RVR Energy Technology Star NE Installation and operating instructions

Pellet boiler
THERMOSTAT MAINSWITCH
RESET
OVERHEAT
TEMPERATURE
PRESSURE
Star
Star
NE
NE
Installation, operation and maintenance
Star NE
2009-03
VB THL product Nº
RVR
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2009-03
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Contents
Function
Combi boiler
STAR is a boiler for pellet operation.
Control
The temperature is controlled by a thermostat.
Water heating
A heat exchanger produces domestic hot water instantly as
it is required. The heat exchanger does not have a tank –
instead, the domestic hot water is heated as it passes through
the heat exchanger on the way to the tap, so that the hot water
is always fresh.
The domestic hot water capacity depends on the power
supplied. STAR complies with Boverket standards applicable
to hot water capacity.
The hot water capacity is impaired by deposits in the heat
exchanger. Check your water for substances that could
produce deposits.
Easy to service
The electrical system is easy to access under the hinged
control panel.
The circulation pump and heat exchanger are easily acces-
sible behind the hinged automation cabinet.
To make boiler cleaning easier, the combustion chamber
hatch is mounted on a swivel arm allowing it to be hinged to
the right or left.
Easy to transport and install
Weighing just 150 kg, its compact dimensions make it easy to
handle.
Product contents
• Angled flue pipe with damper.
• Dirt filter.
• Drain valve.
• Flue gas turbulators.
• Flue pipe cleaner.
Accessories
• Straight flue pipe, product no. 2936
• Pellet hatch, other pellet burner manufacturer,
product no. 902 77
The manufacturer reserves the right to make design changes without notice
Function ................................................................................. 2
Technical data....................................................................... 3
Hot water capacity
HVAC installation.................................................................. 4
System principle
Flue pipe
Expansion system
Vented
Unvented
Shunt
Heating system circulation pump
Hot water outlet
Filling
Water heating
HVAC installation.................................................................. 5
Pellet burner
Flue
Draught regulator
Turbulators
Electrical installation............................................................ 6
Wiring diagram
Supply cable
Circulation pump
Pellet burner
Pellet burner - Viking Bio
Control panel......................................................................... 7
Operation and care............................................................... 7
Commissioning and checks
Water pressure in the system
Bleeding/topping up
Dirt filter
Circulation pump
Safety valves
Boiler temperature
Pellet operation
Overheating protection
If there is a risk of freezing
If the water boils
Flue cleaning
Boiler cleaning
Troubleshooting.................................................................... 8
Components.......................................................................... 8

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Technical data
1. Supply, 22 mm compression ring / R20.
2. Return, 22 mm compression ring / R20.
3. Burner hatch with swivel arm.
5. Cable duct for burner cable.
6. Drain valve.
7. Four-way shunt.
8. High-temperature hot water outlet, R25
int.
°C
Hot water temperature at different flow rates.
l/min
6121824
80
70
60
Hot water capacity
When a large amount of domestic hot water is
drawn with a high flow rate, the temperature
may fall too low after a while.You can coun-
teract this by reducing the flow rate slightly.
Usually, lower flow rates mean that more
domestic hot water is available. If the high-
temperature hot water has a low temperature,
the domestic hot water temperalitre ture will
be low, and vice versa.
The diagram here relates to a boiler tempera-
ture of 80 °C.
9. Adjustable base bolts.
10. Expansion outlet, R25 int.
11. Cold water supply, 22 mm Cu.
12. Domestic hot water, 22 mm Cu.
13. Cable penetrations.
14. Flue pipe with cleaning hatch and
damper.
15. Dirt filter for domestic hot water.
100 200 300
100
200
45°
40°
Boiler volume
Volume of 40/45° domestic volume
relative to boiler volume.
litre
litre
THERMOSTAT MAINSWITCH
RESET
OVERHEAT
TEMPERATURE
PRESSURE
Star
Star
NE
NE
Top view
Side view Front view
1
2
10 1
3
5
6
7
8
9
2
11
12 13
14
15
16
17
18
19
10 11
12
16. Flow switch.
17. Circulation pump, internal.
18. Heat exchanger.
19. Automation cabinet.
20. Control panel on automation cabinet.
Manufactured to 97/23/EC Article 3.3
Weight empty
filled
150
330
kg
kg
Volume boiler
heat exchanger
175
2
litre
litre
Design pressure boiler
heat exchanger
3
10
bar
bar
Test pressure boiler
heat exchanger
2.15
41.6
bar
bar
Max temp 100 °C
Power 15- 20 kW
Draught required 0.05 mbar
Voltage 230 V~, 50 Hz
Current 0,1 A
Protection class IP21
*11 kW if the immersion heater is replaced.
Boiler class 3, acording to EN 303-5.
Manufactured to 97/23/EC Article 3.3

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The boiler must be installed by a qualified and competent person, in
accordance with the relevant clauses of all applicable standards and
recommendations. These include but may not be limited to the following:
All relevant building regulations, Local water by laws, IEE wiring regulations
and Health and Safety legislation.
Failure to install the appliance correctly could lead to prosecution. It is in
your own interest and that of safety to insure that the law is complied with.
Manufactures instructions must not be taken in any way as overriding
statutory obligations.
The boiler must be installed indoors in a cellar or on the ground floor. The
installation site must be designed
for the boiler weight of 330 kg
including water. Make sure that the
flue pipe cleaning arrangements
meet the applicable regulations.
The boiler can support up to 300 kg
of the weight of the flue. The instal-
lation site must be able to support
this additional weight.
The fresh air intake of the boiler
room must have at least the same
cross sectional area as the flue
duct.
System principle
1. Radiator circuit.
2. Circulation pump, heating.
3. Vented expansion vessel.
4. Shunt valve.
5. Circulation pump, water heat-
ing.
6. Hot water mixing valve
7. Heat exchanger for domestic
hot water.
8. Flow switch.
10.Pellet burner.
Flue pipe
The gap between the flue pipe and the flue pipe connection to
the boiler is packed with glass fibre cord (supplied).
The flue gas damper is adjusted using a lever on the front of
the flue pipe.
Expansion system
Vented: The expansion vessel is connected in an unisolatable and
continuous rise from the connection at the top of the boiler.
The distance between the top of the highest radiator
and the expansion vessel must be at least 2.5 metres
in order to prevent oxygen saturation of the water.
Unvented: The boiler must be fitted with a type approved safety valve, 3 bar,
connected using an unisolatable pipe from the top of the boiler,
as well as a venting valve and manometer.
HVAC installation
Location of boiler
in boiler room
Chimney
Boiler
Shunt
The shunt is controlled manually by turning the dial to a suitable
temperature. A motor can be fitted to the shunt for automatic
shunt control.
The shunt dial is marked 0-10, from no heat to full heat.
The shunt is fitted with compression joints, Ø22 mm.
The shunt must be fully open while the heating system is being
filled.
On delivery, the supply side is to the left and the return side is
to the right. The direction can be changed by following these
steps:
A. Remove the shunt from the boiler and move the plastic pipe
from the right port to the left port. Rotate the gasket so the
arrow points in the supply direction. Replace the shunt.
B. Remove the dial and turn the scale back to front. Replace.
Automatic shunt control can be added to the shunt.
Heating system circulation pump
The circulation pump of the heating system is dimensioned ac-
cording to the size, pipe dimensions and design of the system.
Circulation pump installed in the return pipe of the boiler.
Hot water outlet
There is a high-temperature hot water outlet on the rear of the
boiler. Do not forget to seal this outlet if it will not be used.
Filling
The boiler must be fitted with valves for filling and draining. It is
a good idea to connect a permanent filling pipe to the expan-
sion outlet For filling, the shunt must be fully open, position 10.
Water heating
Water is heated in a heat exchanger, using a flow-controlled
circulation pump.
The dirt filter is installed on the cold water side.
The installation must include a mixing valve.
No safety valve is needed because the volume of the heat
exchanger does not exceed two litres.
If a non-return valve is used, the installation must include a
9-bar type approved safety valve.
2
110
8
7
6
5
4
3
Shunt and gasket
on delivery
Gasket Gasket

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Pellet burner
The burner hatch of the boiler is designed for operation of the
Viking Bio pellet burner.
The hatch can also be modified to fit pellet burners from other
manufacturers – follow the instructions of the relevant burner
manufacturer. The output of the burner must be
compatible with the output range of the
boiler.
The hatch can be opened easily
using the two handles on each
side of the pellet burner. If the
hatch can be opened without
removing the pellet feed tube or
disconnecting the electricity sup-
ply to the burner, a safety switch
must be fitted to the hatch. This is
to prevent the burner starting with
the hatch open.
For the most efficient operation,
a modern burner should be used
that can work with a low draught,
≤0.05 mbar. Instruments must be used for initial adjustment.
Pay attention to the flue gas temperature. Otherwise, follow the
applicable installation instructions and the instructions of the
burner manufacturer.
Flue
The flue must produce a draught strong enough to overcome
resistance in the flue duct. The draught requirement of the
boiler is 0.05 mbar.
The cross sectional area should be Ø100- 160 mm, ½ x ½
brick.
Combustion produces water vapour, which rises with the flue
gases into the flue, where it can condense for form water, po-
tentially damaging the inside of the flue.
The prevent condensation, the flue gas temperature must be at
least 70 °C one meter down from the top of the flue. A low flue
gas temperature does improve efficiency, but this must be bal-
anced against the risk of condensation.
Steps to reduce the risk of condensation:
• remove any turbulators
• use the draught regulator
• insulate the flue in cold spaces
• increase the burner capacity
• install a flue liner.
Draught regulator
The flue draft is influenced by the temperature and by weather
and wind conditions, and because the efficiency of combustion
depends on the draught, we should aim to achieve a stable
draught.
The draught regulator is used to allow ambient air from the
boiler room into the flue duct, which has the following benefits:
• more stable draught and flue gas temperature
• reduced downtime losses
If the hatch can be opened without removing the pellet feed tube
or disconnecting the electricity supply to the burner, a safety
switch must be fitted to the hatch.
• flue duct ventilation
• drier flue gases, reducing the risk of condensation
The draught regulator setting depends on the design of the
flue – the damper is usually adjusted so it is open around 10
mm when the burner has just stopped.
Turbulators
The boiler is supplied with long turbulators designed for pellet
operation. The purpose of the turbulators is to introduce tur-
bulence to the flue gases and so extract more heat from them,
thereby improving efficiency. The turbulators increase the flue
gas resistance in the boiler.
If the burner output is low, the flue gas temperature is also low,
with an increased risk of condensation in the flue. Experiment
by shortening the turbulators to obtain a suitable flue gas
temperature.
The flue gas temperature must always be checked near the
boiler and at the top of the flue.
If a turbulator tends to slide out, bend it slightly to brace it
against the tube wall.
HVAC installation
Turbulator

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The electrical installation must be carried out by a qualified and compe-
tent electrician, in accordance with IEE regulations. All other relevant
standards and codes of practise must also be adhered to.
An all-pole main circuit breaker must be installed ahead of the boiler.
The circuit breaker must not be set to position “1” before the boiler has
been filled with water.
The minimum cross sectional area of cable for external units connected
to the boiler is 1.5 mm2.
The terminal block is below the hinged front panel, accessible
after removing the two screws on the front and the dial of the
electric thermostat.
The internal connections of the boiler are already made in the
factory, and external connections are made according to the
wiring diagram.
All cables running to the boiler run from the back in a cable
duct along the left of the boiler. The cable penetrations to the
automation cabinet are located at its rear, which you can ac-
cess by removing the two screws on the front top of the boiler
and allowing the automation cabinet to hinge forward.
Wiring diagram
1. Burner thermostat.
3. Water heating circulation pump.
4. Flow switch for water heating.
5. Terminal block for internal and external connections.
17. Overheating protection.
23. Control switch for boiler.
Supply cable
The cross sectional area
of the supply cable is
selected according to the
installation method as
defined in the IEE Regula-
tions.
The boiler is protected
with 10 A.
Circulation pump
The boiler has a output
for a heating system
circulation pump. The
cable enters through the
top panel of the boiler.
Electrical installation
1
3
4
5
17
23
4
2
1
T
230V
230V
30-95°
30-95°
102°C
102°C
T
S
R
W
V
U
T
BRYTARE
BRYTARE
12
45
N
L N P N N N
VX
VX F B X
230V
230V
L N P N N N
VX
VX F B X
PN
230V
230V
L N P N N N
VX
VX F B X
Blue
Yellow/Green
Black
Brown
Grey
Alarm
Safety Gate
230V
230V
L N P N N N
VX
VX F B X
N F BX
230V
230V
L N P N N N
VX
VX F B X
L N
Pellet burner
Most pellet burners require
a phase supply, terminal F,
and a control phase from
a thermostat, terminal B.
Both are disconnected by
the overheating protection
if overheating occurs.
The cable is laid from the terminal block to the strain relief,
through the cable duct on the rear of the automation cabinet,
and down to the burner. Otherwise, follow the instructions of
the burner manufacturer.
Pellet burner - Viking Bio
See also Pellet burner above.
The terminal X is only a terminal to connect the grey cable,
alarm, from Viking Bio. It has no further connection.

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Control panel
After installation, check with the installer that the system is in perfect
condition. Ask the installer to demonstrate the settings and functions so
you know how to operate and care for the system.
The pressure varies with the temperature, do not add water unnecessarily.
For filling, the shunt must be fully open, position 10.
Always disconnect the power supply to the boiler before:
opening the burner hatch
draining the boiler water
accessing the automation cabinet or units powered by the boiler.
Commissioning and checks
Before putting the system into operation, check that:
- the system is filled with water.
- all connections are watertight.
- flue gas connections to the boiler and to the flue are tight.
- the filling/drain valve has been closed properly.
- the safety valves are working properly.
- the necessary valves are open.
- the circulation pump is working and the direction of flow is correct.
Water pressure in the system
The pressure in the heating system depends on the distance
between the highest and lowest points in the system, the static
head. If the difference is 5 metres, the pressure is 0.5 bar, if it is
10 metres, the pressure is 1.0 bar.
The volume of water changes with the temperature, affecting
the pressure in the heating system. Higher temperatures
increase the volume and pressure. The expansion vessel takes
up the changes in volume in the system.
Bleeding/topping up
Regularly check that there is enough water in the heating
system. The pressure gauge should indicate 0.5- 1 bar. Air may
remain in the heating system for a while after installation, so
bleeding should be repeated a few times. After bleeding, check
the pressure and add water if necessary.
Dirt filter
There is a dirt filter in the cold water pipe leading to the heat
exchanger, preventing impurities getting into the water in the
heat exchanger. If the filter becomes clogged, the pressure of
the hot water will fall. You can clean the filter – after shutting off
the water – by removing the plug next to the filter.
Circulation pump
If the boiler is shut down for a long time, there is a risk that the
heating and hot water circulation pumps might seize up. You
can prevent this by running the pumps from time to time.
THERMOSTAT MAIN SWITCH
RESET
OVERHEAT
TEMPERATURE
PRESSURE
Star
Star
NE
NE
Safety valves
The safety valves in the system must be operated regularly,
around four times a year, in order to preserve the safety func-
tion.
Boiler temperature
The boiler temperature should not fall below 70 °C in pellet
operation.
Pellet operation
In burner operation, the draught must be ≤0.05 mbar.
The boiler temperature is controlled by the burner thermostat – for
the various options, see the energy source selector on page 8.
For optimum reliability and efficiency, it is essential to check
and adjust the burner regularly.
Overheating protection
The boiler overheating protection is triggered when the boiler
temperature exceeds around 95 oC. The protection can be
reset on the front panel once the boiler temperature has fallen
to around 80 oC.
If there is a risk of freezing
In severe cold weather, no part of the heating system should
be turned off as this would involve a risk of burst pipes. The
boiler must not be put into operation if any part of the heating
system is suspected of being frozen. Call the installer.
If the water boils
Disconnect the power supply to the boiler, then fully open the
nearest hot water tap.
Flue cleaning
Ash and soot are formed in pellet operation, so the boiler must
be regularly cleaned, if possible when the flue gas tempera-
ture has risen by around 50 °C compared to when the boiler is
clean.
The turbulators must be checked every time the boiler is
cleaned. Damaged turbulators should be replaced. With a cor-
rectly adjusted burner, flue cleaning will not be necessary be-
tween the regular visits of the flue sweep.
Boiler cleaning
Keep the boiler clean and tidy. Alkaline cleaning agents are use-
ful for removing soot marks from the boiler.
Operation and care
1. Thermostat. Setting of boiler temperature during
burner operation. Recommended setting min 70 °C.
23. Main switch, which breaks the control current to the
boiler, as well as units powered by the boiler.
52. Resetting, overheating protection. Resetting may take
place when the boiler temperature has fallen to approx.
80 °C.
71. Thermometer, shows the boiler temperature.
72. Pressure gauge, shows the water pressure in the heat-
ing system.
123
17
71
72

2009-03
Star NE
Troubleshooting
Components
Product no Component qty
12 00 06 Thermostat, burner 1-pole 1
12 00 07 Dial for above 1
12 00 25 Overheating protection 1
13 00 32 Rocker circuit breaker 2-pole 1
14 00 42 Strain relief 6
24 03 50 Drain valve 1
26 00 05 Shunt valve 1
23 22 01 Combustion plate 1
29 55 13 Burner pipe 1
30 00 34 Hatch gasket 1
37 00 61 Plastic dial M6 2
44 01 90 Inspection glass 1" 1
38 00 06 Thermometer/pressure gauge 1
23 22 24 Turbulator 3
44 00 01 Tube cleaner 57 mm 1
44 00 10 Spring steel shaft 1
24 50 81 Dirt filter 1
24 60 01 Circulation pump 1
35 01 00 Heat exchanger 1
24 05 50 Angled ball valve 2
26 02 11 Flow switch 1
Low room temperature
Shunt valve incorrectly set. Check and adjust the setting.
Main and/or control switch in position 0. Set the switches to position “1”.
Overheating protection triggered. Reset the overheating protection.
This is a warning sign – if it happens more than once, call the service
engineer.
Boiler temperature too low. Check the thermostat settings, adjust the temperature.
Burner malfunction. Check, correct.
Circuit breaker triggered. Check where the short circuit is, correct the problem and reset the circuit
breaker.
Air in boiler or heating system. Bleed and top up the heating system as necessary.
Closed valves in heating system. Open the valves.
Circulation pump switched off or seized up. Check, assisted start of pump.
Low hot water capacity
Domestic hot water flow too high. Reduce the tap flow, see the technical data.
Mixing valve set too low. Check, adjust temperature.
Switch set to position 0. Set the switches to position “1”.
Fully or partly closed valves to heat exchanger. Open the valves.
Overheating protection triggered. Reset the overheating protection.
This is a warning sign – if it happens more than once, call the service
engineer.
Boiler temperature too low. Check the thermostat settings, adjust the temperature.
Burner malfunction. Check, correct.
Circuit breaker triggered. Check where the short circuit is, correct the problem and reset the circuit
breaker.
Air in boiler, pipes or hot water system. Bleed and top up the heating system as necessary.
Circulation pump does not start. Assisted start of pump.
Circulation pump capacity set too low. Check the capacity setting of the pump.
Dirt filter clogged. Clean.
Heat exchanger blocked. Replace the heat exchanger, check the water.
RVR
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RVR Energy Technology Limited t,FONBSF$P,FSSZ*SFMBOEtXXXSWSJFtXXXSWSDPVL
èðéðëéëèèë(ROI)tèêèëêðïèéëè(UKtëíëîìîîìéëìì(INT)