Pelltech PK30 User manual

Pellet boiler PK30/31, PK50/51, PK100 and
PK160
Installation and user manual
DK9803A7

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Table of contents
1 General ......................................................................................................................................................... 3
Application............................................................................................................................................ 3
2 Safety............................................................................................................................................................ 3
Safety instructions for installation, use and service................................................................................ 3
Warnings .............................................................................................................................................. 4
Safety devices ....................................................................................................................................... 4
3 Fuel............................................................................................................................................................... 5
Pellet quality......................................................................................................................................... 5
4 Technical data............................................................................................................................................... 6
Measurements and main parts.............................................................................................................. 7
Control and monitoring devices............................................................................................................. 9
Flue gas circulation in boiler.................................................................................................................10
Permitted usage...................................................................................................................................10
5 Set of components .......................................................................................................................................11
6 Delivery........................................................................................................................................................11
7 Boiler installation .........................................................................................................................................13
Boiler room requirements....................................................................................................................13
Boiler room clearances.........................................................................................................................13
Combustion air.....................................................................................................................................15
Mains supply........................................................................................................................................15
Heating systems water or liquid ...........................................................................................................16
Flue gas tube and chimney connection.................................................................................................16
8 Installation instructions................................................................................................................................16
9 Installation of the PV-series burner...............................................................................................................16
10 Initial start-up and operating instructions.................................................................................................16
Preconditions.......................................................................................................................................16
Filling the fuel container.......................................................................................................................17
Initial start up of boiler.........................................................................................................................17
11 Cleaning the boiler and burner .................................................................................................................17
12 Boiler’s everyday operation......................................................................................................................18
13 Warranty and manufacturers liability .......................................................................................................18
14 Troubleshooting.......................................................................................................................................19
Annex 1 Connection diagram samples for connecting the boiler............................................................................20
Annex 2 Wiring diagrams ......................................................................................................................................21
15 Installation protocol.................................................................................................................................25
Declaration of confirmity ......................................................................................................................................26
Energy label .........................................................................................................................................28

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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.+3726775277
www.pelltech.eu
[email protected]
1General
This manual is intended for all users and contains general information and handling with PK30, PK boiler.
We recommend you pay great attention to the safety regulations. The owner / user shall read and
understand this manual before installation and operation of the burner.
Application
Pellet boiler PK is a highly efficient 2-pass boiler for combustion of wood pellets. It can be used for
heating a single or semi-detached houses or smaller public buildings. PK30 and PK50 boiler is specially
designed to work with PV-series B-version burners. Such combination and integration ensures efficient,
perfect and care free combustion of pellets and helps to save heating costs.
The end-user is obliged to maintain the device according to the following manual in order to avoid any
problems. The need for boiler’s maintenance depends on the quality of the fuel (pellets) and the output
power (fuel consumption) and it varies throughout the year.
2Safety
Read and follow these directions carefully. Read the safety instructions carefully before installation.
Always follow the safety instructions during installation and during maintenance. Follow the safety
instructions on the warning and notice signs!
Installation, operation, service, and other work must be carried out by qualified personnel in accordance
with local codes and regulations.
Always follow the instructions for operations and service.
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 and damage and / or malfunction of the equipment.
•The room where the boiler is installed must fulfill all rules and recommendations in accordance
with local codes and regulations.
•All plumbing and chimney sweeping shall be done by certified and qualified personnel in
accordance with local codes and regulations.

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•Boiler and all accessories operate using 230VAC electrical current. Improper installation or repair
can pose the danger of life-threatening electrical shock.
•All electrical installation and service work shall be done by certified and qualified personnel in
accordance with local rules and regulations. Do not perform electrical work unless you have the
required qualifications. Perform a complete boiler shutdown and disconnect the power supply
prior to performing any work on the device. Observe all guidelines with respect to installation,
service, or cleaning.
•Keep children away and do not touch the equipment during operation.
•There is a risk of fire. Make sure that no flammable or liquid materials are stored in the boiler
room or vicinity of the boiler. Do not use chemicals or fluids to start the burner fire. Do not burn
garbage, gasoline, naphtha, engine oil, or other materials.
•There is danger to life from flue gas poisoning. Make sure there is adequate combustion air
under all circumstances in the boiler room.
•It is recommended to wear a respirator while handling pellets.
•Use only approved pellets as described in the section Error! Reference source not found..
Burning any other type of fuel voids the warranty.
•Follow the manual carefully. Follow the recommended cleaning and maintenance.
Proper installation of the boiler is necessary for safe and efficient operation. 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 burner. This installation must conform to local codes and regulations.
Warnings
•Changing the construction of the boiler without written permission from the manufacturer is
forbidden.
•For personal and operational safety, use only spare parts provided or approved by Pelltech OÜ in
order to avoid any damage to the burner and dangers resulting from it. Use of spare parts not
provided or approved by Pelltech OÜ will void the warranty.
•Manufacturer of burners has the right to make changes in construction of burner and its
firmware.
Safety devices
The boiler is equipped with following safety devices:
•Safety valve (overpressure relief valve): will apply when pressure in boiler exceeds 2,5 bar.
There are several possibilities to mount the overpressure valve. Some examples are depicted in
Annex 1.
•Door switch: does not allow to start the burner when the door of boiler is open. When the boiler
door is opened during work process the burner will automatically shut down and go to end burn
state. By then 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.

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3Fuel
Only wood pellets only shall be used with PK-series boilers. Not only premium but also the industrial
pellets can be used. Burning wood pellets according to recommendations and the specifications set
forth will assure longer burner life and lessen potential maintenance issues. 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 is given in Table 1.
Pellet quality
Not all wood pellets make good fuel. It is always a good idea to review the pellet’s analysis and try some
before committing to several tons. Higher pellet quality allows for more efficient operation. Many
variables contribute to the quality of a wood pellet. Many of these have been identified and are
regularly tested for by most pellet manufactures and distributors.
Pellet material: Pellets should be made of softwood or hardwood or some combination of the two.
Pellets should smell like wood. If not, then other materials may have been used in their manufacturing
process. Examples are cardboard and paper that produce excessive ash and require chemical binders to
hold the pellets together. All wood pellets (100% wood) don’t require binders and rely on the lignin in
the wood to hold the pellets together. A few all wood pellets dropped in a glass of water should swell up
quickly. If they don’t swell up, this may be an indication that the pellets are not entirely made of wood.
The following table represents the pellet properies that are recommended by Pelltech.
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
5 …40 mm
Fines content (<3,2 mm)
< 1 %
Moisture content
< 10 %
Ash content
< 2%
Ash fusion temperature
> 1100 OC
Table 1 Wood pellets

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4Technical data
Table 2 Technical data
Model
Unit
PK30/31*
PK50/51*
PK100
PK160
Heat output range
kW
11-24
18-42
26-90
40-140
Rated thermal load
kW
30
50
100
160
Boiler class according to EN 303-5
-
5
Minimum return water temp.
oC
55
Recommended heating water
temp.
oC
75
Permiss. working tempetature
oC
90
Safety thermostat’s triggering
temp.
oC
95
Permiss. operating pressure
bar
2,5
Test pressure
bar
4
Dimensions WxLxH
mm
600x600x1510
600x800x1510
785x995x1524
785x1175x1592
Combustion chamber’s dimensions
WxLxH
mm
330x400x700
330x600x700
430x840x710
430x969x710
In-take width (w.o side panels)
mm
500
500
685
685
Boiler’s water volume
l
125
150
275
300
Ash box volume
l
38
54
97
115
Boiler’s weight
kg
196
313
495
620
Mains supply
230V, 50Hz
Electrical consumption at ignition
W
400
300
Electrical consumption at stand by
W
3
7
Electrical consumption average
W
50
70
110
Electrical heating element*
(option)
kW
6
9
-
Combustion air inlet hatch
cm2
>200
>300
>600
>900
Number of turbulators
pcs
4
7
14
22
Chimney’s diameter
mm
>100
>120
>150
>180
Flue gas outlet
Ømm
112
150
Burner’s fixing flange
mm
90
130
Boiler top connections
pcs
2xG1“
2xG1,5“
2xG2“
Distance between top connections
mm
125
560
758
Boiler back connections
pcs
2xRp1’’
2xRp1,5’’
2xRp2’’
Required safety valve connection
pcs
1xDN20
1xDN25
1xDN32
Flue gas temp. at full load/min load
oC
120 / 70
130/80
148/79
174/99
Flue gas mass flow at full load/min
load
g/sec
10 / 5
20/10
40/15
70/30
Efficiency at full load/min load
%
93 / 93
92 / 92
92/94
90/92
CO (13% O2)
mg/m3
95 / 59
232 / 148
157 / 119
185 / 49
Dust (13% O2)
mg/m3
15 / 18
18 / 16
16,1 / 23,7
19,8 / 20,9

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Measurements and main parts
PK30 boiler’s main parts are similar to PK50.
1. Boiler main switch
12. Connection G1’’ outflow
2. Boiler thermostat
13. Connection G1’’ inflow
3. Temp. and pressure gauge
14. Pocket for thermostats Rp ½’’
4. Safety thermostat
15. Heat exchangers tubes cleaning motor
5. Handle of furnace door
16. DIN rail for electrical connections
6. Furnace door
17. Heat exchangers tubes cleaning mechanism
7. Handle of ash box door
18. Connection Rp1’’ outflow
8. Ash box door
19. Flue gas outlet tube
9. Burner mount flange
20. Connection Rp1’’ inflow
10.Burners cable lead-out
21. Pocket for pressure cauge Rp¾’’
11. Flue gas outlet tube
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.
PK100
PK160
Front view
Side view
Back view
Top view
Figure 1 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’’
Control and monitoring devices
Boiler PK30, PK50
Boiler PK0031 and PK0051
Boiler PK30+, PK50+, PK100 and PK160
Boiler thermostat
Main switch
Temp. and pressure gauge
ja rõhu mõõdik
Safety thermostat
Safety thermostat
Main switch
Boiler thermostat
Temp. and pressure gauge
El.heat element’s signal lamp
El.heat element thermostat
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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Main switch of boiler enables to turn boiler and burner on-off.
Boiler thermostat controls burners work by switching it on-off according to pre-set 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. You can
reset it manually.
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 thermostat is applied.
Flue gas circulation in boiler
Permitted usage
Present device is a solid fuel boiler that produces low pressure warm water. Usage of boiler for other
purposes is not allowed.
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 3 Flue gas circulation

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5Set of components
The boiler is shipped with following components included:
1. Boiler PK
2. Safety valve (for PK30/31, PK50/51)
3. Screw fastened foot, 4 pcs
6Delivery
The boiler is delivered as a complete unit. Boiler is wrapped in card board sheets and packing-film and
fixed with two metallic angle to wooden pallet. Angles must be removed before boiler’s installation. In
order to remove the angles the side panels must be removed by lifting them up and pulling them to
side.
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 that enables to lift the boiler when needed. The taking-in weights and widths are
given in Table 2.

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PK30/PK50
PK100/PK160
Figure 4 Front, side and back views of boiler

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7Boiler installation
Only persons holding necessary licences, knowledge, skills and equipment can be trusted with
assembly of the boiler.
Boiler room requirements
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 construction 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 hose while
opening 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°.
Figure 5 Installation of pellet container, external auger and hose
Boiler room clearances
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 Figure 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
Figure 8 Distances of PV50b burners

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Combustion air
An adequate supply of combustion air is nessecary for normal burning process. Air delivery shall take
place through the non-closed hole.
Mains supply
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.
Notice: 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 are depicted on Annex 2.
Figure 9 Distance of PV100d burner
Figure 10 Distance of PV180c burner

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Heating systems water or liquid
It is allowed to use in heating system:
•ordinary drinking water (only minimal refilling!)
•softened water
•glycol dilution up to 50%
Flue gas tube and chimney connection
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, which measures are
depicted on Figure 3 . Connecting boiler with flue tube and connecting flue tube to chimney has to be
made strictly according to local regulations.
PK boilers have high efficiency, therefore 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.
8Installation 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 up and pull outwards.
To boiler’s set belong 4 screw fastened feet that 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 2. Some of boiler
connections are depicted on Annex 1.
After completing installation place side panels and upper panel back to place.
9Installation of the PV-series burner
Installation of the PV-series burners in particular is described in their user’s manuals.
10 Initial start-up and operating instructions
Preconditions
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 electrically wired up, burner and external auger sockets are connected firmly
•sufficient quantity of pellets available in container

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•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 is neglected.
Filling the fuel container
The fuel container must be filled before initial start up. Fuel can be added at any time during the
operation. If the container runs empty, the burner stops working safely and turns itself off. In initial
loading and in loadings after run out external auger must fill itself. It can take up to 20 minutes.
Initial start up of boiler
Before initial start up make sure that requirements by 13.1 are fulfilled. If so:
•connect boiler to mains supply
•turn boiler on from main switch
•turn boilers thermostat to desired temperature. Usually it is +75oC
If PV20b, PV30b, PV100b or PV180b burners are used, then
•be sure that in main menu’s submenu PARAMETERS, PAR30 is set to “1” or “0” and PAR50 to “6”.
Now motors of flue gas fan and self-cleaning mechanism are switched on.
•turn burner on from BURNER menu by selecting ON or keep OK button down over 3 seconds.
•burner displays WAITING, then TESTING and then LOADING. First loading may take about 20
minutes.
•if there is enough pellets in the burner, the green LED will lit up
•now follows IGNITING state where hot air coming from igniter ignites pellets in burning chamber
•next state PRE-BURN assures existence of permanent flame, the yellow LED will lit on
•BURNING is routine state of pellets combustion and heat production
•if boiler has reached pre-set temperature the process will be completed by END-BURN and END-
BLOW actions
•after that burner goes back to WAITING state
Read more about PV20b and PV30b burner’s actions from user manuals.
All subsequent statuses are similar with above described ones.
11 Cleaning the boiler and burner
Although the boiler has automatic self-cleaning system which is controlled by burner, maintenance and
emptying the ash box need to be done manually. Boiler self-cleaning system rotates turbulators inside
heat exchangers after time pre-set in PAR56 and PAR57 in order to remove ash from heat exchanger
tubes. The ash is collected to ash box. It recommended to empty the ash box when it is filled up to 2/3.
Depending on intensity of heating and quality of pellets the frequency of cleaning cycles may vary.
It is recommended to clean boilers inner walls from deposited ash and non-burned residues at least
once a month and every time after the end of heating season.

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Before cleaning the boiler turn burner off from main menu. Let burner to finish burning procedure
and wait at least one hour to cool boiler down before attempting any maintenance or cleaning works.
Turn boilers main switch off. Only then you can open safely the boiler doors and start cleaning.
Periodic cleaning helps to prolong life time of devices and improves burning quality significally.
12 Boiler’s everyday operation
Boiler and burner work in fully automated mode and don’t need daily inspection. Boilers everyday work
is controlled by boiler’s thermostat and burner’s controller.
Thermostat switches burner on or off according pre- set temperature.
Controller:
•regulates fuel supply and quality of burning process
•selects optimal power levels
•cleans heat exchangers tubes
•speed of flue gas fan according to underpressure sensor or pre-set power levels
•ensures safety of whole system
In danger situations or mains supply loss the burner will stop work of boiler and makes safety shut
down.
13 Warranty and manufacturers liability
The warranty protects user within 2 years from manufacturer’s defects under conditions that boiler is
operated as assumed in present manual. Warranty starts from date in sales invoice unless not been
agreed otherwise.
Warranty is not valid when faults are caused by:
•transportation and/or handling organized by user
•incorrect installation by installer
•misuse of device
•unauthorized changes in construction of device
•ignoring cleaning and maintenance instructions or leaving unattended
•errors and interruptions caused by ambience

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14 Troubleshooting
Problem
Reason and solution
Boiler doesn’t switch on
Boilers main switch is turned off
•Turn boilers main switch on
Boiler is overheated and safety thermostat has applied
•Discover reason for overheating and eliminate it. Reset safety
thermostat by removing its protective cover by turning it counter
clockwise and pushing thermostates white button.
Boilers thermostat is broken and doesn’t control burner
•Check condition of thermostat. Replace thermostat when needed.
Burners door is not closed and door switch is open.
•Close the door properly.
Boiler emits smoke or
burns back
Flue gas fan doesn’t work
•Turn fan on by selecting PAR30 and „1“ (or „0“ when using
underpressure sensor)
Flue gas fan doesn’t rotate sufficiently
•Add rotations PAR38>100%(PV20b/PV30b burners)
Flue gas fan rotates hardly or makes uncommon voice
•Replace fan
Poor air supply of boiler room
•Improve air supply. Make sure your boiler room has critical air supply
by Table 2.
Boiler’s ash box is full. Chimney or flue tube is full of soot
•Empty ash box
•Call qualified chimney cleaner
Turbulators don’t rotate in
self-cleaning process
Turbulator turning motor is not turned on
•Turn motor on by selecting PAR50 and „6“
Self-cleaning process of
heat exchangers sounds
quite noisy
Usually it means no risk. In self-cleaning process metallic turbulators in
heat-exchangers metal tubes are rotated slowly. Metal touches with
metal and may make uncommon noise. This is not danger.
•Lubrication of cleaning mechanism helps to reduce the noise

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Annex 1 Connection diagram samples for connecting the boiler
Figure 11 Heating systems with accumulator tank
Attention! When using connection diagrams above assure that minimal temperature of boiler’s
returning water would be 55oC.
3-way valve mixer with motor
Heating circuit
Check valve
Expansion tank
Pressure gauge
Thermometer
Safety valve
Ball valve
Circulation pump
Thermostatic load valve
4-way valve mixer with motor
Emptying tap
Figure 12 Heating systems with 3-way valve mixer
mxer
Figure13 Heating systems with 4-way valve mixer