Highland heat Agro Uni User manual

User manual
Maintenance and installation
Agricultural waste boiler
Agro Uni
JSC Aukstaitijos katilai
Linų str. 85, Ukmerge, Lithuania www.highland-heat.com [phone] | [email protected]

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Safety provisions
1. Introduction
1.1. General information
1.2. Standards and regulations
2. Technical parameters
3. Construction
3.1. Boiler components
3.2. Boiler
3.3. Pellet chamber
3.4. Burner
3.5. Controller
3.6. Boiler set
4. Boiler installation
4.1. Location and position of boiler and pellet chambers
4.2. Changing the door direction
4.3. Boiler assembly
4.3.1 Installation of the burner cleaning mechanism
4.4. Connecting the boiler to the chimney
4.5. Connecting the boiler to the central heating system
4.6. Recommended connection diagrams
4.7. Installing the controller
4.8. Starting the burner and controller
5. Using the boiler
5.1. General information and sefety
5.2. Boiler fuel
5.3. Using the boiler in automatic mode
5.4. Using the boiler in manual mode (solid fuel)
5.5. Maintenance
6. Boiler warranty card
7. Burner warranty card
8. Warranty conditions
9. Efciency and emissions
10. Disposal of the boiler
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Agro Uni
Table of content

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Agro Uni
Safety provisions
During the use of the boiler, its individual parts: chimney, door,
individual points of the body - can heat up and cause burns if
touched.
Do not allow children to touch or use the boiler without adult
supervision.
The boiler can be operated by a capable adult who has
carefully familiarized himself with this instruction.
Only a qualied specialist can install the boiler and connect it
to the heating and electrical systems.
If you suspect that the boiler has malfunctioned, please
contact the organization that installed the boiler or
the manufacturer’s representative. Do not under any
circumstances use a malfunctioning boiler.
Improperly connected and used boiler can cause injury or
death.

Agro Uni
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1.1 General information
The Agro Uni boiler models are characterized by an
exceptionally large heat exchanger, which allows to achieve an
efciency of more than 90 percent, and very good tray pellet
burners with a wide range of control options.
Before connecting the boiler to the heating system carefully
read this manual to ensure that all boiler components and
equipment are working properly.
Agro Uni boilers are designed for heating private residential
houses, commercial and auxiliary premises. The boilers belong
to the so-called low-temperature boilers category, i.e. the
average temperature of the heat carrier cannot exceed 90 °C,
and the maximum operating pressure - 1.5 bar.
The manufacturer has the right to make minor changes
that do not signicantly affect the quality of the combustion
process and the operation of the boiler. We do not recommend
equipping the boiler with a stainless steel chimney.
1.2 Standards and regulations
The boiler must be installed and operated in compliance with
the legal requirements of the country to which it is supplied. It
must be installed in accordance with the requirements of the
maintenance and installation instructions.
Otherwise, the manufacturer assumes no responsibility and
does not guarantee repair for any defects.
1. Introduction

Agro Uni
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2. Techniniai katilo parametrai
Models and power output 15 kW 20 kW 30 kW 40 kW
Heated area
Combustion chamber depth
Combustion chamber load
“Zenono” burner
Heat exchanger area
Combustion chamber opening size
Number of horizontal heat exchangers
Volume of water in the boiler
Weight
Chimney inner-outer diameter
Stirring fuel chamber capacity
Lowest operating temperature
Highest operating temperature
Heating efciency
Hydraulic connections size
Highest operating pressure
Required draft in the chimney
150
450
35
3-15
1,9
29x23
3
48
180
150/160
200
450
40
3-20
2,5
34x23
4
62
230
150/160
300
500
65
4-30
3,3
44x23
4
69
270
150/160
400
600
104
8-50
4,2
49x23
4
100
310
185/195
Max m2
mm
l/dm3
kW
m2
cm
pcs
l
kg
mm
400/600 l/dm3
60º C
90º C
90%
G 11/4 inch
1,5 bar
15-20 Pa

3. Construction
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Agro Uni
3.1 Boiler components
1. Chimney
2. Controller
3. Heat exchanger
4. Cleaning door
5. Combustion chamber
6. Cast iron grates
7. Tray burner
8. Mixer
9. Return branch pipe
10. Ash box
11. Adjustable legs
12. Supply branch pipe
13. Thermometer
14. Fastening of the fuel chamber cover
15. Door handle
16. Fuel loading door
17. Fuel chamber maintenance cover
18. Reducer
19. Blower
20. Adjustable fuel chamber leg
21. Adjustable air valve
22. Bottom door
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3. Construction
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Agro Uni
3.2 Boiler
The boiler heat exchanger consists of three main zones. Four
horizontal heat exchangers (three in the 15 kW boiler) are
placed in the area of the upper door (3). The upper door is
used when it is necessary to clean the surface of the heat
exchanger. There is a solid fuel combustion chamber in the
area of the middle door (5). This chamber is designed to use
cheaper solid fuel which is loaded manually. The middle and
lower chambers are separated by cast iron grates (7). It is
recommended to remove the grates during continuous ring in
automatic mode. The tray burner (8) is installed on the side of
the boiler and is connected to the fuel chamber. A blower (19) is
installed on the side of the boiler, near the fuel supply pipe. The
burner has a built-in mixer that helps burn difcult burning fuel
(9). A pull-out ash box (11) is placed under the burner for ash
removal. An air valve is installed in the front of the lower door.
The boiler controller (2) is installed in the front part of the boiler.
The internal heat exchanger is made of bent and welded heat-
resistant steel sheets, and the nish is made of powder-coated
sheets. Underneath the boiler is an insulating layer of glass
wool, which protects against heat loss through the boiler’s outer
walls. Double doors are sealed with heat-insulating material
and painted with heat-resistant paint. Gases generated during
combustion are removed through the chimney pipe (1) installed
in the upper part of the boiler.

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Agro Uni
3.3 Pellet chamber
The pellet chamber is designed to store fuel and supply it to the
boiler in automatic mode. The delivery system can be on the
left or the right side, depending on the order. Fuel is loaded into
the chamber by opening the lid. Fuel falls down to the bottom,
where it is fed to the burner through a feed pipe with the help of
a screw-type feeder. After opening the tank maintenance cover
(17), we can access the cleaning opening. It is designed to
periodically clean the accumulated pellet dust, which reduces
the performance of the pellet feeder.
3.4 Burner
Agro Uni boilers use „Zenono“ tray burner that can burn lower-
quality, difcult burning pellets and other fuels: wood pellets,
grass pellets, grains, oats, beans. A fuel mixer is installed
together with the burner, designed to facilitate the burning
of extremely difcult burning fuel. This is a high quality, long
lasting new generation burner, designed to burn pellets and
other fuels. This is the only (and without any competition)
burner designed and manufactured in Lithuania. Reliable
construction and quality components will allow you to use this
burner for a long time.
3.5 Controller
An Inter Electronics controller is installed in the boiler. The
controller is a modern electronic device designed to control the
operation of the pellet boiler using data from various sensors.
The device is compact and easy to install. It can control the
central heating and hot water circuits and the burner.
3. Construction

The temperature of the heating circuits can be determined by
the data received from the main temperature sensor or the
room thermostat, which turns off the boiler pump.
When connecting the thermostat, it is necessary to ensure the
minimum heat demand for boiler operation in standby mode.
The compatibility with standard room thermostats allows you
to maintain a comfortable temperature in all premises (rooms).
Controlling the boiler is easy and simple. The controller can be
used in households and small industrial facilities.
3.6 Boiler set
1. Boiler
2. Fuel chamber
3. Fuel supply mechanism
4. Burner
5. Controller
6. Stainless steel burner cleaning mechanism (2 pcs.)
7. Blower
8. Set of grates
9. Ashtray
10. Boiler cleaning tools
11. Thermometer
12. User manual
13. Turbulators (ordered additionally)
Agro Uni boilers are sold only complete with „Zenono“ burner
and Inter Electronics controller.
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Agro Uni
3. Construction

4. Boiler installation
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Agro Uni
Agro Uni boilers are equipped with a pellet chamber of 400 or
600 liters.
We do not recommend equipping the boiler with a stainless
steel chimney.
4.1 Location and position of boiler and pellet chambers
The boiler and pellet chamber must be placed on a hard,
smooth and non-ammable dry surface. It should be
convenient to access the bed burner, blower, controller, pellet
chamber, and fuel supply system, ash collector and other
mechanisms. The pellet chamber can be on the left or right side
of the boiler depending on the order. The door opening direction
can be changed.
RightLeft

4. Boiler installation
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Agro Uni
4.2 Changing the door direction
The direction of the upper and middle doors is changed by
turning the door together with the hinge (hinges) away from the
boiler body and screwing it on the opposite side of the boiler.
The door handle is unscrewed, turned over and screwed back.
The direction of the lower door is changed by turning the door
away from the hinge. The hinge is unscrewed from the boiler
body and screwed on the opposite side of the boiler. The door
is screwed to the hinge, and the door handle is unscrewed from
the door and screwed back to the opposite side of the door.
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1. Screw DIN 912 M10x16
2. Screw DIN 912 M10x12
3. Eccentric M10
4. Door handle
5. Spring washer
6. Screw DIN 912 M8x160

4. Boiler installation
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4.3 Boiler assembly
The fuel supply system and chamber are installed in three
stages:
1. The assembled fuel tank is xed to the boiler in the
appropriate place with (1) four M10 screws.
2. The correct height of the fuel tank and feed pipe is
determined by the adjustable leg (3).
3. The blower is xed under the fuel supply pipe, in the
designated place, by xing with four M6 screws (2).
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Agro Uni

4. Boiler installation
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It is necessary to lubricate the connection with heat-resistant
silicone before screwing the fuel supply screws to the burner!
Agro Uni

4. Boiler installation
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4.3.1 Installation of the burner cleaning mechanism
Installation of the burner cleaning mechanism (hedgehog):
The burner cleaning mechanism (2) is installed in the burner by
screwing it to the fuel supply nozzle (1).
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Agro Uni

4. Boiler installation
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Agro Uni
4.4 Connecting the boiler to the chimney
The chimney must be installed according to the requirements
of the country where it is installed. The recommended chimney
draft is 15-20 Pa. If there is too much draft in the chimney, a
draft regulator should be installed.
The boiler branch pipe must be connected to the ue itself with
a rigid steel connection of suitable cross-section and shape.
The connection of the boiler to the chimney must be properly
insulated to prevent burns.
4.5 Connecting the boiler to the central heating system
Delegate the work of connecting the boiler to properly qualied
specialists.
In order to extend the service life of the boiler and to ensure
proper use, it is necessary to follow an installation scheme that
ensures maintenance of the working temperature of the boiler
not below 60°C. With the help of a specialist, make sure that
the condition of the boiler, automation, plumbing connections,
ue tightness and components are working properly. In a
closed heating system, there must be a thermal expansion
compensation vessel of suitable capacity (at least 10% of the
total liquid volume in the system). Safety valves or valves that
restrict ow in this system are prohibited.
Recommended wiring diagrams are provided
in subsection 4.6

4. Boiler installation
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4.6. Recommended connection diagrams
1. Small perimeter pump
2. Big perimeter pump
3. Expansion vessel
4. Four-way valve
5. Reverse valve
6. Boiler
1. Small perimeterpump
2. Expansion vessel
3. four-way valve
4. Reverse valve
5. Boiler
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Agro Uni

4. Boiler installation
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Agro Uni
4.7 Installing the controller
Installation, commissioning and tuning of the controller can
only be performed by certied specialists. The controller is
installed in the upper part of the boiler. The procedure for
connecting the controller is included with the controller
instruction.
The temperature sensor is installed in the sleeve at the top
of the boiler. When installing the temperature sensor in the
boiler, it is necessary to lock the sensor in the sleeve to prevent
accidental removal. If the temperature sensor falls out of the
sleeve, the boiler may boil.
4.8 Starting the boiler, burner and controller
When starting up the boiler for the rst time, a certied
specialist must train the user on how to use the heating
system. Burner start-up, warranty and post-warranty services
are carried out by “Zenono” burner manufacturer: +370 618
63071.
The manufacturer is not responsible for the quality of boiler
operation and malfunctions if the user starts the burner and
controller himself. We recommend delegating the burner
start-up work to a certied specialist.

5. Using the boiler
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5.1 General information and sefety
Agro Uni is a universal boiler, adapted to use extremely
difcult burning pellets or grain products, as well as cheaper
solid fuel using manual loading. Pellets are ignited with a
“Zenono” burner, and a mixer is used to facilitate the burning of
extremely difcult burning fuel. The fuel is ignited manually. The
combustion process of both pellets and solid fuel is controlled
by the controller.
Use the boiler safely and follow the basic safety and boiler
operation rules.
• Check the operation of the safety valve (no more than 1.5 bar)
and open the shut-off valves between the heating boiler and
the heating system.
•Check the water pressure in the system.
• The heating system must be lled with water and bled.
• When starting solid fuel, never use ammable liquids -
gasoline, paint thinners etc.
• Do not burn plastics, rubber and other air-polluting waste.
• The smoke extraction system must be reliably connected and
sealed.
•Unmaintained chimney, insufcient draft can cause monoxide
poisoning.
•Maintain the boiler only after it has cooled down.
If you suspect that the boiler or the heating system is not
working properly, stop using it and contact a specialist.
Agro Uni

5. Using the boiler
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5.2 Boiler fuel
Primary fuel: wood pellets, economic fuel (grains, beans,
oats etc.) Secondary fuel: rewood, sawdust briquettes, peat
briquettes, coal.
5.3 Using the boiler in automatic mode
A properly connected boiler can operate in automatic mode
depending on the heat demand. The combustion process is
controlled by a controller based on data received from sensors.
The burning intensity of the burner is automatically regulated,
the temperature of the boiler is changed according to the
preset parameters. To set the automatic mode when burning
pellets, the select: Menu–>11. “Advanced parameters”–>11.9
“Feeder Type” and select the “Screw” parameter. The burner is
lled with pellets by selecting: Menu->10 „Manual Mode“ and
turning on the feeder. Other receivers can also be tested in
this mode. After lling the burner with pellets, the fuel is ignited
manually and the automatic mode is activated (return to the
main screen of the controller and press the ESC button).
For continuous burning of the pellets, it is recommended to
remove cast iron grates from the combustion chamber of the
boiler.
More information about the controller can be found in the
controller manual.
5.4 Using the boiler in manual mode (solid fuel)
The solid fuel burning process and the operation of the
entire boiler room are controlled by the same controller.
To start burning solid fuel, select: Menu–>11. “Advanced
parameters”–>11.9
Agro Uni

Feeder type and optional parameter “Output”. The controller will
start supplying air for burning solid fuel, but will continue to fully
control all boiler control processes.
In the case of low heat demand or too high draft of the
chimney, due to the natural air inow through the fan, intense
combustion may occur, so the boiler may overheat.
Before starting to burn solid fuel, make sure that the cast iron
grates are in the correct position (“VVVVV”). When stacked in
reverse, wood fractions and ash fall, clogging the gaps. In this
case, the boiler loses its traction and power, the grates fold.
5.5 Maintenance
Maintenance and cleaning of the boiler is carried out
periodically. Cleaning frequency ie determined by the need.
With a well-balanced system, the boiler is cleaned once a
month. The heat exchanger is cleaned by opening the upper
door.
Ash cleaning from the ashtray is carried out as needed,
depending on the type of fuel used and ash content. A full
ashtray can interfere with the correct operation of the burner.
Maintenance of the pellet feeder.
Opening the maintenance cover of the pellet chamber provides
access to the cleaning opening. It is designed to periodically
clean the accumulated pellet dust, which reduces the
performance of the pellet feeder.
Burner maintenance.
It is recommended to clean the bed burner every 2 months.
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5. Using the boiler
Agro Uni