Sunsystem BURNiT Magna WBS-A 450 Owner's manual

TECHNICAL PASSPORT INSTALLATION
and OPERATION MANUAL
EN
Model:
serial №: Version i0.1.1
Solid fuel boiler
WBS-A 450 Magna

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
3-
EN
TABLE OF CONTENTS:
1
EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS
4
1.1. Explanation of symbols
4
1.2. Requirements to boiler installation room
4
1.2.1. Instructions to boiler installer
4
1.2.2. Instructions to installation u
ser
5
1.2.3. Minimum clearances for installation and combustibility of
construction materials
6
2
PRODUCT DESCRIPTION
7
3
FUELS
8
4
TRANSPORTATION OF THE BOILER
8
5
DELIVERY OF THE BOILER
10
6
INSTALLATION OF THE HEATING BOILER
10
6.1. Re
quirements
10
6.2. Assembly / disassembly of the boiler housing
11
6.3. Check door tightness
12
7
SETUP OF THE HEATING BOILER
1
3
7.1. Connecting the boiler to a chimney
1
3
7.2. Connecting the thermostatic draft regulator
-
air flow regulator
14
7.3. Connecting the boiler to the heating installation
16
7.4. Connection diagrams
18
8
FILLING THE HEATING INSTALLATION
20
9
OPERATION OF BOILER
20
9.1. Loading and ignition the boiler
20
9.2. Cleaning of the boiler
20
9.3. Import
ant recommendations for long
-
lasting and correct
operation of the boiler
21
10
CONTROLLER
23
1
1
WARRANTY TERMS
32
1
2
TECHNICAL PARAMETERS
33
1
3
RECYCLING
37

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
4-
EN
1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTION
1.1. Explanation of symbols
CAUTION! - Important recommendation or warning concerning
safety conditions during installation and operation of the heating
boiler.
DANGER! - fault or improper use may cause injury or be hazardous
to the life of humans or animals.
FIRE HAZARD! – fault or improper installation and operation may
cause fire.
INFORMATION - Important information on the proper operation of
the product.
1.2. Requirements to boiler installation room
This manual contains important information for the safe and correct installation,
start-up and trouble- free operation and maintenance of the heating boiler.
The heating boiler can be used for heating rooms only in the manner described in
this manual.
Take note of the boiler type information indicated on the factory sticker and the
technical data provided in chapter 12 in order to ensure proper operation of the
product.
1.2.1. Instructions to boiler installer
During installation and operation, the country - specific requirements and regulations
must be observed:
• Local construction regulations on installation, air supply and exhaust gas extraction
as well as chimney connection.
• Regulations and norms concerning the fitting of the heating installation with safety
devices.
• It is necessary to install a smoke detector in the boiler room.
Use only original BURNiT parts !

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
5-
EN
DANGER of fire when burning flammable
materials or liquids.
- Flammable materials/liquids must not be left in close proximity of the
heating boiler.
- Indicate to the user of the installation the valid minimum distances to
flammable materials.
DANGER of intoxication, suffocation. Inadequate inflow of fresh air to the
boiler room may result in dangerous leak of exhaust gases during boiler
operation.
- Make sure the air inlets and exhaust gas outlets are not clogged or
closed.
- If faults are not remedied immediately, the boiler must not be operated,
and the user must be provided with written instructions on the fault and
the hazard it entails.
CAUTION!
The installation of the boiler must be performed only by authorized service
specialists following the safety instructions.
Customer must undergo boiler operation / maintenance training by
authorized installer/ service shop.
1.2.2. Instructions to installation user
DANGER of i
ntoxication or explosion.
Toxic gases may be discharged when
burning waste, plastics, liquids.
- Use only the fuels indicated in this manual.
- In case of danger of explosion, ignition or discharge of exhaust gases in the
room, stop the heating boiler from operation.
CAUTION!
The installation of the boiler must be performed only by authorized service
specialists following the safety instructions.
Customer must undergo boiler operation/ maintenance training by
authorized installer/ service shop.
CA
UTION! Danger of injury /
damage of system due to incompetent
operation.
- The heating boiler must be serviced only by persons familiar with the
operation manual.
- As a user, you are only allowed to start the boiler up, adjust the
temperature of the boiler, shut the boiler down and clean it.
- Unattended children must not be allowed access to premises with burning
boiler inside.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
6-
EN
Safety rules for user operation:
- Operate the heating boiler at a maximum temperature of 85°C, and to
that end you must regularly inspect the boiler room.
- Do not use flammable liquids for ignition or increase the fire or increase boiler’s
output.
- Collect ash in lid-covered fireproof containers.
- Clean the heating boiler surface using non-flammable agents only.
- Do not place flammable objects onto the heating boiler or in its proximity (see
diagram for the minimum clearances).
- Do not store flammable materials in the boiler room.
1.2.3. Minimum clearances for installation and combustibility of construction
materials
The applicable minimum clearances in your
country may differ from the ones specified
bellow. Please, consult with your installer.
The minimum distance from the heating boiler
or exhaust gas pipe to objects or walls must be
at least 200 mm.
Diagram1. Recommended clearances between the
boiler and walls.
For general safety considerations, we
recommend that the boiler be placed on a
foundation with height of 100 mm made of
class A material, see table 1.
Table 1. Combustibility of construction materials
Class
А
-
non -combustible
Stone,
bricks, ceramic tiles, baked
clay, solutions, plaster
free of organic additives.
Class
В
-
hard combustible
Gypsum board panels, basalt fiber
needled felt, fiberglass
board, AKUMIN, Izomin, Rajolit, Lignos, Velox, Heraklit.
Class
С1/С2
-
Medium combustible
Wood beech, oak
Wood softwood, layered wood
Class
С3
-
easy combustible
Asphalt, cardboard, cellulose, tar,
fiberboard,
cork,
polyurethane, polyethylene.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
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EN
2. PRODUCT DESCRIPTION
WBS-A Magna heating boilers are designed mainly for burning solid fuels - wood,
wood briquettes class B and coal. Designated for indoor climate heating of large
premises - residential and public buildings, industry workshops, etc. They can be
either connected to open- or closed central heating installation circuit.
These impressive-sized renewable energy heating devices combine state-of-the-art
engineering solutions and high-grade materials. Nevertheless, they are easy for
transportation and installation.
WBS-A 450 Magna boilers are designed and manufactured in accordance with EN
303-5.
• Design. Boiler body is made of high-quality boiler steel sheets with thickness of
8mm for the combustion chamber and 5mm for the water mantle.
• Automatic control (Controller).
The automatic control is regulating the functions of the intake air fans and the
circulating pumps of the central heating(CH) and the domestic hot water (DHW)
circuits upon constant temperature indication signals. The power of the intake fans
can be regulated in a broad range depending on the used type and condition of the
fuel and also the chimney draught.
• Efficient. The flue gases make a three-pass movement on their way to the chimney.
This way the gas is cool when it leaves the boiler and its energy has been transferred
to the water in the mantle. The water mantle fully embraces the combustion
chamber to utilize the emitted heat most efficiently. To prevent from losing heat into
the ambience, the boiler is insulated on the outside by 100 mm high temperature
effective mineral wool.
• Versatile. Designed for burning solid fuels. The boiler has an option to adapt to
other fuel sources: by mounting a pellet burner BURNiT PELL 300 Mega or PELL 500
Mega. The mounting is performed by a specially designed opening on the lower door
with the help of special mounting kit for each burner.
• Fuel loading door
• Cleaning doors
• Two blower fans with safety valves for intake air control
• Draft regulating valve, mounted on flue end
• Safety devices of the boiler - a complex of safety devices provide for the safety of
the appliance

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
8-
EN
3. FUELS
The heating boiler can utilize only natural and untreated wood, or coal. Pressed fuels
and briquettes containing only wood may also be used. Log length should be: up to
1500 mm.
For maximum utilization of the wood heating value we recommend only using wood
which has been dried over a period
of at least 1,5 - 2 years. High
moisture content of the wood
decreases its heating value which in
turn reduces boiler output.
Diagram 2.
Relation between wood heating value
and water content.
Table 2. Heating value of the most common wood species
4. TRANSPORTATION OF THE BOILER
We recommend to transport the heating boiler to the installation site in its packaging
placed on the pallet. During transport and installation, depending on the weight,
appropriate safety equipment must be used in accordance with Directive
2006/42/EC. When transporting items weighing more than 30 kg, the use of pallet
jack, forklift or other hoisting devices is a must.
Wood species
Energy
,
contained in
1
kg, dry mass
kcal
kJoule
kWh
Spruce
3900
16250
4,5
Pine
3800
15800
4,4
Birch
375
0
15500
4,3
Oak
3600
15100
4,2
Beech
3450
14400
4,0

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
9-
EN
The large sized boilers BURNiT WBS-A 450 Magna require transportation to be
carried out using a forklift. For this purpose at the lower part of the boiler are
provided transportation openings.
Important: When installing the boile
r, the wooden pallet onto which
the boiler is placed must be removed by unscrewing the bolted
connections using flat ring wrench S13.
WBS-AC Magna A, mm B, mm C, mm D, mm Weight, kg
450
1190
2820
175
2830
3100
Diagram 3. Overall dimension of boiler body and housing, model WBS-A 450 Magna

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
10-EN
5. DELIVERY OF THE BOILER
• Inspect the integrity of the packaging upon delivery.
• Check whether all components have been delivered to you.
Boiler scope of delivery includes:
1) Boiler body with boiler doors.
2) Fire irons.
3) Cleaning brush for flue pipes.
4) Technical passport. Installation and operation manual.
5) Service booklet and Warranty card.
If any of the above items are missing, contact your supplier.
6. INSTALLATION OF THE HEATING BOILER
The assembly, installation and setup
of boiler must be performed by a
technician authorized for such operations.
Installer must indicate to the user of the installation the minimum
clearances from flammable materials and liquids.
6.1. Requirements:
- Boiler room must be frost-proof;
- Boiler room must allow for continuous access of air necessary to maintain
combustion;
- Boilers must not be placed in inhabitable rooms;
- All boiler rooms must have correctly calculated vent depending on the boiler
output. The vent must be protected by means of a net or grate.
The size of the vent is calculated according to the formula:
А=6,02*Q - where: А - area of the vent in cm2, Q - boiler output in kW.
- Remove the packaging without polluting the environment;
- Observe building supervision instructions, in particular the existing
Ordinance on combustion devices and storage of combustion materials, on
building requirements applicable to installation sites and on ventilation;
- The boiler must be placed on a foundation whose surface area is larger than
the base of the heating boiler according to diagram 1;
- The boiler must be placed in a position which allows for the easiest possible
cleaning and servicing;
- Installation must be carried out according to installation diagram 1 which
shows the boiler housing;
- No objects made of flammable materials or liquids may be placed on/near
the boiler

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
11-EN
6.2. Assembly / disassembly of the boiler housing
Diagram 4. Elements of boiler housing, model WBS-A 450 Magna
Table 3
No
Designation
pcs
1
Rightside lower front panel
1
2
Rightside lower back panel
1
3
Leftside lower front panel
1
4
Leftside lower
back panel
1
5
Rightside upper front panel
1
6
Leftside upper front panel
1
7
Rightside upper back panel
1
8
Leftside upper back panel
1
9
Frontside upper left panel
1
10
Frontside upper right panel
1
11
Frontside central panel
1
12
Backside righ
t panel
1
13
Backside left panel
1
14
Assembled main switchboard with controller ST
-
81 model
1
15
Cable laying protection lids/channels
8
16
Blower fan
VA6C 60R
2
17
Blower fan gaskets
2
18
Intake air valve
2
19
Screw
М5 х 25 DIN 7985
23
20
Screw
М
5 х 12 DIN 7985
18
21
Hex screw
М5х12 DIN933
8

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
12-EN
Steps to assemble the panels of the boiler housing:
Step
1:
Fix Rightside lower front panel
1
to the boiler ’s base and body
Step
2:
Mount Rightside lower back panel
2
to the boiler ’s base and body
St
ep
3:
Mount Leftside lower front panel
3
to the boiler ’s base and body
Step
4:
Mount
Leftside lower back panel
4
to the boiler ’s base and body
Step
5:
Fix
leftside
9
and rightside
10
upper front panels
to
panel
s
6
and
5
accordingly, using М5х12mm screws (2 pcs for each panel)
Step
6:
Mount
Rightside upper front panel
5
to the boiler ’s body and to panel
2
Step
7:
Mount
Rightside upper back panel
7
to the boiler ’s body and to panel
1
Step
8:
Mount
Leftside upper front panel
6
to the boiler ’s body
and to panel
3
Step
9:
Mount
Leftside upper back panel
8
to the boiler ’s body and to panel
4
Step
10:
Fix
Frontside central panel
11
to panels
1
and
3
using
М5х25
mm
screws
(6
pcs.)
Step
11:
Fix
Backside left panel
13
onto the boiler’s air distribution body and fixing it
to panel 2 using М5х25mm screws (5 pcs.)
Step
12:
Mount
Backside right panel
12
onto the boiler’s air distribution body and
fixing it to panels 4 and 13 using М5х25mm screws (8 pcs)
Step
13:
Fix
the
main switchboard
14
to panel
5
using
М5х12
mm
screws
(2 pcs.)
Step
14:
Fix
the blower fans
16
onto the boiler’s air distribution body
using
4
pcs
hex screws М5х12 for each fan.
Make sure you have mounted correctly the safety air valves and the fan
gaskets before fixing the fans!
Step
15:
Connect the fans, circulating pumps, sensors and power supply to the main
switchboard and cover all cables with the protection lids. For correct
electrical connections, check diagram 6.
Step
16:
Mount the cable protecting lids and channels by fixing them with screws
М5х12
Make sure the boiler housing is assembled firm and steadily.
* Necessary tool when assembling boiler housing:
- 5-6 mm cross-slotted /phillips screwdriver (“+“ type) with length of at least
120 mm
- a wrench S8 for the fans
- 2-3 mm slotted screwdriver (“−“ type) for the electrical connecons.
6.3. Check door tightness
Open boiler doors. Place paper strips on all sides of the doors and close them, leaving
part of the strips protruding outside. Pull the paper strips. If the strips tear upon
pulling, then the doors are sealed tightly.
Caution! Inadequate adjustment of the hinges may result in air being
sucked in through the doors and the boiler burning uncontrollably.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
13-EN
7. SETUP OF THE HEATING BOILER
7.1. Connecting the boiler to a
chimney
Boiler-to-chimney connection must
always comply with the existing
standards and rules. The chimney
must provide sufficient draught for
extracting of the smoke under any
conditions.
The proper functioning of the
chimney requires adequate sizing
of the chimney itself since the
draught it produces affects
combustion, boiler’s output and life
span.
The draught created by the chimney
is in functional relation to its cross-
section, height and the roughness
of its interior walls. No other
appliance may be connected to the
chimney serving the boiler at the
same time. Chimney diameter must
not be smaller than the flue outlet of the boiler. Flue outlet must be connected to
the chimney opening. In terms of mechanical properties, the flue outlet must
be sturdy and properly sealed (to avoid gas leak) and allow for easy access for
cleaning on the inside. The inner section of the flue outlet must not be greater than
the effective section of the chimney and must not narrow. Avoid using elbow joints.
The chimney cleaning opening has to be in its lowest part. The chimney‘s wall has to
be threeplied where the medium layer is from mineral wool. The thickness of the
insulation is not less than 30 mm when the chimney is setting up inside the house
and the thickness is 50 mm, when the setting up is outside.
Data in the tables
are for indicative purposes. Draught depends on the
diameter, height, uneven sections along the chimney surface and
differences in temperature of combustion products and outside air. We
recommend that you use chimney fitted with flue terminal. Heating
specialist must calculate the precise sizing of the chimney.
The inner diameter of the chimney depends on its real height and the power capacity
of the boiler (see diagram 5). Please entrust choosing a chimney and its installation

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
14-EN
by a qualified professional. The required distance between the boiler and the
chimney is 300 - 600 mm.
Recommended chimney dimensions and characteristics
Power Boiler flue gases exit
diameter
Chimney inner cross
section, diameter
Effective
chimney height
Chimney
draught
450 kW 450 mm
450 mm 15 m
50 Pa
400 mm 20 m
350 mm 25 m
Table 3. Interdependence between boiler rated power and chimney dimensions and
characteristics
7.2. Connecting the boiler to the heating installation.
Such connection must be performed by a technician / service shop
authorized for such operations.
When the boiler is connected to a heating system, it is mandatory to install a 4 bar
relief valve and expansion vessel. No shut-off fittings may be installed between the
relief valve, expansion vessel and boiler.
It is mandatory to install a three
-
way valve (Laddomat or similar) or a
four-way mixing valve which to ensure that the temperature of the
heating medium fed into the boiler from the heating installation is at
least 65°С.
Table 4. TROUBLE-SHOOTING TABLE
Cause
Solution
Installation damage
1.
Due to unsealed connections
1. Install the connection fittings to the
boiler fittings – no pressure allowed
during work. Connect the hot water
outlet of the installation to connection
B. Connect the cold water outlet of the
installation to connection A. Mount the
stopcock to drain outlet Y.
2. Due
to accumulation
of deposits.
Condensate and tar formation may
reduce the performance and life of the
heating boiler. The temperature at the
2. It is mandatory to install a three
-
way
thermostatic valve which will prevent
the temperature dropping under 65°C at
the inlet.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
15-EN
boiler inlet must not be less than 65°C,
boiler water temperature at the outlet
must be between 75°C and 85°C.
-
In order to increase the operational life
of the boiler it is recommended to install
a buffer vessel with capacity of 55 l per
1kW of installed power.
3. Due to freezing
3. If the heating installa
tion, including
the piping network, has not been built
frost-proof, we recommend that you fill
the heating installation with a liquid
which has low freezing point and
corrosion protection and antifreeze
agent.
Output too low
1. Insufficient draught
.
1. C
heck chimney condition and
measure draught. (must be performed
by an authorized service)
2. The heating capacity of the fuel is too
low (not sufficient).
2. Make sure you are using dry fuel.
When using fuels with high percent
humidity it is possible that the boiler
works for a certain period after refilling
with reduced power capacity while the
fuel dries enough.
3. Presence of deposits of soot and
/
or
tar in fume exhaust tubes of the water
jacket of the boiler.
3
.
Open the upper door and clean the
heating surface of the exhaust tubes by
using the brush from the set that
accompanies the boiler. After cleaning,
remove the soot that might fall in the
combustion chamber.
Boiler water too hot, heating bodies too cold
1. Hydraulic resistance is too high
2. Air in the system
3. Inoperable circulation pump
Make sure the circulation pump has
been properly selected and the heating
installation is of the proper dimensions.
(You must contact your installer.)
Boiler temperature too high. Controller failure
.
1.
P
ower grid
fluctuations
2. Power failure
It is mandatory to assure a backup
power generator of corresponding
rated power! (see 12.2)

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
16-EN
7.3. Connecting the boiler to the mains power supply
The boiler must be connected to a 220V / 50Hz mains using a cable and a plug. The
boiler must be placed in a position which allows for unobstructed access to the
power supply plug. Dismount the inspection cover on the back side of housing.
Using a screw driver, connect the power supply and the external components (pump
for the heating circuit and domestic hot water pump). Make sure you have
connected the external components properly according to the enclosed wiring
diagram.Create solid connection with the electrical mains which complies with the
local regulations.
Warning! Be careful when connecting the circulation water pumps: the
controller is only capable of sending signals (voltage) for controlling the
pumps and is incapable of powering them up with electric current (see
10.16)!

Caution
!
ELECTRIC SHOCK HAZARD
!
Before opening the switchboa
rd:
switch off the voltage and secure the switchboard against accidental
restart. Observe installation instructions.
Make sure that the power supply system is properly grounded.

All connection works must only be carried out by
qualified electricians.
Improper cable connections may damage the regulator! The device may be
damaged if struck by a lightning. Make sure it is unplugged during the
storms. It is mandatory to assure a backup power generator of
corresponding rated power! (see 12.2)

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
17-EN
Diagram 6.

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
18-EN
7.4. Connection diagrams
7.4.1. Connection of BURNiT WBS-A Magna boiler in a closed system
Such connections must be performed by a technician / service shop
authorized for such operations.
Diagram 7
1
-
Thermostat
6
-
Hot water collector
2
-
Expansion vessel
7
-
Heating circuit
2
pump
3
-
Safety valve
8
-
Return valve
4
-
Circulation pump
9
-
Heating circuit
1
pump
5
-
Cold water collector
10
-
Mixer valve
11
-
Air vent

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
19-EN
7.4.2. Connection of BURNiT WBS-A Magna boiler in an open system
Diagram 8
1
-
Cold water inlet
5
-
Return valve
2
-
Drainage
6
-
Insulation
3
-
Air vent line
7
-
Hot water outlet
4
-
Expansion vessel (open)

TECHNICAL PASSPORT INSTALLATION and OPERATION MANUAL
20-EN
8. FILLING THE HEATING INSTALLATION
Table 5
Problem
Prevention
Possible installation damage due to
strains in the material caused by
temperature differences.
Fill the heating installation only in cold
conditions (inlet temperature must not
exceed 40°C).
Danger of installation damage due to
accumulation of deposits. Condensate
formation and tar deposits may shorten
boiler’s operational life.
-
Do not operate the heating boiler for a
long period of time in partial load mode.
- The temperature at the boiler inlet
must not be less than 65°C, boiler water
temperature must be between 75°C and
85°C.
- Use the boiler for a short period to
heat warm water in the summer.
9. BOILER OPERATION
9.1. Loading and ignition the boiler
When igniting the boiler for the first time, a condensate is formed which is later
drained (this is not a fault in the boiler). The fuel is loaded through the door of the
combustion chamber and is recommended to load logs of length equal to the
combustion chamber length and stack them tight inside with least possible air gaps.
All three boiler doors and all lids must be well shut and sealed. When humid wood is
burnt the boiler do not work effectively and the following consequences occur:
- significantly increases fuel consumption;
- not reach the desired power;
- lifetime of the boiler and chimney are shortened.
It is recommended to maintain an optimal operating temperature
between 75°C and 85°C.
9.2. Cleaning of the boiler
Caution! Hot surfaces. Before cleaning the boiler, make sure the fire in it
has died out and the boiler has cooled down.