Octagon bio 3 User manual

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OCTAGON
USER GUIDE
Pellet Burner
Series Octagon
Model bio 3 –Fbio 3
3’’

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CONTENTS
SECTION
CONTENTS
PAGE
1
Letter of thanks
3
2
Instructions for use
4
3
Burner’s operating principles
5
4
Burning phases
7
5
Choosing the right burner
8
6
Safety rules
9
6.1
Safety installation instructions to licensed technicians
9
7
Package
10
7.1
Package contents
11
7.2
Pellet burner parts
12
8
Spare parts
13
9
Burner fuel
15
9.1
Technical characteristics of wood pellet according ΕΝ 14961-1
16
10
Fuel feeding - Auger
17
11
Fuel tank
18
12
Burner installation
19
12.1
Installation steps
19
13
Electrical installation - Sensors
20
14
Burner display screen
21
15
1st level - Configuration of the burner
22
15.1
Display symbols and keyboard buttons
22
15.2
Basic configuration of burner
24
15.2.1
Power rating
24
15.2.2
Boiler water temperature
25
15.2.3
Fuel
25
15.2.4
Time
26
15.2.5
Programming
26
15.2.6
Filling of the auger
26
16
2nd level - Configuration of the burner
28
16.1
Access to programming
28
16.1.2
Display of individual parameters of combustion regulation
29
17
Power adjustment of burner
30
18
Troubleshooting
32
18.1
Additional error notifications
33
19
Tables
34
19.1
Table 1, Configuration values, Auger-Fan with pellets of category 2
34
19.2
Table 2, Table of Parameters
36
20
Maintenance and checks to be performed by end user
37
21
Warranty
38
22
Maintenance log
40
23
Brief instructions for initial adjustments and operation
41
24
Certificates
43
25
Quality control checklist
44

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1. LETTER OF THANKS
Thank you for choosing the pellet burner of OCTAGON.
We would like to reassure you for the high quality of our product which we trust will
fully satisfy your requirements.
OCTAGON will always be at your service maximizing the value of your purchase.
For a better future,
more sustainable,
more affordable.
Please read carefully the section under the heading “OPERATION OF THE BURNER” to
ensure proper understanding of the operating principles of the pellet burner.
Management & Production of OCTAGON

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2. INSTRUCTIONS FOR USE
The device can be used by persons over eighteen (18) years of age with full physical, neurological
and mental capabilities and persons with no previous experience and skill or persons being
trained for the use of the device but always under the supervision of person responsible for their
safety.
Do not allow children to play with the device.
The cleaning of the device should not be done by children without the supervision of an adult.

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3. BURNER’S OPERATING PRINCIPLES
First start
The pellet burner has predetermined configurations of maximum and minimum power rating by
the manufacturer.
The authorized trained technician who will fire up the burner has the option –if necessary –to
reduce the maximum power of the burner to fit the power of the boiler or a specific user’s
requirement.
Operation of the burner
First check
Once the start command is given by the user, the burner performs a series of checks to the
whole system in order to ensure that all parameters permit its smooth and safe start.
To this effect the burner checks immediately a number of parameters e.g. the water
temperature or the exhaust gas temperature. The values of all parameters should be within a
predetermined and acceptable range as indicated by the manufacturer to enable start of the
burner.
Combustion of the burner
After the controller performs the first check, the auger feeds the pellet burner with a specific
quantity of pellet and ignition is generated with the use of an electrical heating element.
Burning
When the flame sensor “detects” - within a specific time frame - that the flame’s intensity is
sufficient then the pellet burner will proceed to the BURNING PHASE aiming to the maximum
power level.
Should the flame sensor does not confirm the required intense of flame within the specific time
frame then the starting process is stopped and an “error” notification is displayed which is
accompanied with the code diagnosing the type of error (see §18 “Troubleshooting”).

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The innovation of Octagon pellet burner bio lies with two crucial elements relating to
combustion:
a. The operation of the burner is totally proportional, within the predefined parameters,
subject to automatic adjustment of the level of power (self adjustment). In this way the
pellet burner will provide always the power required by the system and will achieve the
maximum possible fuel economy
And,
b. The pellet burner will control the burning process by the constant and excellent control
of the boiler’s backpressure and the chimney draft. The control of the fan ensures not
only the extraction of the exhaust gas but mainly minimizes the possibility of “backfire”
from the supply pipe.
Gradual reduction of combustion level
As soon as the burner achieves the predefined water temperature it will automatically reduce its
power so as to remain functional within the set temperature range and below the upper safety
limit. At this point the burner operates with the necessary, minimum power meeting the
required thermal need.
END OF BURNING
The smooth termination of burning is achieved by ensuring the complete burning of any
remaining fuel in the combustion chamber. This is achieved by continuous monitoring of the
flame through the flame sensor which drives the fan that will continue to work in order to burn
all residual pellets in the flame tube.
Thereafter, the fan continues at maximum speed for a period of time so as to clean the burning
chamber from the ashes and preparing it for the next fire up.

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4. BURNING PHASES
Everything described in the previous chapter, OPERATING PRINCIPLES, is outlined in the cycle
below which is divided in four sections:
A. FIRE UP, yellow colour
The burner checks whether there is flame in the burning chamber, in case of a KEEP FIRE status,
so as to offer the minimum required power to the system. Whatever the status of the burning
chamber may be, the burner will proceed with full ignition of the fuel intensifying the flame until
the threshold of burning phase is reached.
B. BURNING
The power of the burner rises progressively whilst it performs constant checks to all parameters
of the combustion in order to allow the maximum desired thermal performance with utmost
economy.
C. FIRE DOWN
When the water temperature approaches the set threshold then the burner regulates POWER to
achieve balance in the system. Gradually, the reduction in burning will lead the system to KEEP
FIRE or OFF status.
D. KEEP FLAME OR OFF
The burner at this phase is put in stand-by mode either turned off or keeping the flame. In both
cases it can be put back to FIRE UP status.
OCTAGON Hellas

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5. CHOOSING THE RIGHT BURNER
In order to make to right choice of burner - both technically and practically - you need to take
under consideration certain basic parameters:
1. The burner is designed to burn wood pellets ONLY. The use of any other type of pellet
such as agro-pellets (pellet made of agricultural by-products) without the approval of the
manufacturer is explicitly prohibited.
2. Make sure that your boiler is designed to burn pellets. The manufacturer of the boiler
will indicate the appropriate type of fuel and will provide relevant information for proper
combustion including the following:
Output power for the particular fuel. This should be equal to or less than the
maximum rated power of the burner as indicated on the name plate of the burner.
Minimum chimney draft.
Regulation of the burner’s damper.
Exhaust gas temperature.
3. Additionally, please note that:
The minimum capacity of the combustion chamber should be 0,06 m3in respect of
models bio 2 and 1 and 0,12 m3 in respect of model bio 3 in order to achieve the
maximum power of the burners.
For the unhindered opening of the boiler door both the door and the burning
chamber of the boiler should have minimum width as follows:
oThirty (30) cm in respect of model bio 2
oForty (40) cm in respect of model bio 3
The minimum length of the burning chamber should be:
oForty (40) cm in respect of model bio 2
oFifty two (52) cm in respect of model bio 3
The length of the flame should be at least five (5) cm below the above mentioned
values.
The space in front of the boiler should be free in an arc 90°towards the same
direction to which the door opens and at a distance of at least a hundred (100) cm to
ensure unhindered door opening when necessary.
The burner should be installed ONLY in horizontal position.
POINTS TO REMEMBER
The technician responsible for the installation and the first fire up of your burner is
obliged to provide you with a “Combustion Certificate” which includes the following:
The type of the burner
The type of the boiler
The exhaust gas temperature
The content in CO and CO2.

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6. SAFETY RULES
The pellet burner is an electric/electronic device that operates with 230 V –50 HZ. According to
applicable legislation its installation, connection, regulation, operation and service should be
done by trained personnel authorized by the local authorities.
It is expressly forbidden for anyone to modify parameters of 2nd level of configuration except for
trained licensed technicians.
The private individual and end user of the pellet burner may operate and adjust the burner ONLY
in so far as the basic commands of the burner are concerned and ONLY using the display and
programming touch screen situated on the metal casing of the pellet burner.
6.1. SAFETY INSTALLATION INSTRUCTIONS TO LICENSED TECHNICIANS
Please ensure that the boiler standards comply with applicable legislation. The boiler must be
connected with the hydraulic system and the chimney.
Measure the chimney draft and make sure that it is in line with the requirements of the
manufacturer of the boiler.
Please adhere to all instructions concerning start up and make sure to use only approved and
certified materials.
Never open the door of the boiler while the burner is in operation.
The burner conforms to European Directive ΕΝ 15270
and is CE marked.
ATTENTION
Always ensure that the boiler’s flame damper is
open to allow optimum level of draft.
NEVER fire up the burner when the flame damper
is closed as there is serious DANGER of the flame
returning to the burner.

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7. PACKAGE
The pellet burner will be packed in hard cardboard box of dimensions 60 cm X 40 cm X 40 cm
(Length / Width / Height) and will bear an adhesive label showing the model of the burner as
follows:
Model
Special care is given to the packing of the burner to make sure that it will be delivered to you
safely and free of any damage. The product is wrapped in thick polystyrene sheets and placed in
a plastic bag.
ALWAYS STORE THE PACKED PELLET BURNER IN CORRECT
HORIZONTAL POSITION AWAY FROM MOISTURE.
bio 2

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7.1 PACKAGE CONTENTS
Each package contains:
oA user guide manual with information in respect of installation,
operation and maintenance.
oA burner with its metal casing and the display screen, connected with its
stainless steel burning chamber.
oA stainless steel pipe 2” for the feeding of the fuel.
oA certificate of quality control including the date of production of the
burner at the last part of the manual.
T h e a u g e r i s s u p p l i e d t o g e t h e r w i t h e a c h b u r n e r .
FOR SAFETY REASONS THE DISPLAY SCREEN IS NOT
CONNECTED TO THE ELECTRONIC CONTROL UNIT OF THE
BURNER. THE CONNECTION SHOULD BE EXECUTED BY THE
LICENSED TECHNICIAN.
DO NOT FORGET TO CHECK THAT ALL PARTS OF
THE BURNER ARE FIRMLY CONNECTED.

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7.2 PELLET BURNER PARTS
The pellet burner consists of the following parts:
1) A steel metallic casing electrostatically painted (green).
2) An electronic display and programming touch screen.
3) A connection cable of the screen to the central control unit.
4) A stainless steel frame body with flange for fixing the burner to the boiler.
5) One (1) centrifugal fan of 40 W.
6) An electronic central control unit (plc).
7) An electric heating element of 250 W.
8) A flame sensor.
9) Electric connector.
10) A stainless steel feeding tube 2” with insulating flange.
11) A bimetallic contact thermostat, STB, with manual reset placed in the 2” stainless steel
feed tube.
12) Three (3) cable glands for the accommodation of the connection cables.
13) A high heat resistant stainless steel flame tube for the combustion of the fuel.
14) A high heat resistant stainless steel combustion rack.
15) A screw to hold the rack.
16) A mineral insulation of twenty five (25) mm for the flange.
17) Internal insulation of five (5) mm for the flame tube to the casing.
18) A boiler water temperature sensor.
19) An exhaust gas temperature sensor.
A metallic auger moving the pellets from the fuel tank to the burner via electric motor
of 50 W.
This is packed with a polyurethane flex hose to be connected with the stainless steel
feeding tube.

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8. SPARE PARTS
The table herebelow contains a list of spare parts of a pellet burner by OCTAGON HELLAS
including relevant reference numbers. The reference number should be quoted when an order is
placed.
REFERENCE NUMBER
DESCRIPTION OF SPARE PART
Μ001-1001-1
Steel casing of pellet burner bio 2
Μ001-1001-2
Steel casing of pellet burner bio 3
D100-1100-1
Electronic touch screen LCD
D100-1200-1
Connection cable of screen to the central control unit 1 m.
D100-1200-2
Connection cable of screen to the central control unit 2,5 - 5 m.
D100-1300-1
Wall mounted stainless frame for touch screen
Ρ100-1021-1
Plastic frame for touch screen
Μ001-1100-0
Auger set series OCTAGON , 2 1.2''
Μ001-1100-1
Auger set series OCTAGON , 3''
M001-1400-1
Steel casing for auger motor bio2 & bio3
Ρ100-1011-1
PU flex hose feeding pellet 60 mm (diameter) per m
Ε100-1110-10
Auger motor series OCTAGON
Ε100-1030-1
Cable set for auger
Α100-1001-1
High heat resistant stainless steel flame tube for bio 2
Α100-1001-2
High heat resistant stainless steel flame tube for bio 3
Α100-1011-1
High heat resistant grate for bio 2
Α100-1011-2
High heat resistant grate for bio 3
A100-1021-1
Mineral insulation for the flange 25 mm (thickness) for bio 2
A100-1021-2
Mineral insulation for the flange 25 mm (thickness) for bio 3
F100-0101-2
Internal insulation gasket for flame tube 5 mm for bio 2
F100-0101-2
Internal insulation gasket for flame tube 5 mm for bio 3
A100-1101-1
Stainless steel flanged feeding tube 2’’
F100-0101-1
Insulating flange for stainless steel feeding tube 2''

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S100-1001-1
Flame sensor BRAHMA , FC 8R
S100-1010-1
Electric heating element 250 W
S100-1020-1
Boiler water temperature sensor
S100-1030-1
Exhaust flue gas temperature sensor 1,5 m (length)
S100-1030-2
Exhaust flue gas temperature sensor 3 m (length)
S100-1050-1
Bimetallic contact thermostat with manual reset, STB , for the
2''stainless steel feeding tube
E100-1110-11
Fan with flange series OCTAGON 40 W
D100-1001-1
Electronic central control unit (plc)

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9. BURNER FUEL
The pellet burners of OCTAGON, are designed to burn wood pellets.
The pellets are very small chips of wood along with other logging residues which are compressed
mechanically in order to take a cylindrical shape of around 6 - 8 mm diameter and less than 40
mm of length.
The type of wood used in this process as well as the percentage that each wood contributes to
the final mixture will determine a number of important parameters including the following:
Thermal output (heating power as a value of kW/kg or Kcal/kg or KJ/kg)
Combustion quality (rate of solid residues of burning process)
Cost per kg
The correct regulation of the combustion air in the pellet burner minimizes ash content and
maximizes thermal output. The acceptable rate of ash content is specified by EN 14961-1
(Chapter 7.1, page 14).
It is very important for the proper functioning of the burner as well as fuel economy that the
pellet burner to be fed with certified wood pellet that conforms to European standards and be
supplied from producers who are well established in the market.
The thermal power of wood pellets must be in excess of 4,6 kW/kg so that the final result should
satisfy all the parameters of proper combustion together with your expectations in economy.
DO NOT BUY WOOD PELLETS OF UNKNOWN ORIGIN AND QUALITY.
IT IS TO YOUR BEST INTEREST TO USE ALWAYS THE BEST QUALITY OF PELLETS.

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9.1 TECHNICAL CHARACTERISTICS OF WOOD PELLET ACCORDING ΕΝ 14961-1
The European standard ΕΝ 14961-1, which specifies the technical characteristics of wood pellets,
has not yet been finalized. Upon completion it will become mandatory to all European Union
member states. As at today (September 2012) every member state has its own standards.
SIZE
MEASUREMENT UNIT
VALUE
DIAMETER
mm
6 - 8
LENGTH
mm
3,15 - 40
DENSITY
kg/m3
≥600
FINES
w-% dry
≤1
MOISTURE CONTENT
w-% dry
≤10
ASH CONTENT
w-% dry
≤0,7
THERMAL POWER
MJ/kg
16,5 - 19
Sulphur
w-% dry
≤0,03
Nitrogen
w-% dry
≤0,3
Chlorine
w-% dry
≤0,02
Arsenic
mg/kg
≤1
Cadmium
mg/kg
≤0,5
Chrome
mg/kg
≤10
Copper
mg/kg
≤10
Mercury
mg/kg
≤0,1
Lead
mg/kg
≤10
Zinc
mg/kg
≤100
Nickel
mg/kg
≤10
Additives
%
≤2

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10. FUEL FEEDING - AUGER
The feeding of the pellet burner is achieved using a metal auger which rotates via a motor and
transfers pellet from the fuel tank to the burner.
Between the feeder and the inox feeding tube of the burner, a polyurethane flex hose is used.
Relevant hose is flame retardant for safety reasons in case of gases and flames return from the
combustion chamber through the inox feeding tube to the fuel tank (reverse path). In this case
the tube will melt by the high temperature creating a disruption of the gases direction from the
burner to the fuel tank.
The slope of the auger should be within the range of 40 - 45 degrees.
Relevant slopes are achieved by OCTAGON fuel tanks of 200 and 350 litres. In case of different
slope please contact the manufacturer for instructions as this will interfere with the proper
supply of the fuel.
Never leave the fuel tank without pellets as then you will be required to fill the auger manually
(see §15.2.6 “Filling the auger”).
MAKE SURE THAT THE PLASTIC PIPE IS OUTSTRETCHED WITHOUT CURVES
THE OPERATION OF THE BURNER MAY BE INTERRUPTED
CORRECT POSITION WRONG POSITION
Minimum
height 40 cm.

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11. FUEL TANK
The fuel tank plays an important role in the proper and undisturbed feeding of the burner.
OCTAGON has designed a fuel tank - with special interior - that fully meets the requirements of
the burner by ensuring steady and safe operation of the auger and allowing maximum utilization
of the stored pellets.
DO NOT USE HOMEMADE FUEL TANKS
AS THIS WILL JEOPARDIZE
THE PROPER OPERATION AND FEEDING OF THE BURNER
Diagram of fuel tank of 200 liters (usable volume)