Mareli Systems LCG 22 KW User manual

Mareli Systems
LCG 22 / 32 / 40 / 50 KW
WOOD GASIFICATION BOILER
Assembly and exploitation manual

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Observing the prescriptions of the present manual is in the user’s favour and is one of
the warranty conditions. Compliance with this instruction is in the interest of the con-
sumer and one of the warranty terms.
ese instructions are an integral part of this product. All rights reserved. Reproduction
of content of this document and transfer to third parties is not allowed without written
approval from manufacturer. Make sure the instructions are always with the device,
even if its sale / transfer of another owner to the user or sta authorized for maintenance
or repairs to consult.
• 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 per-
formed by a qualied expert in the eld of heating installations or authorized by “Marelli Sys-
tems’ 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 in-
struction manual. Incorrect setup may cause hazardous conditions and / or incorrect function
of the boiler;
• Do not wash the boiler with water. Water can get inside the replace and damage the electron-
ics 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 bottom door, glass, ue pipe, etc.). Avoid
contact with these parts before assuring yourself that you use temperature resistant gloves as
well as suitable temperature resistant instruments;
• Under no circumstances should the re be ignited with the doors open or broken glass. For
igniting the boiler, only the middle door must be opened.
• e product must be electrically connected to a system equipped with an eective earth con-
ductor. (Must be grounded);
• Turn o the boiler in case of failure or malfunction;
• When installing the product all re safety requirements must be respected.
• Periodically check and clean the smoke outlet ducts of the boiler (connection to the ue pipe);
INSTRUCTIONS FOR SECURITY:

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READ THESE INSTRUCTIONS CAREFULLY BEFORE
INSTALLING THE BOILER TO HEATING SYSTEM!
BOILER MUST NOT OPERATE IN FLAMMABLE AND EXPLOSIVE ENVI
RONMENT.
BEFORE ANY WORK ON THE BOILER, ELECTRIC ENERGY MUST BE
SWITCHED OFF.
!
TECHNICAL DATA
LCG 22 32 40 50
Nominal heat output (kW) 22 32 40 50
Heat output range (kW) 11-22 16-32 20-40 25-50
Boiler class EN 303-5:2021 5
Required chimney underpressure (Pa) 14 18 18 21
Water amount in boiler 120 130 140 150
Exhaust gas temperature at nominal heat output 165 160 150 150
Exhaust gas temperature at minimal heat output 100 100 100 95
Minimum operating time at rated power (nominal Q ) (h) 3 3 3 3
Min. inlet water tem. at the boiler supply water connection (°C) 60
Max. temp. (°C) 90
Fuel type A, wood logs, by norm 14964-5
Fuel moisture content (%) max 25 %
Fuel length (mm) 500 500 500 500
Fuel loading chamber capacity (L) 103 103 103 136
Combustion chamber type UNDERPRESSURE
Required minimum accumulation volume(tank) next to boiler by EN 303-5:2021
Supply voltage (V~) 230
Frequency (Hz) 50
Weight (kg) 424 449 479 526
Max. operating pressure (bar) 3
Flue gas tube - external diameter (mm) 149
Heating appliance working with fan
Heating appliance working under non-condensing conditions
Energy eciency class of boiler A+

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1
2
3
4
5
6
7
8 9
10
11
A
A1
B
B1
C
C1
D

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G 3/4”
G 3/4”
G 1-1/2”
G 1-1/2”
12
13
14
15
16
17
18
19 20
21
22
23
24
E1
E2
E3
E4
E5
E6

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25
26
27
28
29
30

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LCG A
(mm)
A1
(mm)
B
(mm)
B1
(mm)
C
(mm)
C1
(mm)
D
(mm)
E1
(mm)
E2
(mm)
E3
(mm)
E4
(mm)
E5
(mm)
E6
(mm)
22 1135 1016 663 590 1387 1280 Ø149 1180 480 165 943 210 1174
32 1185 1066 663 590 1387 1280 Ø149 1180 480 165 943 210 1174
40 1255 1136 663 590 1387 1280 Ø149 1180 480 165 943 210 1174
50 1255 1136 663 590 1537 1430 Ø149 1330 630 165 1093 210 1324
1Digital boiler display 16 Bottom service door
2Flue gas tube cleaning lever 17 STS thermal safety valve connec-
tion 1 capillary bulb
3Door handle 18 Exhaust temperature sensor
4Upper boiler door 19 Water inlet
5Middle boiler door 20 Drainage valve
6Lower boiler door 21 STS thermal safety valve connec-
tion 2 mains inlet
7Primary air regulator 22 LCG electronic control board
8Fixing screw for secondary air
regulator 23 Exhaust fan
9Secondary air regulator 24 Water outlet
10 Cleaning tool 25 Heat resistant plate
11 Connection for pump 26 Duct for smoke absorption
12 Deaerator 27 Protection cladding
13 Cleaning mechanism for ue gas
tube 28 Open door sensor
14 Turbulator 29 Burner
15 On / O power switch 30 Burning chamber

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Steel boilers LCG, with an rated thermal output 22, 32, 40 and 50 kW are constructed for wood r-
ing and aimed for heating of small and middle sized premises. Due to the applied wood gasication
principle, wood is totally burned. Widely sized combustion chamber enables the ring with wood
pieces of 500 mm.
One lling period lasts min. 3 hours, with the possibility of prolonging it to the whole day, if the
heating requirement is decreased. e functioning of the boiler is steered by the built-in regulation
system. e boiler must be connected to the central heating system through an appropriately sized
water tank.
e LCG boiler is produced in compliance with the EN 303-5 norm, which enables the required
level of functioning and minimal environmental pollution, through the ring with wood. e boiler
is aimed for ring with wood. e system of ue gases conduction and their additional burning
out, enables its high eciency, which makes this product extremely economical. Widely sized com-
bustion chamber door enables ring with large pieces of wood and a very simple and easy cleaning
and maintenance. One lling period lasts minimum 3 hours, depending on the nominal thermal
output. ere is also a possibility of prolonging the ring process to the entire day, if the heating
requirement is decreased.
An integrated controller regulation system controls the functioning of the boiler as well as the
circulation pump and the primary heating circuit. e LCG boiler is very simple to handle, while
the built-in regulation enables its reliable functioning. rough the compulsory connection of the
water tank to the heating system, the optimal functioning of the boiler is achieved and the produced
heat is saved, which enables consumption exactly according to the need. e ring process can be
implemented in suitable period of the day. If the outdoor temperature is not very low, the room
heating and the sanitary hot water production can be extended to the period of few days. e boiler
is delivered together with thermal insulation, covered by a metal casing and it is pre-wired.
1. GENERAL INFORMATION
Fuel: wood having moisture content to 20% (max. 25%).
is demand for moisture content is fullled with wood dried on air at least 12 months.
!!

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MINIMUM DISTANCE FROM THE ROOM WALLS
FLAMMABLE ITEMS MUST NOT BE PLACED ON THE BOILER AND WITHIN THE
MINIMUM DISTANCES SHOWN
2. POSITIONING AND ASSEMBLY
e installation of the boiler has to be carried out by the authorized person. We suggest the boiler to
be installed on the solid concrete basis, which height is between 50-100 mm. e boiler room has to
be absolutely protected from freezing and properly ventilated. e boiler has to be set up in order to
enable it’s connection to the chimney as well as it’s servicing during the functioning process, cleaning
and maintenance. e connection boiler to the central heating system is obligatory through one or
more water tanks, in accordance to the boiler power. It is recommended to connect a minimum
of 12 liters water to each 1 L of fuel loading chamber capacity (i.e. for the 40 kW boiler the recom-
mended water tank should be 1250 liters). e boiler should not be used without being connected
to the water accumulation tank. It must be connected to the water tank exclusively through an 3-way
thermic valve maintains minimum temperature of return water into the boiler above 60°C.
min. 100 cm
min. 100 cmmin. 70 cm
min. 50 cm
min. 150 cm

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2.1INSTALLATION OF THE COMBUSTION FAN
Mount the combustion fan with the threaded screws to the designated connection points. Use the 4
(M8) nuts in the mounting kit with the boiler to x the combustion fan in place.
3. CONNECTION TO THE CHIMNEY
Properly calibrated and built chimney is the precondition for a safe operation of the boiler and eco-
nomic heating. e chimney has to be well insulated, gas-proof and smooth. On the lower part of
the chimney, a cleaning door has to be built in. Brick layed chimney has to have 3 layers with an
stone wool thermal insulation in the middle. e thickness of the insulation should be 30 mm, if the
chimney is situated inside the building, i.e. 50 mm if the chimney is situated outside the building.
Inside chimney diameter dimensions depend on its height and on the boiler capacity. e temper-
ature of the ue gases on their exit point should be minimum 30°C higher then the temperature of
their condensation point. e choice and the construction of the chimney should be performed
by an authorized person. Minimal distance between boiler and the chimney is 500 mm. e ue
gas tube has to have an inclination of 30-45°. In order to unable entering of the condensate from
the chimney into the boiler, 10 mm of the ue gas tube length has to be inserted deeper inside the
chimney. It is recommended to insulate the chimney connection tube with a mineral wool of 30-50
mm thickness. All installation works must be made in accordance with valid national and European
standards. At connecting a boiler to the chimney, ue gas tubes and elbows must not pass behind
the fan since in that case the cleaning and maintenance will not be possible.

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min 500 mm
min 500 mm
10 mm
10 mm
Opening for the
cleaning
Opening for the
cleaning
ermal insulation
ermal insulation
e dimensioning of the chimney is a very
important condition for the operation
of the boiler at optimal parameters. e
chimney must be designed in such a way
as to make the gases escape correctly and
to keep the necessary air in the boiler. e
diagrams below show how to choose the
height of the chimney depending on its di-
ameter and the power of the boiler. Choos-
ing the right insulation for the chimney is
very important and it must be 30-50 mm
thick. e correct choice of the chimney
diameter and height are decisive in the
correct operation of the boiler. To meet
the above conditions, consult the chimney
manufacturer’s specialists. e minimum
height of the chimney for wood-burning
boilers is 6 m. e chimney must be made
of stainless steel elements, to reduce the in-
uence of condensation.

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Example scheme for installation of an anti-condensation valve. It is recommended
that the valve be at least 60 C. At the discretion of the installer, a valve with a higher
return water temperature may be installed.
FRESH AIR OPENING
Each boiler room must be equipped with an opening for supply of make up air which is dimensioned
in accordance with boiler output (minimum opening area according to the below shown equation).
Such opening must be protected with a net or grate. All installation works have to be performed in
accordance with valid national and European standards. Boiler must not operate in ammable and
explosive environment.
A = 6,02 x Q
A - opening area in cm2 Q - boiler output in kW
4. CONNECTION TO THE CENTRAL HEATING SYSTEM
All installation works must be made in accordance with valid national and European standards. Boil-
er LCG can be built to closed and open central heating systems. In both cases boiler must be red
with wooden logs. Installation has to be made, in according to technical standards, by a professional
who will be responsible for proper boiler operation. e inlet pipe from the boiler to the central heat-
ing system must not pass above the top back casing cover, otherwise the removal of the turbulators
and cleaning of ue gas tubes is impossible. Before connecting boiler to central heating system, the
system has to be ushed to remove impurities remaining aer system installation. It prevents boiler
overheating, noise within the system, disturbances at a pump and mixing valve. Boiler should always
be connected to central heating system by connectors, never by welding.

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bbaarr
Example scheme 1 for boiler instalation on closed central heating system with return ow
protection with thermic valve (group)
1
2
3
4
5
1
2
3
4
6
Example scheme 2 for boiler instalation on open central heating system with return ow
protection with thermic valve (group)
above the highest heating body

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1LCG BOILER
2Water storage tank
3Boiler pump
4Return ow protection 3-way thermic valve (min. temp 60°C) or 3-way mixing valve
with motor drive (protection valve)
5Expansion vessel for closed heating systems
(approx. 10% of the total volume of installation)
6Open expansion vessel for open heating systems
(approx. 7% of total volume of installation)
4.1 CONNECTION TO THE OPEN CENTRAL HEATING SYSTEM
If the boiler is aimed to be integrated into an open central heating system, one of possible way how to
connect the boiler to the system is shown on Example scheme 2. In case of the LCG boilers, the boiler
pump obligatory has to be connected to the boiler control unit, in order to make turning on and o
of the pump depending on the temperature of the water in the boiler, to avoid boiler condensation.
Connection to an open central heating system requires the implementation of an open expansion
vessel above the level of the highest heating body (radiator). If the expansion vessel is situated inside
the non heated room, it has to be insulated. e volume of the open expansion vessel is about 7%
of the volume of entire heating installation. e boiler has to be connected with one or more water
tanks, depending on its nominal power. It is recommended to connect a minimum of 12 liters water
to each 1 L of fuel loading chamber capacity (i.e. for the 40 kW boiler the recommended water tank
should be 1250 liters). e boiler should not be used without being connected to the water accu-
mulation tank. It must be connected to the water tank exclusively through an 3-way thermic valve
maintains minimum temperature of return water into the boiler above 60°C.
4.2 CONNECTION TO THE CLOSED CENTRAL HEATING SYSTEM
In closed heating system (as in Example scheme 1) it is obligatory to build in certied safety valve
with opening pressure of 2,5 bar, minimum seat diameter of 15 mm, minimum inlet connection of
1/2”, minimum exit connection of 3/4” and a membrane expansion vessel. Safety valve and expan-
sion vessel must be built in accordance with professional rules and any valve must not be located be-
tween safety valve and expansion vessel and boiler. e closed heating system must have the installed
expansion vessel of larger volume (vessel volume must be approx. 10% of the heating installation
volume). In all boiler types the heating pump must be connected to boiler control unit so that the
heating pump switching on and o would depend on water temperature in the boiler.
e boiler has to be connected with one or more water tanks, depending on its nominal power. IIt is
recommended to connect a minimum of 12 liters water to each 1 L of fuel loading chamber capacity
(i.e. for the 40 kW boiler the recommended water tank should be 1250 liters). e boiler should not
be used without being connected to the water accumulation tank. It must be connected to the water
tank exclusively through an 3-way thermic valve maintains minimum temperature of return wa-
ter into the boiler above 60°C.

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BOILER THERMAL PROTECTION
According to European EN standards, boiler thermal protection must be installed in closed heating
system. Boiler is factory prepared for installation of thermal protection.
IMPORTANT:
In case of any damage of boiler installed in the closed heating system due to its overheating, and
boiler or system are not equipped with any thermal protection at all, or do not have properly
installed thermal protection, guarantee will not be applied.
IMPORTANT:
ermal protection must be connected to the water supply installation of the premises supplied
from the water supply line and not from hydrophor. Namely, in case of failure of power supply,
boiler could be overheated, and then hydrophor is not able to ensure required water supply.
DOMESTIC
water supply
safety
discharge
mains
inlet
Maximum length of the sensor must not exceed 120 mm.
!

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5. IGNITION PROCEDURE
1 2
34
A

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78
1
3 2
5
P1
6

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1
• Open the to and middle doors.
• Check the ash level in the combustion chamber and empty if necessary.
It is recommended that you do not remove the ash in the combustion
chamber during each heating-up process, but rather when the middle
row of holes of the combustion chamber guards is no longer visible. is
protects the combustion chamber.
2
• Insert one layer of rewood.
• Use rewood with a length of approximately 50 cm and arrange it
lengthwise.
• Do not completely cover the burner (A).
3• Aer the rst layer of wood, lay cardboard across the whole area.
4• Fill the fuel loading chamber and close the fuel loading chamber door.
5• Keep the middle door open, insert scrunched up paper and light it.
6• Activate the ignition process with long press on the (P1) button;
7
• Leave the pre-heating chamber door open for approximately 5 minutes
• A bed of embers must form.
• Close the middle door.
8
• Open fully the primary air regulator (1)
• Set the secondary air regulator in the half open position. (2)
• Use the xing screw to hold the position of the secondary air regulator. (3)

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6. CLEANING AND MAINTENANCE OF THE BOILER
Protective gloves must be used. Ash remaining in boiler aer solid fuel ring should be disposed into
metal containers with a cover. As through the wood gasication principle the fuel burns out totally,
the cleaning of the boiler is limited to the upper and lower combustion chamber once in a week and
the cleaning of ue gas tubes on the back side of the boiler is necessary only aer the heating season,
i.e. min. once in one heating season. Cleaning the fan blade and fan box has to be performed when
necessary.
Before each starting of the boiler it is recommended to shake the ue gas tube cleaning lever few
times.
PROTECTIVE GLOVES ARE OBLIGATORY!
Remove the combustion fan from the connection points by unscrewing the 6 socket button head
screw ISO 7380 - M6 x 8 holding it in place.
1 2
COMBUSTION FAN CLEANING

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1
2
3
4
M10
5