Maga DP25 PREMIUM User manual

1
MANUAL FORINSTALATIONAND OPERATIONOF
MAGA PELLETAND WOODBOILER
DP25PREMIUM
Fig.1 MAGA DP25 PREMIUM
Dear customer, thank you for the purchasing of our product. Please, follow the
manual in order to be 100% satisfied with its operation and maintenance.
Team MAGA

MAGA s.r.o., S. Kollára 86, Čerenčany 979 01, Slovak Republic.
[phone], [e-mail],www.magasro.sk Made in Slovakia
2
CONTENT
1 BOILER USE AND ADVANTAGES ..............................................................................................................................3
2 ACCESSORIES ..............................................................................................................................................................4
3 BOILER CONSTRUCTION ...........................................................................................................................................5
3.1 BOILER BODY ......................................................................................................................................................5
3.2 PELLET SILO .........................................................................................................................................................7
3.3 PELLET BURNER ..................................................................................................................................................9
4 OPERATION, REGULATION AND SAFETY ELEMENTS .........................................................................................10
4.1 REGULATION ELEMENTS.................................................................................................................................10
4.2 SAFETY FEATURES ............................................................................................................................................10
5 INSTALATION ............................................................................................................................................................13
5.1 STANDARDS AND REGULATIONS...................................................................................................................13
5.2 BOILER PLACEMENT ........................................................................................................................................14
6 STARTUP INSTRUCTIONS FOR CONTRACTUAL SERVICE ORGANIZATION .....................................................18
6.1 BEFORE-START CHECK.....................................................................................................................................18
6.2 FIRST BOILER OPERATION AND OPERATOR TRAINING .............................................................................19
6.3 BOILER OPERATION .........................................................................................................................................20
7 BOILER CLEANING....................................................................................................................................................22
7.1 BOILER BODY CLEANING .................................................................................................................................22
7.2 PELLET BURNER CLEANING ............................................................................................................................24
8 SAFETY REGULATIONS ............................................................................................................................................27
9 INSTRUCTIONS FOR DISPOSAL OF THE PRODUCT AFTER ITS SERVICE LIFE..................................................28
11 REMAINING RISKS AND THEIR PREVENTION ....................................................................................................30
12 REASONS AND SOLUTIONS OF BOILER BURNER MAL-FUNCTIONING .........................................................32
13 WARRANTY AND GUARANTEE ............................................................................................................................34
LETTER OF GUARANTEE .............................................................................................................................................35
WARRANTY AND GUARANTEE CONDITIONS..........................................................................................................36
RECORD OF GUARANTEE REPAIRS ...........................................................................................................................38

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1 BOILERUSE AND ADVANTAGES
Hot water boiler MAGA DP25 Premium is designed for heating of dwellings,
houses, cottages and other objects demands on the heat source (heating + hot water
system) shall not exceed 20 kW. The recommended fuel is wood pellets of a diameter of
6-8 mm, which are transported by the feeder from the autonomous container into the
combustion chamber. This allows time-saving and user friendly operation and
maintanance. The high efficiency can be achieved by low operating costs. Moreover,
automatic ignition of fuel in the focus guarantees very low emission burden on the
surrounding environment (in the boiler properly set it is practically a "smokeless"
incineration). Regulator is adapted for connection to external control (room thermostat,
equithermic regulation), including control of the circulating pump.
MAGA DP 25 solid fuel boilers are designed for combustion of wood, wood
briquettes in manual application, or burning of 6 mm diameter wood pellets in
automatic mode. Nominal output for DP 25 steel boilers is 20 kW for manual loading of
wood and 3-20 kW for automatic pellet operation. The boiler body is equipped with a
dual heat exchanger (vertical tubular and horizontal vane) which ensures optimal heat
transfer to the system. High quality insulating materials minimize heat losses and
contribute significantly to the high thermal efficiency of the entire facility 94.5 %.
The boilers are fitted with a built-in cooling loop and can be used in both forced
and self-draining systems. Very good price and short delivery times! Of course, the
products we supply are trouble-free and economical operation, low operating costs and
reliability. All of our energy-efficient systems are innovative and environmentally
friendly.

MAGA s.r.o., S. Kollára 86, Čerenčany 979 01, Slovak Republic.
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2 ACCESSORIES
Maga pellet boiler setconsists of following fundamental parts:
A. Basicparts
1. Boiler body (incl. ash tray, cleaning instruments –rounded stick and sharp-
scratch stick)
2. Electronic regulator
3. Pellet burner
4. Pellet feeder (tube, engine, plastic hose with steel fitting to pellet burner)
5. User manual for boiler and regulator
6. Use manual for electronic controler
7. Manufacturer stick (grey) with basic manufacturing data incl. serial No.
B. Reccomended Accessories:
1. EcoNet 3000 –internet module (boiler control online web application for
online operation and distant service
2. The remote room control EcoSTER 200 (boiler operation without the need
for physical presence in the boiler room)
3. Water accumulation tank –buffer of min. volume 800 litres.
Please, make sure your boiler set is complete!
Please keep the manual for installation and operation, as well as all required
document-ation, if necessary, to be able to use them at any time. In the case of
moving or selling the device it is necessary to pass new user/owner, with all the
documents.
Symbols used
This manual contains the following graphic symbols:
- This symbol indicates useful information and reports
-This symbol means important information regarding the protection of life and
health of people and pets or property damage
WARNING: Used symbols are marked with relevant information in the manual.
However the user to remove the obligation to familiarize themselves and comply with
instructions not to designate using graphic symbols!

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3 BOILERCONSTRUCTION
3.1 BOILER BODY
Under-pressure parts of boiler correspond to requirements of Standard EN 303-5: 2012
-Boilers for central heating - Part 5: boilers for central heating, solid fuel, with manual
or automaticdelivery of output up to 300 kW.
The basic parts of DP boiler are: a boiler body, a pellet burner, pellet feeder and
electronic devices. The body is welded from steel plates. All parts of the boiler body, in
contact with the flame and combustion products, are made of metal sheet of thickness 5
mm. The Heat exchanger is tubular with economizers.
Vertical pellet heat exchanger is positioned in the back side of the boiler body
which is connected to the pellet burner chamber situated on the bottom part. The top
part of the boiler includes the horizontal heat exchanger for both pellets and wood. This
is the only part of the DP boiler common for both fuels. Unburned fuel residues fall
through into the ash collector at the bottom of the chamber. Automatically operated
pellet burner controls the air intake, fuel, intensity of burning, ignition and extinction
according to the set parameters.
The proper functioning of pellet combustion is conditioned by a slight negative pressure
in the combustion chamber.
There is an ashtray on the bottom of the combustion chamber. The boiler is feeded
by a pellet screw-feeder from the pellet silo.
The combustion air fan is located inside a compact pellet burner. The heating water
inlet is located at the rear side of the boiler with external thread G 6/4 '' and outlet
located on the top of the boiler to be connected with the heating circuit. Thread inlet at
the top rear G 1/2" function is for the installation of the drain valve.
The chimney is situated in the rear upper part of the boiler there is a chimney for
flue gas discharge into the chimney in horizontal position.
The steel heat exchanger and its lid are insulated with harmless insulation, which
reduces heat loss to the environment. The steel shell of the boiler is color-treated with
powder coating.
The detailed technical parameters are shown in the table Tab.1

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Tab.1 Technic parameters of boiler DP25
DP 25
Dimensions: A
mm
1055
B
mm
745
C
mm
1515
D
mm
460
E
mm
163
F
mm
1220
G
mm
1145
H
mm
285
Power (nominal)pellet
kW
17 or 27
Max. Power pellet
kW
20/27
Upper fuel chamber capacity
l
65
Operational chimney flow
Pa
15-20
Max. Operational water pressure
MPa
0.2
Boiler weight
kg
427
Chimney outlet diameter
mm
159
Water volume
l
89
Connection
6/4“
Heat efficiency
%
94.5
Fuel required
Wood pellets 6 mm
Max. wood length ( ø 60-120 mm)
mm
500
Burners el. consumption
W
100
Pellet silo
l
250, 600, 900

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3.2 PELLET SILO
Pellet silo is another standard part of the boiler pellet silo set, standardly of
volume of 600 liters. There are also additional volumes as 330 or 900 liters avialable.
.
Fig. 2 Set of pellet silo
Single parts need to be connected in the numeric order according the figure 7.
Parts with the same numbers need to be completed at on time (6-6, 9-9). Put the cover
on the top after feeding the silo with pellets.
Pellet silo-tank is not intended for liquid fuel. The tank is designed for pellet
or granules of diameter 6-8 mm according to current EN standards. When using a
fuel that does not meet the standards, the manufacturer is not responsible for the
functionality of the device and is not responsible for any damages caused by
operation of the boiler.

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Fig. 3 Assembly of pellet feeder. 1 oven tray, 2.nut, 3.screw, 4 spring, 5 bolt, 6.screw ,
7.rod, 8 screw, 9. Gearbox with engine motor
For proper operation of the feeder must be inserted through the opening to the bottom
(9), and need to be fixed by holder (4). Feeder need to be turned up side by open side.
Fig. 4 Ending of pellet feeder

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Fig. 5 Pellet tank dimensions 600l
3.3 PELLET BURNER
Fundamental part of the boiler is the pellet burner series PB 25/35 Premium. Pellet
burner need to be pushed into the boiler door and fitted by enclosed screws. To the top
of the burner need to be connected with the tube of the feeder. This have to be done
with all the types of burners.
PB 25/35 PREMIUM
Type Premium also requires the involvement of the relevant cables and a water
temperature sensor. Regulator panel touch screen is usually placed on the wall next to
the boiler.
Fig.6 PB 25/35 PREMIUM, Touch-screen electronig regulator

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4 OPERATION,REGULATIONANDSAFETYELEMENTS
The combined boiler DP25 is equipped with a pellet burner control unit in a pellet
burner to ensure smooth operation of the system.
When switching to pellet mode (pellet indicator light is on), the pellet burner is
automatically put into operation after burning wood in the combustion chamber. After
switching back to the combustion mode, it is necessary to:
1. Turn OFF the pellet burner.
2. Switch ON wood button (LED diode - wood)
4.1 REGULATION ELEMENTS
Boiler regulator setting ecoTouch 850 enables setting of:
• boiler water outlet temperature
• Auto mode Fuel feeder and ventilator
• parameters for the setback mode
• Operation of feeder and fan hand
• The flow temperature of the circulating pump (Central heating)
• The storage tank
• Control pumps for hot
The controller is equipped with an input for room thermostat.
The external regulator - for boiler controller can be connected (potential-free) normal
room thermostat. The thermostat is connected by opening the controller box located at
the bottom part behind the of a burner screw. There are also slots for connection of the
pump.
4.2 SAFETY FEATURES
STB emergency thermostat
The STB safety thermostat represents the protection of the boiler against
overheating. After heating the boiler to a temperature above 95 ° C, the thermostat
switches off, thereby interrupting the power supply to the fuel substation. The boiler
output instantly decreases. To re-start the boiler it is necessary to unscrew the cover and
mechanically push the pin.

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Fig. 8 STB thermostatic protection
Thermal protection of the burner
A temperature sensor connected to the burner control unit is located in the burner body.
In the event of overheating above 70 ° C, an alarm condition and an interruption of the
fuel supply to the burner
Photosensor
The photosensors monitors the flame intensity in the combustion chamber. In the event
of a decrease in light intensity, the burner is extinguished and cleaned. It does not
recommence when the heat demand occurs.
Fig. 9 Photosensor placement in the burner
Motor thermal protection
It is part of the engine and serves to protect it from burning in the event of a blockage of
the fuel feeder.
The boiler can not be operated properly without required chimney draft!

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STB fuse protects a controller against high voltage and short curcuit. It consists of a
tubular glass fuse STB 3.15 A, which after melting stops the feeder –fuel supply is
stopped. Burner then burns out.

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5 INSTALATION
Instalation is provided only by the licenced companies. Instalation by other than
licenced people might result into warranty refusal from the manufacturer.
5.1 STANDARDS AND REGULATIONS
Solid fuel boiler can be installed by a firm authorized to mount this device. The
instalation have to be done according the project respecting the current official
standards. The heating system has to be filled with water which meets the requirements
of STN 07 7401: 1992 and its hardness must not exceed the required parameters.
Tab 2 Water hardness
Hardness
mmol/l
1
Ca2+
mmol/l
0.3
Total concentration of Fe + Mn
mg/l
0.3 (recommended value)
a) Heating system
STN 06 0310 central heating, designing and assembly.
STN 06 0830 Safety set up for central heating and hot water.
STN 07 7401 Water and steam for thermal energy facilities with a working pressure up
to 8 MPa.
STN EN 303-5:2012 Boilers for central heating - Part 5: boilers for central heating,
solid fuel, with manual or automatic feed and nominal heat output maximum 300 kW -
Terminology, requirements, testing and marking.
b) Chimney
STN 06 1610 Parts of flue household appliances.
STN 73 4201 Designing the chimneys and flues.
c)Fire regulations
STN 06 1008 Fire safety of heating equipment.
STN 73 0823 Fire technical properties of materials. Flammability levels of building
materials.
STN 73 0861 Fire safety of buildings. Flammability Testing of building materials. Non-
combustible materials.
EN 60 335-1A55: 1997 Safety of power. appliances for household and similar purposes.
d) Mains
STN 33 0160 Electrotechnical regulations of labeling electrical terminals. objects.
Implementing regulations

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STN 33 2000-4-41 Protection against electric shock.
STN 33 2000-5-51 Electrical regulations. El. equipment. Part 5: Construction of power.
devices.
STN 33 2030 Electrotechnical regulations. Protection against dangerous effects of static
electricity.
STN 33 2130 Electrotechnical regulations. Internal electrical wiring.
STN 33 2180 Connection of electrical devices and appliances.
SNT 33 2320 Electrical regulations. Regulations for electrical devices in areas with
danger of explosion of combustible gases and vapors
STN 33 2350 Regulations for electrical equipment in difficult climatic conditions.
STN EN 60335-1 Safety of electrical appliances for household and similar purposes.
5.2 BOILER PLACEMENT
The location of the boiler regarding to fire regulations
Placing on the floor from combustible material
•boiler on a fireproof thermal insulation pad exceeding boiler on the sides of 20
mm.
•if the boiler is located in the cellar, we recommend placing it on concrete slabs
min. 50 mm high. The boiler must stand horizontally.
Safety distance from combustible materials
•When installing and operating the boiler it is necessary to keep a safety distance
of 200 mm from flammable materials of flammability B, C, and D (according to
EN 13501-1) (Table 3)
•for easily flammable substances degree E, F, which burn quickly and by
themselves also after the ignition source removal (eg. Paper, paperboard,
cardboard, asphalt and tar boards, wood and fibreboards, plastics, flooring
materials) the safe distance is doubled ie. to 400 mm
•safe distance is to be doubled also in case when the flammability level of the
building material is not proved
Tab 3 Flammability levels of building materials and products
Flammability of
Constructing materials
and products
Constructing materials and productsaccordingflammability
degree (selection of EN 13501-1)
A1 - non-combustible
granite, sandstone, concrete, bricks, ceramic tiles, mortars, fire
plasters, ......
A2 - hardly flammable
acumin, izumin,, Lignos, boards and basalt felt, glass fiber boards, .....
B - hardly combustible
Beech and oak wood, OSB, plywood, formica, sirkolit, ....
C, D - medium
pine, chipboard and cork boards, rubber flooring, .......

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combustible
E, F - easily
combustible
Asphalt board, fibreboards, cellulose materials, polyurethane,
polystyrene, polyethylene, PVC, ....
A boiler placement:
• basic environment AA5 / AB5 according to STN 33 2000-3
• Before the boiler must be working space of min. 1000 mm
• The minimum distance between the rear of the boiler and the wall is 400 mm
• on the tray fuel gap min. 500 mm in case of collection of feed screw
• The minimum distance from the left side wall 100 mm
• the boiler at least 450 mm for the possibility exchanger cleaning and refueling
Location of the boiler to the electrical network:
•boiler must be positioned so that the plug in socket (230V / 50Hz) accessible at all
times.
• boiler is connected to power. Fixed network attached corded completed a standardized
plug
• Protection against electric shock must be ensured in accordance with the applicable
EN STN (see Sec. 1.4)
Location of fuel:
• for proper combustion in the boiler is necessary to use dry fuel. We recommend to
store the pellets in their original packaging from the manufacturer (PET bags) on a dry
place.
• It is forbidden to store the fuel for the boiler, stored next to the boiler at a distance less
than 400 mm
• The manufacturer recommends to observe distance between the boiler and fuel min.
1000 mm or put fuel into a different room than the installed boiler.
To the room where the boiler is installed, it must be ensured steady supply and exhaust
air for combustion and ventilation. Pipe connection of the heating system or water
heater ducts have to be provided by a specialist with the licence.
When connecting the boiler to the heating systemit must be at the lowest point
and as close to the boiler a drain valve.

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Fig.10 Boiler placement in the boiler room space

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The boiler is placed:
• Basic environment AA5 / AB5 according to STN 33 2000-3
• Before the boiler, the min. 1000 mm
• The minimum distance between the back of the boiler and the wall is 400 mm
• at the fuel tank side a gap of min. 500 mm in case of removal of the feeding screw
• Minimum distance from the left sidewall 100 mm
• above the boiler at least 450 mm for the possibility of cleaning the exchanger and
filling the fuel
Location of the boiler to the electricity grid
The boiler must be positioned so that the plug in the socket (230V/50Hz) is always
accessible. The boiler connects to the el. network with a rigidly connected movable
supply terminated by a standardized fork
Protection against electric shock has to be ensured according to current STN EN (see
chapter 4.1).
Fuel location
For proper combustion in the boiler it is necessary to use dry fuel. Pellets are
recommended to be stored in their original packaging by the manufacturer (PET bags)
in a dry place. Fuel is forbidden to stow the boiler, store it next to the boiler at a
distance of less than 400 mm. The manufacturer recommends that the distance between
the boiler and the fuel min. 1 000 mm or place the fuel in a different room than the
boiler installed
The room where the boiler is installed must have a permanent supply and exhaust for
combustion and ventilation. The connection of the heating system pipe or DHW heater
piping must be carried out by an authorized person.
When connecting the boiler to the heating system, the drain valve must be
located in the lowest position and as closesttothe boiler as possible.

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6 STARTUP INSTRUCTIONS FOR CONTRACTUAL SERVICE
ORGANIZATION
Starting the boiler into operation can be performed only by the
manufacturer authorized contractual service organization with authorization from
the boiler manufacturer MAGA, s.r.o. As long as the boiler is put into operation by
non-authorized person the damages caused by improper installation will not be
treat as waranty issue! The manufacturer is not responsible for the errors and
malfunctions caused by incorrect boiler start-up!
6.1 BEFORE-START CHECK
Before the boiler is started - the following need to be checked:
A) Filling the heating systemby water
Water for filling the boiler and heating system must be clear and colorless,
without suspended solids, oil and chemically aggressive substances. Its hardness must
correspond to STN 07 7401 and it is essential that if the hardness is unsatisfactory, was
treated. Even multiple heating of water with higher hardness does not precipitated salts
on the walls of the exchanger. Precipitation of 1 mm calcite reduces at a given place the
heat transfer from the metal to water by 10%.
Heating systems with an open expansion tank allow direct contact of heating
water with atmosphere. In the heat period the expansive water in the tank absorbs
oxygen which increases the corrosive effects and at the same time there is a significant
evaporation. The amendment can only use water treated with the desired value
according to STN 07 7401. The heating system must be thoroughly flushed in order to
wash out all impurities.
During the heating season it is necessary to maintain a constant volume of water
in the heating system. When refilling the heating system with water it is necessary to
ensure that no air is sucked into the system. Water from boiler and heating system
should not escape, except in cases such as repairs and the like. Draining water and
feeding with new water increases the danger of corrosion and scaling.
When it is necessary to add a water to the heating system, proceed it only when
the system is cooled off to prevent damage of the steel boiler.
Before starting the boiler into operation it is necessary to check also:
a) heating system tightness
b) connection to chimney - must be approved by a chimney-instalation company
c) Electrical connection

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Finishing of instalation and the first operation must be recorded in the
"Letter of Warranty".
6.2 FIRST BOILER OPERATION AND OPERATOR TRAINING
1
1. Fit the fuel tank as shown in Figure 1 to the boiler - insert a screw conveyor into
the hopper.
2. Attach the hose to the conveyor and secure by the Screw/band hose clamp
Fig. 11 Screw hose clamp
3. Put the pellets in the hopper
4. Plug the conveyor power plug into an electrical socket (leave it running for
approx. 10 minutes if the conveyor is not filled and the pellets do not start to fall
over the hose)
5. Perform calibration of the fuel feeder and set parameters to the control unit
6. Insert the second end of the hose into the burner
7. Now, the boiler is ready for operation
8. Use the control unit to start the boiler - see the operating instructions for the
control unit
9. Heat the boiler to the required operating temperature. Recommended outlet
water temperature is 65-80 °C
10. Check the boiler tightness
11. Familiarize the user with the boiler
12. Add a note on the Letter of Guarantee-Date of putting into operation
1
Always provided by officialy approved company installers

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6.3 BOILER OPERATION
Boiler start (operating the boiler)
1) Connect the boiler controller to the power grid (plugging in)
2) Check the amount of water in the heating system.
3) Check whether the stop valves between the boiler and heating system are
open.
4) Fill the container by specified fuel. After filling, the container need to be
closed by the lid.
5) Turn on heating by touching an icon Power on electronic controller. (The
pellet mode on the main mode button must be on!)
6) After switching on the control unit, the boiler is in automatic mode.
IMPORTANT WARNINGS
The boiler can be operated only by adult persons familiar with these operating
instructions. Leave children unattended by adults at the boiler, which is in operation
is not permitted.
If there is a danger of penetration of combustible vapors or gases into the boiler
room or at works where there is a risk of fire or explosion (gluing the floorings,
painting with combustible paints, etc.), The boiler must be off before the work out
of operation.
On the boiler and closer than the safe distance from it must not be stored articles of
combustible materials.
When removing the ash from the boiler must be at a minimum distance of 1500 mm
from the boiler flammable substances. The ash must be collected in the fireproof
container with a lid.
When operating the boiler at a lower temperature than 60 °C, the steel gets wet and
the exchanger is affected by low-temperature corrosion, which shortens the life of
the heat exchanger. Therefore, the boiler must be run at a temperature of 60 °C and
higher.
After the heating season it is necessary to thoroughly clean the boiler –exchanger,
burner and chimney.
Any interference into the boiler construction and electrical installation is strictly
prohibited!