Pelltech PK250 User manual

User manual for PK250…1000
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Pellet boiler PK250-PK1000
User manual

User manual for PK250…1000
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Contents
1 General.................................................................................................................................................. 4
1.1 References to other documents.................................................................................................... 4
1.2 Unit description............................................................................................................................. 4
2 Safety..................................................................................................................................................... 5
2.1 Safety Instructions for installation, use and service ..................................................................... 5
2.2 Safety instructions regarding maintenance and cleaning............................................................. 6
2.3 Warnings ....................................................................................................................................... 7
2.4 Safety devices................................................................................................................................ 7
2.5 Permitted usage ............................................................................................................................ 7
3 Technical specifications and dimensions .............................................................................................. 8
3.1 Description .................................................................................................................................... 8
3.2 Technical data ............................................................................................................................... 9
3.3 Dimensions.................................................................................................................................. 10
3.4 Recommended distances for the boiler room ............................................................................ 11
4 Monitoring and control equipment .................................................................................................... 12
4.1 Boiler control unit........................................................................................................................ 12
4.2 Internet module .......................................................................................................................... 13
5 Handling and transport ....................................................................................................................... 14
6 Installation........................................................................................................................................... 15
6.1 Installation room requirements .................................................................................................. 15
6.2 Required installation on site ....................................................................................................... 16
6.3 Connecting the boiler to the chimney......................................................................................... 18
6.4 Connecting safety devices........................................................................................................... 19
6.5 Connecting PV-series burner....................................................................................................... 19
6.6 Hydraulic connecton scheme...................................................................................................... 19
7 Electrical connections.......................................................................................................................... 20
8 Liquid in the heating system ............................................................................................................... 20
9 Initial start-up...................................................................................................................................... 21
9.1 Filling the fuel tank...................................................................................................................... 21
10 Cleaning and maintenance.............................................................................................................. 22

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10.1 Instructions for inspection and maintenance ............................................................................. 22
10.2 Maintenance ............................................................................................................................... 23
10.3 Cleaning the boiler ...................................................................................................................... 24
10.4 Cleaning the burner..................................................................................................................... 24
11 Warranty and manufacturer's liability ............................................................................................ 25
12 Declaraton of conformity ................................................................................................................ 26

User manual for PK250…1000
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1General
The instruction manual is an integral and essential part of the product and must be kept by the user or
system manager. Theowner / user shall read and understand this manual before installation andoperation
of the boiler. This manual is intended for all users and contains general information, installation
instructions and handling with following boilers: PK250, PK350, PK500, PK700 and PK1000, which are heat
generators in boiler category 5 for heating systems with hot water with a safety temperature of 110 °C.
PK-series industrial boilers may only be set up and comissioned by specialists. This rules out any incorrect
assembly. We recommend you pay great attention to the safety regulations.
The manufacturer of the equipment, Pelltech OÜ, demands that the operator of the device is competent
and has sufficient knowledge in the field. The manufacturer does not take responsibility any damage
done to the equipment, personal injury, harm to animals or property damage if an incompetent person
or persons performs work for which he is not qualified or if the person operating of the device fails to
observe the instructions contained in the manual.
Note: Operator is the person or persons responsible for the installation, operation, adjustment,
maintenance, cleaning, repair or removal of the machinery.
1.1 References to other documents
Following document is original user and installation manual for PK250, PK350, PK500, PK700 and PK1000
pellet boilers. In this document are references made to:
Maintenance and cleaning manual for the boiler and burner
Software and problem handling manual for the burner
Software and problem handling manual for BBB series burners (PV350a-PV1000a)
Software and problem handling manual for SBB series burners (PV250a)
1.2 Unit description
Present device is a solid fuel boiler that produces low pressure warm water. PK –series boilers are highly
efficient 3-pass boilers which are meant to go together with PV –series pellet burners. All boilers are
equipped with automatic cleaning of the heating surfaces and fully automatic ash removal system which
extend the maintenance intervals and keep the efficiency high.
Main data is given in section Technical specifications and dimensions.

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2Safety
Read and follow these directions carefully. Read the safety instructions carefully before installation.
Always follow the safety instructions during installation and during maintenance.
Installation, operation, service and other work must be carried out by qualified personnel in accordance
with local codes and regulations.
Proper installation of the boiler is necessary for safe and efficient operation. Installing this product
improperly may result to damage of the goods. Contact your local building inspector to obtain any
necessary permits or inspection guidelines before installing the product. Contact local building or fire
officials about restrictions and installation inspection requirements in your area. Contact your local
authority (such as municipal building department, fire department, fire prevention bureau, etc.) to
determine the need for a permit. A working smoke detector is required and must be installed in the same
room as the boiler.
2.1 Safety instructions for installation, use and service
The owner / user shall read and understand this manual before installation and operation of the burner.
For proper function and to avoid accidents and damage, these instructions must be followed. Wrong
handling and incorrect settings can result in injury, damage and / or malfunction of the equipment.
Following instructions apply to PK-series boilers PK250...PK1000:
The boiler room where the boiler is installed must fulfil all rules and recommendations given by the
local authorities.
To guarantee the efficiency of the appliance and ensure that it functions correctly, it is vital that
qualified personnel performs annual maintenance.
Specified safety requirements must be followed in accordance with nationally applicable
regulations, standards and guidelines.
Before performing any cleaning or maintenance make sure that the boiler is switched off from the
main power supply for atleast two hours.
Keep children away from the equipment .
Do not touch the equipment during operation.
Make sure that no flammable materials are stored in the boiler room or nearby 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 rules and regulations.
All electrical installation, plumbing, chimney sweeping and service work must be done by certified
and qualified personnel in accordance with local rules and regulations.

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Do not obstruct the terminals of intake/ outlet ducts.
Ensure that flue systems are clear. Ensure an adequate supply of combustion air.
2.2 Safety instructions regarding maintenance and cleaning
Touching live components can result in life threatening injuries. After switching the control unit off, there
are still live components inside the control unit until enclosure:
Switch OFF the power supply, e.g. a mains, and check the system is disconnected.
Hot surfaces and fluids can lead to burns:
Before maintenance and cleaning work, switch OFF the system and let it cool down.
Never touch hot surfaces on the boiler, burner, flue system or pipework.
Wear suitable personal protective equipment.
Hot surfaces and fire from aperatures can result in severe burns:
Doors, covers and aperatures fastened shut with screws must not be opened during heating
operation.
Allow hot components to cool down before removing.
When operating the ash container, there is a risk of fire and burns:
Wear suitable personal protective equipments.
Only dispose the hot ash in fireproof containers with covers.
Disposal of hot ash in an unsuitable vacuum cleaner creates a risk of fire from ignition of filters and plastics:
Use an ash vacuum cleaner that is specially designed for this purpose.
Never use domestic vacuum cleaners made of plastic with fabric/paper filters.
Wood dust, pellet dust, cinders and soot pose a risk to the eyes, skin and airways:
Wear suitable personal protective equipment, especially breathing equipment and safety goggles.
Note: Before restarting the heating system, all opened covers and flaps on the boiler must be closed again.
Note: Observe the country-specific regulations on the disposal of materials, waste and system components.
Note: Carry out the cleaning at the specified intervals.

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2.3 Warnings
For personal and operational safety, use only spare parts provided or approved by Pelltech OÜ in
order to avoid any damage to the boiler and dangers resulting from it. Use of spare parts not
provided or approved by Pelltech OÜ will void the warranty.
Do not open any boiler door while the burner is in operation.
Before carrying out any cleaning or maintenance operations, disconnect the appliance from the
mains power supply using the system switch and/ or the relevant external components and let it
cool down.
The appliance must not be used by anyone with little excperience and knowledge, unless they are
supervised or have been instructed to use the appliance by the person in charge of its safety.
2.4 Notice
Manufacturer of boilers has the right to make changes in construction of boiler.
2.5 Safety devices
The manufacturerobligates the end user to use following safety devices with appliances that are described
in this manual:
Working thermostat
Safety thermostat
Boil-dry protection
Overpressure valve
Depending on the local laws and regulations there might be the need for following safety devices:
Overpressure pressure switch
Underpressure pressure switch
2.6 Permitted usage
The appliance is only intended to be installed and operated in sealed unvented heating systems, with due
attention paid to the associated installation, service and operating instructions. It is only designed for the
heating of heating water that is of potable water quality. Any usage beyond this must be approved by the
manufacturer in each individual case.
Incorrect usage or operation is prohibited and will result in an exclusion of liability. Incorrect usage also
occurs if the components in the heating system are modified from their intended use (e.g. if the flue gas
and ventilation air paths are sealed) or if other fuels than those intended for this appliance are used.

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3Technical specifications and dimensions
3.1 Description
The PK250…PK1000 pellet boilers are high-efficiency three-pass water boilers for wood pellet burners and
are designed to supply heat energy to multi-storey buildings or industrial buildings. The boilers are also
suitable for heating networks of smaller settlements. All boilers are non-condensing boilers. To ensure
good burning quality and stable underpressure in the furnace, a smoke extractor must be installed. To
reduce air pollution, an ash cyclone can be installed.
The boiler door is designed symmetrically, which enables opening the door both to right and left.
Automatic cleaning of the heating surfaces and fully automatic ash removal improve efficiency and extend
the maintenance intervals. The burner controller controls the frequency of the cleaning cycles according
to predefined parameters. Ash is cleaned from third and second pass pneumatically and from the furnace
with ash scrape and auger. Although the boiler has its cleaning systems, it has to be cleaned from time to
time manually to keep the burning quality and efficiency of the boiler as high as possible.
The boiler is equipped with following cleaning systems:
Pneumatic cleaning –Third pass heat exchanger tubes and second pass tube are cleaned
pneumatically. Residues are blown back of the boiler into an smoke collector box where the ash is
moved with ash augers to ash container.
Ash scrape –Combustion residues that falls on the bottom of the furnace are scraped to ash auger
and moved to ash container.
Ash auger –Accumulated ash inside the boiler and cyclone is moved with ash auger to ash container
behind the boiler or outside the boiler house.
Ash cyclone –Ash cyclone (if in use) catches fine particles to ensure cleanest flue gases.
Ash container –Ash is collected in a suitable container which shall be regularly emptied.
Industrial PK boilers are specially designed for work with pellet burners accordingly:
PK250 with PV250
PK350 with PV350
PK500 with PV500
PK700 with PV700 or PV500
PK1000 with PV1000 or PV700 (additional flange required)

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3.2 Technical data
Boiler model
Unit
PK250
PK350
PK500
PK700
PK1000
Rated heating output
kW
235
329
490
650
893
Rated heat input
kW
250
350
530
700
950
Heat output range
kW
66-235
94-329
150-490
188-650
235-893
Permiss. operating temperature
°C
95 (110*)
Permiss. operating pressure
bar
4
6
Minimum return temperature
°C
55
Test pressure
bar
5.75
9
Required draught
mbar
-0.04 … -0.12
Total height
mm
1349
1349
1618
1785
Total width
mm
1170
1170
1300
1570
Total length
mm
2303
2794
3288
3712
Combustion chamber length
mm
1441
1933
1954
2784
Combustion chamber diameter
mm
475
621
734
Net weight
kg
983
1204
2037
3168
Boilers water volume
l
523
696
947
1850
Boiler flow and return connections
DN65/PN6
DN80/PN6
DN100/PN6
DN125/PN6
Distance between connections
mm
880
1372
1384
2094
Drain connection (inner thread)
¾"
1"
Safety valve connection
pc
1x 1¼
1x R2"
1x R2"
Mains supply
V
230VAC
3 x 380VAC
Electrical consumption at 𝑄𝑁**
W
480
Electrical consumption at 𝑄𝑚𝑖𝑛**
W
Electrical consumption at stand by **
20
Heat exchange surface
m²
11.93
15.83
23.5
42.6
Flue gas outlet
mm
220x200
300x240
420x240
Flue gas temp. at 𝑄𝑁***
°C
150…170
Flue gas temp. at 𝑄𝑚𝑖𝑛***
°C
114
Flue gas amount at rated output
m³/h
1250
<2500
Efficiency
%
94
Boiler class
5
* Safety thermostat must be regulated accordingly
** Given are electrical consumption with burner corresponding to the boiler (e.g. PK250 with PV250,
PK500 with PV500 etc.)
*** Given are flue gas temperatures at boiler water temperature 75°C / 55°C

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3.3 Dimensions
Boiler model
PK250
PK350
PK500
PK700
PK1000
a
196
195.7
216
218
b
271
291
331
c
1490
1982
2000
2828
d
286
285.5
336
335
e
550
550
702
600
f
70
70
70
62
g
2314
2808
2942
3550
h*
1000/2000
1000/2000/3000
i
1470
1517
j
235
235
k
1278
1278
1518
1688
l
1348
1349
1615
1785
m
1170
1170
1400
1570
n
1070
1070
1280
1450
o
3544
4539
p
305
305
308
358
r
880
1372
1384
2084
s
745
991
1000
1400
t
220
300
420
u
200
240
240
v
240
325
450
w
220
265
270
*Different possibilities for ash removal systems also available

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3.4 Recommended distances for the boiler room
Given are the recommended clearances. To enable convenient installation and maintenance, observe the
stated clearance dimensions; maintain the minimum clearances where the space is tight (dimensions in
brackets).
PK250
PK350
PK500
PK700
PK1000
A1
1600
1800
1900
A2
1211
1390
1570
B
1776
2268
2336
2986
3180
C1
1300
1300
C2
570
660
660
D
500 (20)
E
1070
1280
1450
F
550
900
850
G1
610
810
1050
1165
G2
660
860
1100
1215
Figure 1 Single boilerhouse (left side) and dual boilerhouse (right side)

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4Monitoring and control equipment
The operation of the boiler is monitored and controlled by a burner controller and boiler control unit which
consists boiler controller. Boiler controller is meant to be used as a device for controlling boilers work, but
also as a smart home controller. All of the boilers safety devices are connected to the burners electrical
circuit. According to local laws and regulations, pressure and temperature gauges might be needed.
The boiler and burner operate in fully automatic mode and do not require constant monitoring. The daily
work of the burner is controlled by the boiler thermostat and the burner controller. The thermostat
switches the burner on and off according to the set temperature.
Burner’s controller:
controls the fuel supply and the quality of the combustion process
selects the optimal power levels
controls pneumatic cleaning of the heat exchanger tubes of third and second pass
controls the work of the ash scrape and ash auger
regulates the speed of the flue gas fan according to the pressure sensor or a predetermined power
level
ensures the safety of the entire system
In case of burner error/malfunction please look at document: Software and problem handling manual
DK0391 for PV250 and document DK0209 for PV350…PV1000.
Note: In the event of an emergency or power failure during the work process, the burner will shut down
the boiler and finish its cycle safely.
4.1 Boiler control unit
All of industrial PK-series boilers can be equipped with boiler control unit EB0005 which includes the
following:
Touch controller –can regulate up to 2 valves, up to 4 pumps for boiler circulation, up to 7 wired
temperature sensors, wireless sensors for room and outdoor temperature
Internet module for boiler –enables remote control and data observing and logging via internet
2 working thermostats (mechanical and electronical)
Safety thermostat –automatic cut-off switch
Oxygen sensor –for measuring O2 concentration in the flue gas
2 temperature sensors (1m and 2m) –for measuring flow and return water temperatures
Fluegas temperature sensor –for measuring fluegas temperature

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Note: For further information about the use of boiler control unit please look at the document DK8001 –
EP0012 Instruction manual.
4.2 Internet module
Internet module EP0017 enables simple follow up, control and software upgrade of Pelltech burners and
boilers over the internet. Module is connected with burner or boiler control unit and local internet router.
Internet module is already installed with boiler control unit or inside the burner.
Connecting your burner/ boiler online, gives you opportunity to follow device anytime needed in your
laptop or in your phone. You will get a message in case some error should occur, for example when silo
runs out of pellets or there is an unexpected electrical cut off.

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5Handling and transport
Transport the boiler to the installation location in an upright position. It is permitted to lift the boiler using
pallet truck or by the lifting eyes . Any other transport method is prohibited.

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6Installation
Installation must be performed by qualified staff, which assumes complete responsibility for the definitive
installation and consequent good functioning of the product installed. One must also bear in mind all laws
and national, regional, provincial and town council standards present in the country in which the appliance
has been installed, as well as the instructions contained in this manual.
The flue gas exhaust and hydraulic connections must be carried out by qualified personnel who must issue
installation conformity documentation compliant with national standards.
The installation of the boiler is based on the required project documentation and, as a general rule, also a
building permit.
6.1 Installation room requirements
The boiler room must meet all the requirements, instructions, standards and regulations established by
local legislation, which means that the entire installation process requires the existence of project
documentation to the extent required by law.
Installation location requirements:
Dry, frost-proof and free of dust
High humidity levels to be avoided
Room must be at sufficient height, area and required fire resistance
Max. ambient temperature 30 °C
Reliable supply of fresh air
Room must provide possibility of installing (modular) chimney
The boiler must be positioned on a non-combustible substrate
The size and location of the pellet tank depends on the capacity of the boiler and the available free space
in the building or outdoors. In outdoor conditions, it is expedient to use prefabricated metal tanks with a
volume that guarantees the required amount of fuel for at least 7-10 days when the boiler / burner is
operating at maximum power. If there is a sufficient interior space, it is expedient to build a pellet tank in
the room adjacent to the boiler house. In both cases, there is a wide range of technical solutions that can
be determined with the help of a specialist.

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6.2 Required installation on site
Step 1: Mounting ash auger under the boiler body

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Step 2: Mounting an ash auger extension
Step 3: Mounting linear motors

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Step 4: Mounting boiler side panels
6.3 Connecting the boiler to the chimney
Although PK boilers are highly efficient, flue gas temperatures below 90 °C can occur during partial load
operation of the boiler. Therefore moisture resistant flue gas duct and chimney should be connected to
the boiler. A boiler flue connection with condensate trap in the flue pipe should also be installed.

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6.4 Connecting safety devices
The pressure relief valves in the boiler must not exceed the permissible operating pressure of the boiler
(see Technical data). To install the pressure switch, the boiler has a 3/4"pipe nipple on top of the boiler.
The dry-boiling protection is installed according to the design of the hydraulic part. The electrical switches
of all safety devices are connected to the pellet burner connector X13.
6.5 Connecting PV-series burner
Installation of the PV-series burner on the boiler door is described in document: Installation manual of
PV250…PV1500 pellet burner.
6.6 Hydraulic connecton scheme
Depicted are two samples of possible solutions for connecting the boiler. Inside the green square is the
consumer side of the system.

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7Electrical connections
None of the boilers have external electrical connections. All electrical equipment installed on the boiler is
connected directly to the burner. When using a boiler controller, all of the safety devices are connected
to the boiler controller. In the absence of the controller, the electrical connections of the safety devices
must be connected in series to the burner safety circuit.
The boiler comes with the following electrical equipment:
Linear motor for moving the ash scrape
Linear motor for the flue gas collector chamber damper
Pneumatic valve controller
Ash auger
PK250 is designed to operate from 230V/50Hz supply. The other boilers are designed to operate from
3x380V 50Hz supply. A description of the electrical connection diagram for the boiler and burner is given
in section “Electrical connections” of the corresponding pellet burners installation manual.
All of the electrical connections to the equipment may only be made by qualified personnel. All applicable
norms, rules, instructions and standards must be observed when performing electrical work. In
overvoltage hazardous areas, it is advisable to protect the equipment with appropriate overvoltage
limiters.
8Liquid in the heating system
Unsuitable fill water increases the level of deposits and corrosion, and may lead to system damage.
Flush the heating system thoroughly before filling.
Only fill with water of potable quality.
Special antifreeze suitable for heating systems can be added to the fill water.
In the heating system is allowed:
softened water
up to 50% glycol solution