Highland heat Bio Kompakt User manual

Pellet fuel boiler
Bio Kompakt
User manual
Maintenance and installation
JSC Aukstaitijos katilai
Linų str. 85, Ukmerge, Lithuania www.highland-heat.com [phone] | [email protected]

Bio Kompakt
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
4. Boiler installation
4.1. Boiler assembly
4.2. Boiler location and position
4.3. Changing the door direction
4.4. Installation of a rotary pellet burner
4.5. Installation of the control unit
4.6. Connecting the boiler to the chimney
4.7. Connecting the boiler to the central heating system
4.8. The distance of the boiler from the walls of the boiler
room
4.9. Recommended connection diagrams
4.10. Installing the controller
4.11. 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. 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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Table of content

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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.

1.1. General information
The Bio Kompakt boiler models are characterized by a large
heat exchanger, which allows to achieve an efciency of more
than 90 percent, and very good automatic rotary pellet burners
with wide 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.
Bio Kompakt 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.
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
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2. Technical parameters
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Models and power output 12 kW 16 kW 20 kW
Heated area
Combustion chamber load
Rotary modulated pellet burner
Heat exchanger area
Horizontal heat exchanger number
Volume of water in the boiler
Weight
Lowest operating temperature
Highest operating temperature
Heating efciency
Chimney inner-outer diameter
Hydraulic connections size
Highest operating pressure
Required draft in the chimney
120
120
4-12
1,7
2
44
155
160
160
4-16
2,0
2
50
175
200
190
4-18
2,4
2
58
195
Max m2
l/dm3
kW
m2
pcs
l
kg
60º C
90º C
90%
130/140 mm
G 11/4 inch
1,5 bar
15-20 Pa

1. Control panel
2. Pellet feeder
3. Chimney
4. Turbulators
5. Heat exchanger
6. Branch pipes
7. Flame deector
8. Ceramic ame chamber
9. Ash box
10. Adjustable legs
11. Control unit
12. Boiler thermal fuse
13. Pellet chamber lid
14. Granule chamber
15. Flexible pellet feeding hose
16. Doors
17. Door handle
18. Rotary burner
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1
2
3
4
5
6
7
8
9
11 12 13
14
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16
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3. Construction
3.1 Boiler components
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3. Construction
3.2 Boiler
The boiler heat exchanger consists of three main zones. Two
horizontal heat exchangers (5) and turbulators (4) are placed
in the upper zone to increase heating efciency. In the middle
zone there is a combustion chamber with a ceramic ame
deector (7), which serves as a catalyst and protects the rear
wall from overheating. In the middle zone there are ceramic
plates (8) that improve the combustion process and a rotary
burner (18) that is installed in the door (16). A pull-out ash
box (9) is placed in the lower area for ash removal. The boiler
control panel (1) is installed in the front part of the boiler, and
the electronic control unit (11) is installed in the rear part. The
internal heat exchanger body of the boiler is made of bent and
welded heat-resistant steel sheets, and the nish is made of
powder-coated sheets. Under the boiler nish is an insulating
layer of glass wool, which protects against heat loss through
the boiler’s outer walls. The double doors are sealed with heat-
insulating material and painted with heat-resistant paint. The
gases produced during combustion are removed through the
chimney pipe (3) installed in the rear part of the boiler. The
burner and boiler control unit (11) is installed in the rear part
of the boiler, to which all boiler control sensors are connected.
An emergency thermal fuse (STB) (12) is installed on the side
of the control unit. When the boiler overheats, it disconnects
the supply of pellets and the operation of the fan. All other
functions remain active.
The STB can only be reset by manually pressing the fuse
button.
Reset the STB only after nding out and eliminating the fault.
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3.3 Pellet chamber
The fuel chamber (14) is mounted on top of the boiler. It is lled
with pellets by opening the lid of the chamber (13) at the top.
The fuel in the chamber falls down to the bottom, where it is
supplied to the burner with the help of a screw-type feeder (2)
through a protective hose (15).
3.4. Burner
Bio Kompakt boilers use a „Kipi Rot Power“ rotary pellet burner,
which can burn pellets of lower quality. This is a high-quality,
long-lasting burner of the new generation with an automatic
ignition and cleaning system. The combustion chamber of
the burner has a rotating mechanism. Thanks to this design,
slag is not allowed to form in the burner, it is easier to remove
slag, and the combustion chamber of the burner works over
the entire area. The burner has a mechanism for regulating
the ratio of primary and secondary air, which greatly increases
the efciency of the burner. Reliable construction, quality
components and quality ceramic spark plugs will allow you to
use this burner for a long time. More information is available in
the burner manual.
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3. Construction

3.5 Controller
The boilers are equipped with the latest „Plum“ controller.
The controller is a modern electronic device designed to control
the operation of a pellet boiler, using the display of an optical
ame intensity sensor. The device is compact and easy to
install. It can control central heating and hot water circuits and
the operation of up to 5 heating circuits. The temperature of the
heating circuits can be determined by the data received from
the main temperature sensor or by separate room temperature
sensors for each of the circuits. Also, the compatibility
with standard room thermostats allows you to maintain a
comfortable temperature in all premises (rooms). The controller
can turn on the backup boiler (gas or liquid fuel).
The controller can operate according to preset parameters or
„Fuzzy logic“ operating principle.
An additional control panel located in the living room or another
room and an additional module with a Lambda sensor can be
connected to the boiler controller.
Controlling the boiler is easy and simple. The controller can be
used in households and small industrial facilities. It is possible
to monitor and control the combustion process of the boiler by
connecting to the controller via the Internet.
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3. Construction

Module A. Standard equipment
Module B. (Additional)
Module C. (Additional)
Control of fan, smoke pump, automatic supply and ignition
of pellets, control of heating and water circuit pumps, control
of mixing pump and valve, control of room and outdoor
temperature sensors, control of smoke temperature sensor,
summer and winter mode, emergency shutdown, possibility
to connect Lambda sensor, additional boiler control, audible
emergency signal, possibility to set working time modes.
Management of storage capacity and additional circuit.
Control of two additional contours.
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3. Construction

4.1 Boiler assembly
The Bio Kompakt boiler models are delivered to the buyer fully
assembled. The boiler is delivered packed on a pallet, attached
to the soles of the pallet with screws. The burner, the pellet
feeding mechanism and the control unit are delivered packed
in a cardboard package. The boiler control panel is installed in
the factory and ready to be connected to the control unit.
Standard equipment
1. Pellet boiler Bio Kompakt
2. Burner „Kipi Rot Power“
3. „Plum 920“ controller and 3 m long boiler sensor
4. Flexible pellet feeding hose
Bio Kompakt boilers are only sold complete with „Kipi Rot Power“
burner and „Plum“ controller.
4.2 Location and position of the boiler
The boiler must stand on a hard, smooth and non-ammable
dry surface. It should be convenient to access the rotary
burner, control unit, pellet container, screw feeder, ash collector
and other mechanisms. The door opening direction can be
changed.
4. Boiler installation
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1
2
5
4
3
6
1. Screw DIN 912 M10x16
2. Screw DIN 912 M10x12
3. Spring washer
4.3 Changing the door direction
4. Door handle
5. Eccentric M10
6. Screw DIN 912 M8x16
The direction of the 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.
4. Boiler installation
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4.4 Installation of a rotary pellet burner
3
2
1
1. Fastening
2. Pellet feeding hose
3. Transition pipe
4. Rotary pellet burner
The rotary pellet burner (4) is supplied with components in a
cardboard box. The burner is xed on the door with M8 nuts.
The pipe (3) and the pellet feed hose (2) are inserted, the pellet
feed hose is tightened with clamps (1).
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4. Boiler installation
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4.5 Installation of the control
3
2
The control unit (2) is installed in the rear part of the boiler by
hooking it on M4 screws (1).
1. Bolt M4
2. Control unit
3. Boiler
1
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4. Boiler installation

4.6 Connecting the boiler to the chimney
The chimney must be installed to meet 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 ue pipe must
be connected to the ue itself with a rigid steel connection of
suitable cross-section and shape.
The connection of the solid fuel boiler to the chimney must be
properly insulated to prevent burns.
4.7 Connecting the boiler to the central heating system
Dedicate the work of connecting the boiler to properly qualied
specialists.
In order to extend the service life of the boiler and to ensure
adequate comfort of use, it is necessary to follow such an
installation scheme that ensures the 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 connection schemes are presented in
subsection 4.8.
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4. Boiler installation

4.8 The distance of the boiler from the walls of the
>300
>300
>300
>500
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4. Boiler installation

7. Heating circuit pump
8. Circuit temperature sensor
9. Hot water reservoir
10. Hot water pump
11. Hot water sensor
12. Air temperature sensor CT4-P
Scheme with a four-way valve controlling the circuit of the heating system.
1. Boiler
2. Burner
3. Controller
4. Boiler temperature sensor CT4
5. Smoke temperature sensor
6. Four-valve engine
4.9 Recommended connection diagrams
13. Room thermostat ecoSTER200 or standard room thermostat
14. Return temperature sensor (not necessary for system operation)
15. Boiler fan
16. Reverse valve
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4. Boiler installation

Scheme with storage capacity.
1. Boiler
2. Burner
3. Controller
4. Boiler temperature sensor
5. Smoke temperature sensor
4.9 Recommended connection diagrams
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20
4. Boiler installation
6. Boiler pump
7. Storage reservoir
8. Hot water pump
9. Hot water reservoir
10. Mixing valve motor
11. Hot water temperature sensor
12. Room circuit temperature sensor
13. Perimeter pump
14. Room thermostat ecoSTER200 with room thermostat function
15. Thermostatic three-way valve for backow protection
16. Accumulator reservoir high temperature sensor
17. Accumulator reservoir low temperature sensor
18. Air temperature sensor
19. Additional module B.
20. Balance valve

Scheme with storage tank and 5 mixing heating circuits
1. Boiler
2. Burner
3. Controller
4. Boiler temperature sensor CT4
5. Smoke temperature sensor CT2S
6. Boiler pump
7. Storage reservoir
8. Hot water pump
9. Hot water reservoir
10. Circulation pump
11. Three-way valve with motor
12. Perimeter mixer pump
13. Perimeter sensor
14. Room sensor CT7
15. Room sensor CT7
16. Accumulator reservoir high temperature sensor
17. Accumulator reservoir low temperature sensor
18. Air temperature sensor CT4-P
19. Room thermostat ecoSTER200 with room thermostat function
20. Standard room thermostat
21. Additional module B
22. Additional module MX.03
23. Hot water temperature sensor / accumulator low temperature sensor
24. Balance valve
4.9 Recommended connection diagrams
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4. Boiler installation

4.10 Installing the controller
Installation, commissioning and tuning of the controller can
only be performed by certied specialists.
The controller is delivered fully assembled at the rear of the
boiler, and the controller panel is mounted at the front of the
boiler.
The electrical wiring diagrams of the controller are provided
together with the controller manual.
The temperature sensor is installed in the socket at the back
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.
4.11 Starting the 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.
During the start-up, the „Act“ for the operation of the burner is
drawn up and the „Guarantee“ sheet is lled out.
„Kipi Rot Power“ carries out pellet burner start-up,
warranty and post-warranty service JSC „Degus“, info@
protingasiluma.lt, [phone].
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4. Boiler installation