Robus BIOPEL User manual

Biopel Pellet Boiler
Installation manual

Dear Customer.
Thank you for choosing Robus Biopel pellet boiler system. This product is designed and
manufactured to the highest standards in the EU.In order for you to get the most out of your
product, we strongly recommend that you carefully read this manual prior to installation and
operation. In the event that you encounter any difficulties during installation or operation, we
recommend that you first refer to this manual or contact Robus Energy Ltd for further
assistance.
Note: Help text on all menu items is displayed in the controller and is therefore not described
here in this manual. It is recommended to study the menus prior to initial start.
Save this manual, so you always have it available when needed.
Page 3: Comments on the Manual
Page 4: The Clean Air Act 1993 and Smoke Control Areas
Page 4: Fuel requirements
Page 5: Boiler Specifications
Page 6-8: General installation guidelines
Page 9-10: Hydraulic installation of the Boiler
Page 11: Pellet Hopper
Page 12: Vacuum Transport
Page 13: Wiring Diagram
Page 14: Electrical Connection Scheme
Page 15: Optional Equipment
Page 16-17: Internet Connection
Page 18: Cloud Service
Page 19: First Time Start-up
Page 20: Cleaning the Burner/Boiler
Page 21: Service and Maintenance
Page 22-23: Troubleshooting
Page 24: Condensation of Flue Gas
Page 25: Warranty
Page 26: CE Declaration of Conformity

Comments on the manual
Never handle the auger, blower, nor crawl in the hopper when the system is powered.
There will be no warning prior to the activation of these components. The boiler must
not be operated without the shield on the burner.
Thesystemis provided with an electrical current of 230V/50Hz. An improper installation
or improper repair can caus e life-threatening electrical shock. Electrical connections
must be performed by the person who has the right skills and training. Performance of
electrical installation must becarried out in COMPLIANCEwith therelevant rules. Always
disconnect the system from the electrical supply prior to starting maintenance work or
servicing. The system must be connected to a separate electrical circuit, which is
equipped with the proper circuit breaker and earth leakage breaker.
The boiler must be mounted to a functioning chimney. In the event that you smell smoke
or see any other indication of improper draft of the chimney, all operation of your
system must cease immediately and must remain so until a solution to the draft problem
has been resolved. Continuing operation may result in death or injury.
Always read the manual before system installation or repair. If in doubt, seek
professional help.
Open top covers etc. with extreme caution. When the boiler is in operation, there is a
risk of high temperature surrounding the top covers, which can result in injury. Avoid
handling the boiler whileitis in operation. Never open the ash tray whilethe boiler is in
operation. The system may be operated by skilled people. If you are in doubt as to the
safe operational use of the boiler, contact your dealer.
The menu structure etc. for the controller is supported by the help texts found in the
control box itself. Due to constant updates and new features, the menu structure of the
controller will not be described here in this manual. Instead, it is recommended to
browsethecontroller thoroughly prior to useand to receivean overview of all functions,
etc. by your installer.
This manual must be kept with the boiler!

The Clean Air Act 1993 and Smoke Control Areas
The Robus Biopel range of boilers listed below has been recommended as suitable for use in smoke
control areas. The recommended fuel for the boiler is 6mm or 8mm diameter wood pellets to EN 14961
Part 2 class A1 wood pellets only.
Robus Biopel 15
Robus Biopel 20
Robus Biopel 30
Robus Biopel 40
Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a
smoke control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any
fixed boiler if located in a designated smoke control area. It is also an offence to acquire an "unauthorised
fuel" for use within a smoke control area unless it is used in an "exempt" appliance ("exempted" from the
controls which generally apply in the smoke control area).
The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise
smokeless fuels or exempt appliances for use in smoke control areas in England. In Scotland and Wales this
power rests with Ministers in the devolved administrations for those countries. Separate legislation, the
Clean Air (Northern Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that fuels
burnt or obtained for use in smoke control areas have been "authorised" in Regulations and that appliances
used to burn solid fuel in those areas (other than "authorised" fuels) have been exempted by an Order made
and signed by the Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here
http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including designation and
supervision of smoke control areas and you can contact them for details of Clean Air Act requirements”
Fuel and warranty
The Robus Biopel pellet boilers are designed for use with EN-plus A grade wood pellets only. The use of
substandard fuels will compromise the efficiency, reduce the life span and invalidate the warranty of the
appliance.
What is EN-Plus?
EN-Plus is the European Quality Standard for the manufacture and supply of wood pellets. Manufacturers
and Distributors who have the EN-Plus standard have been certified as meeting the required quality
standards and they are entitled to display the EN-Plus logo and their own unique License Number.

General installation guidelines
1. The boiler must only be installed by qualified engineers. Installer product training is available at
Robus Energy Ltd.
2. All local building regulations must be observed (downloads available from the Robus Energy
website).
3. The boiler must not be installed on combustible surfaces.
4. The chimney and ventilation system must be fit for purpose and installed in accordance with
Approved Document J (Combustion appliances and fuel storage systems).
5. Chimney draft should be between a minimum of 5PA and a maximum of 23PA and be stable.
Overpressure must not occur as this will cause inefficient boiler operation and a lack of control of
the boiler temperature. It may be necessary to install a draft stabilizer.
Installation of the burner
Installing the burner on the boiler:
1. Check that the burner is not damaged during transport.
2. Check that the burning grate is inserted correctly in the burner (see image below).
3. Mount the burner and tighten the burner with the two wing nuts supplied. Never use locknuts, as
the seal between the boiler and the burner can leak over time.
4. Make sure that the burner is horizontal and that all connections are tight.
Burner description:
The main parts of the burner are the fan, internal auger/auger motor, burner grate, fire sensor and igniter.
The external auger (in the hopper) drops pellets down the drop shaft where they are moved on to the
burner grate by the internal auger. The fan ensures a supply of air to the grate for clean combustion. The
igniter provides the heat for the automatic ignition of pellets. The grate is removable for easy cleaning.
Fire sensor detects the light of flame. When the fire sensor detects the light during ignition process, the
control unit switch off the igniter and the boiler starts normal operation mode (PID work). There are
different sizes of Biopel pellet burner (10 –200 kW) but main function is always the same.
Drop shaft: new pellets are fed in to the burner.
Internal auger: moves pellets on to the grate
Mounting holes: these holes are for connecting burner onto the boiler
flange.
Ignition outlet: hot air comes from this hole during ignition phase.
Grate: there are several types of burner grate depending on
burner size/output. Combustion air comes from to these holes.

Biopel burner
First check proper position of the grate (see picture) and then place burner
into the boiler flange. On all Biopel boilers you can choose left or right side of
the boiler for burner installation. However the opposite flange on the boiler
bust be always sealed.
For example if you choose left flange for burner connection make sure that
right flange is properly sealed. Burner is fitted on the boiler flange using the 2
M8 studs and wing-nuts supplied in the ashpan.
Burner grate locked in Burner blanking plate
Burner mounting flange Burner M8 studs

Insert burner into the burner flange and secure with wing nuts.
Connect burner pipe into the hole located on the top of
the burner and secure with 2 x burner pipe screws.
Attach PVC tube on the burner pipe and from the other side on the
external auger outlet. You can cut the PVC tube if necessary. Pellets
must drop from the external auger outlet into the burner without
obstructing PVC tube.

Plumbing schematics
The use of a buffer tank or thermal store will prevent frequent ignition of the boiler and
will prolong the life of the igniter. The min buffer/thermal store capacity should be;
10 litres/kW output (eg. 200 litres for Biopel 20)
The load valve, supplied with the boiler, must be installed in the boiler return pipe work as
shown in the diagram above

Biopel V8 controller
The V8 controller has two different mounting options depending on the type of pellet hopper
chosen
With Compact hopper With external/bulk silo
The V8 controller comprises of two main components:
1. Controller screen
2. Connection board
All interconnecting cables between the screen and connection board are pre-wired
with simple plugs to allow for quick installation.
When using the Compact type hopper the connection board can be fixed to the sloping wall
of the hopper near the burner with the screws and bracket supplied.
Boiler temperature sensor, flue temperature sensor, over heat sensor, pump supply and
incoming power supply can all be routed through the cable duct in the hopper lid.
Ensure the temperature sensors are secured into the pocket on the flow connection of the
boiler.