Stalmark PID 10 Installation guide

OPERATION AND MAINTENANCE
DOCUMENTATION
FOR THE
BOILER OF
„PID” TYPE
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TECHNICAL DOCUMENTATION FOR THE
BOILER OF „PID” TYPE
Maintenance of PID boiler - output 10-60 kW
NOTE!
Before installing and using the boiler, the user should study this
manual thoroughly.

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Table of contents
Introduction 4
Boiler usage 4
Advantages of the boiler 4
1. Fuels 5
2. Technical data 5
3. Construction of the boiler 6
4. Installation guidelines 6
4.1 Setting of the boiler 7
4.2 Ventilation 7
4.3 Connecting the boiler to the chimney 7
4.4 Connecting the boiler to the central heating system 7
4.5 Filling the boiler up with water 8
4.6 Electrical installation 8
5. Starting the boiler 9
5.1 Connecting the circulation pump and tap water pump 9
5.2 Operating temperature of the boiler 10
5.3 Starting up 10
5.4 Cleaning 11
6. Stopping the boiler 11
7. Troubleshooting 11
8. Maintenance 11
9. Transportation of the boiler 11
10. Notes 12
11. Procedure in case of soot fire in the flue duct 12
12. Closing remarks 12
Warranty Card 13
List of repairs under the warranty 14

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Introduction
This technical documentation applies to boilers of PID type. The ecological and innovative
PID water boilers are equipped with an extended exhaust circulation as well as with the most
technologically advanced microprocessor controller which regulates the power of the boiler.
All STALMARK boilers are CE marked.
Precise study of this documentation will allow for the safe use of the PID boilers.
This instruction manual includes essential information concerning the construction and maintenance of
the boilers. It also contains guidelines for the proper handling and exploitation of the boilers. If the user
does not follow the rules and guidelines presented in this manual, the manufactuer will be released of all
liabilities and obligations.
Before installation, the user should:
- check if the boiler has not been damaged in transport
- read this operation and maintenance manual
- check if the equipment is complete

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1. Fuels
Basic fuel for the PID boiler:
- hard coal of cube type I/II, nut type I/II, pea type I/II, had I/II
Alternative fuel:
- wood, coal briquettes, and wood pellets
Use of alternative fuels changes thermal efficiency of the boiler. Constant use of excessively wet fuels
leads to increased wearing of the boiler, and corrosion of the furnace plates and of the external plates
located under the flue, since the emission of the combustion products, such as water, nitric oxide, sulfur
oxide, causes corrosion of steel elements of the boiler. It is forbidden to use wet, unseasoned wood. Any
failures and technical problems resulting from the fact that the user do not follow the recommendations
included in this documentation, cause the loss of warranty.
2. Technical data
Tab. 1 Technical specification of PID boilers
Parameters specified above are approximate values and may slightly change due to technological
modifications.

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3. Construction of the boiler
Fan-----------------------
Flue gas outlet to the
chimney ------------------------- --------- Door for cleaning heating ducts
------------- Door for loading fuel
-------- Water jacket
----------- Furnace door
---------- Water grate
------------ Ashpan door
Fig. 1 Boiler cross-section
4. Installation guidelines
The boiler is supplied as assembled. Prior to the boiler alignment and connection to the central heating
system and the chimney flue, it shall be checked whether all sub-assemblies are operational, and
whether the boiler has full equipment for operation and cleaning (see tab.2.).
Specification
Amount
1
Liquid thermometer
1
2
Ash scraper
1
3
Technical and maintenance documentation
1
4
Warranty Card
1
Tab. 2 List of additional equpiment

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4.1 Setting of the boiler
The boiler room is not a place meant for people to stay there neither temporarily nor permanently.
Minimum height of the boiler room is 2,2m for the new buildings, and 1,9m for the already existing
ones.
The boiler must be set on a non-flammable surface. If the boiler is placed in a cellar, it is recommended
to set the boiler on a foundation of minimum 50mm.
The adjustable legs allow for accurate leveling of the boiler.
Setting of the boiler should enable easy handling, cleaning, and maintenance of the boiler. The
minimum distance:
- from the boiler to the side walls is 0,5m
- from the boiler to the back wall is 0,5m
- in front of the boiler is 1,5m.
4.2 Ventilation
The boiler room should be secured against the ingress of the groundwater, and fitted with ventilation
system ensuring the air supply necessary for the combustion process.
In boiler rooms with capacity up to 25kW, the air should be supplied through an open air hole with a
minimum size of 200cm2, and exhausted through the exhaust grating with a minimum diameter of 14 x
14cm.
In boiler rooms with capacity ranging from 25 to 2000kW, there should be an air supply duct with a
diameter of not less than 50% of cross-sectional area of the chimney, but not less than 20 x 20cm. The
outlet of the air supply duct should be located at a height of minimum 1m above the floor level. There
should also be an exhaust channel with the diameter of not less than 25% of cross-sectional area of
the chimney, and with the air supply hole. The exhaust channel should extend above the roof, and it
should be located near the chimney. The cross section of this channel should be not less than 14 x
14cm.
The minimum cross-sectional dimensions of the chimney are 20 x 20cm.
4.3 Connecting the boiler to the chimney
The connection of the flue to the chimney should be made of 3mm steel pipe. It must be mounted on
the flue outlet, inserted into the chimney, and sealed. The pipe should go slightly upwards (min. 5 ).
The accurate height and cross section of the chimney have major influence on the proper work of the
boiler. Before connecting the boiler to the chimney it should be checked if the cross section of the
chimney is proper, and if any heating objects have already been connected to the chimney. Technical
condition of the chimney should be assessed by a chimney sweep. In order to secure the chimney
against the wind, it should extend above the roof for at least 1m. The chimneys made of steel should be
15-20% higher than the chimneys made of brick. The chimney should be constructed so as the flue
draft required by the manufacturer is ensured throughout the working range of the boiler.
4.4. Connecting the boiler to the central heating system
As the boiler is set in the boiler room and connected to the chimney, the following installation works
should be performed:
- before connecting the boiler to an old central heating installation it is necessary to rinse the system in
order to remove the sluge from pipes and radiators
- the boiler should be connected to the central heating installation by screwing with a threaded joint
- the reduction and drain valve should be screwed in one of the return pipes.
It is recommended to use either three- or four-way valve.
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Installation of the boiler must be carried out by an authorized person, who is familiar with the boiler
operating instructions. An user obligation is toensure that the boiler installation is carried out in
accordance with applicable regulations.
Fig. 2 Boiler connection diagram
4.5. Filling the boiler up with water
The boiler may be filled up with water from water supply system (through the boiler’s drain cock) by
means of a flexible hose, which should be disconnected from the boiler after filling the installation up
NOTE!
The installation must meet all norms and regulations concerning the security of water heating
devices working in open systems, of the country in which it is being used.
Major terms for the installations covered by PN-91/B-02413 norm:
- it is forbidden to retrieve water from heating installation for other purposes; the opearting pressure
cannot be higher than the maximum pressure allowed for all the devices and elements of the installation
- securing of the open water heating system should include basic safety devices as well as
supplementary accessories
- the internal diameter of the overflow pipe should be larger than the internal diameter of the expansion
and safety pipes
- the internal diameter of the safety pipe should be minimum 25mm
- the internal diameter of the overflow pipe should be minimum 25mm
- the internal diameter of the vent pipe and signaling pipe should be minimum 17mm

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NOTE!
It is forbidden to put valves and other devices, which may reduce the internal cross diameter of the
pipe, on the safety pipes, overflow pipes, and vent pipes.
- all the accessories for the expansion vessel as well as the way of placing it are specified by norms and
regulations of a given country.
In the area where the expansion vessel, safety pipes, expansion pipe, signaling pipe, and overflow pipe
are located, the temperature should do not drop below 0 C.
If the expansion vessel is placed in an area where the temparature drops below 0 C, the circulating
pipes and safety valves connecting the vessel to the boiler should be used along with thermal insulation,
all in accordance with norms and rules of a country in which it is being used. Thermal insulation of the
safety devices is designed to protect them against freezing only during short stoppages of the boiler.
4.6. Electrical installation
Both the electrical installation and the boiler control panel are designed for power supply of 230V/50Hz.
The boiler room must be equipped with an electrical installation that meets all norms and regulations of a
given country. The electrical system socked must have the protective earth terminal. Using the socket
without connected terminal may cause electric shock. It is advisable to use separate electrical circuit to
supply the boiler with power. The socket should be located at a safe distance.
5. Starting the boiler
Before firing the boiler up, it is necessary to fill both the boiler and the installation with water. It should be
checked if there is water in the expansion vessel, which is situated at the highest point of the installation.
The checking should last few seconds, to make sure that water flows out the vessel.
5.1. Connecting the circulation pump and tap water pump
Connection of the circulation pump and tap water pump should be done in accordance with the
instruction manual of the controller. It should be done by a licensed electrician.
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NOTE!
Lack of thermal insulation, inadequate positioning of the expansion vessel, i.e. not in accordance with
the norms and regulations of a given country, along with mounting valves on the overflow pipe may
cause warranty loss. The warranty services may be denied especially during the time when the
temperature drops below 0 C.
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5.2 Operating temperature of the boiler
If water supplying the central heating installation has the temperature below 55 C, steam will condense
on the sides of the boiler, and water may leak out. Operating the boiler at low temperature may cause
corrosion. Thus, it is recommended to use the boiler with water temperature higher than 55 C.
Using the boiler with water temperature lower than 55 C causes intensive precipitation of tar from the
combusted fuel, which concentrates in the heat exchanger and the chimney duct. The deposits of tar in
the heat exchanger and the flue are dangerous, as they might catch fire.
Maximum water temperature in the boiler must not overreach 90 C.
The PID boilers may be used in central heating systems with natural or forced water circulation. The
boiler should be secured in accordance with norms and regulations of the country in which it is being
installed.
5.3 Starting up
Firing up for the furnace on the water grate:
- fire up with wood in the furnace
- when the wood is burning, put small amount of basic fuel on it
- turn the controller on
- add desired amount of fuel to the furnace
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NOTE!
Turn the controller off before poking the fire. It is forbidden to add fuel to the furnace during the
combustion cycle. You musn’t stand in front of the boiler while opening the door! It may cause severe
burns. In order to avoid burns, it is necessary to open the ash pan and wait few minutes before
opening the door. Extreme caution and safety measures are required while opearting the boiler.

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5.4. Cleaning
To maintain the highest efficiency of the combustion process, the smoke channels, air supply holes, and
plates inside the furnace, should be kept clean. Soot, dust, and ash, which appear as a side effect of
burning, decrease the efficiency of the combustion process. The smoke channels, and furnace plates
should be cleaned with a scraper. Ash and combustion residues should be removed through the
ashpan door.
NOTE!
Any activities related to maintenance and cleaning of the boiler must be performed after disconnecting
the power supply by removing the power plug from the socket.
6. Stopping the boiler
When the heating season ends, or during the break in the heating season, the boiler should be cleaned,
and the combustion residues should be removed. Use scraper to clean the walls of the boiler, and leave
it open to ventilate. During the break in the heating season, water should not be drained neither from the
boiler, nor from the heating system.
7. Troubleshooting
If the maximum temperature is overreached, the mechanical temperature limiter will turn the fan off.
However, if the temperature is still rising, it is necessary to:
- check whether the fan is not working, and whether the fan damper has been closed, so that the air
supply to the furnace is stopped
- check if all the doors are closed, and whether the blow frequency is not set for too often.
If the temperature does not drop, despite taking the above steps, the content of ashpan should be
removed to non-combustible metal container, with the extreme caution and using personal protection
measures.
IT IS FORBIDDEN TO REPLENISH THE BOILER WITH COLD WATER WHILE IT IS HEATED. IT IS
ALSO FORBIDDEN TO USE WATER TO EXTINGUISH THE BOILER!!!
8. Maintenance
Inspection and repair should be done on a regular basis. In order to inspect the boiler and further
determine the extent of possible repairs, the boiler must be thoroughly cleaned from the residues. After
the heating season, it may be necessary to repair some minor defects, even if the boiler is used
properly. Most of the minor defects can be repaired by the user. However, the more extensive repairs
due to mechanical damages, breakdowns, improper usage, or the wearing of the boiler, should be
made by a qualified person. Any reparations of the electrical elements of the boiler must be carried out
by qualified electrician. Before making any inspections and repairs, it is of vital importance to unplug the
boiler from the power supply.
9. Transportation of the boiler
The boiler is supplied as assembled. It must be transported in a vertical position. It is forbidden to attach
ropes, chains, etc. to the boiler, as it may cause its damage. The boiler should be fastened with tension
straps at the upper frame of the door and the flue.

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10. Notes
The boiler may be only used by adults who have read this documentation. It is forbidden for children to
be near the boiler without the supervision of adults. Do not use flammable liquids to ignite the boiler.
Use solid fuel, wood, or paper. Do not keep combustible materials either on the boiler, nor on the boiler.
Use only the fuel recommended by the manufacturer, delivered by licensed supplier. Both the power
cord, and the connection to the pump and the hot water must be kept away from the heat sources (the
door, smoke conuit). It is forbidden to interfere with electrical and structural parts of the boiler.
11. Procedure in case of soot fire in the flue duct
In case the soot in flue duct catches fire, notify the fire brigade immediately. People staying in heated
rooms should be warned and prepared for immediate evacuation. The air supply to the stove should be
stopped. While waiting for the fire brigade, it should be observed (if possible) whether the fire does not
spread to flammable objects via sparks, or overheated chimney pipe.
12. Closing remarks
The main characteristic of the PID boilers is that their construction ensures high efficiency along with
the low fuel consmption. Make sure that you receive the Warranty Card when you purchase the boiler.
When issuing a complaint, it is necessary to specify the type of the boiler, its serial number, and the year
of production.