Kostrzewa Mini Bio User manual

Dear users of Mini Bio
and Mini Bio Luxury boilers.
Before you connect and start your Mini Bio / Mini Bio Luxury boiler,
check the chimney parameters (stack effect, chimney cross-section)
with the data from the Table, as well as adjust the parameters of the
equipment to the heated surface (the calculated heat demand of the
building).
Basic safety instructions
of boiler operation!!!
1. Before you start your boiler, please read the manual.
2. Before you start your boiler, please check if the connection to
the central heating and chimney flue complies with the manufac-
turer’s guidelines.
3. Do not open the boiler’s door when the device is running.
4. Under no circumstances should the fuel tank be fully emptied.
For your own safety and comfort, please FILL OUT CORRECTLY (ALL
ENTRIES AND STAMPS MUST BE COMPLETED) the most recent copy
of the warranty and the quality attestation of boiler’s completeness (the
last page of this Servicing and Installation Manual) and send it back to the
address:
SERWIS KOSTRZEWA
ul. Przemysłowa 1, 11-500 Giżycko, POLAND
woj. warmińsko - mazurskie
Phone no.: [phone] or [phone]
e-mail: [email protected]
By sending back the warranty form you enable us to regi-
ster you with our Mini Bio and Mini Bio Luxury boilers user da-
tabase and provide you with fast and reliable servicing.
IMPORTANT !!!
WE WOULD LIKE TO INFORM YOU THAT NOT SENDING BACK THE
WARRANTY AND THE QUALITY ATTESTATION OF BOILER’S COMPLE-
TENESS, OR SENDING IT FILLED OUT INCORRECTLY, WITHIN THE
PERIOD OF TWO WEEKS FROM THE DAY THE BOILER WAS FIRST
STARTED BUT NOT EXCEEDING TWO MONTHS FROM THE DATE OF
PURCHASE, WILL RESULT IN THE LOSS OF THE WARRANTY FOR
THE EXCHANGER AND ALL SUBASSEMBLIES. THE LOSS OF THE
WARRANTY WILL CAUSE A DELAY IN CARRYING OUT THE REPA-
IRS AND THE USER WILL BE FORCED TO COVER ALL THE REPAIR
COSTS TOGETHER WITH THE TRAVEL EXPENSES OF OUR SERVICE
TECHNICIAN.
Thank you for your understanding.
Yours sincerely,
SERVICE KOSTRZEWA
ENGV 02.14
Dear user of
KOSTRZEWA
equipment!
We are glad that you have made the right choice
and decided upon our equipment. You have chosen
a product of the highest quality, manufactured
by a renowned company appreciated throughout
Poland.
The KOSTRZEWA® company was established in
1978. From the very beginning the company has been
manufacturing heating equipment fired with biomass
and fossil fuels. By way of its over 30-year-long tradition,
the company constantly focuses on the improvement
and modernization of its equipment and thus it has
become an undisputed leader among Polish manufactu-
rers of solid fuel boilers.
The company has started a new department, the
aim of which is the continuous development and
implementation of new technologies.
With the support of companies that will provide
professional representation of our own company,
we intend to reach each and every customer.
In this respect, your opinion on our company and
partners really matters.
As we try to do our best at all times, we will be
more than happy to receive any feedback on the
functioning of our equipment and the services
rendered by our Partners.
Have the warm and comfortable days
through the whole year!
KOSTRZEWA sp.j.

Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
Index
Mini Bio / Mini Bio Luxury Boiler manual
Foreword 4
1. General information 4
2. Scope of delivery 4
3. Specifications 5
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device) 9
5. Design guidelines 18
6. Boiler start-up, operation and stop including emergency stop 25
7. Installation 27
8. Boiler operation and maintenance 32
9. Notes, guidelines and tips 35
10. Boiler decommissioning 36
11. Quick reference guide - Fire and safety 36
12. End notes for installers 36
13. Troubleshooting 37
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Foreword
A series of Mini Bio / Mini Bio Luxury 10 kW and 20 kW nominal power
boilers with an automatic pellets/oats feed system sets new trends in
biofuel combustion. An advanced boiler featuring a tubular design,
well known from the gas and oil boilers, demonstrates the design and
production capabilities of our company. A heat exchanger is integrated
with a fuel storage hopper, a burner and a boiler control system within
a complete heating system. Mini Bio/ Mini Bio Luxury boiler is a high
quality complete and automatic product.
The tubular boiler design allows for optimal use of a heating surface
and does not expose an exchanger section to excessive thermal
loads while maintaining compact dimensions.
Our company offers reliable, durable and cost-effective solutions.
A simple and intuitive operation of a boiler/boiler room control system
is also important to the user. A large graphic display and an ergonomic
and clear interface of the boiler control system make our solutions
easy to use.
1. General information
The Operation and Maintenance Manual is an integral part of a boiler
and must be provided to the User of this device.The device installation
must comply with the manual, the relevant standards and the good
building practices. The boiler operation conforming to the User Manual
guarantees safe and failure free functioning and is a precondition for
the manufacturer’s warranty coverage. The specifications may change
without notice.
KOSTRZEWA is not liable for any damages resulting from incorrect
installation of the device and failure to comply with the terms and
conditions of this Operation and Maintenance Manual.
2. Scope of delivery
Mini Bio / Mini Bio Luxury boiler is shipped on a single pallet as a
complete set of ready to install:
• components: Mini Bio / Mini Bio Luxury boiler -
protective film wrapped
• burner (Mini Bio version control system) - packed in carton
• cleaning kit - packed in carton
Mini Bio boiler - Main components
• tubular boiler body (heat exchanger)
• front and rear door with insulation material lining
• mineral wool thermal insulation
• powder coated steel sheet boiler casing
• built-in storage hopper and fuel chute
• fuel feed system (gear motor, rigid feed duct and screw feed)
Platinum Bio v02 burner:
• Platinum Bio v02 burner (power determined by the boiler model)
• flexible feed duct with clips
Mini Bio boiler control system:
• Platinum Bio boiler control (wall mounted control system)
• safety temperature limiter (STB)
Cleaning kit:
• shovel
• cleaning rod
• scraper
Optional accessories:
• broadband oxygen sensor:
– ML-2 expansion module-oxygen sensor module
– broadband oxygen sensor probe
• room temperature sensor
• outside temperature sensor (with expansion module only)
• domestic hot water temperature sensor
• grate - oats
• CAN modules:
– expansion of supported heating circuits
(up to 16 heating circuits with mixing valve control)
– buffer tank support
– solar domestic hot water system support
– second domestic hot water system support
Foreword | 1. General information | 2. Scope of delivery
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2. Scope of delivery | 3. Specications
Mini Bio Luxury boiler - Optional accessories:
• ceramic chamber
• Platinum Bio burner ceramic cover
• flue gas swirl vanes
• SLIM operator panel
• Mini Bio Lux distribution board
• broadband oxygen sensor:
– ML-2 expansion module-oxygen sensor module
– broadband oxygen sensor probe
• I/O expansion module No. 0
• safety temperature limiter (STB)
Mini Bio/Mini Bio Luxury boiler must be secured in transit against
tipping from vertical position (working position) and shifting using
recommended accessories (straps and wedges). Store the boiler in
a dry room.
3. Specications
Mini Bio/ Mini Bio Luxury type boiler is a low temperature hot water
tubular boiler with a three flue gas passes combustion circuit. The
boiler features a hot combustion chamber (flue tube) used as the first
and the second flue gas pass and the return chamber connecting the
second and the third flue gas pass. A flame from the fuel combustion
at the burner grate with a primary and a secondary air supplied by
the blower has a conical opening along the flue tube. The flue tube
walls in the entire volume, i.e. the effective flame area are lined with
high quality ceramics to maintain stable and durable combustion and
after-combustion conditions (Mini Bio Luxury). It guarantees excellent
boiler operating conditions: high efficiency, high durability with an
advanced heat exchanger and low emission of hazardous substances.
The flame does not contact the water wall thus extending the device
life.
Mini Bio/ Mini Bio Luxury boiler is classified in the highest emission
and efficiency class (Class 5) as per PN-EN 303-5.
The basic dimensions of Mini Bio / Mini Bio Luxury boiler series are
showed in the following diagram (see ‘Mini Bio boiler dimension
diagram’) and the following table (see ‘Mini Bio boiler dimension
data’).
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
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Table: Mini Bio /Mini Bio Luxury
boiler dimension data
Basic boiler dimensions of the
Mini Bio / Mini Bio Luxury series
3. Specications
Table: Mini Bio /Mini Bio Luxury boiler dimension data
SYMBOL unit MB / MBL 10 MB / MBL 20
A mm 650 752
B mm 1658 1638
C mm 1110 1209
D mm 832 932
E mm 766 866
F mm 166 166
G mm 354 404
H mm 678 773
I mm 156 156
J mm 566 647
K mm 366 416
L mm 246 185
ØK1 – boiler
flue connector
mm 133 159
ØK2 –
power supply
G 1” 1 1/4”
ØK3 – return G 1” 1 1/4”
ØK4 – thermal
safety device
R 1/2” 1/2”
ØK5 – drain R 1/2” 1/2”
ØK6 – Boiler
temperature
sensor housing
– Ø inner
mm 16 16
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
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3. Specications
Mini Bio /Mini Bio Luxury boiler dimension diagram
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
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Table – Mini Bio/ Mini Bio Luxury boiler data sheet
3. Specications
PARAMETER SI MB / MBL 10 kW MB / MBL 20 kW
Flue draught mbar 0,15-0,25 0,15-0,25
Water capacity dm348 90
Maximum working pressure bar 2 2
Test pressure bar 4 4
Flue gas temperature at nominal power °C 140 140
Flue gas temperature at minimum power °C 100 100
Flue connector diameter mm 133 159
Hot water boiler heat output kW 10 20
Hot water boiler power range kW 3 – 10 6 – 20
Mini Bio efficiency at nominal power % 92.5 92.5
Mini Bio efficiency at minimum power % 90.8 92.4
Boiler class as per EN 303-5:2012 5 5
Combustion time at nominal power (fuel calorific value) : 18,305 kJ/kg) h 56 31
Temperature control settings range °C 50-80 50-80
Minimum water temperature at boiler return °C 45 45
Fuel type Class Sawdust granulate
(wood pellets) made
to as defined
in EN 303-5:2012 -
Class C1
Sawdust granulate
(wood pellets) made
to as defined
in EN 303-5:2012 -
Class C1
Storage hopper capacity L 220 240
Feed opening dimensions mm 558 x 558 658 x 658
Average power input W 90 90
Max. power input W 430 430
Max. noise level dB 52 52
The boiler meets Class 5 requirements for heat efficiency and gas emission as defined in PN-EN 303-5: 2012 provided that the boiler is installed
in a central heating system with a buffer tank.
Minimum buffer tank capacity: VSp= 15TBxQN ( 1 - 0,3 )
• VSp -buffer tank capacity in litres;
• QN -nominal heat output in kW;
• TB -fuel combustion time in hours;
• QH -building heat load in kW;
• Qmin-minimum heat output in kW;
The size of a hot water storage tank for multi-fuel boilers is selected for the fuel which requires the highest storage tank capacity. The minimum
hot water storage tank capacity is 300 litres.
QH
Qmin
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
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4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
4. Mini Bio /Mini Bio Luxury boiler
design (as a complete heating device)
1. Platinum Bio v02 burner
2. front door
3. flexible hose
4. operator panel (Mini Bio Luxury)
5. storage hopper cover
6. STB safety temperature limiter
7. rear door
8. oxygen sensor (Mini Bio Luxury)
9. cleanout
10. fuel feeder
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
4.A Boiler body
Boiler body materials
• inner cylinder – P265GH (as per DIN EN 10028) – boiler steel
for pressure tanks
• external cylinder – S235JR, thickness 5 mm (EN 10025-2) –
general purpose common steel, thickness 4 mm
• boiler smoke tubes – P265GH (as per EN 10216-2) – flue ducts,
thickness 3.2 mm
• fire partitions, mesh – P265GH (as per DIN EN 10028)
• boiler casing – DC01 – powder coated – steel sheet 0.8 mm
• boiler body insulation – 50 mm insulation wool with aluminium
foil
Mini Bio/Mini Bio Luxury is a boiler with a three flue gas passes
combustion circuit. All boiler components are MAG - 135 welded.
Most of the boiler components are welded with fillet welds and butt
welds.
4.B. Boiler door
The boiler door is right sided as standard (left sided door optional, to
order).
Mini Bio /Mini Bio Luxury boiler flue gas circuit
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
1. door handle
2. thermal insulation
1. thermal insulation
2. oxygen sensor nut
3. boiler flue connector
4. cleanout
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
Fig. Mini Bio / Mini Bio Luxury boiler front door
Fig. Cleanout rear door
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
4.C Platinum Bio v02 burner
Locally manufactured Platinum Bio v02 burner is a device dedicated
for solid fuel (wood pellets) combustion. The burner components in
contact with the flame are made of heat resistant steel. A selected
burner power is determined by the target Mini Bio/Mini Bio Luxury
boiler power. The following diagram (see ‘Platinum Bio v02 burner
dimension diagram’) and the following table (see ‘Platinum Bio v02
burner dimension data’) shows standard dimensions of Platinum
Bio v02 burner. The following table (see ‘Platinum Bio v02 data she-
et’) shows basic specification of Platinum Bio v02 burner. Mini Bio/
Mini Bio Luxury boiler may also be fitted with optional grate for oats
combustion (replacement, see section 7.G).
Platinum Bio v02 burner
dimension data
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
Table: Platinum Bio v02 burner dimension data
unit PB-16-v02 PB-24-v02
A mm 245 245
B mm 222 222
B1 mm 180 180
C mm 258 258
D mm 497 537
E mm 247 247
F mm 123 123
G mm 232 272
H mm 119 119
I mm 119 119
Platinum Bio v02 burner dimension diagram
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
4.D Fuel feeder unit
A locally manufactured fuel feeder is a dedicated system
conveying fuel from the storage hopper to the burner.
1. storage hopper
2. feeder
3. feed duct
4. feed screw
All electrical connections must conform
to the general guidelines on wiring systems,
see section 4.G ‘Wiring system’.
4.E Storage hopper
Mini Bio/Mini Bio Luxury 10 kW and 20 kW boilers are fitted with a
220 l and 240 l storage hopper, respectively, compatible with biofuels
(wood pellets and oats).
Fig. Storage hopper
Fig. Feeder unit
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
4.F Boiler sensor installation
The boiler is fitted with a safety temperature limiter STB factory set to
90°C. If the set temperature is exceeded, the STB stops the burner
and the fuel feeder operation and an alarm message is displayed.
Check and remove the cause for boiler overheating. Allow the boiler
to cool, remove the STB nut and press the button.
The boiler temperature sensor [5] and the STB [4] must be installed in
the boiler temperature sensor casing [6]. The sensors must be fixed
securely.
1. safety temperature limiter (STB) switch cover
2. safety temperature limiter (STB) mounting nut
3. safety temperature limiter (STB)
4. safety temperature limiter STB temperature sensor
5. boiler temperature sensor
6. boiler temperature sensor housing,
Caution!
Incorrect boiler sensor
installation may result in
overheating and faulty
system operation.
Fig. Sensor installation
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Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
4.G Wiring system
General guidelines on the wiring systems of a boiler control, a boiler
and its accessories:
1. A 230 V/50 Hz power system conforming to local standards and
regulations must be available in the boiler room.
2. The wiring system must be terminated with a plug-in socket and
a protective conductor contact.
3. The wiring system must be installed in accordance with the
electrical diagram and local regulations concerning electrical
safety.
4. The device (boiler/control system) must be connected to an
individual system with an overcurrent protection and a residual
current device.
NO OTHER EQUIPMENT MAY BE CONNECTED TO THE
BOILER’S ELECTRICAL SYSTEM.
5. The wiring system may be installed and repaired by authorised
personnel only.
6. Disconnect the power supply before servicing.
7. The boiler temperature sensor must be installed and secured in
a submersible sleeve in the water section. The remaining cable
must be coiled and laid in the external boiler casing or other
safe location (secured against sliding off from the sleeve).
8. The cables should not be bent or broken and the insulation
should not be damaged.
9. Do not allow water, moisture, dust and dirt inside the device,
otherwise it may result in short-circuit, electric shock, fire or
damage.
10. Ensure proper ventilation of the device (control) and free air flow
to the vents and air circulation around the device.
11. The electrical equipment (control, distribution board, burner and
sensors) are intended for indoor installation.
4.H Mini Bio/Mini Bio Luxury control system
A detailed description of the control system functions is included
in the Platinum Bio control User Manual.
WARNING!!! Using the socket without
a protective conductor contact may
result in electric shock!
Platinum Bio control for Mini Bio boiler
Platinum Bio Slim control for Mini Bio Luxury boiler
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
Platinum Bio operator panel main board for Mini Bio boiler
Main board from ver. L5B v10.4/10.5
INPUT DESCRIPTION EXPLANATION
Foto Brightness sensor in the burner.
Tkotła Boiler temperature sensor.
Tpalnik Burner temperature sensor.
Tc.w.u. Domestic hot water temperature sensor.
Tpokój Room temperature sensor.
GND Electronic ground for connecting sensors.
Pcwu Circulating pump of domestic hot water.
Zapalarka Burner igniter.
Pco Circulating pump of central heating.
Dmuchawa Burner flower.
Pod.zas. Tank feeder.
Pod.pal Burner feeder.
N Neutral permanent.
N1 Neutral disconnected, eg. via STB.
PE Ground wire
przewód podajnika zasobnika tank feeder wire
brązowy brown
niebieski blue
żółty-zielony yellow-green
zasilanie 230 V Power supply 230 V
STB Protection STB
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Experts in biomass heating
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device)
Fig. CAN module
Fig. Platinum Bio Slim operator panel main board for Mini Bio Luxury boiler
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Mini Bio and Mini Bio Luxury User Manual - ENGV 02.14
Experts in biomass heating
5. Design guidelines
The installation and all connections must comply
with the relevant standards and regulations!
5.A Burner location requirements
The distance of boiler walls and accessories from the room walls must
guarantee easy and failure free operation of the hot water boiler (boiler
control system operation, efficient manual fuel feeding to the storage
hopper, repairs, inspections etc.). Ensure sufficient space when
planning and installing the boiler and its accessories in the distance
required to open all boiler doors, clean the combustion chamber and
the exchanger baffles.
Thefollowingdiagram(see‘Boilerlocationintheboilerroom-dimension
diagram’) and the table (see ‘Boiler dimension data’) shows recom-
mended installation space for the boiler and its accessories.
Table - Boiler room dimension data
4. Mini Bio /Mini Bio Luxury boiler design (as a complete heating device) | 5. Design guidelines
Boiler room dimensions
Marking unit Values
A mm ≥ 500
B mm ≥ 500
C mm ≥ 500
D mm ≥ 1000
E mm ≥ 2000
F mm ≥ 50
Fig. Oxygen sensor connection (Mini Bio Luxury)
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