Kozlusan Propel 40 User manual

Green Energy Engineering Ltd, 198 Lurgan Road, Dromore, Craigavon, Co.Down, Northern Ireland. BT25 1HL
Tel: [phone] Fax: [phone] Email: [e-mail]
MODEL: PROPEL
BE SURE TO READ THIS MANUAL AND KEEP IT NEAR THE HEATING SYSTEM
FOR EASY REFERENCE

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TABLE OF CONTENTS
Section Page
Introduction 3
Safety instructions 4
How to biomass system Works 6
Specifications 8
Installation 11
Operating the Heating system 14
Maintenance Overview 15
Troubleshooting 18
Installation Scheme 20
Electrical Scheme 22

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INTRODUCTION
Congratulations on your purchase of a biomassfired heating system from KOZLUSAN HEATING
SYSTEMS.
With proper installation and maintenance, your heating system will provide years of non-polluting,
low cost heat for your home.
To insure correct installation and safe operation of your Kozlusan biomass heating system, you
should:

Hire a licensed heating contractor to install the biomass heating system and integrate it with
your heating system. This contractor should have experience with installation and operation of gas, oil,
and solid fuel heating appliances and be familiar with local building codes, fire codes and other
regulations.
Read this manual and learn how to safely operate and maintain your Kolzusan biomass heating
system.
The assembling and start up (setting) of Kozlusan biomass boiler has to be carried out by
our own customer service or by authorized qualified technicians.
Do not use any other fuels than specified below:
Ö-Norm M 7135
DIN-PLUS Norm
SWISSPELLET
Diameter: 6 mm Length: 5-30 mm (20% - 45 mm)
DD: CEN / TS 14961 : 2005
Only this way low-emission, economical and reliable operation can be guaranteed. Any disregard of
these requisites leads to immediate expiry of warranty.

The pellets must be stored in dry conditions to enable them to be transported without problems
and to achieve trouble-free operation with optimum combustion combined with the greatest possible
efficiency.
We do not assume any liability for unauthorized technical modifications, and resulting damages
are not covered by warranty.
Operational procedures or alterations of any sort, carried out by unauthorized persons, as well as
disregarding the general guidelines and the indicated safety instructions as specified here, result in
immediate termination of all warranty claims.
Please read the safety instructions below before operating the system. Disregarding the safety
instructions may lead to injuries, perilous situations or damage the pellet boiler.

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SAFETY INSTRUCTIONS
The pellet heater system may only be operated be in faultless technical condition. Malfunctions
and damage which affect or could affect safety must be corrected immediately by our trained
personnel.
The assembly may only be conducted by our customer service, or by a certified specialist. The
system is equipped with rotating parts, which move with a relatively large turning movement
(crushing hazard).
Under the casing and in the terminal box there are voltaged components. Do not remove the casing
or terminal box.
Never open the inspection openings of the boiler while in continuous operation, hot exhaust gas
and dust may escape.
The system should be turned off before the implementation of maintenance work. Wait until the
pellet boiler has cooled down (check the temperature on the display).
The boiler needs to be switched off before carrying out the cleaning of the chimney. Wait until the
pellets have burned down completely (approx. 20 minutes –danger of explosion through back up of
exhaust gas.
Never pour flammable liquids into the burner.
Never perform independent repair work on our system, call trained personnel!
Put a signboard into the heating room that forbids to smoke or to use open light or fire.
A certified fire extinguisher must be installed in the boiler room.
Ensure enough air supply in the heating room.
Secure the boiler room against unauthorized access, especially by children.
Once a month, test the boiler doors and the water connections for leaks and damage.
Once a year, test the safety temperature limiter.
Safety and monitoring devices may not be removed, bypassed or taken out of service in any other
way.

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Always wear a dust mask when cleaning the system and when removing ashes to avoid damages to
your health.
When setting the domestic water temperature above 60 °C, you have to ensure that the hot water is
mixed with cold water to avoid scald.
The pellet heater system may only be set up and operated in heating and plant rooms which
comply with legal requirements.
Provide an appropriate air relief valve on top of the boiler.
Annual control of safety devices by a specialist.
Regular control of expansion tank by a specialist.
Regular control of pellet feeding devices, automatic ignition devices and feeding features.
Please note that even when the system is turned off, different functions are in operation. (For
example the anti-freeze protective device; pumps and mixers are moved periodically during the night
avoid an accumulation of the storings). To ensure that no electricity runs through the system, take
off the system from electricity.
Make sure that the return temperature does not drop below 50 °C. Disregarding leads to expiry of
warranty!

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How the biomass heating system works
The Kozlusan biomass heating system produces few emissions and achieves a high level of heating
efficiency because of its unique design. The fully automated fuel delivery is „poured from top‟into
an air fed burn pot where the fuel is self ignited before the full modulation control system controls
the burn for minimum emissions with maximum heat output.
To understand how the Kozlusan heating system works, have a to look at the flow of air, fuel
and gases through the heating system and the transfer of heat from the superheated gases to
the thermal transfer fluid. We also need to understand some of the terminology used to
describe the systems operation;
Air Flow through the Biomass heating system
1. Fuel is fed from the fuel store via an auger. The fuel is poured from the top into the cylindrical burn
pot to maintain a physical separation between the fuel store and the fuel feed. There is sucktion fan
availabe for the combustion. Various sensors measure temperature in the boiler (a thermostat that
works in water) a flue gas temperature sensor (probe in the chimney), outside temperature sensor (the
weather or room temperature) and a safety cut off temperature sensor to protect against overheating
(high limit stat).
2. As air flows through the firebox, its temperature rises to nearly 1000º C.
3. This superheated air rises upwards and then through a series of heat tubes where the heat is
transferred into the thermal fluid.

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4. By the time the exhaust air reaches the flue, most of its thermal energy has been absorbed. The final
temperature of the escaping flue gas is less than 175° C.
Fluid Flow through the Heating system
1. Kozlusan heating systems recommends a mixture of water and propylene glycol as a heat transfer
fluid. Glycol is a non-toxic solution that works like the antifreeze in your car to prevent corrosion and
freezing.
2. A pump pushes fluid around the heat transfer jacket which absorbs heat from the combustion gases.
The fluid exits the internal manifold at about 80-85º C.
3. The fluid flows past an aquastat (water thermostat) that regulates the burn rate of the heating system
in conjunction with the flue gas temperature sensor that measure the temperature in the flue. This
information is used to determine the amount of air and fuel being used to ensure efficient heat transfer
and to ensure the fan does not simply blow the heat up the flue. The heated fluid is used to transfers
the heated fluid to your home system where it provides warmth to your home, garage, basement and
other structures; preheats your domestic hot water; heats your pool; and/or melts snow on your
driveway.
4. Having transferred the heat to the home system, the fluid exits the external heat exchanger and
repeats its path through the internal manifold.

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SPECIFICATIONS
Propel-25
Propel 40

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FOR PROPEL 25
FOR PROPEL 40
AIR ELIMINATOR VALVE &
BLOW OFF
AIR ELIMINATOR VALVE &
BLOW OFF

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TECHNICAL DATA
PROPEL 25
PROPEL 40
Max. Heat Performance(kW)
25
40
Min. Heat Performance (kW)
5
8
Max. Boiler Temperature(°C)
90
90
Max. Utility Water Temperature(°C)
80
80
Max. Operating Pressure (bar)
3
3
Test Pressure
4,3
4,3
Max. Suction Flow Rate Of Flue(m³/h)
60
100
Exhaust Fan sucktion pressure at full
load(pascal)
-7
-10
Dimensions
Total Weight(kg)
420
480
Water Content (lt)
65
127
Bunker Capacity(kg)
220
240
Ash Box-Useable(lt)
20
20
Water & Chimney Connections
Hot Water Outlet
1’’
1’’
Cold Water Inlet
1’’
1’’
Safety Outlet
¾’’
¾’’
Boiler Emptying (Mains Water Inlet)
¾’’
¾’’
Chimney Diameter(mm)
128
128

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INSTALLATION
Your Kozlusan heating system must be installed by a qualified heating contractor who is thoroughly
familiar with gas, oil, and solid fuel heating appliances. Also, you must be sure to comply with local
building codes, fire codes and other regulations when installing the heating system.
Safety Practices
Hire a licensed contractor with experience in design and installation automated heating systems.
Comply with local building codes, fire codes and other regulations when installing this heating
system.
Minimum clearances to combustible surfaces. 1000mm circumference.
Make sure to identify sources of make-up air in the room where the heating system is located. The
Kozlusan Heating System, exhaust fans and other appliances all draw air from the room. Be certain
there is an adequate source of fresh air (ventilation) to offset these demands or you may create
negative pressure in the room and prevent the heating system of combustion and create draft problems
in your flue.
Connect the heating system to a properly installed and operating chimney and vent it to the
outside.
Be sure your chimney is safely constructed and in good repair. Before installation, have the
chimney inspected by a qualified inspector.
Be sure to provide thermal spike protection for the heating system
(see Wiring and Controls pg. 30).
DO NOT connect the heating system to an aluminum Type B gas vent.
DO NOT vent the heating system to another room or inside a building.
DO NOT share a chimney flue with another appliance.
DO NOT install the heating system in a mobile home or trailer. Instead, install the heating system
outside in a covered enclosure and pipe the hot water into the mobile home.

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Chimney Installation
A chimney performs two functions: it removes smoke and flue gases from the heating system, and it
provides “draft” for the fire. Draft is the term used to describe the suction that occurs when hot air
rises and creates a vacuum in the firebox. That vacuum draws fresh air into the firebox and feeds
combustion of the wood. No heating system can operate properly without adequate draft.
Proper installation of the chimney flue is critical to the performance of your Kozlusan Heating System.
The majority of problems encountered after installation are attributable to a flue that is improperly
sized or otherwise provides inadequate draft to the heating system.
You may connect the Kozlusan Heating System to an existing flue or chimney subject to the following
conditions.
1. A qualified professional has inspected, repaired (if necessary), thoroughly cleaned the chimney and
determined it is suitable for use with a residential heating appliance that burns solid fuel.
2. The chimney or flue should be at least 3-4 m tall and sized correctly for the Kozlusan Heating
System model installed.
3. Do not share a flue with another heating system, appliance or fireplace. Do not use a flue that
already provides make-up air to the cellar or basement.
4. Tightly close the cleanout opening in the base of the chimney.
Frost & Overheat Protection
The heating system is leak-tested at the factory during final assembly, and the heat transfer fluid
drained for shipment. The recommended solution is a mix of 30% propylene glycol to 70% water
unless you are located in a very cold climate, or you plan to leave the heating system unused for a long
period of time. A 30% solution of propylene glycol is adequate to lower the freezing point to -13º C
and raise the boiling point to 102º C.
CAUTION: DO NOT use ethylene glycol-based (automotive antifreeze) coolant in your Kozlusan
Heating system or in your home’s heating system. Always use propylene glycol-based coolants.

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OPERATING THE HEATING SYSTEM
Safety Practices
1. Keep fuel dry.
2. DO NOT use chemicals, gasoline, lantern fuel, kerosene, charcoal lighter fluid or other flammable
liquids to start or “freshen up” the fire, always let the automatic ignition start the fire.
3. DO NOT open the access doors unless the system is off.
4. DO NOT BURN anything other than pellets in this heating system.
WARNING EXPLOSIVE GASES
Gasses formed during solid-fuel combustion may cause a small explosion when the
heating system is refueled.
Always clean burner and remove access pellets before refueling.
5. Use the tools provided if it is necessary to rake ashes or unburnt fuel from the burnpot
6. DO NOT open the access door during operation try to add.
7. DO NOT throw fuel into the burnpot via the access door
8. Keep the access door closed tight except when tending the burnpot.
9. Keep the heating system area clear of combustible materials, gasoline, and other flammable vapors
or liquids.
10. DO NOT forget to regularly empty the ash collection box.
11. DO NOT store fuel or combustables within the appliance installation clearances or within the
space required for fueling, ash removal, and other routine maintenance operations.
12. DO NOT allow anyone who is under the influence of drugs or alcohol or is unfamiliar with the
correct operation of the heating system to add fuel or otherwise use this heating system.
13. DO NOT let children play around the heating system when in operation. Alert all persons to the
hazards of hot heating system surfaces.
14. For adjustments of digital control panel, please read the “TCNet Boiler Controller Manual”
that is provided together with the boiler you bought.

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MAINTENANCE OVERVIEW
Safety Practices
1. Check your fuel supply regularly and allow suitable time for deliveies –try not to run out of fuel
2. Check the ash box and empty regularly.
3. Inspect chimney, flue pipes, flue pipe joints, and flue pipe seals regularly to ensure that smoke and
flue gases are not drawn into, and circulated by, your home‟s air circulation system. If you observe
rust or any smoke leakage, replace the pipe immediately.
4. Exercise the safety relief valve at least once a year.
5. Check the water pressure is between 1 and 2 bar –if too low top up system with more water.
6. DO NOT clean heating system surfaces when the unit is hot. Wait until the unit cools and then
clean with soap and water.
ATTENTION
This work may only be performed by certified specialists or by Kozlusan customer
service personel. The boiler requires a minimum of 1 anual service by certified personel
to maintain warranty guarantee!
Periodical Maintenance
Brushing Burnpot
Take out front door cover Unloose the star handles Remove burnpot door





Brush inside the burnpot and remove the flue ashes in the combustion chamber with vacuum cleaner

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Cleaning the residual ashes below exhaust fan





Unloose the wing nuts to take out door
Via the help of a vacuum cleaner, remove the residual ashes
ATTENTION
We recommend to let the boiler cool down for at least 6-8 hours later switching off the
system before proceeding with these works.
Yearly Maintenance
Cleaning Heat exchanger and baffles
Remove outer body cover and internal cover insulation





Unscrew all bolts and remove cover to access baffle tubes and cleaning springs
Remove baffles and springs, clean components and vacuum all chambers

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Cleaning of secondary air channels in burnpot and the base of burnpot





Disconnect hopper from boiler and unscrew internal pellet feed auger from cumbustion chamber



Unscrew burnpot from cumbustion chamber and remove for cleaning
In Addition
Inspection of the grate cleaning lever
Inspection of gaskets on the combustion chamber door and ash box
Operational test of the heat exchanger cleaning
Cleaning of the exhaust sensor
Test the ignitor tube for residue
Test upper and lower parts of the burner for damage and leaks
Test the intervals of the sensors (grate motor, separator)
Lubrication of the heat exchanger cleaning drive and grate bar
Exhaust gas measurement
Maintenance every 3 years
Maintenance volume from the yearly maintenance and the following additional work
Visual check and cleaning of the hoist basket lever for the heat exchanger cleaning:
In addition, remove the boiler cover, vacuum out the existing ashes and check the function of the hoist
basket lever. According to function control, using caulking strip newly caulk the boiler cover and
reassemble.
Cleaning of secondary air channels in burnpot and the base of burnpot.
Detach the hopper tank from the boiler firstly. Then remove the burnpot carefully.
Test run of all electrical equipment

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TROUBLESHOOTING
FAILURE
CAUSE
REMEDY
Dark Screen
Emergency switch turned OFF
Turn it ON
Safety Temperature Limiter has relased
Let the boiler coll down to 80°C
Reset the safety temperature limiter and
search for cause (e.g. defect pump)
Error:Out of Pellets
No more pellets in fuel hooper
Refill
Defective pellet level sensor
>Inform customer service
Error :Ignitions failed
Too cold ambient temperature
The ambient temperature should be 0-45°C
for proper working
Low quality pellets
Change pellets
Ignition device malfunction
>Inform customer service
Exhaust fan malfunction
>Inform customer service
Error:Overtemperature detected
Boiler temperature exceed 95°C
Let the boiler cool down
Circulation pump malfunction
>Inform customer service
Defective controlled board
>Inform customer service
Defective temperature sensor
>Inform customer service
Error:Back burning to auger
The temperature of the augerexceeded
the limit thermostat’s value
Back burning to auger
Defective back burning detection
thermostat
>Inform customer service
Lost connectivity between the controller
and back burning detection thermostat
>Inform customer service
Error:Memory allocation error
Problem occured in the control panel
Reset controller
İf the problem persists after reset
>Inform customer service
Error:FLASH checksum error
Problem occured in the control panel
Reset controller
İf the problem persists after reset
>Inform customer service
Error:FILESYSTEM error
Problem occured in the control panel
Reset controller
İf the problem persists after reset
>Inform customer service
Error:Sensor malfunction(sensor no)
T3:boiler-defective sensor
>Inform customer service
T2:weather- defective sensor
>Inform customer service
T1:buffer tank- defective sensor
>Inform customer service
Tc1:exhaust- defective sensor
>Inform customer service

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TROUBLESHOOTING
FAILURE
CAUSE
REMEDY
Burner creaks
Burner is new (wait)
Chimney is sweating
Poor insulation
Insulate the chimney well
Low exhaust temperature
Increase the minimum power/ the boiler
temp.. , it may be necessary to restore the
chimney
Pellet boiler is sweating
Check return flow increase at external
control
Heating circuits do not work/
Heating system is slow to heat up
The boiler is on utility water operation mode
Change operating mode
Hydraulic problem
Contact installer
Altered heating curve
Adjust
Heating circuit pump is defect
>Inform customer service
Air in the system
Bleed air from system
Pumps run on wrong ration speed
>Inform customer service
High temperature value on screen
No water in boiler
Fill the system with sufficient water
Circulation pump is not working
Active/Inform customer service
Air in the system /boiler
Remove /emliminate/Inform customer
service
Defective boiler temperature sensor
>Inform customer service

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