ThermoFLUX Pelling 25 Operating instructions

ThermoFLUX d.o.o., Bage br. 3, 70101 Jajce, Bosna i Hercegovina, Tel/Fax: [phone]
www.thermoflux.ba
[email protected]a
USER AND MAINTENANCE MANUAL

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ThermoFLUX
Pelling
Content:
1Notes on the manual .................................................................... 5
1.1 Introduction .......................................................................................................... 5
1.1.1 Easy and safe operation ...................................................................................... 5
1.1.2 Reading the manual............................................................................................ 5
1.1.3 Technical changes .............................................................................................. 5
1.1.4 Copyright .......................................................................................................... 5
2Safety notes ................................................................................ 6
2.1 Proper use ............................................................................................................ 6
2.1.1 Basic principles .................................................................................................. 6
2.1.2 Using the boiler.................................................................................................. 6
2.1.3 Permissible fuel for the Pelling boilers ................................................................... 6
2.1.4 Recommended wood pellets................................................................................. 6
2.2 Warnings and safety symbols used .......................................................................... 7
2.3 Other risks of the side effects .................................................................................. 8
2.4 Duty to inform....................................................................................................... 8
2.5 Safety devices....................................................................................................... 8
3Installation and commissioning of the boiler .................................. 10
3.1 Conditions ...........................................................................................................10
3.2 Chimney and flue gas pipes ...................................................................................10
3.3 Minimum distances of the boiler from wall and objects ..............................................11
4Functional description ................................................................. 12
4.1 General overview..................................................................................................12
4.2 Pellet boiler PELLING .............................................................................................13
5Funcioniranje kotla ..................................................................... 15
5.1Overview of the controls and display and their basic functions ....................................15
5.2 Principle of boiler operation....................................................................................17
5.3 Schematic representation of the menu control..........................................................18
5.3.1 Clock adjustments .............................................................................................20
5.3.2 Adjustments of the programmed on and off mode .................................................21
5.3.3 Boiler has possibility for programmed on and off mode during a day and this option is
regulated on three ways: ..............................................................................................21
5.3.4 LANGUAGE OPTIONS .........................................................................................23
5.3.5 STAND BY mode...............................................................................................23
5.3.5.1 STAND BY mode with installed sensor for water temperature...............................23
5.3.5.2 STAND BY mode with room thermostat connected..............................................24
5.3.6 Option Buzzer ...................................................................................................25

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5.3.7 Filling of spiral dispenser ....................................................................................25
5.3.8 STATE OF THE BOILER .......................................................................................25
5.3.9 Technical settings..............................................................................................25
5.3.10 FUEL TYPE.....................................................................................................26
6Ignition and shutting down of boiler ............................................. 27
6.1 Ignition ...............................................................................................................27
6.2 Shutting down of boiler .........................................................................................28
6.3 Boiler power adjustments ......................................................................................28
6.4 Adjustment of water temperature in boiler ...............................................................29
6.5 Modulation...........................................................................................................29
6.6 Cleaning of FIRE-POT ............................................................................................30
6.7 Burning of wood ...................................................................................................30
7Cleaning and maintenance .......................................................... 33
7.1 Daily cleaning.......................................................................................................33
7.2 Weekly cleaning ...................................................................................................34
7.3 Monthly cleaning...................................................................................................35
8Connection options..................................................................... 37
8.1 Hydraulic schemes for connection ...........................................................................37
8.2 Scheme for electric connection ...............................................................................39
9Alarms...................................................................................... 41
10 Instruction about safety removal and proper disposal of boiler...... 43
10.1 Disposal ..............................................................................................................43
11 Guarantee .............................................................................. 44
11.1 Guarantee period..................................................................................................44
11.2 Guarantee terms ..................................................................................................44
11.3 Exemption from the guarantee ...............................................................................44

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ThermoFLUX
Pelling
1Notes on the manual
1.1 Introduction
1.1.1 Easy and safe operation
This manual contains important information for proper and safe operation of the
Pelling boilers. Following these instructions you will avoid danger and repair costs,
and also increase the operational life of the boiler.
1.1.2 Reading the manual
This manual must be read and applied by everyone who operates or works on the
Pelling boiler.
1.1.3 Technical changes
ThermoFLUX continuously develops and improves its boilers. The information in this
version is correct at the time of going to press. All details in this manual on
standards and regulations should be checked before use and should be compared
with the installed boiler. We reserve the right to make changes which may then
deviate from the technical details and illustrations in this manual.
1.1.4 Copyright
Written agreement is required from Thermo FLUX d.o.o. for any reprints,
storage in a data–processing system or transmission by electronic, mechanical
or any other means, for copies and publications, in whole or in part.

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2 Safety notes
2.1 Proper use
2.1.1 Basic principles
Pelling boiler was built in accordance with safety regulations. However, its use can
result in the injury or death of the user and/or third part and in impairments to the
boiler itself or to other material goods.
2.1.2 Using the boiler
Use the boiler only when it is in perfect condition. Use it properly, as described in this
manual. Stay aware of the safety and of the dangers involved. Have any faults which
can impair safety immediately fixed.
The boiler was designed to burn wood pellet and wood. The manufacturer will accept
no responsibility for any damage resulting from improper use. Proper use includes
maintaining the installation, operation and maintenance specified by the
manufacturer. The user may only enter or change the operating values specified in
this manual. Any other entries will affect the boiler's control program and operation,
which can lead to a malfunction.
2.1.3 Permissible fuel for the Pelling boilers
Only wood pellets and wood are permissible as fuel for the boiler. Wood pellets are
pressed into a cylindrical shape. They consist of untreated sawdust from the wood
processing industry as well as unprocessed forestry waste. They have a standardized
diameter and length and very low water content.
2.1.4 Recommended wood pellets
Thermo FLUX d.o.o. recommends wood pellets with a diameter of 6 mm and a
length of 10 - 30 mm.
Other requirements on the fuel result from either standard O-Norm M 7135,
DIN plus 51731,
UNI CEN/TS 14961
Pay particular attention to the wood pellet quality.

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2.2 Warnings and safety symbols used
DANGER OF ELECTRIC SHOCK.
Work on areas marked with this symbol may only be done
by a qualified electrician.
WARNING!
Warning about a dangerous location. Work on areas marked
with this symbol can lead to serious injuries or to extensive
material damage.
CAUTION!
Hand injuries. Work on locations marked with this symbol
can lead to hand injuries.
CAUTION!
Hot surface. Work on locations marked with this symbol can
lead to burns. .
CAUTION!
Danger of fire. Work on locations marked with this symbol can
lead to a fire.
CAUTION!
Frost danger. Work on locations marked with this symbol can
lead to frost damage.
Notes on disposal.

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2.3 Other risks of the side effects
Despite the precautions taken there are also certain risks of side effects:
DANGER OF CARBON MONOXIDE.
If the boiler is running during cleaning time may occur
transmission of CO through the open door. Do not open the
door longer than necessary.
2.4 Duty to inform
Reading the manual
Everyone who works on the boiler must have read the Use and maintenance manual
before starting work and, in particular, have read the second chapter „Safety notes“.
This holds especially true for persons who only occasionally work on the boiler e.g.
when cleaning or maintaining the boiler. This manual must be kept ready to hand at
the boiler's installation location.
Pay particular attention to the applicable local standards and guidelines.
2.5 Safety devices
Boiler is equiped with safety devices that in case of unexpected situations
stop the power supply and thereby stop the operation boiler.
Boiler electronic regulation: operates directly and stops the operation of the boiler
until it cools down.
* In case of the suction fan failure, failure of the motor for auger (doser), black out
(if the blackout was longer than 10 seconds), an unsuccessful firing.

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Fuse F 4 A 250V : Fast fuse , protects the boiler from large voltage changes of
electricity and short circuits inside the boiler.
Safety thermo switch (STB) : intervenes by breaking the circuit in the boiler
(automatically stops motor of the auger and exhaust gasses fan) if the boiler
temperature reaches the limit of 95 °C.

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3Installation and commissioning of
the boiler
Commissioning system in the operation is performed by personnel
authorized by ThermoFLUX Ltd or autorized seller.
Commissioning includes referral to operation with the basic operations and
maintenance of the boiler. Authorized service for the first start, must control the
functioning of the boiler at least during one full operating cycle.
Danger from material and body due to improper
commissioning. If the commisioning is performed by
unautorished personel, it may cause damage to the boiler
and heating system.
3.1 Conditions
The following conditions must be fulfilled before the system is put into
operation.
Turn OFF electrical power.
Check mechanical connections
Check that all components are properly connected
Check that all mechanical components are connected.
Check whether combustion chamber properly seated
Check hidraulical connections
Check whether the circulation pump and the mixing valve is properly
connected.
Check whether the safety equipment properly connected.
3.2 Chimney and flue gas pipes
The chimney should be calculated and constructed in accordance with the EN
13384-1 standard.
The venting of flue gas must be done in accordance with all applicable laws
including those related to dimensions of the chimney and materials used for its
production. Flue gas channel should be made of adequate materials, such as steel
tubes, with various sealing.

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In any case, materials that could potentially catch fire, e.g. wooden planks,
beams, cloth, should be adequately protected with non-combustible material. For
the sake of parity of dimensions, chimneys that are round in shape of the inner
part should have an advantage over the rectangular-shaped chimneys.
Too small inner zone can cause irregular flow from the boiler to the top which
could lead to poor boiler performance and excessive exhaust gas production that
discharges the exhaust gas to the environment. Gas flue pipe should be
permanently installed and it would be good to make safety door which would
enable the cleaning of inner parts, especially the horizontal parts.
Smoke pipe should be installed fixed. It would be good to leave safety gates that
could do the interior cleaning, especially in their horizontal parts.
You should avoid as much as possible horizontal mounting parts. Horizontal parts
must have a slope of at least 3% upwards.
Length of the horizontal part should be minimal and in any case not more than 3
meters.
ALL PARTS OF THE FLUE GASN PIPE NEED TO BE SECURED AND REPLACEABLE
IN ORDER FOR INTERNAL CLEANING.
AVOID MULTIPLE HORIZONTAL DEVIATION AND ANGLES.
3.3 Minimum distances of the boiler from wall
and objects
A –minimum distance front - 100 cm
B –minimum distance from side (BOILER BODY) - 20 cm
C –minimum distance back side- 20 cm
D –minimum distance from side (SILO) - 40 cm
ThermoFLUX leaves itself the right to later perform changes without notice.

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ThermoFLUX
Pelling
4Functional description
4.1 General overview
Accompanying material
1 –Tools for the pipeline and firebox cleaning
2 –Instructions booklet
3 –Guarantee

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4.2 Pellet boiler PELLING
1. Combustion burner
2. Combustion chamber
3. Heater
4. Exhaust fan
5. Control unit
6. Silo
7. Dispenser

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In the Pelling boiler the pellets introduced into the combustion burner 1. They are
automatically ignited with an electric heater 4. Burnt pellet (ash) is collected in the
ash pan 3. which is placed under the combustion burner. The air necessary for
combustion is supplied to the combustion burner.
Through sensors:
1. The boiler power is adjusted to the heat requirement.
2. The boiler efficiency is optimised.
3. Flue gases are optimised.
Technical data:
RB
Pelling 25
Pelling 35
Pelling 50
Pelling 75
Pelling100
1
Heat output
kW
8-25
11-35
20-50
30-75
50-100
2
Water content
l
60
90
120
154
181
3
Boiler weight
kg
267
348
392
494
580
4
Inlet / Outlet water
connection
"
1''
5/4''
5/4''
6/4''
2''
5
Flue gas temperature
C
cca 160
cca 160
cca 160
cca 160
cca 160
6
Max water
temperature
C
85
85
85
85
85
7
AHeight to center of
flue pipe
mm
1420
1600
1630
1750
1770
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BDepth
mm
948
948
1098
1240
1390
9
CWidth without silo
mm
410
510
510
560
650
10
DHeight
mm
1245
1385
1385
1528
1532
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EWidth with
standard / maxi silo
mm
710/910
810/1010
810/1010
1060
1150
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FFlue pipe diameter
mm
120
120
120
150
150
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GHeight of Inlet /
Outlet
mm
88.2/1282
85/1415
85/1415
70/1568
75/1532
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Pellet silo capacity
standard / maxi
kg
75/135
95/151
110/185
270/ -
290/-
15
Electric consumption
nominal/ max
W
175/350
175/350
190/380
190/380
240/480
16
Min/max water
temperature
C
55/85
55/85
55/85
55/85
55/85
17
Door opening (h x w)
mm
250x315
350x375
350x375
380x440
484x466
18
Min/max consumption
of pellet
kg/h
1,6/5.5
2,2/7,5
3,1/11.1
4,9/16.6
6,1 /22.2
19
Max. Length of
firewood logs
mm
400
400
500
500
500
20
Fuel
_
pellet/wood
pellet/wood
pellet/wood
pellet/wood
pellet/wood
21
Flue exhaust direction
_
up
up
up
up
up
22
In accordance to
EN
EN 303-5
EN 303-5
EN 303-5
EN 303-5
EN 303-5

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5Function of boiler
5.1 Overview of the controls and display and
their basic functions
Button
Description
1-
Increasing temperature and program functions
(adjusting days, time...)
2-
Decreasing temperature and program functions
(adjusting days, time...)
3-
Changing –accepting program
4-
ON / OFF, program exit
5 -
Decreasing power, navigate through the menu
6 -
Increasing power navigate through the menu
1
2
1
3
4
5
6
7
8
9
10

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Display
8
Info
9
Clock
10
Water temperature indicator
Regulation on the boilers ''Pelling'' is most important electronic component.
It is consisted of key controling modul set under the cover of the boiler and
controling unit with display set on the front side of the boiler. With controling
unit it is possible to control functions of the boiler and also to check information
about present state of the boiler.
Due to the possibilty to work in 5 (five) different powers, regulation can
satisfy needs to increase or decrease heating by automatic adjustment of
power.
If there is a need to increase power, this is registered by regulation and
regulation gives a signal to increase power by adding more pellet as well as
proportional increase of air flow in the burning basket.
When desired temperature is reached (need for heating energy is satisfied)
regulation is decreasing power ( modulates ), or when room thermostat gives
signal that set temperature is reached, boiler then goes into SHUT DOWN mode
(if mode STAND-BY is ON )
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When mark is visible
Clock
programmed ignit. active
Heater
heater active
Pelet dosage
auger active
Smoke fan
fan active
Primary air fan
fan active
Circulating pump
pump active
Alarm
alarm active
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5.2 Principle of boiler operation
Principle of the boiler operation is very simple.
When button for start is pressed boiler goes into IGNITION MODE. START is
displayed, and after that PELLET IGNITION. Usually this phase lasts for 5-15 minutes
depending on type of the boiler and pellet quality. At that point dosing system is
activated, igniter and suction fan. Dispenser is making initial dosing of pellet into
burning basket. At the same point igniter starts to ignite pellet and suction fan is on
and is making necessary underpressure needed for combustion. When temperature
sensor for flue gasses detects that temperature in the chimney has reached
necessary value, regulation then changes working mode of the boiler into FLAME
STABILIZATION.
This phase (FLAME STABILIZATION) lasts for 2-3 min. (depending on the type of the
boiler and in this phase igniter goes off. After flame stabilization, boiler goes into the
normal working mode and changes power from power 1 to set power. On display is
written WORK. On the right side set power is displayed and in the last
Start PELLET IGN. Flame
stabilization WORK

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5.3 Schematic representation of the menu
control
By pressing button SET we enter general menu.

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5.3.1 Clock adjustments
Clock adjustments can be done on following way: