H2.1 452 504 532 mm
H2.2 737 789 817 mm
H3 778 813 848 mm
H4 606 641 676 mm
Flue diameter φ 127 mm
Tank capacity 155 195 240 l.
Fuel charging hole (see draw
Figure 27)
width x
length 406 x 555 456 x 610 506 x 665 mm x mm

3.2. Technical parameters
Tabela I - Zestawienie parametrów technicznych kotła
Parameter Value Unit
Boiler nominal
power 10 , 5 15 twenty 25 thirty kW
Thermal power
range 3-10 , 5 4-15 5-20 6-25 7-30 kW
The required
exhaust draft MINIMUM 0.15 mbar
Boiler water
capacity thirty 41 52 l.
Exhaust gas
temperature 69.1 66.8 67.2 64.8 62.2 ⁰ C
(nominal power)
Exhaust gas
temperature 53.2 51.4 53.4 52.5 52.7 ⁰ C
(minimum power)
Flue gas mass flow
(nominal power) 0.00847 0.0093 0.0115 0.0152 0.0178 kg / s
Flue gas mass flow
(minimum power)
0.00403 0.0044 0.0057 0.0062 0.0073 kg / s
Water flow
resistance
( nominal power )
0.09 0.08 0.08 mbar
Water flow
resistance
(minimum power)
0.05 0.01 0.01
Boiler
class according to
EN 303-5: 2012
5 -
Continuous
flammability
(nominal power)
47 31 29 23 24 h
Continuous
flammability
(minimum power)
152 114 114 95 88 h
Temperature
controller setting
range
50-85 ⁰ C
Minimum water
temperature in
the boiler feed
pipe (d)
45 ⁰ C
Fuel Type According to PN-EN-303-5_2012 : C (Pressed wood)

Amount of
auxiliary
electricity
required (nominal
power)
61 62 70 78 85 IN
The required
amount of
auxiliary
electricity
(minimum power)
50 41 45 49 52 IN
Required amount
of auxiliary
electricity (stand-
by)
3 IN
Cold water
temperature
required
45 ⁰ C
Required water
supply pressure min 3 bar
Boiler volume db
Boiler weight
4 Transport of the boiler
WARNING!
It is forbidden to transport the boiler filled with water and / or
fuel. Empty the boiler before transport!
4.1 Delivery of the boiler
The boiler is supplied by the manufacturer on a Euro pallet with standard dimensions of 1200x800
mm. The boiler should be transported on a pallet to its destination, and then removed from
it. Similarly, if there is a need to transport the boiler to another place, it should be placed and secured
on a pallet, adhering to the following guidelines:
 Pay attention to the weight of the boiler was on his feet, so as not to have the
possibility of falling into the boards between the pallet (1) ,
 The boiler should be protected with stretch foil (if necessary)
 The boiler should be attached to the pallet with bandages (2) ,
 Use cardboard angles (3) to prevent damage to the housing

Figure 9 - Method of transporting the boiler
The boiler packed in the above manner can be transported with forklift.
4.2 Unloading from the pallet
Steps when removing the boiler from the pallet:
1. Cut the bandages and remove the mounting angles
2. Unwrap the cauldron from the foil
3. Dismantle the ash container
4. Hold the boiler from below with straps or rope

Figure 10 - Removing the boiler from the pallet (WO, WZO, WZO + gp )
Figure 11 - Removing the boiler from the pallet (W, WZ, WZ + gp )
WARNING!
Dismantle the ash pan before removing the boiler from the pallet
5 Installing the boiler

WARNING! - SAFETY INFORMATION
 Assembly, installation and first start-up of the boiler must
be performed by a trained / authorized specialist in this
field
 Be sure to use gloves during assembly
The boiler must be installed before its start-up. The stages of installing the boiler should be carried
out in the following sequence:
a) Place the boiler in a suitable place and at appropriate distances from the walls,
b) If necessary, change the side of door assembly,
c) Connect the boiler to the chimney system
d) Connect the boiler to the heating system (water)
e) Connect the boiler to the electricity network
WARNING! - SAFETY INFORMATION
Boiler installation or uninstallation can only be performed, and only if:
 The boiler is turned off and cooled down
 The boiler is disconnected from the electrical system
Before starting the boiler installation, check:
 whether the purchased boiler is free from mechanical defects and damage,
e.g. during transport ,
 the plumbing system of central heating works correctly (with no debris, rust),
etc., which could cause incorrect operation of the boiler (eg. increase resistance of
flow of water in the boiler) .
 the chimney is provided with an insert made of stainless steel, or the way and
whether or not a valid string ,
 is there adequate ventilation in the boiler room in accordance with applicable
standards,
 whether the electric network has the correct voltage (230 V) and whether the
phase cable (L) is properly connected and the electrical socket is secured with a
protective contact .
5.1 Positioning the boiler
The boiler must be installed in a separate room - the boiler room. The boiler room must meet the
requirements of local regulations and standards for the location of solid fuel boilers.
The floor under the boiler must be made of non-flammable material and have a strength
proportional to the weight of the boiler. The boiler itself must be perfectly aligned during
installation. The location of the boiler should provide access for maintenance and service. The
minimum distances from the walls are shown in Figure 12 .

Figure 12 - The minimum dimensions of the walls of A = 0.5 m B = 10m, C = 0.8 m, D = 0.6 m
WARNING! - INFINITION INFORMATION
All combustible materials ( pellet fuel and others) should be kept at a
safe distance from the boiler.
5.2 Fitting the burner to the boiler
The burner for the boiler can be mounted or dismounted using an allen key . The figure below
shows how to install the burner to the boiler
Figure 13 - Installing the burner

5.3 Change of door assembly sides
WARNING!
Before removing the door, first remove the burner.
The manufacturer can supply the boiler with the door that opens to the right or left. If necessary,
the installer or user can change the door hinge side. Figure 14 shows how to remove or install the door.
The sequence of steps when removing the door:
1. Unscrew and remove the burner
2. Remove the door handle
3. Unscrew the main screws (hinge) and remove the door,
4. Unscrew the hinge bar
5. Unscrew the blanking screws
6. Door catch - unscrew and disconnect the limit switch wires
7. Break a hole for a hook on the other side of the exchanger (use appropriate
tools for this)
8. Screw back all parts symmetrically to the opposite side of the boiler in the
reverse order.
Figure 14 - Changing the door assembly sides
5.4 Disconnecting the chimney installation
WARNING!
It is not allowed to connect any additional devices to the flue to which
the boiler is connected, nor to use it additionally for other purposes (e.g.
ventilation) .

The chimney system to which the compact boiler is to be connected should meet the applicable
regulations and standards. Both the diameter of the chimney and the material it is made of should be
produced in accordance with DIN EN 13384-1 devices slow-burning.
The compact boiler is characterized by high heat exchange efficiency. This means that the flue gas
temperature in the boiler flue is much lower than in conventional boilers, coal or wood. Low flue gas
temperature at the boiler outlet and its further decrease in the chimney system generate water vapor
condensation on the chimney walls. To avoid the negative consequences of condensation in the
chimney system (e.g. stains and eruptions on the internal walls of rooms directly adjacent to the
chimney, boiler corrosion) , follow these recommendations:
 the chimney system should be resistant to the accumulation of moisture ,
made of acid-resistant steel or appropriate ceramic materials,
 if we are dealing with a traditional brick chimney , an insulated stainless steel
insert should be used . From To ensure the sound he tightness and reduce the risk of
efflorescence on walls,
 condensation drain from the chimney should be provided
WARNING!
The manufacturer is not responsible for any damage caused by plugging
the boiler into an improperly adapted chimney system.
In addition, for the boiler to function properly and without failure with the chimney system:
 ensure tight connection of the installation with the boiler flue ,
 regularly clean the chimney system,
The diameter of the boiler flue is 120mm. The boiler can be connected to a chimney system of a
different size or shape, but the cross-sectional area must not be smaller than that of the
flue . Connecting to an installation with a larger diameter (than the flue diameter) should be made by
means of a reduction from the chimney system used during the installation.
Figure 15 - Connection to the chimney system - simple 1 - Chimney duct; 2 - Chimney cleaning; 3 - Insulated
connection to the chimney