Robus Black Star 10 Comfort User manual

Black Star Pellet System

Robus Energy Ltd
2 of 26
MCS 0001RE
Issue 2.1
March 2014
Contents
Dear Customer.
Thank you for choosing Robus Black Star 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

Robus Energy Ltd
3 of 26
MCS 0001RE
Issue 2.1
March 2014
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.
The system is provided with an electrical current of 230V/50Hz. An improper
installation or improper repair can cause life-threatening electrical shock. Electrical
connections must be performed by the person who has the right skills and training.
Performance of electrical installation must be carried out in COMPLIANCE with the
relevant 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 while it is in operation. Never open the ash tray while the 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
browse the controller thoroughly prior to use and to receive an overview of all
functions, etc. by your installer.
This manual must be kept with the boiler!

Robus Energy Ltd
4 of 26
MCS 0001RE
Issue 2.1
March 2014
The Clean Air Act 1993 and Smoke Control Areas
The Robus Black Star Comfort 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 Black Star 10 Comfort
Robus Black Star 14 Comfort
Robus Black Star 24 Comfort
Robus Black Star 45 Comfort
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 Black Star and Robus Black Star Comfort 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.

Robus Energy Ltd
5 of 26
MCS 0001RE
Issue 2.1
March 2014
Boiler Specifications

Robus Energy Ltd
6 of 26
MCS 0001RE
Issue 2.1
March 2014
General installation guidelines
1. The boiler must only be installed by qualified engineers.
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 5 PA 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 left).
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.
5. Mount the shield and the connector on the burner.
6. Install electricity for safety cut-off thermostat according to the wiring diagram. SAFETY
THERMOSAT MUST ALWAYS BE FUNCTION TESTED!
The thermostat can be tested by using an electric kettle. The thermostat must switch off
when the temperature probe is dipped into boiling water. If
necessary, adjust the switch-off temperature lower by turning the
screw inward. Reset the thermostat by pressing hard on the red
button!

Robus Energy Ltd
7 of 26
MCS 0001RE
Issue 2.1
March 2014
External auger:
1. Install the auger output over the burner.
2. Auger should be at an angle between 40 and 50 degrees.
3. The flexible hose should be angled enough as to allow for
the free passage of the wood pellets to the burner without
getting stuck in the PVC hose.
Temperature sensor on the boiler:
Mount the sensor within a sufficiently long thermostat pocket.
Secure sensor to prevent accidental slippage.
Safety thermostat:
Mount on either the left or right side of the boiler as displayed
in image. Note: Functional testing of the high limit safety
thermostat is required before starting up the boiler. To test,
press moderately on the disc (shown in A) in the direction
towards the temperature feeler. A small "click“ will occur, signalling
that the connection between C and C2 is
interrupted and that the high limit safety
thermostat is triggered, to reset the
thermostat press hard on the red button
marked (B) in the drawing. You will also hear
a "click", signalling that the connection
between C and C2 is restored and that the high limit safety thermostat
is activated and ready for use.

Robus Energy Ltd
8 of 26
MCS 0001RE
Issue 2.1
March 2014
Self cleaning:
The boiler cleaning system must be connected with 230V AC
through the socket located on the back of the boiler. In the
control box, make a connection to output (L5-L10). The
cleaning system will run every time the burner conducts a
blower cleaning sequence typically 5 seconds every 10 min.
These settings can be configured under the Cleaning menu
in the controller.

Robus Energy Ltd
9 of 26
MCS 0001RE
Issue 2.1
March 2014
Hydraulic installation of the boiler
A correctly executed installation ensures that the system functions properly. Both national/local
guidelines and requirements must always be observed. The boiler can be installed on a pressurized
system up to max 2.5 bar.
Standard load valve installation
Failure to correctly install the load valve will void any future warranty. The load valve, supplied with
the boiler, must be installed in the boiler return pipe work as shown in the diagram. This maintains a
minimum 55°C return temperature to prevent condensation forming within the boiler.
Basic Y-plan installation
The 3 port valve must “spring return” to a heating position. 230V is only applied to the valve during
hot water mode.

Robus Energy Ltd
10 of 26
MCS 0001RE
Issue 2.1
March 2014
Weather Compensation installation
Weather compensation allows a motorised 3 way mixing valve to give a variable flow temperature
depending on the outdoor temperature. The mixing valve mixes high temperature water from the 3
port valve with cooler return water from the heating system. The 3 way valve is controlled by the
Version 10 controller. The outdoor temperature can either be measured by a temperature sensor
connected to T5 or the weather data can be automatically taken from Stokercloud if the controller
has been linked to the internet.

Robus Energy Ltd
11 of 26
MCS 0001RE
Issue 2.1
March 2014
Wood Pellet Hopper
There are several hopper solutions, Examples include a steel hopper, fabric hopper and mini hopper;
which is built together with the boiler. All hoppers can be extended
for bulk storage/feeding via the vacuum transport.
Steel Hopper:
Available in 4 different models
60x60cm = 200L = 140 kg
80x80cm = 320L = 220kg
80x140cm ext. = 500L = 350kg
100x100cm = 500L = 350kg
Fabric Hopper:
Available in three different models. With gate over the
auger inlet.
60x60cm = 300L = 210 kg
80x80cm = 400L = 280kg
100x100cm = 500L = 350kg
Mini hopper, built together with boiler:
Available in 3 different models: Can be mounted
either side of the boiler.
BS10 & 14 mini, 150 kg
BS24 mini, 200kg
BS45 mini, 250kg

Robus Energy Ltd
12 of 26
MCS 0001RE
Issue 2.1
March 2014
Vacuum Transport
The Vacuum System for wood pellets makes it easy to customize various delivery forms for your
system. Here are a few examples of ways to configure your vacuum transport.
Big bag.
Throw the mole in the bag.
Easy way to transport 1 ton.
Flat bottom hopper:
Is a top-fed option that maximizes space by
minimizing ceiling height requirements.
V bottom hopper:
Transports pellets via a bottom auger. Is a
stable and secure way to transport pellets, but
requires more headroom.
.
Fabric hopper:
An inexpensive bulk hopper solution.

Robus Energy Ltd
13 of 26
MCS 0001RE
Issue 2.1
March 2014
Wiring Diagram.
There may be factory installed wiring on the outputs L5-L10. L5 may be factory fitted for the moving
grate. L6 may be factory fitted for the compressor cleaning. Remove these if there is a need for
other equipment on the outputs.

Robus Energy Ltd
14 of 26
MCS 0001RE
Issue 2.1
March 2014
Electrical Connections

Robus Energy Ltd
15 of 26
MCS 0001RE
Issue 2.1
March 2014
Optional Equipment
The controller supports the following equipment to aid in making adjustments, cleaning and trouble
shooting.

Robus Energy Ltd
16 of 26
MCS 0001RE
Issue 2.1
March 2014
Internet Connection.
The web-based controller can be updated automatically from the Internet. Operating data can also
be uploaded to www.stokercloud.dk
How to get the controller on the web:
1. Connect the controller to your router through an RJ45 cable.
Since this is a direct cable connection no passwords etc are
required. Once connected, a small icon will appear on the
screen indicating that the controller is online.
If you do not have the possibility of a direct cable connection,
these adapters picture on right, can be used. They can establish
a connection to your router through your
household power cables. This provides an easy
PLUG and PLAY solution.
2. Find your control number and password under
the "system" in the controller.
3. Go to www.stokercloud.dk and find your
controller in the drop-down at the top of the page.
Or type your control number in the search box.
4. LOG IN, and follow the instructions.
5. Enter your personal information, new user name
and new password.

Robus Energy Ltd
17 of 26
MCS 0001RE
Issue 2.1
March 2014
Internet Connection.
6. Specify where you live, displayed on
www.stokercloud.dk . Click on your property to give
your location.
Once your settings are saved you will have your
own page and burner dashboard.
After a short period of time you should see data
streaming from the burner.
If you would like to view your system from your
smart phone then download our App for the
following devices:
Android Play for android mobile phone.
Search "StokerKontrol“
ITunes for iPhone mobile phone.
Search "StokerKontrol“
WindowsPhone for Windows Mobile phone.
Search "StokerKontrol"

Robus Energy Ltd
18 of 26
MCS 0001RE
Issue 2.1
March 2014
Cloud Services.
If your burner is online via our website www.stokercloud.dk we can help you keep an eye on your
system. If something unexpected happens such as too many ignitions, unstable operation, improper
PI regulation etc. then we have the opportunity to help you ONLINE.
How it works: -
-NBE observes abnormalities on your graphs.
-You will be contacted by E-mail, where we ask
your permission to make changes.
-NBE will assess your graphs and the burner
reaction pattern, and make adjustments based
on the observations.
-You can always see the changes in your LOG.
- After adjusting, it should look like this ...
NBE's Cloud Service ensures:
-Fewest possible number of electrical ignitions.
-Best possible PI regulation.
-An optimized system for your house.
-Lower wood pellet consumption.
-Peace of mind.
-The latest updates to the controller.

Robus Energy Ltd
19 of 26
MCS 0001RE
Issue 2.1
March 2014
First time start up.
Once the system is assembled, filled with water, and power is connected to the system a few basic
adjustments to the burner is required.
1. Fill the auger with pellets by force starting the auger either through the controller or directly via a
230V connection.
2. When the augur appears full, run for an additional 15 min. to
ensure correct weighing later.
3. Activate the 6 min. test run in the controller and collect the
dispensed pellets with a plastic bag.
4. Using a kitchen scale, weigh the pellets from the test run and enter the amount into the controller
under "Auto calculation" Repeat again after 7 days!
5. Adjust minimum output as low as possible, typically 10% of the burner's rated output (i.e. if 20kW,
set to 2.00kW). If the chimney draft is high, adjust the minimum output up until you have a stable
flame at 10% power.
6. Once the burner is activated an ignition will be made. After approx. 20 minutes the burner will
reach a nominal output (100%). If necessary lock the burner output at 100%. Now you can perform
an evaluation as to whether the fan is providing suitable supply of air to the flame. If necessary,
adjust in the fan menu.
The flame at 100% should fill the entire width of the grate, have
redish spikes, and reach the opposite wall.
7. Lock the burner to 50% power. Wait 5 minutes for the flame to
stabilize. Again, assess fan performance in relation to the flame.
The flame at 50% should be approx. 10 cm out of the burner and is
yellowish in colour.
8. Lock the burner to 10% power. Wait 5 minutes for the flame to
stabilize. Assess fan performance in relationship to the flame.
The flame at 10% should be small and short.
The photo sensor reading may fluctuate, however, it should not have a
0 LUX reading for a period >10 sec. If the chimney draft is too high,
increase the minimum effect of the burner to increase flame size.

Robus Energy Ltd
20 of 26
MCS 0001RE
Issue 2.1
March 2014
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 BS1016, BS2030 and BS4050 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.