FUWI Pellets Boilers User manual

FU-WI Sp. z o.o.
Grochowska 5B
82-300 Elbląg
tel. [phone] www.fuwi.pl
fax [phone] e-mail: [email protected]

page 29
NOTES

page 28
Introduction 2
Boiler Application 3
Boiler Construction 4
The pattern of Boiler FUWI on Pellets 5
Boiler Technical Data 6
Exploitation of Boiler in Automatic Mode 7
Assembly of Plex (PCV pipe) connector to fuel feeding system 8
Basic Functions of Controller (the operator panel) 9
Scheme with boiler location in boiler room 11
Modes of Boiler Functioning 12
Pattern of Full Menu Options in Operator Panel 13
Service of Operator Panel 14
Schemat of Automatic Connection (Module) with Boiler Elements 16
Settings of Boiler Burner 17
Service Mode Password for Boiler 18
Before Calling Service 19
Room for Boiler Installation 20
Safety at Work Conditions 21
Warrantee Conditions 22
Warrantee Confirmation 23
Warrantee Report 24
Scheme with location of vermiculite plates on the burner 25
Raport of first starting the boiler 26
Notes 28
page 1
TABLE OF CONTEST
NOTES

Ladies and Gentlemen, we welcome You in team of Our Customers with pleasure. We thank
You for purchase of our equipment.
The exact introduction with service instructions were made for safe, correct and long-term
exploitation of boilers of the c.o. type FUWI on Pellets. Every user before start of installation and
exploitation of boiler should carefully learn the service instructions, this is necessary for correct and
safe use. The non following by user of recommendations presented in instruction slows down the
manufacturer of Heating Boiler from every obligations and warrantee .
The heating boilers, type FUWI on Pellets, are low temperature steel water boilers. In result of
research of heating Boilers production line FUWI on Biomass, conducted by The Institute of
Heating and Sanitary Techniques in Radom, and Certification Laboratory of Boilers and
Heating Device in Łódź (Accreditation Certificate Nr AB 087) confirms, that the described type of
boiler answers requirements of standard PN-EN 303-5:20 02, as well it got according to this
standard the highest III class of thermal efficiency and release CO, at the same time the given
examination of the automatics by PN-EN 60730-2-1:2002. boilers FUWI on Pellets are not subject
to the registration by the Region Bureau of Technical Supervision.
Technical contained data in present instruction can be changed in result of development
continuous of product, without information.
The following signs are used in the instruction:
This sign warns that device should be cared appropriately according principles of safety. It used in text of
instruction to mark important information for your attention that you should follow during service and boiler
operation.
The marked with this sign places can warm up to high temperatures, what can cause burn.
The marked with this sign places can cause fire and heat, your attention should be attracted to it in order the
place not to turn into fire.
The marked with this sign places endanger by work of metal units (worm gear, mode). Placing your hand close by
these units endangers damage of hand.
The sign prohibits some actions in certain conditions and situations.
The Heating Boiler the FUWI on Pellets is the heating possessing device with the newest automatic system of
feeding and burning of granulate solid type fuel - Pellets.
It is the integral unit of present instruction the instruction of manufacturer of automatics from which
one should necessarily to acquaint before starting the Heating Boiler the FUWI on Pellets.
page 2
page 27
RAPORT OF FIRST STARTING THE BOILER
INTRODUCTION

page 26
The low temperature steel water Heating Boiler FUWI on Pellets with automatic arrangement
of burning of solid fuel - Pellets, designed to work as installation device of central heating and to
prepare warm usable water in different housing building (little houses, economic rooms, trade
pavilions, multifamily houses and different buildings).
The Heating Boilers FUWI on Pellets are characterized as the newest automatic technology of
burning of granulate solid fuel - Pellets:
Wood Granulate - Pellets (ø 6mm - ø8mm),
Agro Granulate - Pellets (ø 6mm –ø 8mm)
The operation regulator of boiler controls not only boiler but also central heating system of mode as
well as the warm usable water. Also there is the possibility of connecting the current pumps and their
steering as well as possibility of connecting the exchanger of warm water.
The device possesses the function of priority of warm usable water, it means that during heating
boiler receives signal from temperature detector of usable water tank about lowering the temperature
of water. After achievement of necessary temperature of water in tank, automatics releases warm
water pump for working cycle of central heating. There is also the possibility of heating of only
warm usable water in summer period, without working cycle of central heating.
The highest temperature in Boiler cannot be higher than 940C.
Boilers can be applied in installations of open system central heating with gravitational
circulation of water and working thrust 3 Bar. Safe has to be according requirements
PN-91 / B -02413 –it is connected with protection of open system water heating. It is
also possible to work with closed arrangements PN -99 / B -02414, under condition of
additional equipment for device or by using the excess of warm distributing
circulations through exchanger. Installation of boiler is incompatible / not flowing
these principles causes the loss of warrantee .
With regard on high efficiency of boiler that should have low temperature of exhaust
gas, in order to protect funnel with chimney input or the ceramic input, the diameter
should be not smaller then diameter of exhaust chimney pipe presented in table
page 6.
page 3
BOILER APPLICATION
REPORT OF FIRST STARTING THE BOILER

Introducing on the market mentioned heating device called Heating Boiler FUWI on Pellets, we
offer you the newest technology with feeding of solid fuel, burning it and exchanges warmth between
exhaust gas and water in boiler. Applied in this device burner and technical solution is subject to the
patent protection of RP of No. P375326.
Qualified staff should install present device, accordingly to technical standards as
well as valid state and local standards. Moreover it should be done according to the
present instructions for safety use, installation and storage.
The Heating Boiler FUWI on Pellets is a device in shape of a steel cube, equipped with burner,
tank with solid fuel of the type –Pellets, that automatically come from feeder to the burner in
such quantity of solid fuel (pellets) that is necessary to obtain the temperature programmed
by user on temperature control panel. The controller based on microprocessor made by the
Polish manufacturer's, gives possibility of full automatic steering option of boiler.
The control unit of boiler with instruction is the integral part of boiler that you
should learn.
Water block is made of steel sheet (with thickness about 4mm and 6mm) as well as seamless
pipes. Isolation of boiler is made of mineral wool, from outside it is covered with metal sheet. The
smoke pipes in upper unit of water block are the exchangers of warmth, and the chamber in bottom
unit of water block in which burner is burning is made of heat-proof steel and of nickel chrome where
there are openings to air. The cast-iron fire grate on bottom of burner is placed according to
efficient and effective ash cleaning of chamber. The process of burning of pellets as well as state of
hearth is controlled by photodiode (probe of clearness). Airing as well as exploder of the burner are
equipped with regulated electric blower and automatic lighting of the pellets that operate
simultaneously. Below burning chamber there is chamber of ash-pan to which pellets go after
burning as ash.
Safety of exploitation of Boiler FU-WI on Pellets is assured by multi-stage protection system, based
on protection of flame withdrawal to fuel container (temperature sensor of feeder), protection before
overheating of boiler (thermal switch), regulator of temperature of boiler (the sensor of temperature),
regulator of temperature of usable water (sensor of temperature), external regulator of temperature
of boiler (weather sensor), regulator of temperature in rooms (optional).
page 4
Top view –boiler room: values given in millimeter
Front and side view –boiler room:
page 25
BOILER CONSTRUCTION
SCHEME WITH LOCATION OF VERMICULITE PLATES ON THE BURNER

Warranty Report NO. …….
H
HE EA AT TI IN NG G B BO OI IL LE ER R F FU UW WI I O ON N P PE EL LL LE ET TS S
Factory no. ……………………………………………
Date of production …………………………………………
The following defects were found:
…………………………………………………………………………
…………………………………………………………………………
…………………………………………………………………………
…………………………………………………………………………
…………………………………………………………………………
…………………………………………………………………………
………………………………...................................................................
.........................................
User:
……………………………………………………………………...........…
………………………………………………………………………………
………………………………………………………………………………
………………………..............................................................................................
.................................
Address:………………………………………………………………………
………………………………………………………………………………
………………………………………………………………………………
………………
Phone number:
………………………………………………………………………
………………………………
user's signature
page 5
THE PATTERN OF BOILER FUWI ON PELLETS

page 6
Warranty Confirmation No. .……/ 20 ......…
HEATING BOILER
FUWI ON PELLETS
Grochowska 5b str.
82-300 Elblag
tel. [phone]
fax. [phone]
Power of boiler:
9
9k kW W
,
1
15 5 k kW W
,
2
22 2 k kW W
,
3
30 0 k kW W
,
4
44 4 k kW W
,
5
55 5 k kW W
,
8
80 0 k kW W
,
1
10 00 0 k kW W
Date of production ………/ ……/ 20...…
Date of sale ………/……./ 20...…
Factory no. ……………………….
…………………………... ............……………………
selling party signature manufacturer's signature and stamp
TECHNICAL DATA OF BOILER

Period of warrantee is 60 and 12 months, it starts from the date of sale.
The warrantee is on:
water block of boiler - 60 months;
durable and efficient working mechanical devices, electric and electronic fireplace - 12 months.
Seller confirms warrantee for boiler by stamp, date of sale as well as signature, and also by report of
first boiler start of operation that should be correctly filled, signed and sent to Producer.
The manufacturer is obliged to fulfil warrantee repair in 14 days deadline from date of notification by
Buyer that boiler needs to be repaired.
Buyer can claim warrantee rights in court in case when Producer will not fulfil their warrantee
obligations.
The warrantee authorization in order to fulfil warrantee repair is a free document. Warrantee is not
valid without stamp, person's signature and selling dates as well as without stamp, Producer’s
signature and date. In case of loss of warrantee document, the duplicates will be given –are to be
paid for.
Warrantee stops to be valid in case of not proper installation of the boiler and application of safety
means non-complying with local and state law regulations and standards described in PN -91 / B -
02413, PN -99 / B -02414.
Regarding complaints Producer is to be notified by sending a full reclamation report to Producer’s
address, stamped by sales department, responsible for service. If complaint will turn out to be
groundless, all costs connected with arrival of manufacturer's representative should be covered by
person that placed claim.
Please remember, before cleaning smoke tubes, remove upper plate of burner
(building of burner).
Cast iron grate which is the balton of the burner isn’t subject of the guarantee.
Any alterations, and change of constructional modifications of Boiler cause
immediate loss of the manufacturer's warrantee.
Alteration and starting of Boiler should be fulfilled with suitable authorizations in
this range.
Chamolte brick and heat resisting plate located on the burner aren’t subject of the
guarantee
page 22
Central heating boiler FUWI on Pellets is ready for independent work after loading of tank by
granulate fuel - Pellets and after temperature of boiler is displayed on control panel. While
granulate fuel-pellets from tank dose to burner, it lights automatically, and then according to
demand ( the achievement or maintenance of set temperature) it doses for burner the next
portion of solid fuel from tank.
You should periodically load reservoir with pellets and clean up from dust gathered during work.
There is possibility of placing additional container of granulate fuel but in considerable distance from
boiler also, which requires modernization in the way of installation of additional device for pellets
passing.
Automatic burning process of pellets as well as state of hearth are controlled by photodiode (probe
of clearness), airs as well as burner spark are equipped buy regulated electric blower for automatic
lighting of pellets simultaneously.
The exploitation of Boiler, standard version:
During exploitation of boiler you should remember about cleaning the burner and chamber of burning
from chamber of ash-pan, that are in bottom unit of boiler, at least once a week, and fill up boiler
tank with fuel. Cleaning should be made while removal of covering as well as cleaning around. Using
arm placed on the boiler exhaust vanes are cleaned. By multiple, energetically pulling the arm down
, is followed the movement of the steering wheel, thereby pollutants are discharged into the furnace
chamber. You should remember about cleaning of smoking pipes that are in upper unit of boiler at
least once a month. Cleaning is made by removal dust covering with help of steel brush (rifle
cleaning-brush). Below burning chamber there is chamber of ash-pan to which after burning solid
fuel goes as accompanied ash. Chamber of ash-pan should be periodically emptied from dust and
ash with help of furnace rake.
Making any work in range of cleaning as following: burner, ash-pan as well as
smoke pipes, remember to make sure that there is no access to open fire.
Minimal temperature of heating factor return: 50oC.
page 7
EXPLOITATION OF BOILER IN AUTOMATIC MODE
WARRANTEE CONDITIONS

PCV pipe –diameter 60mm, length 300mm
Assembly of PCV pipe in FUWI Pellets Boiler (back of the boiler –feeder)
A) B)
page 8
1. Boiler has to be placed according to fire-safety standards, relating to solid fuels heating
sources assembled in closed rooms PN -87 / B -02411.
2. It is prohibited to use burning materials other then inflammable materials that provided in
service instruction.
3. It is prohibited to assemble any valves on return pipes of central heating system.
4. Controller socket to which the feeding connection is made, should be earthed.
5. Installation of central heating is safe as open system installation PN - 91 / B -02413. Boiler
can also be installed in closed system arrangements, but under condition of using of
additional equipment for device or by use the excess of warmth distributing
circulations through exchanger PN -99 / B -02414.
6. Switching boiler off after heating season is made by pressing switch off button and boiler as
well as steered devices will be disengaged. It should be made for cleaning of boiler.
7. Full shutdown of boiler is made by extraction of boiler connector from feeding socket.
It is prohibited and illegal to refill water during work of boiler, especially when
boiler is strongly hot, because in this way it is possible to cause damage or shake
water block.
Please remember, before cleaning smoke tubes, remove upper plate of burner
(building of burner).
page 21
ASSEMBLY OF PLEX (PCV PIPE)CONNECTOR TO FUEL FEEDING SYSTEM
SAFETY AT WORK CONDITIONS

The room in which the device FUWI on Pellets is installed has to serve exclusively to this aim, it
should always be in conformity with the technical standards valid for this range of equipment, as well
as there should be appropriate ventilating openings and air blowing.
The built-in on solid fuel boiler rooms should fulfil the requirement of standard PN-
87/B-02411 the " built-in on solid fuel Boilers".
Boiler room according to above mentioned standard should follow the following requirements:
1. boiler should be placed in separate room, possibly centrally in relation of heated rooms,
2. boiler room should have artificial lighting, or natural lighting is recommended also,
3. distance of boiler from walls of room should be enough to have free access to boiler when
cleaning and preservation.
4. height of boiler room should be at least 2,2 m, in existing buildings the height of boiler room allows
minimum 1,9 m only with correct ventilation (supply-exhaust ventilation),
5. supply-exhaust ventilation should be with opening that can be closed, it goes for section of
minimum 200cm2, outlet should be 1,0 m over floor level.
6. ventilation exhaust channel should be made of non-flammable material with minimum diameter
14cm x 14cm of inlet opening under ceiling of boiler room. Exhaust channel should led out over roof
and be placed in vicinity of chimney.
7. in vicinity of heating room should be fuel store likely in separate room. The fuel store should be
such big that it would be possible to accumulate fuel for whole heating season,
Distance of back of boiler from wall should not be smaller than 0,7 m, the side of
boiler from wall not smaller than 1,0 m, however the front of boiler from opposite
wall not smaller than 2,0 m
Smoking channels and funnels of unsuitable type or dimensions (see: Table page 6)
can cause condensation problems, and influence negatively on burning parameters.
page 20
Controller of boiler is two-module device (in standard), consisting from following units:
1.Operator Panel, installed in front unit of boiler and for user is visible part of device together with
keyboard and alphanumeric display.
2. Operating Unit, is installed on DIN rail in front of boiler and built-up with electrical distribution box,
where all sensors and operator panel are connected to.
Operation Unit has to be connected with all sensors needed for proper functioning of boiler as well
as all executive unit –standard or optional (see page 10):
Tzew - external temperature sensor,
Tco - temperature sensor of heating medium after mixing valve,
Tk - temperature sensor of heating medium on exit from boiler,
Tcwu - temperature sensor of warm usable water,
Tpow - temperature sensor of heating medium return to boiler,
Tpod - temperature sensor of fuel feeder,
Foto - photocell (clearness probe).
page 9
BASIC FUNCTIONS OF CONTROLLER (THE OPERATOR PANEL)
ROOM FOR BOILER INSTALLATION

M0 - mixer servo-motor –M0 - closing,
M1 - mixer servo-motor –M1 - opening,
CW - hot service water pump,
CO - central heating pump,
ZAP - igniter,
W1 - output supplying the Lambda probe module 230 ~V,
DM - blower,
ZTK - boiler thermal protection,
POD - feeder motor.
3. Controls of mixing 4-ways or 3-ways valve (Option),
Controller manage mixing 4-ways valve, adjustment is made by maintaining set temperature of
heating medium in heating system. Controller has also a task of protection of boiler from too low
temperature of heating medium coming back from heating system.
4.
R
RO OO OM M T TH HE ER RM MO OS ST TA AT T, ,
Automatic of boiler can cooperate with any room thermostat with terminals
shorted.
Before connection of
Regulator, please remove
coupler ( electric bridge )
from pins of room
thermostat on executive
module in this place
please install/place
coupler of room thermostat.
Regulator should be mounted in a location representative of temperature in the flat at a height of
about 1.5 - 2 meters.
Do not install the regulator near heat sources, direct sunlight or areas exposed to drafts because it
can negatively influence the operation of the system.
page 10
We remind, that in case of groundless call to service, customer covers costs of arrival and
work of service mechanic.
Before you will make a phone call to ask for help of service, make sure about the following: the most
often problem of work of fireplace, is bad quality of Pellets.
The symptoms of failure
of boiler work
Methods of their elimination
Blocking of feeder
Check electric connection between boiler and
feeder.
If feeder was blocked - hit throughout the
length of pipe of feeder with hammer several
times,
Check if fuel is not stuck in chute –in case of
fuel stacking clean it up
P
PA AN NE EL L D DI IS SP PL LA AY Y B BL LI IN NK KS S W WI IT TH H Y YE EL LL LO OW W: :
„shortage of fire or fuel”
It is necessary to check, if there is fuel in the tank, since it
could block feeder. In this case instructions regarding “Block
of feeder” should be followed.
„overheating of feeder”, it
means that boiler has to be
cleaned up
It is necessary to open upper cover of boiler, take out guide
rings of combustion gases and with help of round metal brush
clean inside part of smoke pipes. Clean also bottom of
chimney and burner.
It is necessary to check pipe of chimney.
page 19
BEFORE CALLING SERVICE
BASIC FUNCTIONS OF CONTROLLER (THE OPERATOR PANEL)

Service mode is accessible if on the controller of boiler is in mode "OFF” and as well as of service
password is known. After inserting of password, access to additional adjustments is granted. Service
mode password is the sum of set temperature of boiler in manual mode and number 77.
Password: Boiler temperature set + 77
Example:
Boiler temperature set = 600C
Password: 60 + 77 = 137
Description of function.
Minimum temperature of pump work
Minimal temperature of
pumps functioning is 450C
Mentioned parameter defines about minimum temperature of boiler
in which pumps can be started
Functioning of burner of Boiler FUWI on Biomass
Functioning of burner lighter [min]
2
Time of preliminary heating of burner lighter
Max. time for lighting [min]
3
Max. time for lighting, functioning of fan
together with lighter. Control of flame.
Preliminary pellets loading [s]
60
Defines time of pellets loading needed for
start-up burning
Limit of photocell activation
2
If light of flame exceeds set value - controller
treats it as existence of flame.
page 18
Top view –boiler room: values given in millimeter
Front and side view –boiler room:
page 11
SCHEME WITH BOILER LOCATION IN BOILER ROOM
SERVICE MODE PASSWORD FOR BOILER

Heating Boiler FUWI on Pellets can work in one of three modes:
1. Manual 2. Weather mode 3. Summer
1. Manual mode of work:
User with help of Operational Panel in submenu of Boiler set temperature for work of boiler
manually (purpose of buttons Increasing or Decreasing - see page 11)
Manual mode means only and exclusively manual settings by user of Boiler
temperature.
2. Weather mode of work:
Present mode requires installation of external temperature sensor as well as central heating
temperature sensor. Temperature of work is set by linear programmable heating curve, thanks to
that there is not necessity to adjust boiler temperature by hand in case of outside temperature
changes. In principally at night is always colder than during day time. It is temperature of boiler work
in external temperature function. Setting of boiler temperature is counted on basis of this curve and
is about 200C higher.
SEE!!! Integral part of present manual is boiler automatics manual.
3. Summer mode of work:
Controller in this mode is used in summer to heat of warm usable water. In this mode (apart from
alarms) heating water pump does not start. Temperature of boiler is set manually using parameter
"set boiler temperature. ”.
If boiler temperature for warm water purposes is lower from temperature set in
manually mode or weather mode, then temperature set of boiler work will be this
higher temperature.
page 12
Very important items connected with proper functioning of Heating Boiler FUWI on Pellets are
proper settings in boiler controller (Operator Panel) in submenu: Burner, namely:
1. Feeding:
Fuel feeding is the very important process for boiler functioning. For more efficient setting of
standstill time for fuel feeding there is a preset the same parameter for all powers of boiler and
which is 10 seconds. It has to be set only time of fuel feeding. It has to be made in according to
Table Nr 1 (see below, page 15), but in individual cases it can be changed in range not more 1
or 2 second. It depends from caloricity and shape of used pellets fuel as well as from energetic
demand of heated object.
2. Blower:
It is the second very important factor of correct boiler functioning. Maximum use of fuel energy
depends on it, as well as correct ecological burning.
Settings of blower power in Heating Boiler FUWI on Pellets are individual and depend on many
external factors, influencing mainly on chimney draught. This adjustment should be made for every
boiler starting from ventilator settings (enlarging or reducing). This action has to be execute in
temperature of boiler minimum 600 - 700, than it is correct.
In situation of using Lambda Sensor adjusting the power of blower would be executed automatically
by enlarging or reducing air flow.
Table No. 1
3. Function of modulation of burner power:
The boiler is equipped with the function of modulation of burner power.
The above-mentioned function starts operating in the moment of achievement by the boiler
temperature set by user (eg. 60o) and starts reducing the power of the burner (by modulating
simultaneously the parameters of van and fuel feeding). The function of modulation will reduce
the burner power till the moment of achievement by boiler temperature about 5ohigher and after
achievement of this temperature the boiler stops fuel feeding and burns fuel left on the burner
and afterwards switches off automatically or burner power will be enlarging in case of
temperature fall.
In relation with necessity of burning fuel to end and cleaning combustion chamber the boiler
should periodically be switched off.
In the boiler controller is applied the function of return to "factory presets”, permitting on restoration
of Manufacturer presets previously altered by user or servicemen.
page 17
MODES OF BOILER FUNCTIONING
SETTING THE BOILER BURNER

page 16
Full accessible Menu on Operator Panel
In the above mentioned pattern of Operator Panel Menu we represent the standard
(suggested) parameters of Heating Boiler FUWI on Pellets.
Settings for some power of c..h boiler FUWI for pellets - table no 1 on page 17th
page 13
PATTERN OF FULL MENU OPTIONS IN OPERATOR PANEL
SCHEMAT OF AUTOMATIC CONNECTION (MODULE)WITH BOILER ELEMENTS

Settings of boiler temperature are made individually in dependence of heating space, where
it’s used and user demand of warmth as well .
Automatics is the integral part of Heating Boiler FUWI on Pellets, before starting device,
service instruction of Controller of Boiler Work "Control M RS 420 ” has to be learned
carefully.
In order to start or switch off automatics of Boiler (Operator Panel), you should press
present button for 3 seconds (HE / OFF / ESC):
To enter the main menu you should press button ENTER:
Main menu is displayed on screen of Operator Panel.
Main menu is described with large letters where you can move up or down with following buttons:
To enter Submenu from main menu you should press button ENTER::
In order to come back to higher level you should press button ESC
Individual Submenu serves to adjust current parameter (value) to change value of given parameter
you should press button ENTER:
then buttons: increase or decrease value of parameter.
page 14
Button of change acceptance of value or status of given parameter is made with the help of ENTER:
Pressing button ESC: escape cancels changes of value or status of given parameter.
Drawing of full accessible Menu on Operator Panel is shown on page 13
On main screen of Operator Panel in period in the circuit exploitation of Heating Boiler the FUWI on
Pellets, displayed it is:
Current state of procedures
"OFF ” - switched off (active service of alarm states as well as manual work of
blower and feeder),
OFF –Boiler is in vigil state and is under voltage, in case of alarm state appear all
suitable preventive processes still will be undertaken.
„
O
ON N
”–switched on (active service of all procedures and modules of automatics)
ON –if controller is not be used for long period of time or in case of carrying out any
service activities on controller, the device should be indispensably switched off by
plugging it out from electricity.
Operator panel displays on Main Screen the following symbols:
chp - work of central heating pump;
fee - work of fuel feeder –Pellets;
fn30 - work of blower, current power;
wwp - work of warm usable water pump;
zap - work of electric lighter;
page 15
SERVICE OF OPERATOR PANEL
SERVICE OF OPERATOR PANEL