Kostrzewa Twin Bio User manual

ENGLISH
EN

Dear User
of KOSTRZEWA
equipment!
We would like to thank you for choosing us. You
have purchased a superior quality product made by
a renowned Polish company.
Kostrzewa was established in 1978. From the very
beginning we manufactured central heating boilers
fired with bio- and fossil fuels. We have been ac-
tive for over 30 years and during that time we con-
stantly improved and modernised our equipment in
order to retain the leading position among Polish
manufacturers of solid fuel boilers.
We established an implementation and project
department for new technologies whose aim is to
constantly improve our products and to implement
new technologies.
We would like to reach each and every customer
through companies which will professionally rep-
resent us.
We really value your opinion about us and our
partners. As we strive to constantly improve our
products, please send us any remarks you may
have concerning our equipment as well as services
provided by our Partners.
We wish you warm and comfortable days all year
round
KOSTRZEWA
Dear users of Twin Bio boilers.
Before you connect and start up your Twin Bio boiler, please
check the parameters of your flue with the data in the enclosed
table (flue draught, flue cross-section), as well as whether the
device is fit for the heating of the given surface (the building’s
heat demand).
The basic principles of the safe use
of the boiler!!!
1. Please read the user manual carefully before boiler
start-up.
2. Before you start up the boiler check whether it is
connected to the central heating system and the flue in
accordance with the manufacturer’s recommendations.
3. Do not open the door while the boiler is working.
4. Do not allow the fuel tank to empty completely.
For your own safety and the comfortable use of the boiler,
please send us the CORRECTLY FILLED IN (I.E. ALL ENTRIES
AND STAMPS) latest copy of the warranty card and the
confirmation of the completeness of the boiler (the last page of
this user manual) to the following address:
KOSTRZEWA SERVICE CENTRE
ul. Przemysłowa 1, 11-500 Giżycko
Warmińsko-Mazurskie Voivodeship
Tel. [phone] or [phone]
e-mail: [email protected]
Sending back the warranty card will allow us to register you in
our database of Twin Bio boiler users and to provide you with
fast and reliable servicing.
IMPORTANT!!!
PLEASE BE AWARE THAT IF YOU DO NOT SEND OR YOU SEND
AN INCORRECTLY FILLED WARRANTY CARD (INCL. CONFIR-
MATION OF BOILER QUALITY AND COMPLETENESS) WITHIN
TWO WEEKS FROM THE BOILER INSTALLATION DATE, BUT NO
LATER THAN WITHIN TWO MONTHS FROM THE PURCHASE
DATE, YOUR WARRANTY FOR THE HEAT EXCHANGER AND
ALL COMPONENTS OF THE BOILER WILL BE VOIDED. LOSING
THE WARRANTY WILL DELAY ANY REPAIRS AND REQUIRE
THE BOILER’S USER TO COVER ALL REPAIR COSTS AND THE
REPAIRMAN’S TRAVEL EXPENSES.
Thank you for understanding.
Yours faithfully,
KOSTRZEWA SERVICE CENTRE

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Experts in heating User Manual Twin Bio - PLV 09.13
Contents
II. Twin Bio User Manual
Foreword ......................................................................................................... ?
1. General ............................................................................................................ ?
2. Scope of delivery .............................................................................................. ?
3. Boiler specifications ......................................................................................... ?
4. Twin Bio boiler design (as a complete heating device) .......................................... ?
5. Design guidelines ............................................................................................. ?
6. Boiler start-up, operation and stop including emergency stop ............................... ?
7. Installation ..................................................................................................... ?
8. Boiler operation and maintenance ..................................................................... ?
9. Important notes, guidelines and tips .................................................................. ?
10. Boiler decommissioning ................................................................................... ?
11. Quick reference guide – Fire and safety ............................................................. ?
12. End notes for installers – SERVICE ..................................................................... ?
13. Example equipment failures and remedies ......................................................... ?

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Experts in heating User Manual Twin Bio - PLV 09.13
1. General | 2. Scope of delivery | 3. Boiler specications
Foreword
The Twin Bio boiler, with maximum power of 16, 24 [kW]
with automatic pellet/oats feeding, and manual wood chip
feeding sets new trends in utilising biological fuel. The Twin
Bio boiler can, without exaggeration, be called a ‘heating
system’, as this one device constitutes the best quality, fully
equipped and automated product. The planar boiler design
with water ‘tongue pipes’ allows for the optimal use of the
device’s heating surface and does not expose the exchanger
section to excessive thermal loads while maintaining
compact dimensions. Our company offers reliable, durable
and cost-effective solutions. The device has the capability to
automatically burn biomass in the form of pellets or pellet-oats
mixture. It is possible to manually load fuel in the form of wood
chips - you can therefore use a variety of biomass fuel types.
A simple and intuitive operation of a boiler/boiler room control
system is also important to the user. The large graphic display
and the ergonomic and clear interface of the boiler control
system make our solutions easy to use.
1. General
The Operation and Maintenance Manual is an integral part
of the boiler and must be provided to the User of this device.
Thedevice installation must conform to the manual, the
relevant standards and good building practices. The boiler
operation conforming to the User Manual guarantees safe
and failure free operation and is a precondition for the
manufacturer’s warranty coverage. The specifications may
change without notice. KOSTRZEWA shall not be held 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:
The Twin Bio boiler is provided on a wooden 1350x900 mm
pallet including:
• boiler heat exchanger;
• Platinum Bio burner (flexible duct, Ø70, length 1 m);
• ceramic cover, feeder chute, optional grate for oats;
• storage hopper 286 l;
• feeder chute to the storage hopper with cap;
• fuel feeder;
• Platinum Bio control;
• cast iron grates for burning wood slabs (13 pcs. – 16 kW;
17pcs. – 24 kW);
• cast iron grate support;
• cleaning tool kit;
• user manual.
3. Boiler specifications
The Twin Bio type boiler is a low temperature boiler with
a three flue gas passes combustion circuit. Its design
is characterised by an appropriate shape and length.
Theadvantages of this solution include its lesser susceptibility
to ash deposits on the exchanger’s walls and baffles.
The ash falls into the ash pan by gravity. This helps the boiler
to achieve great operational parameters: high efficiency,
long life thanks to the appropriate design of the exchanger,
and low emissions of hazardous substances. The boiler was
manufactured in accordance with the EN 303-5:2012 standard.
The basic dimensions of Twin Bio boiler series are showed
in the following diagram (see ‘Twin Bio boiler dimension
diagram’) and the following table (see ‘Twin Bio dimension
data’).

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Experts in heating User Manual Twin Bio - PLV 09.13
3. Boiler specications
Twin Bio boiler dimension data
Table: Twin Bio boiler dimension data
SYMBOL unit TB 16 TB 24
A mm 1383 1383
B mm 1285 1385
C mm 862 862
D mm 789 889
E mm 698 698
F mm 154 154
G mm 1106 1106
H mm 1210 1210
I mm 258 308
J mm 170 222
ØK1 mm 159 159
ØK2 – power supply cal 1 1/2” 1 1/2”
ØK3 – return cal 1 1/2” 1 1/2”
ØK4 – thermal safety
device cal 1/2” 1/2”
ØK5 – drain cal 1/2” 1/2”
Fig. 01. Twin Bio boiler dimension diagram

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Experts in heating User Manual Twin Bio - PLV 09.13
3. Boiler specications
PARAMETER SI Twin Bio 16 Twin Bio 24
Flue draught mbar 0,15-0,25 0,15-0,25
Water capacity dm358 65
Maximum working pressure bar 2 2
Test pressure bar 4 4
Flue gas temperature at nominal power °C 113 136,2
Flue gas temperature at minimum power °C 78,5 81,8
Flue gas mass flow at nominal power g/s 9,42 13,14
Flue gas mass flow at minimum power g/s 7,74 8,21
Flue connector diameter mm 159 159
Boiler flow resistance for 10 K mbar 1,7 3,8
Boiler flow resistance for 20 K mbar 0,5 1,1
Max. Hot water boiler heat output kW 16 24
Hot water boiler nominal heat output kW 14 21
Hot water boiler power range kW 4 – 16 6 – 24
Efficiency at nominal power % 90.8 90.4
Boiler class as per EN 303-5:2012 5 5
Combustion time at nominal power (fuel calorific
value): 18.305 kJ/kg)
h 72 48
Temperature control settings range °C 50-80 50-80
Minimum water temperature at boiler return °C 45 45
Fuel type Class Sawdust granulate (pellets)
made in accordance with EN
303-5:2012 – Class C1
Sawdust granulate (pellets)
made in accordance with EN
303-5:2012 – Class C1
Storage hopper capacity L 286 286
Feed opening dimensions mm 696x456 696x456
Nominal 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 = 15TB x QN ( 1 - 0,3 QH
Qmin
)
• 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.
Minimum hot water storage tank capacity is 300 litres.

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
drzwiczki popielnikowe
drzwiczki załadunkowe
drzwiczki górne
automatyka kotła
palnik
zbiornik
podajnik
zsyp
STB
1.
2.
3.
4.
5.
6.
7.
8.
9.
4. Twin Bio boiler design (as a complete heating device)
Fig. Boiler design
1. ash pan door
2. feed door
3. top door
4. boiler control system
5. burner
6. storage hopper
7. feeder
8. chute
9. STB safety temperature limiter
Fig. Flue gas circulation

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4.A. Boiler body
• inner shell assembly – P265GH (as per DIN EN 10028)
–5mm boiler steel for pressure tanks
• outer shell assembly – S235JR (EN 10025-2)
–generalpurpose common steel, thickness 4 mm
• fire partitions – P265GH (as per DIN EN 10028)
–thickness5 mm
• boiler casing – DC01 – powder painted 0.8 mm steel sheets
• boiler body insulation – mineral wool
Twin Bio 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
Boiler door is made of S235JR (EN 10025-2) 3 mm thick
structural steel. It is fitted as left-side door as standard (itcan
be fitted as right-side door as well). It has double thermal
insulation.
1. thermal insulation
2. thermal insulation
3. rope seal
Fig. Door insulation

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4.C. Top door
This door is located on the upper side of the boiler, under
thecover (dismounting – see 7.C). It allows for easy cleaning
of the exchanger walls and baffles. It has double thermal
insulation. The exchanger’s baffle is fitted into a special groove
in the insulation plate, which closes the flue gas circulation.
4.D. Platinum Bio pellet burner
The locally manufactured Platinum Bio burner is a dedicated
device for solid fuel (wood pellets) combustion. The burner
components in contact with the flame are made of heat
resistant steel. Burner power must be selected on the basis
of the given Twin Bio boiler unit. The following diagram
(see ‘Platinum Bio v02 burner dimension diagram’) and the
following table (see ‘Platinum Bio v02 burner dimension data’)
show standard dimensions of the Platinum Bio v02 burner.
The following table (see ‘Platinum Bio v02 data sheet’) shows
the basic specifications of the Platinum Bio v02 burner. As
standard, the Twin Bio boiler is fitted with a ceramic cover, and
optionally with an additional oats grate (exchanging – see 7.J).
Burner dimension data
Table: Platinum Bio v02 burner dimension data
SYMBOL 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 247,5 247,5
F mm 123,5 123,5
G mm 232 272
H mm 119 119
I mm 119 119
Fig. Top door
Fig. Platinum Bio v02 burner dimension diagram

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4.E. Fuel feeder unit
The locally manufactured fuel feeder is a dedicated system conveying fuel from the storage hopper to the burner.
A - 1595 mm
B - 88 mm
Fig. 02. Feeder dimension diagram
1.
2.
3.
4.
1. feed screw
2. feed duct
3. socket
4. gear motor
Fig. 02. Feeder construction diagram
All electrical connections must conform to the general guidelines on wiring systems, see section 4.H. ‘Wiring system’.

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4.F. Fuel storage hopper
KOSTRZEWA recommends a 286 l storage hopper for the efficient and effective feeding of Platinum Bio burners. It is made of DX01
galvanised sheets. The storage hopper is shipped disassembled (in a cardboard box). A swivel chute is mounted on the storage
hopper base for its easy positioning by the boiler.
Hopper location possibilities:
Fig. 02. Twin Bio boiler hopper location possibilities

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4.G. 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.
Alarm is displayed. Check and remove the cause of boiler
overheating. Allow the boiler to cool, remove the STB nut
andpress the button.
The boiler temperature sensor [3] and the STB [4] must
be installed in the boiler temperature sensor casing [7].
Thesensors must be fixed securely.
pok
nak
czu
czu
kan
ele
ogr
bez
obu
tem
1.
2.
3.
4.
5.
6.
7.
WARNING!!!
Incorrect boiler sensor installation may result
inoverheating and faulty system operation.
1. safety temperature limiter (STB)
switch cover
2. safety temperature limiter (STB)
mounting nut
3. boiler temperature sensor
4. safety temperature limiter STB
temperature sensor
5. electrical cable duct
6. safety temperature limiter (STB)
7. boiler temperature sensor
housing
Fig. Sensors
4.H. Wiring system
General guidelines on the wiring systems of boiler control,
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.
WARNING!!!
Using the socket without
aprotective conductor contact
may result in electric shock!

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Experts in heating User Manual Twin Bio - PLV 09.13
4. Twin Bio boiler design
4. The device (boiler/control system) must be connected
toan individual circuit with an overcurrent protection
andaresidual current device.
NO OTHER EQUIPMENT MAY BE CONNECTED
TOTHEBOILER’S ELECTRICAL LINE.
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 must not be bent or broken and the insulation
must 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.
overcurrent
protection mustbe
selected specically
for the installation
boiler T
boiler T
burner T
room T central heating pump
STB
N1
N1 N N PE PE
PE
N
N
L
L
N N
PE
PE
12345 7 6
N N N N PE PE PE
PE
Pch
domestic hot water pump
storage hopper
feed duct
brown
230V POWER SUPPLY
blue
yellow-green
dhw T
dhwT
GND GND
foto
room T
dhwP
igniter
burner wire
Pch
blower
for hopper
for burner
dhw P
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.I. Twin Bio control system
A detailed description of the control system functions
isincluded in the Platinum Bio control User Manual.
Fig. Platinum Bio control system
Fig. Main board from ver. L5B v10.4/10.5 Platinum Bio

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Experts in heating User Manual Twin Bio - PLV 09.13
5. Design guidelines
5. Design guidelines
The installation and all connections must
conform to 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 fault 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. The following diagram (see ‘Boiler location in the
boiler room - dimension diagram’) and the table (see ‘Boiler
dimension data’) shows recommended installation space for
the boiler and its accessories.
Table ‘Boiler room dimension data’
Boiler room dimensions
Marking unit Values
A1 mm ≥ 500
B1 mm ≥ 700
C1 mm ≥ 500
H1 mm ≥ 2000
g mm ≥50
Fig. Boiler location in the boiler room – dimension diagram

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Experts in heating User Manual Twin Bio - PLV 09.13
5. Design guidelines
5.B. Boiler room requirements
a) Boiler foundation min. 0.05 m
Boiler foundation requirements:
• the foundation must protrude over the boiler room floor;
• the foundation edges must be secured with steel angle
sections.
b) Boiler room floor
Boiler room floor requirements:
• the boiler room must be made of non-flammable materials,
resistant to extreme temperature changes and impact;
• the floor must descend in the well direction.
c) Boiler room ventilation
Boiler room ventilation requirements:
• do not use mechanical ventilation systems in the room with
solid fuel furnace if the combustion air is supplied directly
from the room and the flue gas is discharged gravitationally
via a duct from the device;
• the boiler room must be fitted with a ventilation duct with
a cross section of at least 50% of the flue cross sectional
area, min. 20x20 cm2;
• the boiler room must be fitted with a ventilation duct with
across section of at least 25% of the flue cross sectional
area with the outlet under the boiler room ceiling;
• the outlet duct cross section must be min. 14x14 cm2;
• the vents must be made of non-flammable materials.
5.C. Hydraulic system requirements
• the hydraulic system must be made in accordance with the
good building practices, relevant standards and regulations,
and the design input
• the boiler may operate in a sealed heating system (sealed
diaphragm tank) provided that the boiler supply and return
line is fitted with a dual action relief valve
• a pressure reducer must be installed with a relief valve to
avoid safety valve opening in case of a rapid increase in
boiler water pressure
• an expansion tank must be installed in the highest point of
the heating system and protected against frost
• the expansion tank should be installed at the boiler return
• to guarantee proper working conditions and failure free
boiler operation, ensure minimum temperature at the boiler
return by installing the boiler pump with a mixing valve
(boiler mixing system)*
*Water temperature at the boiler return must be min. 45°C
to prevent boiler corrosion as a result of undesirable and
excessive flue gas condensation in the boiler. The boiler
circulation pump must be fitted with a control valve.
The pump output must be approx. 40÷50% of the nominal
water flow through the boiler. The boiler circuit design must
guarantee the difference in temperature between the supply
and the return of max. 15°C.
CAUTION!
The boiler pump must be installed between two cut-off
valves. To protect the pump against high pressure
difference between the suction and discharge:
• install the boiler pump at the system return
(especially in systems with high water capacity,
where the discharge pressure is very high);
• protect the boiler pump at the suction against low
pressure.

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Experts in heating User Manual Twin Bio - PLV 09.13
5. Design guidelines
MMM
domestic hot water
expansion tank expansion tank
water supply system
Platinum Bio control
GSM-Module
Central heating
temperature sensor
Central heating
temperature sensor
Central heating
temperature sensor
Domestic hot water
temperature sensor
Room temperature sensor
Room temperature sensor
Room temperature sensor
Room temperature sensor
Optional
Expansion modules
CAUTION! System expansion requires additional modules CAUTION! The diagram does not include all system components
Twin Bio boiler
Optional

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Experts in heating User Manual Twin Bio - PLV 09.13
5. Design guidelines
Optional
domestic hot water
Platinum Bio control
expansion tank
water supply system
buer
tank
MMM
Expansion modules Expansion modules
bottom buer tank temperature sensor top buer tank temperature sensor
CAUTION! System expansion requires additional modules CAUTION! The diagram does not include all system components
Room temperature sensor
Room temperature sensor
Room temperature sensor
Room temperature sensor
Central heating
temperature sensor
Central heating
temperature sensor
Central heating
temperature sensor
GSM-Module
Optional
Twin Bio boiler
expansion tank
Domestic hot water
temperature sensor

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Experts in heating User Manual Twin Bio - PLV 09.13
5. Design guidelines
Optional
Optional
buer
tank
MMM
Platinum Bio control
expansion tank
Expansion modulesExpansion modulesExpansion modules
Room temperature sensor
Room temperature sensor
Room temperature sensor
Room temperature sensor
Central heating
temperature sensor
Central heating
temperature sensor
Central heating
temperature sensor
GSM-Module
Twin Bio boiler
bottom
buer tank
temperature sensor
bottom buer tank temperature sensor
top
buer tank
temperature sensor
top buer tank temperature sensor
top buer tank temperature sensor
CAUTION! System expansion requires additional modules CAUTION! The diagram does not include all system components
expansion tank
Domestic hot water
temperature sensor domestic
hot water
expansion tank
water supply system