Pelltech PK100 User manual

Pellet boiler PK30, PK50, PK100 and PK160
Installation and user manual
DK9803A3

Pellet boiler PK30 PK50 PK100 PK160
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Table of contents
Safety............................................................................................................................................................ 4
Warnings ...................................................................................................................................................... 4
Notice ........................................................................................................................................................... 4
Permitted usage ........................................................................................................................................... 4
Forbidden usage........................................................................................................................................... 4
1 Set of components ............................................................................................................................... 7
2 Delivery................................................................................................................................................. 7
3 Application............................................................................................................................................ 8
4 Boilers safety devices ........................................................................................................................... 9
5 Technical data..................................................................................................................................... 10
6 Pellets ................................................................................................................................................. 11
7 Control and monitoring devices......................................................................................................... 11
8 Boilers’ main parts and measures ...................................................................................................... 13
9 Flue gas circulation in boiler............................................................................................................... 15
10 Boiler installation............................................................................................................................ 15
Boiler room requirements.......................................................................................................... 1610.1
Positioning and aligning of the boiler......................................................................................... 1610.2
Combustion air ........................................................................................................................... 1910.3
Mains supply............................................................................................................................... 19
10.4
Heating system’s water or liquid................................................................................................ 1910.5
Flue gas tube and chimney connection...................................................................................... 2010.6
Safety valve................................................................................................................................. 2010.7
11 Installation instructions.................................................................................................................. 20
12 Installation of the PV-series burner................................................................................................ 20
13 Initial start-up and operating instructions ..................................................................................... 20
Preconditions.............................................................................................................................. 2013.1
Filling the fuel container............................................................................................................. 2113.2
Initial start up of boiler............................................................................................................... 2113.3
14 Cleaning the boiler and burner ...................................................................................................... 21
15 Boiler’s everyday operation ........................................................................................................... 22
16 Warranty and manufacturers liability ............................................................................................ 22
17 Troubleshooting ............................................................................................................................. 22
Annex 1 Connection diagrams’ samples for connecting the boiler ........................................................... 24
Annex 2 Wiring diagrams ........................................................................................................................... 25
Warranty .................................................................................................................................................... 29

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Manufacturer of pellet boilers PK : Pelltech OÜ
Manufacturers address: Sära tee 3, Peetri, Rae vald, 75312 Harjumaa ESTONIA
Name of product: Pellet boiler PK
Ph.. + 372 677 5277
www.pelletikeskus.ee
[email protected]
Related standards ja directives:
EN 303-5
EN 15270
EN 60730-2-5
EN 60335-2-102
EN 61000-6-2 ja EN 61000-6-3
97/23/EU
2006/42/EÜ

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Safety
The boiler and related accessories i.e. burner, auger and hose reflect the state of the art and meet all
applicable safety regulations.
The specified safety requirements are to be followed in accordance with nationally applicable
regulations, standards and guidelines.
Boiler and all accessories operate using 230 VAC electrical current. Improper installation or repair can
pose the danger of life-threatening electrical shock.
Always make sure that the boiler is switched off from the main power supply before performing any
cleaning or maintenance.
Keep children away and do not touch the equipment during operation.
Make sure that no flammable or liquid materials are stored in the boiler room or vicinity of the
boiler.
It is recommended to wear a respirator while handling pellets.
The room where the boiler is installed must fulfill all rules and recommendations in accordance with
local codes and regulations.
All electrical installation, plumbing, chimney sweeping and service work shall be done by certified
and qualified personnel in accordance with local rules and regulations.
Warnings
Changing the construction of the boiler without written permission from the manufacturer is
forbidden.
Only spare parts provided or approved by the manufacturer are allowed to use in order to avoid any
damage to the boiler and dangers resulting from it.
Welding is allowed only after disconnecting the burner from electric supply. The burner’s controller
must be removed from the burner before welding.
Boiler’s door must be closed while the burner is in operation.
Notice
Manufacturer of boilers has right to make changes in construction of boiler.
Present user manual is original user manual for PK boillers.
Permitted usage
Present device is a solid fuel boiler, what produces low pressure warm water. Usage of boiler for other
purposes is not allowed.
Forbidden usage
Outdoor usage of the boiler is case of forbidden usage.

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Boiler’s label

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1Set of components
The boiler is shipped with following components included:
1. Boiler PK
2. Safety valve
3. Screw fastened foot 4 pcs
2Delivery
The boiler is delivered as complete. Boiler is wrapped in card board sheets and packing-film and fixed
with screws with help 2 metallic angle to wooden pallet. Angles shall be removed before boiler’s
installation. To do that boiler’s side panels shall be removed by lifting them slightly up and pulled to
your side. In order to avoid scratches it is recommended to place side panels back after connecting the
boiler. Mounting foots may be used when install boiler to uneven ground.
Safety valve and mounting foots are situated in boilers ash box.
If boiler is delivered together with the burner, so then it is situated in separate cardboard box.
The boiler can be lifted and carried to the installation site by using a pallet truck. There is a welded hook
on the top of boiler what enables to lift the boiler when needed.
The taking-in weights and widths are given in Table1.
PK30/PK50

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3Application
Pellet boiler PK is a highly efficient 2-pass boiler for combustion of wood pellets. It can be used for
heating of single or semi-detached houses or smaller public buildings. PK boiler is designed specially to
work together with PV-series b-version pellet burners. Such combination and integration ensures
efficient, perfect and care free combustion of pellets and helps to save heating costs.
Burner is fixed to boilers door with flange. Door can be opened together with burner.
The boilers body is comprised of welded steel elements.
Boiler is insulated from ambient medium with mineral wool. It reduces dispersion of heat to a minimum.
Boiler side panels are made of tin and are simply to remove. That helps to reduce taking-in weight and
avoid scratches during installation. All boiler panels are covered with high quality powder paint.
The need for boiler’s maintenance depends on the quality of the fuel (pellets) and the output power
(fuel consumption) and varies throughout the year.
Boiler has self-cleaning system that enables simpel and periodical cleaning of heat exchangers tubes.
Controller controls frequency of cleaning cycles according to parameters set up. Self- cleaning system
delivers collected ash to capacious ash box. It is simple to pull ash box out and to empty.
There are two doors enabling access into boiler: burners door and ash box door.
Ash box has to be taken out from ash box door.
For connecting, filling and emptying heating system the PK30 and PK50 boilers have 2 connection
fittings with 1’’ internal thread on back side of boiler and 2 connection fittings with 1’’ external thread
on up side of boiler in distance 125mm.
PK100/PK160
Figure 1 Boilers’ views from front, sides and back

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For connecting, filling and emptying with heating system the PK100 and PK160 boilers have 2
connection fittings with 1,5’’ or 2’’ internal thread on back side of boiler and 2 connection fittings with
1,5 or 2’’ external thread on up side of boiler.
The flue gas fan what adjusts boiler’s draft is integrated to boiler’s outgoing smoke tube. Burner’s
controller controls the rotation of flue gas fan according to underpressure in burners burning chamber
or on selected power level.
The location of smoke tube is possible to change from horisontal to vertical by using intermediate
flange.
Boiler has two thermostats- safety thermostat and boilers thermostat. Boiler has temperature and
pressure gauges. Sensors of all thermostats are mounted into ½ ’’thermostat tube.
Pressure sensor is mounted to ¾ ’’ tube.
PK31 and PK51 boilers have factory installed accordingly 6kW (3x2kw) and 9 kW (3x3kW) electrical
heating elements. Heating elements are equipped with separate thermostat, what switches heating
element on and off, when temperature of heating water differs from pre-set.
Electrical elements need extra mains supply cable. 6 kW element has to be connected with 5x2,5mm2
cable and protected with 3x10A separate fuse or MCB. 9 kW element has to be connected 5x2,5mm2
cable and protected with 3x16 A separate fuse or MCB.
4Boilers safety devices
The boiler has following safety devices against dangerous situations
Safety valve (overpressure relief valve)
Door switch
Safety thermostat
Safety valve applies when pressure in bolier exceeds 2,5 bar. There are several capabilities to mount the
overpressure valve. Some examples are depicted in Annex 1.
Door switch does not enable to start burner when boliers door is open. When to open the boilers door
during burning the door switch interrupts burners work and burner goes to end burning state. By closing
the door burner continues normal burning.
Safety thermostat interrupts boilers work when its temperature rises over 95oC. Safety thermostat has
to be reset manually.
The PV-burner has following safety devices against back-burning and other dangerous situations:
melting hose
temperature sensor
controller
back up battery
safety thermostat
Read more about safety devices of PV- series burners from its user manual.

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5Technical data
Model
Unit
PK30/31*
PK50/51*
PK100
PK160
Rated thermal output
kW
28
47
95
150
Rated thermal load
kW
30
50
100
160
Boiler class according to EN 303-5
5
Minimal returnig water temp.
oC
55
Recommended heating water
temperature
oC
75
Highest working tempetature
oC
90
Safety thermostat’s applying
temperature
oC
95
Permissible operative pressure
bar
2,5
Test pressure
bar
4
Boiler’s water volume
liter
125
150
275
300
Boiler’s weight
kg
196
313
495
620
Dimensions WxDxH
mm
600x600x1510
600x800x1510
785x995x1524
785x1175x1592
In-take width (w.o side panels)
mm
500
500
685
685
Combustion chamber’s
dimensions WxDxH
mm
330x400x700
330x600x700
430x840x710
430x969x710
Mains supply
230V, 50Hz
Electrical consumption at ignition
W
500
Electrical consumption at working
W
50
50
70
200
Electrical consumption at stand
by
W
3
3
3
3
Combustion air inlet hatch
cm2
>200
>300
>600
>900
Ash box volume
l
38
54
97
115
Burner’s fixing flange
mm
90
90
130
130
Number of turbulators
pcs
4
7
14
22
Flue gas outlet
Ømm
112
112
150
150
Chimney’s diameter
mm
>100
>120
>150
>180
Boiler top connections
pcs
2xG1’’
2xG1’’
2xG1,5
2xG2’’
Distance between top
connections
mm
125
125
560
758
Boiler back connections
pcs
2xRp1’’
2xR1p’’
2xRp1,5’’
2xRp2’’
Required safety valve connection
pcs
1xDN20
1xDN20
1xDN25
1xDN32
Electrical heating element*
(option)
kW
6
9
-
-
Flue gas temperature at rated
output
oC
150…180
Efficiency at boiler’s temperature
70 oC
%
94
Table 1 Technical data
1At boiler temperature 75oC, O2=7%, pellets 5kWh/kg

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6Pellets
Wood pellets or saw dust granules are concentrated and homogenized wooden fuel made by extrusion
of sawdust, cutter shavings and stem wood. No extra materials are added, pellets are held together by a
natural ingredient found in wood –lignin. Pellets are CO2neutral, renewable fuel. Its burning doesn’t
spoil CO2balance in the atmosphere. Pellets must be stored in a dry and ventilated room. PK boiler is
foreseen to burn ENPlusA1, A2 ja EN-B wood pellets. Some key data for pellets are given in Table 2.
7Control and monitoring devices
Boiler PK30, PK50
Boiler PK0031 and PK0051
Raw material
Sawdust, cutter shavings, stem wood, logging residues, bark,
chemically untreated byproducts and residues
Calorific value
4600-5200 kWh/tonne
Bulk density
> 600 kg/m3
Volume of 1 ton
1.5-1.6 m3
Diameter
6-8 mm
Length
3,15 …40 mm
Fines content (<3,2 mm)
< 1 %
Moisture content
< 10 %
Ash content
< 3%
Ash fusion temperature
>1100 OC
Boiler thermostat
Safety thermostat
Main switch
Main switch
Temp. and pressure gauge
ja rõhu mõõdik
Boiler thermostat
Safety thermostat
Temp. and pressure gauge
El.heat element’s signal lamp
El.heat element thermostat
Table 2 Pellets key data

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Boiler PK100 and PK160
Main switch of boiler enables to turn boiler and burner on-off.
Boiler thermostat controls burners work by switching it on-off according to set up temperature.
Integrated temperature and pressure gauge shows actual temperature and pressure in boiler
Safety thermostat switches boiler and burner off when bolilers temperature exceeds 95OC. To reset
thermostat the protective covering has to be removed by turning it counter-clockwise. Push white
button of thermostat and turn protective covering back to its place.
Electrical heating element’s thermostat switches heating element on when boiler’s temperature drops
down temperature set on heating element thermostat and off when temperature exceeds pre-set level.
Orange signal lamp of electrical heating element is lit up when heating element is switched on.
Red signal lamp is lit when safety thermostate is applied.
Main switch
Safety thermostat
Safety thermostat’s signal lamp
Boiler thermostat
Temp. and pressure gauge
Boiler’s controller
Figure 2 Control and monitoring devices

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8Boilers’main parts and measures
PK30 boiler’s main parts are similar to PK50 ones.
1. Boiler main switch
11. Flue gas outlet tube
2. Boiler thermostat
12. Connection G1’’ outflow
3. Temp. and pressure gauge
13. Connection G1’’ inflow
4. Safety thermostat
14. Pocket for thermostats Rp ½’’
5. Handle of furnace door
15. Heat exchangers tubes cleaning motor
6. Furnace door
16. DIN rail for electrical connections
7. Handle of ash box door
17. Heat exchangers tubes cleaning mechanism
8. Ash box door
18. Connection Rp1’’ outflow
9. Burner mount flange
19. Flue gas outlet tube
10.Burners cable lead-out
20. Connection Rp1’’ inflow
21. Pocket for pressure cauge Rp¾’’
Top view
Front view
Back view
Side view
Flange of flue gas outlet tube
21
PK50

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PK100 boiler’s main parts are similar to PK160 ones.
PK100
PK160
Front view
Side view
Back view
Top view
Figure 3 Boilers’ main parts and measures

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1. Boiler main switch
13. Flue gas fan
2. Safety thermostat
14. Connection fitting Rp1½’’ or Rp2’’ outflow
3. Safety thermostats signak lamp
15. Connection fittting for over pressure cauge G1’’
4. Boiler thermostat
16. Connection fitting Rp1½’’ or Rp2’’ inflow
5. Temp. And pressure gauge
17. Flue gas fan
6. Boilers controller
18. Connection fitting G1½’’ or G2’’ outflow
7. Burner’s cable lead- out
19. DIN rail for electrical connections
8. Furnace door
20. Heat exchangers tubes cleaning motor
9. Handle of furnace door
21. Heat exchangers tubes cleaning mechanism
10.Handle of ash box door
22. Connection fitting G1½’’ or G2’’ inflow
11. Ash box door
23. Pocket for pressure cauge Rp¾’’
12.Burners mounting flange
24. Pocket for thermostats Rp ½’’
9Flue gas circulation in boiler
10 Boiler installation
Only persons holding necessary licences, knowledge, skills and equipment can be trusted with
assembly of the boiler.
1. Flue gas fan
2. Heat exchanger’s tube
3. Stone wool
4. Connection
5. Ash box
6. Furnace
7. Water jacket
8. Connection
9. Connection
10. Connection
PK0030/50
PK100/160
Figure 4 Flue gas circulation

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Boiler room requirements
10.1
Any room with normal air humidity and temperature is suitable for boiler’s installation. Room has to be
provided with a chimney connection, sufficient draft and fresh air supply. It is not allowed to install
boiler to room that is very dusty or humid. The boiler room should not be too small otherwise boiler’s
heat radiation could overheat it.
Boiler room has to satisfy all local statutory regulations and directives.
Boiler, burner, external auger and pellet container form common system. The size and location of the
pellet container depends on needs and archidtcture of boiler room or boiler house. It is recommended
to install the container to the left from boiler. In this case there is no need to remove augers plastic hose
while open the boiler door. While choosing the pellet container keep in mind that:
if the pellet container is in the same room with the boiler, then the size of the pellet container must
not exceed 500 liters (appr. 350kg).
the container must be made of fireproof materials
the container must be positioned in a way that the raising angle of the feeding auger does not
exceed 45°.
the container could be closed with a cover.
Figure 5 Installation of pellet container, external auger and hose
Positioning and aligning of the boiler10.2
Position of the boiler has to be as close as possible to the chimney in order to avoid having a long flue
connecting pipe. Boiler should be set on a non-flammable heat insulating pad or concrete floor.
In order to enable safety installation and later maintenance, follow recommended clearance
dimensions. Minimal clearance dimensions in centimeters are in brackets. See Figure 6.
The boiler door opens to the left (PK30/50) or to both sides (РК100/160).
In Figures 7, 8, 9 and 10 are depicted dimensions of burners farther edge in millimeters from boiler’s left
side panel when boiler’s door is opened.
45o max
40-70 cm
10 .. 20 cm

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120(100)
30
10(0)
10(5)
40(30)
10(0)
100(80)
A
C
B
A Container
B Boiler
C Burner
Figure 6 Boiler room clearences
Figure 7 Distance of PV20/30 burners farther edge from PK30/31 boiler’s left side panel when boiler’s door is opened

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Figure 8 Distances of PV50b burners farther edge from PK50/51 boiler’s left side panel when boiler’s door is opened
Figure 9 Distance of PV100c burner farther edge from PK100 boiler’s left side panel when boiler’s door is opened

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Combustion air10.3
An adequate supply of combustion air is absolutely essential for normal burning process. Air delivery
shall take place through the non-closed hole, whats cross-sections are given in Table 1.
Mains supply10.4
The boiler is designed for supply voltage 230V/50Hz. TN-S earthing system is used. The boiler and burner
are pre-wired in factory. Boiler has to be connected to mains supply with 3-core cable. It is
recommended to protect burner and boiler against short circuit with 6A fuse or 6A C type MCB or RCD.
It is recommended, that boiler and boiler room lighting system have a different mains supply circuits.
For elelctrical supply of electrical heating element the heating elements have to be connected with 5-
wire 5x2,5 mm2cable. To protect heating elements 3x10A (boiler PK0031) or 3x16A (boiler PK0051) B
type MCB is used.
Installation of electrical components may only be performed by a qualified technician. The regulations
and specifications of local ordinances must be followed.
In areas with increased power surge risk (e.g., lightning strikes in regions prone to storms) installation of
an appropriate surge protector is reccommended.
Electrial diagramms of boilers’ is depicted on Annex 2.
Heating system’s water or liquid10.5
It is allowed to use in heating system:
ordinary drinking water (only minimal refilling!)
softened water
glycol dilution up to 50%
Figure 10 Distance of PV180c burner’s farther edge from PK160 boiler’s left side panel when boiler’s door is opened to left

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Flue gas tube and chimney connection10.6
PK30 and PK50 boilers have 110 mm flue tube outlet for chimney connection. PK100 and PK160 have
150mm flue tube outlet. Flue tube is connected with boilers flue tube flange, whitch measures are
depicted on Figure 3 . Connecting boiler with flue tube and flue tube connecting with chimney has to be
made strictly according to local regulations.
PK boilers have high efficiency, thereof outcoming flue gases have low temperature. If fluegas
temperature in the top of chimney is below 80oC then pitch and water condensate will appear. With
cold weathers they will damage chimney within few years. To protect chimney of the condensate a
metal stainless tube has to be mounted into chimney.
Safety valve10.7
Boilers have 2,5 bar safety valve (overpressure relief valve) in set. Safety valve has to be set to specified
place on boiler. For PK100 and PK160 boiler safety valve is mounted in factory.
11 Installation instructions
To avoid scratching side panels it is recommended to remove side panels and upper thin of boiler before
installation. In order to remove side panels lift them little up and pull to yourself.
To boiler’s set belong 4 screw fastened feet what enable to adjust installation level. In order to mount
the feet boiler has to slope slightly firstly to one side and screw feet to its nests. Then slope boiler
slightly to other side and screw feet to its nest. By screwing feet up or down adjust suitable level of
boiler.
Boiler is lifted to planned place and connected to chimney and plumbing according to project by using
specified materials. The volumes of PK boilers expansion tanks are given in Table 1. Some of boiler
connections are depicted on Annex 1.
After completing installation place side panels and upper thin back to place.
12 Installation of the PV-series burner
Installation of the PV-series burners in particular is described in their user’s manuals.
13 Initial start-up and operating instructions
Preconditions13.1
The following preconditions must be met before initial start-up:
boiler is installed correctly and connected to waterworks and heating system
central heating system is rinsed, filled and vented, heat consumption is provided
domestic hot water boiler is connected and filled
boiler is connected to chimney
no dampers in a fluegas duct
system is fully wired up electrically, burner and external auger sockets are connected firmly
sufficient quantity of fuel (pellets) available in container
external auger is connected to burner and auger is installed according to requirements
boiler’s doors and hatches are closed and all combustion air comes from the burner
boiler’s thermostat is set to lowest temperature
burner is installed correctly, the neck of burning chamber sits correctly in burner’s housing.
burners body and burning chamber are firmly fixed
The initial start-up cannot be carried out if any of these points above are neglected.