Nibe PELLUX 100 User manual

INSTALLATION AND MAINTENANCE INSTRUCTIONSMOS GB 1248-1
PELLUX 100
231259 PELLUX 100
APH

For Home Owners
General
System description
Area of use 3
Product description 3
Heating 3
Hot water heating 3
System diagram 3
Front panel
Functions on the front panel 4
Start and stop 6
Control 7
Dealing with malfunctions and maintenance
General 9
Causes and actions in event of malfunctions 10
For the Installer
General information for the installer
Boiler room 12
Chimney 12
Connection 12
Pipe connections
Electrical connections
Connection 14
Internal fuse protection 14
Connecting the control computer 14
Connection burner 17
Connecting the outside sensor 17
Connection of flow sensor 17
Output for external circulation pump 17
Installing the boiler
Burner 18
Pellet hopper and pellet screw 18
Draft limiter 19
Service
Service menus 20
Resetting temperature limiter 37
Sweeping 39
Electrical circuit diagram
Boiler 41
Burner 42
Component positions
Boiler 43
Burner 44
Electrical components 45
Dimensions and location coordinates
Technical specifications
Enclosed kit
Accessories
1PELLUX 100
Table of Contents

General
Thank you for relying on us to supply your boiler and congratulations on choosing PELLUX 100, a high quality pellet boiler with
a long service life.
In order to get the ultimate benefit from your PELLUX 100 you should read through these Installation and Maintenance Instructions.
PELLUX 100 is a boiler intended for firing with wood pellets. The boiler is intended for houses with waterborne heating.
The controls are gathered and easily viewed in the front panel.
The serial number*, must always be stated in all correspondence with NIBE.
069_ __________
Installation date
Installation engineers
"Max boiler temp" setting (On delivery: 75ºC)
"Fuse size" setting (On delivery: 16 A)
"Heating curve offset" setting (On delivery: 10)
"Heating curve offset" setting (On delivery: -2)
Make any changes to the default settings here.
Datum__________________________ Sign___________________________
*The serial number is located on the left of the top of the housing.
This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
Rights to make any design or technical modifications are reserved.
©NIBE 2012.
PELLUX 1002
For Home Owners
General

System description
Area of use
PELLUX 100 is heating boiler intended for heating houses
and other small buildings.
Product description
PELLUX 100 is a boiler developed for pellet firing.
An upright convection system and automatic sweeping facil-
itate cleaning. This also gives a high and even level of effi-
ciency. A generously sized ash and soot box facilitates the
normal maintenance.
PELLUX 100 has a top connection and is equipped with
automatic charging for preparation of domestic hot water.
PELLUX 100 is also equipped with a climate controlled
automatic shunt.
Available output with pellet operation is 20 kW.
Heating
The boiler water is led from the top of the boiler to the radi-
ator circuit via a shunt valve, where the desired temperature
to the radiators is maintained by mixing the hot boiler water
with the cooled return water from the radiator circuit.
Hot water heating
The boiler is equipped with automatic charging to charge an
external water heater.
The external circulation pump starts when the temperature
in the heater falls below the set values.
System diagram
M
M
Note! This is an outline diagram. Actual installations must be planned according to applicable standards.
3PELLUX 100
For Home Owners
System description

Front panel
ENTER
ON/OFF
INFO
ESC
12:05
Control computer Menu screen
LED lamp
Buttons
OFF Th
The control computer has two different menus that are dis-
played in the menu window:
Simplified - gives quick access to the control computer basic
functions. Enter the simplified menu by pressing the Up or
Down arrow.
Main menu - gives access to all functions in the control
computer. Enter the main menu by pressing Enter.
To quickly return to the start menu press ESC until you are
back.
Functions on the front panel
Control computer OFF.Continuous green light.
Control computer on.
Burner off.
Pulsing green light.
Control computer on.
Burner on.
Continuous orange light.
Burner in function.Pulsing orange light.
Unacknowledged alarmContinuous red light.
Acknowledged but re-
maining alarm.
Pulsing red light.
LED lamp
On/Off. Press the On/Off button for a minimum
of 3 seconds to start or switch off the control
computer.
NOTE
The boiler does not switch off!
It is only the control computer that is
switched off.
Heating. Allows possibility of setting the different
parts of the heating system.
HW. Allows possibility of setting the different parts
of the hot water system.
INFO. Opens an information window for the differ-
ent settings.
Escape. Moves up a level in the menus or erases a
parameter setting.
Arrow up. Makes it possible to navigate in the
menus and to raise a set value.
If you are on the start page you can move to the
simplified menu by pressing arrow up.
PELLUX 1004
For Home Owners
Front panel

Arrow down. Makes it possible to navigate in the
menus and to lower a set value.
If you are on the start page you can move to the
simplified menu by pressing arrow down.
Enter.
Press Enter to:
႑open the menu that you have up at present.
႑change to entered value.
႑confirm an alarm.
5PELLUX 100
For Home Owners
Front panel

Start and stop
The boiler burner is completely automatic and manages start
and stop itself if the control computer is connected.
Start
The first time one starts or if the fuel has run out and been
refilled, one should first allow fuel filling to run until pellets
fall out of the fireproof hose.
1. To start the boiler press the main switch.
2. To start the burner press the control computer ON/OFF
button for at least 3 seconds.
3. Before the burner is lit 2 cleaning cycles are carried out.
(Factory setting can be set to 2–5.) The control computer
menu displays the boiler status CLEANING.
4. When the cleaning is finished the start process continues.
AThe control computer displays IGNITION
BAn adapted amount of pellets is fed forward (factory
setting 50 seconds).
CLighter and burner fan are started.
DThe photo cell registers when the pellets are lit and
shuts off the ignition pod.
EThe kindling process begins and KINDLING is dis-
played in the menu. This process takes 3 minutes
and means that the fan speed and fuel feed are in-
creased by stages.
FWhen the Kindling process is completed the boiler
returns to the suitable control program.
TIP
Normal firing up takes approx. 9 minutes. If during
this time the photocell does not register any flames
the lighter will attempt to light a maximum of 5 times.
If no flames are registered after 5 attempts an alarm
is given and the firing up attempt is stopped.
Stop
1. To stop the burner press the control computer ON/OFF
button for at least 3 seconds.
2. The Menu displays OFF.
3. The fuel feed is shut off.
4. The burner fan operates until no flames can be re-
gistered.
NOTE
The control computer does not control the heat pump
circulation pumps when the boiler is stopped in this
way.
In order for the control computer to control the heating
system circulation pumps, the simplified menu must be used
at stop.
1. Go to the burner menu.
2. Press Enter.
3. Scroll to Settings using the Up or Down arrow.
4. Confirm using Enter.
5. Scroll to Burner on and click Enter.
6. Use the Down arrow to change from Yes to No.
AThe stop sequence is started immediately.
BThe control computer still controls the heating sys-
tem's circulation pumps.
NOTE
Emergency stop
Switch off the boiler at the main switch. This means
that all processes are stopped.
Remember that the remaining fuel will not be extin-
guished but must burn out.
PELLUX 1006
For Home Owners
Front panel

Control
General
All the most common settings are made from the panel as
well as control computer instructions such as comfort etc.
that you require the heating system to fulfil. In order for the
installation to be used optimally, certain default settings must
have been made and the installation carried out according
to the relevant instructions.
Start page
Boiler status Week day
Hot water program
Time
Set boiler temp.
Boiler temp.
Processor temp.
Monitoring status
Heating program
Number unacknowledged
alarms
Burner program
OFF Th
OFF
This is the menu that is displayed when PELLUX 100 is in its
normal/start mode. The menu displays the boiler status, set
temperature for the boiler and the present temperature. One
can also see the date, time, whether the control computer
is being used or not, which hot water program is being run,
what heating program is being run, how many unacknow-
ledged alarms there are and the processor temperature.
Boiler status
Boiler status states what the boiler is doing right now.
ExplanationStatus
Burner OFF and boiler monitoring are not
running.
OFF
Cleaning the boiler.Cleaning
Settings of fuel volume for firing up, start of
the firing up sequence and fans.
Firing up
When the fuel has been ignited and a flame
can be detected, the fuel volume is increased
until the correct amount and speed is
reached.
Starting
The burner is operating at 100 % outputPower 1
The burner is operating at a preset value of,
for example, 50 % output
Power 2
The burner is operating at an adapted level.Modulation
Extinguishes the fire and controls the fans
until the flames have died down completely.
Burning off
The burner does not operate when the boiler
set temperature has been reached.
Stop
Control computer
The boiler is controlled by a computer that ensures that all
component parts work in the most efficient way for the rel-
evant operation.
The control computer controls and monitors heating and hot
water production and provides information about set control
conditions. In the event of a malfunction, an alarm and
warnings are transmitted to the display to keep the user in-
formed about the conditions at all time.
The control computer controls the boiler in a way that pre-
vents damage to the installation.
7PELLUX 100
For Home Owners
Front panel

Simplified menu
After opening the simplified menu using either the Up or Down arrows these can be used for orientation in the menu that one
wishes to look at. When you have found the menu that you wish to change or see sub-menus in open it by pressing Enter.
ExplanationMenu
You can see the heat pump's present (large digits) and the set temperatures (small digits) here.
Boiler Temperature
To change the set boiler temperature, press Enter.
You can see the hot water's present (large digits) and the set temperatures (small digits) here.
Hot Water Temperature
To change the set hot water temperature, press Enter.
This menu applies to section 1.
Here you can temporarily (once) let the boiler heat the hot water to a comfortable temperature
regardless of the settings.
NO
Heat Now
This menu applies to section 1.
There are three different hot water controls:
Hot Wather Program
Manual
1. Interval - heats the hot water in relation to set time intervals.
2. Continuous - ensures that the hot water always maintains a comfortable temperature
regardless of the set time intervals.
3. Disconnected - does not create hot water.
This menu applies to section 1.
You can see the room temperature in room number 1 (large digits) and the set temperatures
(small digits) here.
Central Heating Temperature
To change the set room temperature, press Enter.
This menu applies to section 1.
Heat control for section 1.
Heating Program
Time
1. Interval - heats the section in relation to set time intervals.
2. Continuous - ensures that the section always maintains a comfortable temperature
regardless of the set time intervals.
3. Disconnected - does not produce heat.
This menu applies to section 1.
Here you see if the burner has permission to operate.
Burner Work
If the burner does not have permission to operate the control computer monitors the heating
system but does not start the burner even if the boiler/heating system temperature falls below
the set values.
Manual start of fuel feed from the pellet hopper.
Feed Fuel
After filling an empty pellet hopper this function must be used until the fuel starts to come
out of the fire proof hose from the pellet auger.
PELLUX 1008
For Home Owners
Front panel

Dealing with malfunctions and maintenance
General
Alarm
In event of unacknowledged alarm the LED lights with a
continuous red light.
In event of an acknowledged alarm the LED on the control
computer lights with a flashing red light.
To see what has occurred, go in under the Alarm menu
where you will find an alarm code. For explanation of alarm
codes see page 31.
ENTER
ON/OFF
INFO
ESC
12:05
/(' ODPS
2)) 7X
Pellet burner
For the best economy and minimum environmental impact
ensure that the pellet burner is always optimally adjusted.
Checking and adjusting is carried out by a specialist and
should be carried out before every firing season. For further
information about this refer to the relevant manual for the
pellet burner.
Circulation pump
Even if the circulation pump, for a longer period is set to
“OFF”, the boiler’s computer will run the pump for 3 minutes
twice a day. This is so that the circulation pump does not
jam.
Sweeping
Fire regulations state at what intervals a boiler and its chim-
ney must be swept; contact a professional chimney sweep
for more information.
!WARNING!
The current to the boiler must be switched off during
service and maintenance of the boiler and burner.
The boiler is equipped with automatic sweeping of the flues,
which means that manual sweeping of these is not required
between the chimney sweep’s normal visits. In order to obtain
the optimal efficiency with a modern and correctly adjusted
pellet burner the boiler’s other fire affected surfaces should
be cleaned/swept occasionally between the chimney sweep’s
visits.
Before the sweep visits, the hatch for any draft limiter must
be locked by turning the locking screw a quarter turn to the
side of the hatch. This is to prevent soot from entering the
boiler room when the chimney is swept. After sweeping the
hatch must be unlocked again. For more instructions see the
sweeping chapter page 8.
9PELLUX 100
For Home Owners
Dealing with malfunctions and maintenance

REMEMBER:
When the door for the combustion chamber opens, all cur-
rent to the pellet burner is automatically cut. The hatch must
be fully closed in order for the burner to start incandescing.
Check the optimum setting of the burner flame through the
sight glass.
APH
At the bottom of the hearth there is a removable ash box
and a soot box. The ash box and soot box are generously
sized and have room for ash and soot from two month’s
normal firing.
NOTE
Ash can still contain glowing embers after a long
period of time. Therefore, always use a non-inflam-
mable container and protective gloves when emptying
ash and soot.
Causes and actions in event of malfunctions
In the event of a malfunction or disruption to normal
operation, first check the points below:
!WARNING!
If work behind covers or panels must be carried out
the safety breaker must be locked or the group fuses
removed!
The boiler water section must be water filled before
starting, otherwise the temperature limiter function
and immersion heater may be endangered.
NOTE
A tripped temperature limiter is a warning, if it occurs
more than once a repairman must be called.
Low room temperature
႑Incorrectly set shunt valve (when manually shunting).
႑Tripped temperature limiter. It may have tripped during
transportation.
႑Air in the boiler or radiator system.
႑Closed valve in the radiator circuit.
႑The circulation pump is switched off or has jammed, see
section "Helping the circulation pump to start".
႑Malfunctions in the pellet burner. See special instructions
for the burner.
႑Miniature circuit breaker tripped.
႑The load monitor or some external control unit may have
blocked the power output.
႑Max flow line temperature set too low.
႑Possible earth circuit-breaker tripped.
႑Switch set to 0.
႑External control may have blocked the burner.
႑Circuit or main MCB tripped.
High room temperature
႑Automatic heating control system settings incorrect.
Resetting temperature limiter
There are two temperature limiters on the boiler. One on the
boiler and one on the burner.
The temperature limiters break the power to the burner and
pellet screw if the temperature exceeds 90 °C.
Before the burner and the pellet screw are started again the
tripped temperature limiter must be reset, see page 38.
PELLUX 10010
For Home Owners
Dealing with malfunctions and maintenance

Auxiliary start of the external circulation pump
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႑Shut off the circulation pump.
႑Loosen the venting screw with a screwdriver. Hold a cloth
around the screwdriver blade as a certain amount of
water may run out.
႑Insert a screwdriver and turn the pump rotor.
႑Screw the venting screw into place.
႑Start the circulation pump and check that the circulation
pump functions.
It is usually easier to start the circulation pump if it is switched
on. If helping the circulation pump to start is performed in
switched on mode, be prepared for the screwdriver to jerk
when the pump starts (external circulation pump not included
in delivery).
NOTE
When returning to normal mode do not forget to reset
the shunt knob to its original position by turning the
knob until it springs out.
NOTE
The product's serial number should always be stated
with all correspondence with NIBE.
069______________
Accessory (if connected)
Low hot water temperature
႑Abnormally large hot water usage.
႑Mixer valve set too low.
႑Closed or throttled shut off valves to heat exchanger (or
to hot water heater if present).
႑Tripped temperature limiter. These may have tripped
during transportation.
႑External circulation pump set for low capacity, or does
not start.
႑Too high domestic water flow.
႑Malfunctions in the pellet burner. See special instructions
for the burner.
႑Load monitor or external control may have blocked the
burner.
႑Circuit or main MCB tripped.
႑Possible earth circuit-breaker tripped.
႑Switch set to 0.
႑Incorrectly set operating modes.
႑Closed or throttled filler valve for the hot water heater.
႑The load monitor or some external control unit may have
blocked the power output.
႑The hot water temperature is set at too low a value.
NOTE
A tripped temperature limiter is a warning, if it occurs
more than once a service engineer must be called.
11PELLUX 100
For the Installer
Dealing with malfunctions and maintenance

General information for the installer
Boiler room
The boiler room must be built in accordance with applicable
building regulations.
The floor must not be flammable or must otherwise be
covered by a 0.7 mm thick steel sheet that extends at least
0.5 m out from the boiler in each direction.
Provision for good air supply. The boiler room’s air intake
must have an area of at least 200 cm².
NOTE
Ensure that sweeping can be carried out in accordance
with the applicable regulations. If in doubt, contact a
chimney sweep.
Chimney
It is important that the flue is of sufficient diameter and
height that over pressure does not occur in the boiler and
flue.
PELLUX 100 has an upward top connection with an internal
diameter of 125 mm and is intended for connection to a
chimney with a minimum internal diameter of 125 mm. The
recommended minimum chimney height for this diameter is
6 m at 16 – 20 kW output. The chimney draft is very import-
ant and should be 15 - 25 Pa. For the best combustion and
the lowest environmental impact a draft limiter should be
used. The boiler is supplied with a draft limiter and an angled
flue pipe for rear connection. Straight flue pipe for connec-
tion upwards available as accessory.
The flue needs to be inspected and approved before installa-
tion.
Connection
Pipes are to be installed in accordance with the applicable
heating and hot water standards. Internal support bushes
should be fitted when annealed steel or copper pipe is used.
The supplied drain valve is installed in the connection on the
boiler’s right or left sides.
The overflow pipe from the safety valves must be routed to
a floor drain to prevent hot water splashes when checking
the valves or when bleeding the boiler. The outlet of the
overflow pipe should be visible. The overflow pipe must be
laid frost free and sloping along its entire length.
The hot water circuit must be equipped with a mixer valve
to prevent scalding.
Current regulations require the heating installation to be in-
spected before it is commissioned. The inspection must be
carried out by a suitably qualified person. The installation
inspection must be documented. The above applies to install-
ations with a closed expansion vessel. If the boiler or the ex-
pansion vessel is replaced, the installation must be inspected
again.
If the heating system is equipped with an open expansion
vessel, the distance between the highest radiator and the
expansion vessel may not be less than 2.5 m.
Min 2,5 m
NOTE
The pipe system must be flushed before the boiler is
connected so that any residual contaminants will not
damage the components.
PELLUX 10012
For the Installer
General information for the installer

Pipe connections
This shows the outline diagram for pipe installation when one has a water heater, buffer tank or buffer tank with solar heating
.
PELLUX 100 standard installation
M
M
PELLUX 100 with buffer
M
PELLUX 100 with buffer and solar heating
M
P
13PELLUX 100
For the Installer
Pipe connections

Electrical connections
Connection
Disconnect the heat pump before insulation testing the
building.
PELLUX 100 must be installed via an isolator switch with a
minimum breaking gap of 3 mm.
The boiler requires 230 V NAC 50 Hz
Voltage/supply is connected to terminal block X9.
The boiler must be connected to a dedicated power cable
protected by a 10 A fuse and an earth-fault breaker.
NOTE
Electrical installation and service must be carried out
under the supervision of a qualified electrician. Electric-
al installation and wiring must be carried out in accord-
ance with the stipulations in force.
NOTE
No other consumers may be connected to the boiler's
power supply.
Internal fuse protection
The automatic heating control system, circulation pump,
burner and their wiring are internally fuse protected by a
miniature circuit breaker.
Connecting the control computer
NOTE
Power supply to the heating system must be broken
when the control computer is connected!
The control computer must be connected to all units in the
heating system in order to control them.
Accessories are required to be able to connect all units to
the control computer.
Connection is via a CAN bus which permits connection of:
႑up to 16 heating circuits.
႑two hot water circuits.
႑a buffer tank.
႑solar heating system.
႑extra boiler modules (exhaust fan).
႑a lambda sensor.
PELLUX 10014
For the Installer
Electrical connections

NOTE
Remember to install a terminator at the end of the
CAN-bus to prevent an echo.
There must be a terminator on the CAN bus even if
only one module is connected to it.
The control computer is connected to the CAN bus and the
power supply according to the image below.
15PELLUX 100
For the Installer
Electrical connections

Installing sensors to the control computer
NOTE
Under no circumstances may the protective earth conductor (PE) be connected to the neutral conductor (N)!
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ConnectionsExplanationComponent
IN1, GND--Temperature sensor boiler
IN2, GNDThe safety circuit that stops the burner if it overheats.Temperature limiter circuit
IN3, GND--Temperature sensor hot water
IN4, GND--Temperature sensor supply line
IN5, GND--Room thermostat
IN11, GND--Outside temperature sensor
IN12, GNDLight sensor for the burnerPhotocell
Common neutral potential for sensorsGDN
DO1, NCirculation pump heatingPump
DO2, NShunt openShunt motor
DO3, NShunt closedShunt motor
DO4, NControl grid cleaning in module L1Grid cleaning L1
DO5, NLighter for burnerGlow coil
DO6, NControl grid cleaning in module L2Grid cleaning L2
AO1, N1Fresh air fan for the burner.Fan
AO2, NControl of turbulator cleaningPipe cleaning
AO3, N1--Pellet screw
AO4, N--Circulation pump hot water
--Neutral conductorN
--Protective earthPE
PELLUX 10016
For the Installer
Electrical connections

Connection burner
႑Connect the burner's connection plug to the boiler's
burner socket.
Connecting the outside sensor
Install the outdoor sensor in the shade on a wall facing north
or north-west, so it is unaffected by the morning sun. The
sensor is connected with a two core wire to the CAN bus
model, see table page 16. The minimum cable cross-section
should be 0.4mm2up to lengths of 50 metres, for example,
EKKX or LiYY.
Connection of flow sensor
At delivery the flow line sensor is located in front of the shunt
motor. Pull out the sensor and install it on the flow line. It is
important that the sensor has a good connection with the
pipe and that it is well insulated.
Output for external circulation pump
External circulation pump is connected to CAN bus module,
see table option. 16. The pump is operated using the set
values in the control computer.
17PELLUX 100
For the Installer
Electrical connections

Installing the boiler
Burner
APH
The burner is installed in the outlet for the burner on PELLUX
100s burner hatch. The burner is then secured into position
using the knobs supplied for the burner.
Pellet hopper and pellet screw
PELLUX 100 fuel is fed from a pellet hopper of an external
pellet screw. The pellet screw should be inclined at a rising
angle of 35-45° for best function and most even pellet feed.
The pellet screw that is used should feed approx. 10 kg/h at
continuous operation. The hose must be a little bent and the
hose connections slightly offset from each other.
The pellet screw and pellet hopper are accessories, recom-
mended pellet hopper and pellet screw are:
႑Nibe pellet hopper ZP 300
႑pellet screw from the Nibe PP series.
These are specially adapted to function with PELLUX 100.
The pellet hopper must be positioned in direct proximity to
the boiler.
NOTE
Use only one of the fireproof hoses supplied with the
feed screw to connect the pellet screw to the burner!
NOTE
Ensure that the boiler door cannot be opened when
the fireproof hose is connected to the boiler!
LEK
1. Position the pellet hopper in a suitable location and open
the appropriate hole in the front.
2. Install the pellet screw in the opened hole and to the
feed pipe in the bottom of the pellet hopper.
3. Install the hose and hose clips on the pellet screw outlet
pipe and the burner feed pipe.
4. Make any adjustments of the hose lengths. The hose
must have slight bends to prevent sawdust collecting in
it. The pellet screw outlet section must be slightly offset
in relation to the burner's inlet section.
5. Connect the pellet screw connector to the burner and
connect it to the control computer.
6. Disconnect the hose from the feed pipe and run the
pellet screw via the control computer to feed the pellets
up. When pellets fall down through the hose, ideally into
a bucket, run for a couple of minutes to ensure even
feeding.
7. Reinstall the hose on the feed pipe.
PELLUX 10018
For the Installer
Installing the boiler