gerkros Woodpecker 20 kW User manual

Woodpecker 20 / 30 / 40 / 50kW Model
(incorporating Gerkros Boiler Management System (BMS))
User / Installation Manual

2
Contents
1. Introduction ………………………………………….. 3
2. Installation Instructions.
2.1 Unpacking your Woodpecker………………….. 4
2.2 Quick-Step Installation Guide …………………. 4
2.3 Locating and Installing the Boiler…………….. 5
2.4 Locating and Installing the Hopper / Auger … 5
2.5 Plumbing Connections …………………………. 6
2.6 Flue Connections & Free Air Requirements… 8
2.7 Boiler Features …………………………………. 13
2.8 Fuel ………………………………………………… 14
2.9 Electrical Connections ……………………… … 15
2.10 Setting Up the Burner ………………………… 16
2.11 Commissioning ………………………………….. 17
3. Servicing / Maintenance ……………………………… 18
3.1 General Maintenance for the Householder … 18
3.2 Servicing ………………………………………….. 21
4. Boiler Controls …………………………………………. 21
4.1 Buttons ……………………………………………. 21
4.2 LED’s ………………………………………………. 22
4.3 Displays …………………………………………… 23
4.4 Indication of System Functioning States…… 25
4.5 Error Messages …………………………………. 27
4.6 User Menu ……………………………………….. 29
5. Warranty / Call Out Policy ……………………………. 31
6. Installation Regulations ……………………………… 32
7. Health & Safety Information ……………………….. 33
8. Technical Data …………………………………………. 36
9. Pre-Commissioning Checklist ………………………. 37

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1. Introduction
This manual is produced for the reference and guidance of Gerkros registered
installation/servicing engineers and most importantly, the householder. EU legislation
governs the manufacture, testing, operation, efficiency and installation of all domestic
wood pellet boiler appliances. The Gerkros “Woodpecker” range of wood pellet
boilers meet the essential requirements of the appropriate EU standards.
Your “Woodpecker” wood pellet boiler is a free standing boiler fitted with a highly
efficient wood pellet burner controlled by the Gerkros Boiler Management
System(BMS) to provide hot water for your heating circuits and domestic hot water.
For domestic hot water it is recommended that a Gerkros “Dolphin Range” indirect
stainless steel cylinder in used in conjunction with the wood pellet boiler. These
boilers are intended for use with a fully pumped central heating system or a gravity
primary system. For use in a sealed system it is the responsibility of the boiler
installer to ensure that an appropriately sized expansion vessel is used and correctly
installed. The “”Woodpecker” is designed with the installer, service engineer and user
in mind by providing easy access to all pipe tappings and simple and user friendly
control panel. Timer control of the boiler can be by the BMS time clock on the
controller or by a remote time clock or digital programmer in the house.
All boilers are tested and certified to meet the essential requirements of the EU
Directives, in particular EN 303-5.
All finished goods also meet the essential requirements of the Low Voltage Directive
(Annex 1 of Council Directive 73/23/EEC) and the EMC Emissions testing.
All Gerkros Boilers are designed and manufactured to the highest standards with only
H.R.4, H.R. I5, ST 37/2 grade steel being used. All boiler shells carry a
manufacturer's five-year warranty. Gerkros recommend that only the woodpellet
products outlined in the “Fuel” section of this manual be used in conjunction with this
product.
All Gerkros products carry a unique serial number and this number must be quoted on
all service queries. All Gerkros boiler products must be commissioned by Gerkros
authorised technicians. The BMS will remain locked until such time as the installation
is to the requirements of Gerkros and all local bye-laws and Building Regulations.
Commissioning may be arranged by sending the completed Pre-Commissioning
Checklist to Gerkros. The Commissioning Report at the back of this booklet must be
fully completed, signed by the householder and returned to Gerkros within 14 days of
commissioning for the warranty to be put in place.
It is recommended that boilers are installed by fully qualified and experienced
personnel. Damage caused to the boiler, burner or BMS by poor installtion or
mis-use will invalidate the warranty. Commissioning must only take place by a
Gerkros authorised technician.

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2. Installation Instructions
2.1 Unpacking your Woodpecker
When you receive delivery of your “Woodpecker” pellet boiler the customer should
check that the following items have been included as part of the kit :
•“Woodpecker” pellet boiler c/w BMS controller
•Flue starter pipe with draught stabiliser
•Pellet Burner (complete with fixing flange with gasket (20/30kw) or holding
bolts (40/50kw) and sealing rope.
•Exhaust fan with gasket.
•Ash Pan
•1.3m long auger complete with motor
•Standard 150kg hopper complete with lid.
Any items which may have been inadvertently omitted from the delivery must be
communicated to Gerkros within 5 working days.
2.2 Quick-Step Installation Guide
1. Locate the boiler as per section 2.3
2. Connect the starter flue (with draught stabiliser) onto the smoke box at the rear
of the boiler. (section 2.6)
3. Position the insulated flue pipe (or elbow) roughly onto the starter flue to mark
the wall/roof through which the flue will run.
4. Cut the opening for the flue pipe in the wall/roof and connect the flue to the
starter pipe. Make sure the flue is well supported and is to the required height.
(section 2.6).
5. Make the plumbing connections to the rear of the boiler. (section 2.5).
6. Fit the exhaust fan to the rear of the boiler connect it to the fan power cable.
7. Locate the hopper, insert the auger and fit the auger motor. fit the flexi-pipe to
the auger.
8. Connect the pump power cable to the circulation pump.
9. Connect the mains power cable to the 5 amp fused spurs. (section 2.9)
10. Remove the burner from it’s packaging and configure it for fitting to the
burner door on the boiler (section 2.10). Connect the burner power cable to the
burner.
11. Flush out the plumbing system with water.
12. Fill the system to the required pressure.
13. Turn on the Permanent Power supply to the boiler
14. Run the pump to vent out all the air from the system. (hold the ESC button for
3 seconds until the beep). To turn off the pump hold the ESC key for 3
seconds.
15. Fill the hopper with pellets. (Only EU standard pellets may be used).
16. Fill the Auger with Pellets. Press MENU. Scroll up with button 3 until you
reach the LOAD menu. Press MENU to select. Press MENU again to run the
Auger. This will run the auger for 10 minutes. Press ESC 3 times to return to
the main screen.
17. Fill out the Pre-Commissioning checklist and return to Gerkros so a date can
be arranged for commissioning by Gerkros personnel only.

2.3 Locating and Installing the Boiler
The “Woodpecker” boiler is recommended to be located in a garage or boiler house.
All current building regulations (Part J – Heat Producing Appliances) must be
complied with when installing heat producing appliances.
The boiler should be located on a constructional hearth of a solid, non-combustible
level surface such as a concrete plint at least 125mm thick, which must be able to take
the weight of the appliance when full. The constructional hearth must extend beyond
the appliance as indicated in Diagram 1.
Diagram 1 Diagram 2
Allow for adequate clearance around the boiler for connection of the pipework, allow
250mm at the back of the smoke box (to fit an exhaust fan), removal of the fan at the
rear and for servicing and general maintenance Refer to Diagram 2.
2.4 Locating and Installing the Hopper / Auger
Once the hopper has been assembled the hopper should be located as per the footprint
in Diagram 3.
Fit the motor onto the end of the 1.3m long auger pipe, as per assembly instructions,
and fit the end of the auger into the receiving box fitted to the underside of the hopper.
Move the hopper so that the outlet from the top of the auger is positioned so that a fall
of 45°exists between the auger outlet and the top of the pellet inlet pipe to the burner.
Secure the ends of the pellet flexi-pipe onto the auger spigot and the pellet inlet pipe
adaptor of the burner with the jubilee clips provided. A slight offset on the flexi-pipe
is recommended to prevent the pellets travelling too fast into the burner. It is
recommended that the hopper is kept a minimum of 1/3 full at all times. This will
prevent bridging of pellets in the bottom of the auger and allow for a uniform power
input into the burner. Level sensors may be installed on the small hopper as an
accessory at an additional charge.
The lid or cover must be closed on the hopper after every fill to prevent any foreign
matter ingress into the pellet storage.
5

Diagram 3
.5 Plumbing Connections
2
6
iagram 4 indicates the water connections at the rear of the boiler for connection to
& B - 1” Flow Connections
s
model)
)
is recommended that the boiler is plumbed into an
is
s
D
your plumbing system.
A
C & D – 1” Return Connection
E – 1 x ½” connection (20/30 kw
2 x ½” connections (40/50 kw model)
(For use with automatic air vent and pressure relief valves.
F – ½” drain connection
It
open vented system (the maximum static head of
water permissible is 90 ft. (27.44 metres)), but if it
being connected to a sealed system an appropriately
sized expansion vessel should be used and installed a
per manufacturers instructions. The expansion vessel
should be sized based on a water capacity in the boiler
of 65 litres in the 20/30kW model and 75 litres in the
40/50kW model. Guidance is given in the formula
below for the most appropriate size of vessel :
Diagram 4

7
If the system volume is known, expansion vessels can be sized with the formula:
1 – p1
n vessel. It is not the
acceptance volume. (See product description).
1 atmospheric or gauge
ressure plus one Bar).
nts.
.032485 85
te the warranty.
V= eC + 25% Contingency
p2
V The total volume or nominal size of the expansio
C The total volume of water in the system.
P The fill pressure of the system in Bars absolute (
pressure plus one Bar).
P2 The setting of the expansion/pressure relief valve in Bars absolute
(atmospheric or gauge p
e The expansion factor that relates to the maximum system requireme
Expansion factor ‘e’ Temperature °C
0
0.035990 90
0.039695 95
0.0434100 100
Note : Incorrectly sized expansion vessels will invalida
s the
oiler. It is recommended that a bypass pipe between the flow and return is used. A
g
is required from the boiler the other remaining flow
nd return connections can be plugged. Flow and return connections should be taken
re relief valve must be connected to the ½” socket
dicated “E”. On the 40/50kw boiler there are two connections to serve this purpose.
t boiler can be installed into an existing conventional
lumbing system but for improved efficency Gerkros recommend that a buffer tank is
er can vent the system by running the pump by holding down the ESC
utton on the control panel for 3 seconds. To turn off the pump the hold down the
by the controller on the boiler. It is factory set to
ctivate at 50°C and de-activate at 47°C. The control system has in-built frost
The pump must always be placed on the return water pipe just before it enter
b
valve should be located on the bypass to regulate the quantity of hot water returnin
to the boiler from the flow pipe.
If only one flow and one return
a
from opposite side of the boiler.
An automatic air vent and pressu
in
Pressure relief valves should be piped to the ground or to a drain to prevent injury to
technicians or the Customer.
The Woodpecker wood pelle
p
used. Buffer tanks (direct cylinders) can achieve the optimum running of the system
in terms of efficiency and running costs. An indicative schematic is outlined in
Diagram 5
The Custom
b
ESC button again for 3 seconds.
The circulation pump is controlled
a
protection which will activate the pump at water temperatures less than 4°C.

Diagram 5
2.6 Flue Connections & Free Air Requirements
It is the responsibility of the customer to ensure that a natural draught exists in the
boiler when connected to the flue (min. 10 Pa) and this will be checked by the
Commissioning Engineer before the burner is run. If this is not the case then the
customer must take the necessary measures to ensure a draught. A revisit by the
Commissioning Engineer to complete commissioning if the flue is inadequate will
incur an additional charge.
The proper draught conditions in the flue pipe is critical for the efficient working of
woodpellet boilers. Gerkros recommend that it’s Therm-inox range of 5” stainless
steel twin-walled insulated flue pipe is used with its “Woodpecker” boilers. A
draught stabiliser is fitted as standard to the short section of flue pipe that connects to
the boiler. This will help stabilise draught in average wind conditions. The flue can
exit the boiler house/garage through the roof or through the wall by using a bend on
the flue. Diagram 6 indicates recommended flue layouts Installation must comply
with the current Building Regulations and local by-laws. Reference should also be
made to the following British Standards BS 5401 , BS 4543, BS 4876, BS 1181 and
BS 715.
In order to avoid down draught, the chimney or flue must terminate in a position at
least 600mm higher than the highest point on a roof, tree or building within a
distance of 9 metres (30 ft.). Down draughts will affect the performance of the
burner and must be eliminated and will cause the safety features on the appliance to
come into operation.
8

Diagram 6
Flue Pipe Existing Through a Wall
Flue Pipe Existing Through a Roof
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Down Draught:
Guidance on the correct height is detailed in Diagram 7. If the proper flue height
cannot be achieved the commissioning engineer may refuse to commission the boiler.
Whenever possible, the flue should terminate above the apex of the roof; if this is not
possible, use a cowl that is specified as anti-downdraught by the cowl manufacturer.
Use as few bends as possible but when necessary 135º bends are recommended. In
cases where the boiler is commissioned with a lower height flue but the necessary
draught conditions are achieved on the day of commissioning, the Customer must sign
the Commissioning Report stating that any issues arising from the flue not to the
required height will not be covered under warranty.
The chimney or flue must have a cross- sectional area throughout its whole length that
is at least the area of flue outlet of the boiler and must be sealed to the boiler with fire
clay or another suitable compound.
Diagram 7
Extract from Building Regulations – Part J Heat Producing Appliances.
Draught Regulation
10

The chimney or flue should be of sufficient height to provide draught of min. 10 Pa
measured at the test hole in the top of the boiler. Draught conditions that are
excessive, measured at the test hole in the top cleaning door of the boiler, due to
chimney height or location should be controlled by means of the draught stabiliser
fitted to the chimney to ensure a draught of not more than 40 Pa exists. In some
instances where the boiler is located in exposed sites a second stabiliser may be
required where natural draught exceeds 40 Pa.
The newly developed design of the regulator makes it possible to install it on the flue
pipe in all possible positions, angled, vertically as well as horizontally. The regulator
can be fitted the short flue section supplied with the boiler. Possible leaks can easily
be sealed off with a gasket, putty or other suitable sealing substances.
Counterbalancing the flap
After installation the two screws should be loosened and the balance spindle turned to
a horizontal position when the flap is closed. Tighten screws.
Diagram 8
Adjustment of Underpressure
Adjustment of the underpressure opening the flap is made by pressing the clamp on
which the weight is fitted and move it along the spindle. The underpressure is
changed approx. 1 Pa every 2mm the weight is moved, see fig. 2. The values are
approximate and must be controlled with a draught indicator if exact under-pressure is
required. The flap it set at approx. 10 Pa at delivery.
Opening of the flap on the regulator differs depending
on the adjustment as well as the draught in the
chimney. The draught varies considerably depending
on the chimney, the weather and if the burner runs or
not. This means that the function can vary between
different installations, e.g. the flap opens more or
less when the burner is running, flutters when the
burner starts or a door is being closed, etc.
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Diagram 9

External Flues:
All external flues of metal or other materials should have cleaning facilities and be
well insulated to maintain the correct draught conditions.
Internal Flues:
The exposed flue pipe between the boiler flue off-take and the chimney proper (either
internally or externally) must not be of asbestos. Vitreous Cast Iron, Steel or similar
materials should be used and insulated. When connecting a boiler to an existing
chimney, a flexible liner must be used and the space between flexible and existing
flue be filled with insulation and sealed top and bottom.
Low Level Flues:
The use of low level flues is not recommended.
Choice of Materials
The materials used in the construction of chimneys and flues should be such that the
construction is non-combustible, durable, resistant to temperatures likely to be
encountered, to rapid changes in temperature and resistant to external and internal
corrosion. Materials for lining flues should have a reasonably smooth finish and thus
not unduly impede the flow of the combustion gas products. They should be resistant
to potential attacks by flue gases and to spalling.
Materials used should be resistant to temperatures in excess of 300º C.
Free Air Requirements
Provision for air for combustion and ventilation:
General:
A sufficient permanent air supply to the appliance will be required for:
(a) Correct combustion of fuel an effective discharge of combustion products to the
open air.
(b) The ventilation of any confined space in which an appliance is installed to
prevent overheating of the appliance and any equipment in and near the
appliance.
(c) The satisfactory operation of any draught break or stabiliser which may be
fitted.
It should be both the Architect’s and the installer’s concern that the air required for
these functions be introduced so as to cause as little discomfort as possible to building
occupants and thus to offer them the least temptation to obstruct ventilation.
Air for Combustion:
Example
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• Boiler rating 20 kW
• Air for Combustion 550 mm2/kW
= 550 * 20 = 11,000 mm2
= 105 mm * 105 mm ( 4 inch square)
• Air for Combustion 850 mm2/kW
(with stabiliser)
= 850 * 20 = 17,000 mm2
= 130 mm * 130 mm ( 5 inch square)

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This requirement will be satisfied if the room or space in which the appliance is
installed has an opening or duct which is designed to allow the passage of air at all
times equivalent, in total free area, to 550 square mm/kW(2.5 sq. inches per 10,000
Btu's) of the appliance rating.
If the space containing the appliance has an extraction fan fitted, the supply of air
should be such that the operation of the appliance and flue is unaffected when the
windows and doors are closed and the extractor fan is running.
Air for Ventilation:
For an appliance in a confined space, care should be taken to provide air for
ventilation. A working guide to the minimum free area of openings to be provided in
addition to that for combustion air is as follows:
(a) Where the air is taken from a heated space, 1100 sq. mm/kW (5.0 sq. inches per
10,000 Btu's) at low level.
(b) Where the air is taken from outside, 550 sq. mm/kW at both high level and low
level (2.5 sq. inches per 10,000 Btu's)
The warranty for such boilers could be affected if proper free air requirements are not
provided.
Gerkros recommend that two air vents should be provided into the room containing
the appliance. One should be located at least 100mm above finished floor level and
the other at high level. A single vent at high level may prevent fresh air from reaching
the burner if the ambient temperature surrounding the appliance is high.
2.7 Boiler Features
The “Woodpecker” boiler is manufactured from a 5mm mild steel internal shell and
3mm external shell. The boiler has a 30mm external water jacket (E) with a main
internal “L” shaped waterway (B) and a top waterway (C). Transfer fins are used on
the “L” shaped waterway and the top waterway to increase the heating surface area to
maximise the heat transfer to water. Within the combustion chamber (A) the passage
of the flue gases is influenced by a refractory baffle in front of the burner flame. This
baffle is reclined at a 3º angle to allow the gases to travel to the top of the chamber.
The passage of gases is indicated by Diagram 10.
On the 20kW and 40kW model there is only one series of baffles accessed through
cleaning door “A” in Diagram 5 and placed in flue gas passage way “D” and “B”
respectively. In the 30kW and 50kW model there is one extra series of baffles in
flueway “C” in each model. The baffle in flueway “C” can be removed for cleaning
through cleaning door “A”. The back flue-way “F” is accessed through the top
cleaning door “D” and by removing to the steel plate “E”.

14
(20/30 kW Boiler) (40/50 kW Boiler)
Diagram 10
The ash pan in the boiler is used for the removal of ash for the boiler combustion
chamber. Care should be taken when handling hot ash. Guidelines and advice is given
in the Health and Safety section of this manual. To prevent excessive distortion of the
ash pan it is recommended that a layer of ash is maintained in the ash pan to act as an
insulating barrier.
2.8 Fuel
For the correct operation and efficient working of your wood pellet boiler system
Gerkros recommend that only pellets that conform to European-wide CEN standard
are used with their products . It is the responsibility of the Customer to ensure that
only a quality grade pellet is used for the appliance. Issues arising for poor quality
pellet and which necessitates a visit by a Gerkros technician is not covered under
warranty and a call out charge will apply.
If you change your fuel brand or supplier contact your local servicing/commissioning
Engineer (or Gerkros) for guidance on whether the burner needs to be adjusted.
Pellets must be stored in a dry and well ventilated storage area free from moisture.
Incorrect storage of pellets may degrade the pellet quality and may affect the
performance of the burner.
In cases where the pellets appear to have a high fines/dust content the auger system
may need to be cleaned periodically to maintain the correct feed rate of pellets to the
system. Some pellet brands may require the burner to be cleaned at regular intervals
to remove any residues which may be left behind.
Wood fuels that conform to the European-wide CEN standard means that the product
is of the highest quality and that the consumer can have every confidence in choosing
wood heating. CEN, the European Committee for Standardisation, established a
Technical Committee to define standards for solid biofuels.

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Recommended Specification for Wood Pellets for Domestic Heating:
Origin: Chemically untreated wood without bark
Moisture content: ≤10 %
Dimensions: ≤6 mm ± 0.5 mm and L ≤5 x Diameter or ≤8 mm ± 0.5 mm, and L ≤4
x Diameter
Ash content: ≤0.7%
Sulphur content: ≤0.05 %
Mechanical durability: 97.5% after testing
Amount of fines: ≤2.0 %
Additives: < 2 w-% of dry basis
Energy density: Min. 4.7 kWh/kg.
EU Standards : Austria: ÖNORM M1735 Sweden: SS 187120 and SS 187121
Germany: DIN 51731
2.9 Electrical Connections
The boiler and controls require :
Permanent Live 230V 1 phase 50Hz electric supply with a 5 amp fused spur. (Black)
Switched Live 230V 1 phase 50Hz electric supply with a 5 amp fused spur. (Brown)
Neutral (Blue)
Earth. (Yellow/Green)
The 4 cables exiting the boiler at the left hand side are :
White 4 core cable – Mains Supply
White 3 core cable – Pump Supply
Black cable – Auger Supply
Grey 12 core cable – Burner Supply.
Power isolation (by means of a 5A fused spur, not a switch spur) should be provided
adjacent to the “Woodpecker” so the power can be cut to all electrical components
during installation and servicing. The central heating pump is controlled by the BMS
controller and is preset to run at 50°C and turn off at 47°C.
Electrical installations should only be carried out by suitably qualified and
certified electricians. If in doubt on any issue relating to the electrical
connections on the appliance contact Gerkros Technical Support for guidance.
Only authorised Gerkros personnel may open the control panel on the boiler. Any
interference with the wiring in the control panel will invalidate the warranty.
The boiler and complete plumbing system must be adequately earthed and bonded.

Diagram 11
2.10 Setting Up The Burner
20/30kW Model
The pellet burner is to be mounted into the cast iron flange supplied with the burner.
The flange is mounted to the to the bottom front door of the boiler by lining up the
slots on the flange with the threaded holes on the door plate. Make sure the gasket
provided is intact and is placed between the flange and the door. Secure the flange to
the door with the 4 no. M8 bolts provided and tighten to ensure and adequate seal.
Loosen the locking screw on the flange and insert the blast tube of the burner into the
flange until the front plate is against the shoulder of the flange. Once the burner is
located in a vertical position tighten the locking screw.
40/50kW Model
Remove the green cover from the burner and use the 4 M8 fixing bolts provided to
secure the burner onto the bottom door of the boiler. Make sure the sealing rope
provided the placed around the blast tube of the burner before tightening the bolts to
make a seal between the front plate of the burner and the door face. Use the lock nuts
on the bolts to make any small adjustments.
16
Ensure the pellet re-tarder is fitted into the stainless steel pellet feeding tube before
the burner is commissioned. Remove the tube from the top of the burner by undoing
the allen head screws. Insert the deflector plate into the tube so the fixing tab aligns
with the screw. Tighten the screw until the deflector plate is secured in place. Make
sure the deflector plate is facing downwards as indicated in the diagram.

Fit the safety thermostat to the underside of the pellet feed
pipe making sure the disk face is in contact with the
surface of the tube. Place the stainless steel cover over the
thermostat and secure it in place with the two fixing
screws provided.
Connect the power cable for the burner in onto the socket
on the side of the burner and secure it with the two screws
on the plug head
Diagram 12
2.11 Commissioning
Once the installation has been completed the Pre-Commissioning Checklist at the
back of this manual must be sent to Gerkros and our Technical Support Team will
advise the Customer on a time and date for commissioning. It is important that the
Customer is present at the end of the commissioning so that the Commissioning
Engineer can provide the Customer with User Instructions, Health & Safety
Information and Maintenance Instructions. The Commissioning Report will also need
to be signed in order to validate the Warranty.
The Commissioning Engineer may refuse to commission the boiler if items on the
checklist have not been completed. Any return visits to commission the boiler will
incur a re-visit charge.
Note : Only Gerkros personnel may commission this appliance. The controller is
locked with a locking code on delivery and any interference with the controller
hardware will invalidate the warranty.
17

18
3. Servicing / Maintenance
Important !!!!!!!
Always turn off the time clock and isolate the electrical
supply to the boiler when cleaning/ servicing the boiler
and burner.
Please refer to the Customer CD for Audio / Visual
instruction and how to maintain the appliance.
3.1 General Maintenance for the Householder
Emptying the ash pan.
It is recommended that you observe the ash content over the first few weeks of the
burners operation to determine how often the ash needs to be emptied. Generally, on
average usage ( 5 hours daily), the ash should be emptied once every 3-4 weeks as the
ash content from wood pellet is generally regarded as being approx. 0.1 – 1%. Care
should be exercised when emptying the ash pan as it may be heavy or may contain hot
ash. Always use heat resistant gloves when handling the ash pan. The following
procedure should be followed when emptying the ash pan.
•Turn off the time clock.
•If the boiler has been running wait at least half an hour before attempting to
remove and empty the ash pan.
•Disconnect the flexible pipe from the burner and open back the burner door.
•Check to see if the ash pan is cool enough to be handled with gloves.
•Carefully remove the ah pan and dispose of the ashes in a non combustible
container. Never place hot ash in a plastic bag or plastic bin or in a metal bin
with combustible material stored inside.
•Replace the ash pan and close the burner door securely.
•Reconnect the flexible pipe to the burner.
Burner cleaning.
It is recommended that the burner is cleaned periodically to remove any residues with
may form in the blast tube. These residues are formed from impurities which are non-
combustible and may build up over time. The customer should observe the amount of
residue in the blast tube when emptying the ash pan to determine how often the burner
needs to be cleaned. The cleaning procedure is as follows :
•Remove the pellet stop from the front of the blast tube.
•With the tube scraper provided remove the reside from the tube.
•Replace the pellet stop carefully in the two locating holes.
Boiler cleaning.
If the flue gas temperature exceeds 250ºC then there is some ash or soot preventing
the heat from being transferred to the heating water in the boiler. If this is the case
then the boiler surfaces must be cleaned to maintain efficiency and combustion
quality. Always use heat resistant gloves when handling the ash pan and baffles.
Cleaning the flueways in the boiler is done by the following procedure :

•Turn off the time clock.
•If the boiler has been running wait at least half an hour before attempting to
open the burner door.
•Disconnect the flexible pipe from the burner and open back the burner door.
•Check to see if the ash pan is cool enough to be removed with gloves.(A)
•Open the center door of the boiler.
•Remove the access panel and open the two nuts which secure the cleaning
door. (B)
•Remove the cleaning door and remove the baffles taking note of the
orientation and arrangement of the baffles.
•Carefully remove the refractory baffles (E) in the combustion chamber. The
main target board may be remove by lifting it approx 20mm and pulling out
the bottom gently so it can drop to the base of the boiler.
•With a small brush or scraping tool brush the ash down into the ash pan area
ensuring that all the metal surfaces of the boiler are clean.
•A vacuum cleaner may also be used to remove the ash.
•Carefully replace the refractory baffles in the combustion chamber and metal
baffles in the flue gas passages.
•Replace the cleaning door, access panel and ash pan.
•Close all doors and reconnect the flexible pipe to the burner.
Diagram 13
Auger Cleaning
An excessive amount of dust in the pellets could lead to a failed ignition (Er12) or the
flame may die out in running mode (Er13). This is caused by the dust in the pellets
collecting at the base of the hopper restricting the entry of the correct quantity of
pellet into the feeder screw for transport to the burner. If the above errors appear on
the display then the auger may need to be cleaned. This can be done even when the
hopper is full of pellets. It can be cleaned as follows :
19

20
•Turn off the appliance at the time clock.
•Disconnect the auger motor cable from it’s power supply.
•Mark the bottom of the auger pipe when it meets the front face of the hopper
with a pen or marker.
•Pull the auger out of the receiving box on the base of the hopper and through
the hole at the front of the hopper.
•Holding the pipe upright tap the end of the pipe on the ground until it is
completely empty.
•To replace the auger push the pipe through the hole in the front of the hopper
and into the receiving box.
•Using some force push the pipe into the pellets rotating it slightly until it can
go no further.
•Reconnect the auger motor to it’s power supply. On the control panel press
MENU and scroll through the menu until you reach LOAD. Press MENU
again so OFF appears on the display and press MENU again to run the auger.
•After approx 2 minutes push the pipe further into the hopper base until it can
go no further.
•Repeat the above steps until the mark on the underside of the pipe meets the
front face of the hopper again.
Note : It is the responsibility of the customer to ensure that the boiler and burner are
cleaned regularly and that the ash pan is emptied as often as is appropriate. Service
calls for issues that have arisen due to the regular maintenance not being carried out
by the customer are chargeable.
3.2 Servicing
It is recommended that the boiler and burner are serviced annually. This will involve a
Gerkros registered technician undertaking a complete clean of the boiler and burner.
The ignition element in the burner will be changed during the annual service. All
burner and boiler components will be checked to ensure they are working
satisfactorily. The boiler will be run for a short period after the service to ensure the
efficiency and flue gas emissions are within the prescribed levels. The Technican may
give some recommendations to the Customer on the correct operation and
maintenance of the appliance.