Mareli Systems ECOPELLET STAR User manual

Mareli Systems
ECOPELLET STAR - CONDENS BOILER
Assembly and exploitation manual
Please read these instructions carefully before installing and/or lighting the appliance for the rst time.
Keep this document near the appliance, in a place which can easily be reached.

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Mareli Systems
INTRODUCTION :
Dear customer,
e biomass boiler with condensation technology sets the bar very high in terms of energy ecient while
keeping the emissions levels low. is technology allows it to reach 106 % which is much higher then even the
most high-end modern pellet boiler without this technology.
Condensation technology
As solid fuel is used (pellets) during the combustion process the moisture contained in the fuel is released.
is product reuses the heat that usually is eliminated with the ue gases through the chimney in traditional
boilers. us, the ue gas temperature of the ECOPELLET STAR boiler is below 50°C under condensation
conditions. When the water temperature is between 30-50 C is when the boiler has it’s highest eciency. As
the water temperature gets higher the condensation eect diminishes.
is boiler complies with current regulations and has been tested in external laboratories accredited for cer-
tifying this type of product. Installation of the boiler, checking and maintenance should be carried out by
authorised personnel.
• is appliance is not intended for use by people (including children) with limited physical, sensory or mental abilities or
lack of experience and knowledge. e installation must be performed by a qualied expert in the eld of heating installa-
tions or authorized by “Mareli Systems’ service. e place and way of connecting the boiler should be selected carefully in
accord with the safety instructions. Install away from ammable objects!
• Before starting any operation, the user must read and fully understand the contents of this instruction manual. Incorrect
setup may cause hazardous conditions and / or incorrect function of the boil;
• Do not wash the boiler with water. Water can get inside the replace and damage the electronics and cause an electric shock;
• Do not put clothes to dry on the boiler. Any clothes hangers and other objects must be located within a reasonable distance
from the replace. Fire hazard;
• e user is fully responsible for the proper use of the product which exempts the company from liability of any users errors
or misbehaviour or omissions;
• Any intervention or replacement that is made by unauthorized people or using non original spare parts for the product can
be risky for the user and release the company from all liability;
• Most surfaces of the boiler are extremely hot (the door handle, glass, ue pipe, etc.). Avoid contact with these parts before
assuring yourself that you us temperature resistant gloves as well as suitable temperature resistant instruments;
• Under no circumstances should the re be ignited with the door open or broken glass;
• e product must be electrically connected to a system equipped with an eective earth conductor. (Must be grounded);
• Turn o the boiler in case of failure or malfunction;
• All unburned pellets in the burner aer each unsuccessful attempt ignition must be removed before a new ignition;
• When installing the product all re safety requirements must be respected
If there is a re in the ue pipe, extinguish the boiler, disconnect the power cord and never open the door. Call competent
authorized service technicians;
• Do not light the boiler with ammable materials if the ignition system failed;
• Periodically check and clean the smoke outlet ducts of the boiler (connection to the ue pipe);
• Pellet boiler is not a cooker;
• Always keep the cover closed;
SAFE DISTANCES:
When installing the product a safe distance of at least 600 mm must be respected. is distance applies to the
product located near materials of B or C ammability level. e safe distance is doubled if the product is close
to materials of C3 combustion level.
INSTRUCTIONS FOR SECURITY:

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Mareli Systems
1. PURPOSE
e boiler is purposed to heat domestic and public premises by the means of pellets. e boiler is
equipped with a steel water jacket designed for heating systems with water temperature up to 90º
C at a maximum super pressure up to 0,15 Mpa. Tests are run at pressure of 0,3 Mpa.
e boiler is designed and manufactured to work with A-class pellets only
( DIN plus 51731 ) with the following characteristics:
What are the pellets.
e pellets are produced by compressed wooden
waste le from the production of various furniture,
sawmills and others. is type of fuel is environ-
mentally friendly because in the production pro-
cess no agglutinate agents (glues, resins and oth-
ers) are added. Actually, the integrity of the pellets
is guaranteed by the lignite – a natural ingredient
contained in the wood itself. While the wood has a
calorie capacity of 4.4 kW/kg (15% humidity at 18
months drying), the pellets have 5.2 kW/kg.
• Material 100% pure conifer or broad-leaf wood;
• Diameter Ф6/8 mm;
• Length 20-30mm;
• Calorie capacity 5.2 kW/kg;
• Ash content < 8%;
e use of pellets with characteristics dierent from the recommended may result in power de-
crease, unstable and inconsistent work of the boiler.
Info: To ensure the proper work of the boiler the pellets must be stored in a dry place!
Recharging of pellets can be done during work, with the following sequence:
1. Open the bunker (located at the top of the product);
2. Fill the hopper, using non-combustible container;
3. Close the lid of the bunker;
Attention!!! Use gloves! Beware of hot surfaces!
e boiler consists of a boiler body, pellet hopper and a pellet burner. e burner can be tted
to the right of the boiler or le, upon request.
e boiler body is constructed of sheet steel, stainless steel and corrosion resistant materials
throughout the ue gas circuit as well as all parts that may be in contact with condensate. Com-
bustion chamber is cylindrical and the ue pipes are arranged around this chamber.
At the rear of the boiler there are placed hydraulic connections as well as ue gas pipe and
condensate drain. e condensate discharges through a drain at the bottom of the boiler, where
a water trap is installed.
e boiler includes an automatic cleaning system of the burner plate, which wipes ashes onto a
manually removable ash drawer. It also includes an automatic water jet system for cleaning the
heat exchanger ue gas pipes.

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2. TECHNICAL DATA
211 mm 746 mm
158 mm
1120 mm
1132 mm
383 mm
1133 mm
1358 mm
490 mm
467 mm

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1
23
4
5
1
2
3
4
5
Boiler body
Ash box
Boiler burner
Pellet hopper
Exhaust fan

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A
B
C
D
E
1
2
3
4
5
6
7
D
2
A. Neighboring wall.
B. e rear wall.
C. Sidewall.
D. Floor protection.
E. Ignitable element.
1 = 50 (mm)
2 = 600 (mm)
3 = 400 (mm)
4 = 300 (mm)
5 = 1500 (mm)
6 = 60 (mm)
7 = 800 (mm)

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1 2 4
35
6 7 8 9 10 11
1
2
3
7
8
Exhaust Fan
Condensation chamber turbulators
Combustion chamber spirals
Condensation chamber cleaning mechanism
ermal isolation combustion chamber
4
5
10
11
Burning pot
External ash container
Combustion chamber temperature sensor
Combustion chamber cleaning mechanism TOP
9 Refractory plate combustion chamber
6 Condensation chamber water connection

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12
13
14
15
16 17
18 19 20 21
12
13
14
18
19
Touch screen display
Lambda regulation (Optional)
Vacuum sensor
Combustion Fan
Motor cleaning mechanism Burning pot
15
16
21Combustion chamber cleaning mechanism Bottom
Motor cleaning mechanism TOP
Auger Motor return ame protection
20 Auger Motor
17 Vacuum pump (Optional)

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3. ASSEMBLY
3.1 General conditions.
All national, regional and European requirements for safe operation of the appliance
must be respected during installation and operation.
Prior to installation, load capacity of the place where the boiler will be intended must be
ensured. e weight of the boiler is specied in the technical data table.
To ensure the correct and safe operation of the boiler, the following conditions must be
met:
e installation of the boiler and its accessories must be carried out by authorized per-
sons.
e oor where the boiler is installed should be at and horizontal, made of re-resist-
ant materials at least 1500 mm in front of the replace and not less than 400 mm on both
sides and at the back of the wall.
Minimum distances from the wall to the boiler should be at least 400 mm. e mini-
mum space in front of the replace should be 1500 mm. e minimal distance of the
boiler from combustion materials should be no less than 1500 mm.
e door of the replace should be closed tightly during the work process. Opening it
during work is absolutely forbidden.
When installing the boiler, the connections between the individual pipes and the chim-
ney rooop must be dense.
When the re is rst ignited, a smell occurs as a result of the paint being heated.
e replace is painted with heat-resistant paint, which achieves its ultimate resist-
ance aer repeated use of the boiler. THEREFORE KEEP OUTSIDE INTERACTIONS
WITH THE COATING TO A MINIMUM in order not to damage it.

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CHECK ITEMS
BEFORE INSTALLATION
Chimney exit
Chimney
Connection to
chimney
Connection to
the boiler
Security
distances
e oor
Inlet air
e chimney
revision door

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3.2 Basic rules and prescriptions.
e boiler with water jacket operates on water heating boiler principle.
e advantage of this type of heating system is the maximum utilization of the heat that is pro-
duced during the combustion process. With this method the heat from the combustion chamber
is taken to remote and hard to reach for a normal heat exchange premises in order to maintain an
even temperature and warmth comfort.
• Ensure that every branch and element of the installation is airtight at every single moment of its ex-
ploitation.
• All elements of the installation must be protected from freezing, especially if the enlarging pot or
other parts are situated in non-heated premises.
• e circulation pump can be chosen by the capacity required by using the following formula:
G=0,043. P , (m³/h), in which:
P, kW is the heat output of the water jacket. e circulation pump can be turned on and o by
the means of a thermostat in combination with an electric switch.
• e rst service cleaning of the pump’s lter must be done immediately aer testing the installation.
• If an old installation is going to be used it must be washed several times to ensure the removal of any
accumulated dirt on the surfaces of the water jacket.
• Do not drain the circulating water of the installation during the non-heated season.
• Chemical treatment of the circulating water is not recommended.
Radiator
Deaerator
Expansion vessel
Return Valve
Lyra
Boiler
BOILER
Pump
RadiatorRadiatorRadiator
“Mareli Systems” provides a warranty and out of warranty service and replacement of the water
jackets. e warranty is not valid in case of a boiler with a swollen water jacket which is a result
of pressure increase in the system and improper connecting. e water jackets are tested under
pressure of 400 kPa (4 bar).
It is recommended that the assembly is performed by an authorized specialist.
3.3 Assembly of the duct components.
Duct components and pipes
For the assembly of the duct pipes the use of non-ammable materials, resistant to the ammable
products and condensation is obligatory. e assembly must be performed in such a manner so
it guarantees the airtight sealing and prevents condensation. If possible, avoid adding horizontal
sections. Direction shi is done by using knee joints with a max angle of 45˚.
For heating devices equipped with a smoke ventilator, i.e all of the “MARELI” boilers, the follow-
ing instructions must be observed:

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• Horizontal sections must have a minimum incline
of 3° upwards;
• e length of the horizontal sections must be as
short as possible, but without exceeding 3 m;
• More than four direction shis are forbidden,
including the cases where a T-shaped element is
used;
• e duct components must be airtight and to be
insulated if extending outside the premises in
which the replace is installed;
• e duct components must allow a soot cleaning;
• e duct components must have a constant sec-
tion. A section change is allowed only in the
chimney joint;
CHIMNEY EXITS (ANTI-WIND)
Chimney
e chimney or the duct component must conform with the
following requirements: to be airtight, waterproof and prop-
erly insulated, to be constructed with materials resistant to
the normal mechanical wear and to the heat coming from the
combustion products and condensation.
e chimney must be built out o a stainless steel material re-
sistant to the aggressive action of temperature and combustion
products.
• To be kept away from ammable materials.
e recommended chimney dra at work - from 12-20 Pa.
45
5 m (MAX)
(MAX)
Attention!!! In case of a re hazard turn o the product from the display. is will stop the oxygen
ow to the product.
Roof incline ≥ 10 °
Height above the roof = 40 cm
90°
Distance measured at 90 ° from
roof area = 1.3 m

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3.4 Types of connection to the chimney
Chimney exit
Moisture channel
Chimney
ermal insulation
External wall
Connection to chimney
Flue gas connection
“T”
connection
e chimney
revision door
Heat generator
Attention!!! In order for the product to function eciently the chimney must be built out of a
stainless steel material resistant to the aggressive action of temperature and combustion products.

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3.5 LAMBDA PROBE KIT
As an option, a lambda probe can be in-
stalled on the ECOPELLET STAR boiler.
e Lambda system improves the quality
of combustion through the analysis of the
exhausting smoke.
e system controls the devices regulat-
ing combustion, keeping it within optimal
set-point parameters, by managing both
secondary post-combustion and primary
combustion.
3.6 VACUUM SENSOR
e Vacuum sensor is installed on all the ECOPELLET STAR boiler.
It’s main function is to regulate the air pressure in the combustion
chamber. us, the optimal conditions for best combustion are re-
spected and maintained. In the cases when the chimney dra is no
longer sucient the vacuum sensor compensates for this by increas-
ing the RPM of the exhaust fan.
4. Cleaning
Cleaning the replace should be done only when cold. e cleaning of the combustion chamber
must be carried out daily.
For this purpose, make sure the replace has ceased operation and is completely cold. Pull up the
combustion pot and remove it from the boiler and then clean it from soot.
When removed fuel pot at the bottom of the combustion chamber opens a hole designed for the
accumulated ash. Collect ashes in the ashtray and return fuel pot in place and then close the door.
e replace is ready for operation.
Cleaning of ues and chimneys are conducted once every 1.5 tons of fuel used

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Combustion chamber cleaning
mechanism for the Turbulators
Condensation chamber
cleaning mechanism
for the Turbulators

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Cleaning mechanism for the
Burning pot
Cleaning mechanism for the
Ash chamber
Motor cleaning mechanism for
Ash chamber

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PROCEDURE FOR SERVICING THE BURNING CHAMBER
TOP DECORATION
THERMAL
INSULATION
1
1
Remove the top decoration in order to access the top door of the
burnning chamber.

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2
2
Remove the sensor for measuring the temperature inside the burn-
ing chamber.

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3
3
Remove the 4 scrwos from each side of the combustion chamber
door.

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4
4
User the 2 handles in the center to remove the combustion cham-
ber door. Here you have access to the automatic cleaning mecha-
nism for the turbulators.