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.

Control board wiring connections
Most of the electrical connections on the board are factory wired to allow for a simple and
quick installation on “standard” installations. Connections that will need to be made by the
installer are:
•CH PUMP –This is the boiler pump
•ROOM REGULATOR –Room thermostat (volt free)
Other connections for optional accessories are;
•DHW PUMP –Used to control a pump or 2 port valve for hot water production.
•KOMPRESSOR –Connections for the solenoid valve of the compressor cleaning kit
•VACUUM –Used to control pellet vacuum system
•DE ASHING –Ash compression system
•CLEANING –Heat exchanger cleaning system
•DHW SENSOR –Used to control hot water/buffer re-heating (low voltage)

2. First boiler start up
-Set time - set the actual time, important for Timetable and online functions.
-Set date –set the actual date, important for Timetable and online functions.
-Burner size –choose the right burner size. Auger run times and fan speed are calculated.
-CH temperature –maximum boiler temperature
-DHW temperature –maximum hot water temperature if pump is connected
-Filling auger –fill the auger with pellets. Wait until pellets start to drop down from the auger to the
burner chamber.
-Start the boiler –starts the boiler for the first time.
CONTROL UNIT V8 MENU DESCRIPTION
The V8 control unit is designed to offer the home owner and installer a series of simple menus to give
full control of all boiler settings and parameters. The controller has 3 levels of PIN protection in order
to prevent the home owner unintentionally altering boiler parameters. The home owner can alter
heating and hot water temperatures and times without entering a PIN.
First boiler start-up: 1001
Installer settings 5162
Service engineer XXXX
1. Menu structure
-First boiler start up - Setup which has to be made during fitrst start up of the boiler.
-Ignition/Extinction - Start and stop the burner.
-Basic settings - Setup which can be done by user of the boiler.
-Plumber settings - Accessories activation and setup.
-Service setup - Combustion setup and main operational parameters.
-Factory setup - Reset to factory settings.

1.1.1 Basic settings
-Main screen
oDisplay CH
oDisplay service
-CH temperature –central heating temperature, which is maximum boiler flow temperature.
-DHW temperature –domestic hot water temperature, which is maximum temperature inside water
tank. DHW sensor must be connected into the Connection board.
-Room temperature decrease –works with room termostat RT10. Determines when should room
termostat start the boiler again after set temperature drop.
-Operation mode –operational mode for connected pumps.
oOnly CH –only CH pump works
oDHW priority –DHW pump priority for hot water inside the tank
oPumps CH + DHW –both can work at the same time.
oSummer mode –sets the burner power to an half value. To be specific - Feed time max and
Feed interval min is reduced to half.
-Cleaning –cleaning of the grate during PID (modulation) work.
oActivation –activate or deactivate cleaning function
oCleaning period –how often should fan clean the grate
oFan operation time –for how long time fan cleans the grate
oFan speed –speed of the fan during cleaning
-Tray filled –sets when you fill the with pellets. Then it will show you the real amount of pellets
inside the hopper.
-Timetable –timer for boiler operation. Set different temperatures for each hour per day.
oActivate –activation of timer
oMode 1 (Mo-Su)
oMode 2 (Mo-Fr) (Sa-Su)
-Set mode 1 –set working temperature for each day
-Set mode 2 –set working temperature for weekends separatly
-Alarm history –history of alarms.

-Max of ignitions –max number of ignitions. Can be reset back to zero.
-Factory setup –reset to factory setup.
-Program version –version of uploaded software.
1.1.1 Plumber settings
-Fan correction –correction of fan speed +- 50%
-Power factor –correction of burner power
Changes values in Feeder time max and Feeder interval min in range of + - 50%.
Example: if you set +30% in Auger correction +30% it means, that: value in Feeder time max is
increased by 30% and value in Feeder interval min is decreased by 30%.
Feed time
max
Feed interval
min
Auger
correction
Fan
correction
Fan max
work

2.0 FIRST BOILER START UP
1. There is function called First boiler start up which is functuon used for exact setup of main boiler
functions. Installer is responsible for this setup. First boiler start up has to be done before turning
on the burner for the first time.
a. Time
2. Set real time. Some features as Time table, history or online functions needs time for running
properly.
a. Date
3. Set real date, which is used in the same functions as shown abowe.
a. Burner size
4. Burner size is responsible for exact auger run times during PID work. So you have to set it correctly.
Check burner package, or sticker which is on the burner to be sure that the size in Kw is correct.
5. Burner size changes values in Service settings shown below:
6. Auger setup, Ignition:
a. Feed time –for how long pellet auger supplies pellets on the burner grate
b. Fan speed –speed of the fan during ignition phase.
c. Lumidity –fire sensor sensitivity. Lower number means higher sensitivity.
7. Auger setup, Work:
a. Feeder time min –auger run time for minimum power
b. Feeder interval max –auger wait time for minimum power
c. Feeder time max –auger run time for maximum power
d. Feeder interval min –auger wait time for maximum power
e. Min fan speed –speed of the fan during minimum power
f. Max fan speed –speed of the an during maximum power
8. Auger setup, Extinction:
a. Extinction time –fan works all the time during this process and tries to clean all ashes from
the grate
b. Fan speed –speed of the fan during extinction phase.

3.0 COMBUSTION ADJUSTMENT
Preset values for proper combustion are set during First boiler start up by choosing Burner size. However
there are situations where correction has to be made for good combustion. Chimney draft, pellet types or
oxygen inside the room can influence proper combustion.
There is function inside Plumber settings for this reason, where you can change fan speed and number of
pellets going on the grate by %.
oFlame parameters
By flame size and color you are able to correct combustion folowing examples below:
Low pellets
Flame is small. Doesn‘t touch the opposite wall of the boiler.
Then you should increase fan speed or pellet quantity.
High pellets
Flame is to long. If you open top doors flame goes out of the
boiler. Often red color and black ends. Then you should decrease
fan speed or pellet quantity.
Low O2
If there is not enough O2 inside the boiler, the flame has red
color with dark smoke comming from the chimney. You have to
decrease number of pellets, or increase fan speed.
High O2
If there is a lot of O2 inside the boiler, than the flame is yellow
with really agresive look. Often small as well. You have to
decrease fan speed, or increase number of pellets.
Correct flame
Flame should be orange collor and should touch the opposit wall of the boiler. Below you can find
two functions which are used for combustion correction in %. Use these functions to correct the
flame during operation.
min power max power

Service settings
Auger settup, Work,
Feeder
time max
Feeder
interval min
Plumber settings
Power correction
Service settings
Auger settup, Work,
Max fan
speed
Plumber settings
Fan correction
4.0 Fan correction
Fan correction is responsible for changing the flame size. You change fan speed only for max burner
power, but by changing this you basicly change all modulation range for fan speed.
What you change
You can adjust Max fan speed by changing % value in Fan correction. You can increase or decrease
this number which means you change full range of fan speed from minimum to maximum burner
power. If you decrease Max fan speed, the maximum limit for PID regulation is lower which means
speed of the fan is decreased in all PID modulation range.
Power correction
Power correction is responsible for changing number of pellets going on the grate. You change Feeder
time max and Feeder interval min in Service setup, which are values only for maximum burner power.
However by changing this value you basicly change the full modulation range. So it changes number
of pellets from min to maximum power.
What you change
You can adjust Feeder time max and Feeder interval min by adjusting % in Power correction. What
happends if:
you adjust minus value in Power correction: than you decrease number in Feeder time max
and increase Feeder interval min in the same time.
you adjust plus value in Power correction: than you increase number in Feeder time max and
decrease Feeder interval min inthe same time.

Cleaning of the burner / boiler.
Cleaning should be carried out regularly and as needed. There is a big difference in the frequency of
maintenance required from system to system. The setup, adjustment, and wood pellet quality play
an important role on how frequent maintenance should be performed.
The table is only a suggestion and applies only to the Biopel 15, 20, 30 and 40 kW boilers!
Always use personal protective equipment. Dust, ash and soot are hazardous to health!
Turn off the controller and allow the boiler to cool for approx. 5 min. Once the burner is completely
turned off, it is ready for cleaning. Unplug the burner, remove the shield, drop shaft, and detach the
burner from the boiler so work can be easily performed.
Boiler.
All surfaces inside the boiler must be brushed clean from any deposits and the ash can must be
emptied. When empting the ash can, pay special attention to any build-up of ash in the rear smoke
chamber and flue, since the Chimney Sweeper may not always be removing the ash from the
chimney flue.
Never dispose of hot ashes in the trash, but let it cool in a metal bucket. Hot ashes can re-ignite.
Burner head.
Remove any ash or cinders from the grate. Remove any pellet remnants under the burner grate.
Wipe the photo sensor clean. When re-inserting the photo sensor, ensure that the sensor points
towards the combustion grate. Ensure that there is nothing lodged in the fan and that it can rotate
freely.
Hopper.
Since pellets naturally contain dust, you should periodically empty the hopper completely. The more
dust there is present in the hopper the less the auger will dispense, and the more unstable the
dosing. The boiler will go out of adjustment with greater risk of downtime. How often one should
empty the hopper depends greatly on the quality of the pellets you use.
Put 1litre of cooking oil or similar into the hopper each time it is emptied (poured over the last
pellets) and the hopper will automatically empty the sawdust.
Start-up after cleaning.
Once the pellet boiler is reassembled, turn on the controller and the burner will start itself up.
Remember to reattach the shield so that the temperature reading on the burner is correct.

Service and Maintenance.
Proper maintenance of your system reduces the risk of unnecessary downtime. The controller has
service indicators that informs you when to change parts and perform service. Please note that service
indicators are only expectations based on experience. Components can easily have a longer lifetime
than suggested by the service indicator. It is recommended to perform an inspection of your system
once a year.
Start-
up.
Your
authorised installer will review your system with you and talk to you about optimization strategies
and adjustments.