THERMOSTAHL PELLET STAR User manual

PELLET STAR
PELLET STAR Bio Unit
INSTRUCTION MANUAL
ver. 1.1

PELLET STAR BOILER
INSTRUCTION MANUAL
ver. 1.1

THERMOSTAHL would like to thank and congratulate you for purchasing this
BIODROP boiler and to ensure that you made the right choice. PELLET STAR
boiler is a fail-proof product made of the highest quality materials by a large,
known and reliable production factory. THERMOSTAHL guarantees
satisfaction for the customer.
Please read this Operation and Maintenance Documentation (OMD) and get
familiarized with the terms and conditions of the guarantee before installing
and operating the boiler.

Ch. I PREFACE
This booklet contains useful and important information about the correct operation and
maintenance of the central heating boiler PELLETSTAR. In addition, important instructions
are give to avoid accidents and serious damage, in order that the installation and the
operation of the boiler will be safe and with no problems.
Read these instructions carefully, before you put the boiler into operation. Familiarize
yourself with its operations and controls and follow strictly the instructions given!
If you have any questions or you need more information about particular points concerning
the PELLETSTAR boiler, please do not hesitate to contact us. The technical data contained in
this booklet are based on the most recent information and are submitted to eventual reviews,
since new design improvements require it. Our company reserves the right to change the
design or/and the disposition of our products in any time, without being obliged to adjust in a
corresponding manner the previous products, too.
Ch. II DESCRIBING –APLICATION
The steel hot water boiler (PELLETSTAR) is a horizontal, compact construction fire-tube type,
with three pass for the burning gases, the heat transfer from the burning gases towards the
water is done primarily by thermal radiation in the first two pass, and in the third is done by
thermal conduction. The return of the gases from the second way toward the third way is
done in the door upper side, which is not cooled.
The boiler’s door is case with refractory material, and it is hinged allowing the burning
chamber and the smoke pipes inspection .The boiler’s door is fitted with a montage flange for
the burner and a thermo-resistant glass eye slit for the flame’s surveillance. The stainless
turbulators delay the burnt gases from the boiler towards the chimney and increase the
thermal transfer. The exhausts evacuation from the boiler to the chimney is realize by the
burnt gas box fastened on the rear tubular plate by screws.
The water has an ascendant circulation in the boiler in a reversed sense with the burning
gases, washing efficiently the walls of the fire chamber and the smoke pipes walls.
The Pelletstar boiler is a new product designed to work in an economic way to produce hot
water for the central heating installations, in urban spaces with industrial destinations and for
other uses that require technologic hot water. For preparation of domestic hot water there will
be used certain equipment, such as heat exchanger (grid type accumulator, boiler with heat
accumulator or half accumulator, etc). The boiler is designed and built for use of solid, liquid
and gas fuels.
The boiler is made from steel an ideal material for thermal fluctuations, dilatation and
contraction resistant. Moreover, this boiler is protected against thermal shocks. PELLETSTAR
boiler is built in such a way that all the surfaces that are exposed to the flame to be cooled by
water, including the inferior side where the ash and the burning rest are collect. The 3 smoke
pass from the superior side, the great number of exhaust pipes and the stainless steel
turbulators, big firebox volume and the water from the boiler, as much as the symmetric
construction determines a high efficiency.
1.2. DELIVERY -TRANSPORT
The PELLETSTAR boiler is delivered together with the following:
Steel boiler body
Boiler insulation
Brush for the exhaust pipes and a poker for cleaning the ash inside the boiler.
Draining valve
Safety collector (3 bar safety valve, manometer, automatic air valve)
Recirculation pump
Stainless steel turbulators
Metal covers
Pellet burner
Feeding auger

Silo for pellets
Control panel
An elevator or a crane does the loading of the boiler. Secure the boiler during the transport on
the transport vehicle to prevent falling. Take notice the fact that the weight center is closer to
the door due to the refractory material on it. That means special care must be taken during
transport and unloading the boiler.
The boiler is provided with a stamp plate where it is printed the ID data of the boiler and the
characteristics: type and serial of the boiler
Boiler power (kCal and kW)
Maximal working/ testing pressure
Year of manufacturing
Serial number
The burner is controlled by the control panel, and the connection made simply by the
connecting wires.
The burner operates at 230 V and it has powers between 10- 20 KW according the power of
the boiler.
2. BURNER
Thanks to the construction with a forward burning flame, this burner will give the most
effective combustion and it is easy to fit it to the boiler. There are 3 models available and
suitable with the boilers. The models are; MPB 35, MPB 50 and MPB 80. The heat output of
the burners are 10-35kW, 25-50kW and40-80kW and it is adjusted depended on the heat
losses and the boilers it is installed.
MPB 35 burner
3. PELLETSTAR BOILER CHARACTERISTICS
3.1 MATERIALS USED
Steel OLT-37.2, STAS 500/2-80~S235JR SR EN 10025/90+AI/93
Steel for the tubular plates and burning chamber: K 4120.2b STAS 2883/2
88~P265GH SR EN 10028-2/96
Smoke tubes made of OLT 35KII STAS 8184-87~P 245 GH EN 10216-2/2000
Metallic covers with thickness of 0,7 mm (steel sheet DKP) electrostatic painted at
200oC.
Insulation with glass fiber of 30 mm thickness covered with aluminum foil.
Door insulation with refractory cement (FONDU LAFARGE).
3.2 ADVANTAGES
Steel offers numberless advantages of great importance for the modern heating technique.
We can mention from these the exceptional mechanical proprieties, lightweight - a great
advantage of the Thermostahl boilers is the great amount of water that allows exact regulation
of temperature, without special requirements concerning the water flow. The internal energy

of the boilers increases the capacity of stocking the thermal energy and reducing the numbers
of ignitions.
- Reliability
- Energy Saving
- Environmental friendly
- Modern Design
- Solid Construction
- Easy maintenance
- Big fire box
- Rich radiant surface
- Three smoke pass
- Increased efficiency ≥78 90%
- Uniform thermal load
- Reduced temperature of the burnt gases in the chimney(170 -220oC).
- Long autonomy
- Exceptional draught
- Big water Volume
- Possibility for automatic functioning with solid or liquid fuel.
3.3 OPERATION
PELLETSTAR boiler functioning is based on the simplest burning method, with freely
evacuation of the burnt gases through the chimney. During the burning, the flame develops
towards all the points and heats uniformly the boilers walls that are cooled by water.
After that, the bunt gases are lead through the smoke tubes and into the smoke box. The
remains of the burning fall in the lower part of the boiler and become ashes.
When the water is still cold, the thermostat gives the signal to start the burner, which is fed
with pellets and starts automatically. When the temperature reached set, power supply and
the pellet burner enters in the transition period and cannot be started until after exhaustion of
the set to consume the quantity of pellet burner located in the tray after the flame sensor is
not lit. Thus, the flame control is achieved.
If somebody tries to increase the temperature of the thermostat during this time, the control
panel will indicate the presence of electric power in the burner but this will not start until the
transition time is over.
This is not a defect but assures a starting without problems after the transition time finishes,
(it guarantees that no unburned remains are accumulated in the burner blocking in this way
the tray with holes for the primary air).
If this time is being reduced in the burner setting, then problems will arise with automatically
restarting of the burner because of the remains that will block the air from entering the burner
tray and you will have to clean the burner more often than normal. The same is valid if the ash
content of the pellets is bigger than 0.3 %.
3.4 Pellets Consumption /hour/day/month
The quality of the pellets is very important (calorific power, humidity and ash content) and the
power at which the burner is set for ex, 10 -20 kW.
According to the chosen power the feeding time may vary from 3,68 seconds to 8,21
seconds, time between feedings is 15 seconds.
So you may reach consumptions of 0,7- 1,25 kg/hour at temperatures of -5ºC that is 16- 30
kg/day or 480-900 kg/month.
For a silo of 530 liters, the autonomy can be of almost 10 days.
If agro-pellets are used (sunflower), they will burn but you will have to clean the burner 3
times a day because the great ash content that may block the burner by accumulation.
If you use a different burner, the cleaning can be done once a day for the same agro-pellets.
Normally if using pellets with low ash content (DIN + quality certification) you need to clean
the burner once a week or even once every 2 weeks.
The safety kit is made from a safety valve (3 bars), an automatic venting valve and a
manometer to show the pressure inside the boiler.
The PELLETSTAR boiler can work with liquid or gas fuel as an alternative solution.
For this purpose there is need to fasten at the boiler’s door a special flange for adapting
another burner type.

For increasing the efficiency, a delay of the exhaust gases was made by using special
turbulators who will increase the thermal transfer.
3.5 Boiler/ burner cleaning interval.
Depends on the content of inorganic ash from the pellets which is specified in the (DIN Plus)
quality certificate of those.
Normally this should be between 0,03 -1 % but not to surpass 1 % so at 100 Kg pellets it
should result 1 Kg of ash.
So at a consumption of 30 Kg/day it is recommended to clean the boiler after 10 days of
continuous function of the boiler when the amount of ash in the boiler is over the burner level
preventing blocking it with ash which is over 3 Kg, if the ash content is greater the cleaning
should be done more often.
Request quality certification and test bulletins from the pellet producers and use only pellets
certified with DIN + and an ash content under 1% and humidity between 6-10%.
The calorific power is another very important factor on which the performances of the burner
and the boiler depend.
The burner may work for 7-10 days with no need for cleaning if used pellets certified with
DIN+.
For a function without problems (low consumptions and optimal thermal transfer), we
recommend cleaning the burner every 2-3 days and the system after the following timetable:
NOTE: No welding works may be done to the installation until the electric power is
disconnected and the electronic plate (the burner) removed.
According the pellets type, it is compulsory to clean the boiler every week or every 2 weeks.
First stop the power by pressing the on /off button (This should be done after the fire is off).
The boiler door should be open together with the ashbin from below and the ash from the
base of the boiler is removed with the poker like in the picture above the ash should fall
directly into the ash bin.

Then the burner is to be removed (after disconnecting the power plug and it should be bent
down to make the ash and the burning remains to fall into the ash bin.
The fine wood dust is to be blown through the pipe when the burner is downwards.
The mobile grid is to be removed and checked if the ventilation holes are clean and not
obstructed.
The burner is to be refitted in reversed order. After refitting of the feeding plastic hose, you
may start again the burner.
3.4 TECHNICAL DATA - DIMENSIONS
Boiler type
PLS
PLS
23
PLS
35
PLS
47
PLS
58
PLS
69
PLS
81
PLS
93
PLS
105
PLS
116
PLS
140
Power
kW
23
35
47
58
69
81
93
105
116
139
Mcal/h
20
30
40
50
60
70
80
90
100
120
Fuel
Pellet –Oil –Natural gas
Efficiency
%
92
92
92
92
91
91
91
91
91
91
CE Certification
Instit.
ISCIR CERT
Dimensions
Length
mm
800
800
900
1000
1100
1100
1200
1300
1400
1500
Width
mm
570
570
570
570
570
620
620
620
620
620
Height
mm
1300
1300
1300
1300
1300
1380
1380
1380
1380
1380
Boiler combustion
chamber (Length x Ø)
mm
390x400
490x
400
590x
400
690x
400
650x
450
750x
450
850x
450
950x
450
1050
x450
Chimney diameter
mm
150
150
150
180
180
195
195
195
220
220
Inlet-Outlet
inch
1 ¼
1 ¼
1 ¼
1 ¼
1 ½
1 ½
1 ½
1 ½
2
2
Max operating
temperature
oC
95
95
95
95
95
95
95
95
95
95
Max operating
pressure
bar
3
3
3
3
3
3
3
3
3
3
Content of water
lit
110
120
130
145
170
195
225
250
285
320
Boiler weight (empty)
kg
230
250
275
300
340
375
410
450
490
530
Average temperature
of exhaust gases
oC
160
160
160
160
160
160
160
160
160
160
Volume of ash
collector
lit
14
16
18
20
32
36
40
44
48
56
Chimney draught
Pa
12
12
15
15
15
15
17
19
20
15

3.4.1 BOILER BODY
PELLETSTAR boiler is horizontal with smoke tubes.
The principal body of the boiler is made from hot laminated steel sheet St 37.2 STAS 500/2-
80~S235 JR SR EN 10025/90 according DIN 17100. Cutting is made with an automatic
plasma-cutting machine. The boiler is designed in such a way that all its parts touched by fire
to be cooled by water. Section, number and length of smoke tubes are specially designed for
a maximal exploitation of the burnt gases.
Welding are made according the 288-1 and 288-3 and DIN 50120, 50121-50145, SR EN
1011.1/2001 standards, by using of electric welding equipment (MIG-MAG) after the sock
currents method, for realizing the penetration of the material intended to be welded on all the
iron sheet thickness. The quality of the welding cords is checked according DIN 8563. The
welding process is according 131-ISO 4063.
The smoke box is screwed and has a special door for cleaning, insulated with a fireproof
plate, which works also as an explosion door (safety). The chimney of the smoke box is wide
enough to insure the exhaust of the smoke resulted after the burning process.
For increasing the efficiency, a delay of the exhaust smoke is made by using special
turbulators that will increase the thermal transfer factor.
Every boiler is separately tested at a hydraulic pressure of 4-5 bars (according the type) for
checking the tightness and strength. A thick insulation covers the whole boiler body.
The access door at the smoke pipes and burning chamber is protected inside with refractory
material for a good resistance against high temperatures. It is also provided with a glass fiber
braid for a very good tightness against NOx from the burning chamber. The door is provided
with an eye slit for an optical control of the burning process.
The door is also provided with a special flange adapted for mounting a pellet or a diesel
burner, if so is desired. Meanwhile it is compulsory that this flange to be well fitted so there
will be no smokes coming out from the burning chamber.
4. Boiler installation
Jackets assembling:
Jacket (covers) assembling on the boiler body is done easy and fast respecting the following
instructions.
Fitting order is the following:
a. Fit first the insulation and the side covers.
b. Fit the upper cover.
c. Screw in the upper front of the side covers the control panel and in the back the
cover for the smoke box.
d. Fit the insulation and cover for the front door by screwing first the connecting
screws between the door and jacket.
The boilers can be installed in their own room, in the basement, ground floor or the upper
floors of the production buildings from category C, D and E of fire danger warehouses of
incombustible materials and civil buildings, according the valid legislation.
ATTENTION! It is prohibited to install a boiler in a room with a common wall with rooms with
people that cannot evacuate themselves (hospitals, shops, kindergardens, daycare centers,
etc) or under the evacuation ways of those.
BOILER LOCATION must be separate of the joined rooms by walls, incombustible doors and
without window holes.
Space dimensions:
We advise that the boiler installation must be made in such a way that there is enough space
for easy cleaning and maintenance.
Boiler must be installed on horizontal plan and if possible easy to be accessed on all sides.
Burner must be installed on the front door and fastened with the screws on its special flange.
The auger must make an angle of 45 degrees with the floor.
The distance between the front wall and the boiler: at least 1,5 m.
The distance between the front wall and the boiler: the adequate distance that allows an easy
access for checking and maintenance.
The distance between the side wall and the boiler: at least 0,6 m.
The high of the boiler room: –at least 2,5 m.

According PT C 9-2003 the access in the boiler room of foreign people except the boiler
operator is prohibited.
The ISCIR-INSPECT IT inspectors and the technical surveillance personal may enter the
boiler room, any time on the basis of control written approval.
ATTENTION! It is forbidden to give another destination to the boiler room except the one
established by project.
The access and maintenance spaces must be always free and the access doors.
In the boiler rooms with nominal power greater than 300 kW there must be a telephone or
other means of fast communication with the exterior that may avoid unjustified departures of
the operators from the boiler room.
In the boiler room there will be placed in visible places operating instructions for the specific
boilers in the room. There will be also posted internal instructions and obligations of the
operating personnel and the way of operating the boiler.
Space dimensions:
We advise that the boiler installation must be made in such a way that there is enough space
for easy cleaning and maintenance.
Boiler must be installed on horizontal plan and if possible easy to be accessed on all sides.
Burner must be installed on the front door and fastened with the screws on its special flange.
The auger must make an angle of 45 degrees with the floor.
The distance between the front wall and the boiler: at least 1.5 m.
The distance between the front wall and the boiler: the adequate distance that allows an easy
access for checking and maintenance.
The distance between the side wall and the boiler: at least 0,6 m.
The high of the boiler room: –at least 2,5 m.
According PT C 9-2003 the access in the boiler room of foreign people except the boiler
operator is prohibited.
The ISCIR-INSPECT IT inspectors and the technical surveillance personal may enter the
boiler room, any time on the basis of control written approval.
ATENTION! It is forbidden to give another destination to the boiler room except the one
established by project.

The access and maintenance spaces must be always free and the access doors.
In the boiler rooms with nominal power greater than 300 kW there must be a telephone or
other means of fast communication with the exterior that may avoid unjustified departures of
the operators from the boiler room.
In the boiler room there will be placed in visible places operating instructions for the specific
boilers in the room. There will be also posted internal instructions and obligations of the
operating personnel and the way of operating the boiler.
Observation:
The boiler room must be:
a. clean;
b. without flammable objects;
c. with drainage system;
d. supplied with enough fresh air;
e. separated by the liquid fuel tanks who will be installed in well ventilated, separate
spacesoutsidetheboilerroom.Iftheyareplacedintheboilerroomthey’llbeseparatedbya
wall, in conformity with the valid safety regulations;
f. a fire extinguisher with dry powder, and next to the door a portable extinguisher;
g. with a safe chimney with an adequate section;
h. with a smoke detector installed on the ceiling in case the building is designed with
a fire alarm system;
i. the door must be metallic without grids or windows and to open in the outside;
ATTENTION! It is forbidden to install the boiler in spaces with lots of dust, dangerous gases,
and in wet areas such as bathrooms with great humidity.
5. CHIMNEY
According DIN 4705 and DIN 18160, burnt gas evacuation in the atmosphere and the
reducing of temperature of those on the way must be done in such a way so that
condensation and its bad results be avoided.
The correct function of the chimney is very important for the boiler function.
The chimney tightness: cold air should not enter through cracks or holes because in
this case the burnt gases get cold and produce condensation. There is danger that the
condensed gases may enter the boiler and produce corrosion, moreover it must be avoided
the entering of rainwater inside the chimney.
Evacuation of the burnt gases must be free, without obstacles –(bricks, bird’s
nests, wood, grass, etc).

Chimney cleaning especially in the exit points of the boiler and at curves where the
gases change their way.
Chimney insulation is compulsory.
An untight chimney can produce many problems to the boiler, for example:
blocking, a lot of soot, noise, bad functioning of the burner, etc. In addition, a great problem is
creating of a drift and turbions that may prevent the easy exit of the burnt gases.
The chimney must be higher above the building.
The burning residue should not influence the material, from which the chimney is
made.
For all the above reasons a regular checking of the chimney is compulsory especially at the
beginning of the winter season.
ATENTION:
A very small diameter of chimney gets charged and obturated very quickly. A very big
diameter chimney gets cold and produces condensation of the burnt gases. So the chimney
must not be too small or too big.
At the roofs with a steep of up to 20%, the height of the chimney towards the roof, measured
must be of minimum 1000 mm.
In case of some elements that are higher than the roof surface (attics, fireproof walls) the
chimney must overcome that height with at least 1000 mm, except the chimneys placed at a
distance smaller than 3000 mm of these elements, in this case the difference may be reduced
to 500 mm.
At the roofs with a steep >20%, the height of the chimney depends of the material and the
position of the chimney towards the ridge, so:
-chimneys placed until a distance of 1500 mm from the ridge must surpass the ridge with 500
mm for incombustible covering and with 1000 mm for flammable coverings.
-the chimney placed at greater distance must have the evacuation opening at a height of at
least 1000 mm from the covering and to overpass the plan that goes through the ridge and
has an inclination of 100 towards the horizontal.
Causes of defective function of the boilers with solid fuels:
1) Small Active height of the chimney
2) Untight masonry of the chimney
3) Too narrow masonry of the chimney
4) Obturation or narrowing of the chimney section
5) Untight diaphragm
6) Wrongly set draught limitator
7) Smoke opening in the chimney
8) Untight joints at the smoke opening
9) Untight chimney Cleaning door
10) A big part of the smoke opening without insulation, too little inclination
11) Untight joints (flanges), defective insulation
12) Reduced draught because of soot layers on the smoke tubes
13) Soot layers
14) Untight doors and covers

15) Broken draught regulator
16) Auxiliary niche for burning air
17) Very high temperature of the burnt gases (very strong draught or boiler too little
for covering the heating needs)
18) Very low temperature of the burnt gases (evident functioning under the boiler
parameters, boiler bigger than the heating needs).
19) Fuel with a lot of humidity (with a low calorific power).
7. CONTROL PANEL
7.1 GENERAL CARACTERISTICS
The boiler control panel includes all the connections and measurement instruments needed
for controlling the boiler and its good functioning.
All the electrical connections in the panel are made by the producer. The installation of the
panel and the probes of the measurement instruments.
The instruments (thermometer, thermostats and safety thermostat) have brass probes to read
the water temperature in the boiler. In order to a better transmission of the parameters there
must be a nonvolatile liquid (oil) in the special place for them in the boiler.
a) the thermometer shows the instant temperature from the boiler at the above part of the
water chamber.
b) the burner thermostat switches off the burner when the temperature reaches the desired
level. It is recommended that the water temperature should not be less than 65 C. The
recommended temperature is between 70-90 C.
c) the pump thermostat is responsible with its starting. The starting temperature of it is
normally between 40-45 C.
d) the safety thermostat activates when the water reaches the maximal temperature, it
switches off immediately the burner. So the risk of vaporizing of the water at temperatures
above 90 C is avoided. For the system to restart its function we must wait for about 5
minutes, while the pump will remain working and the boiler temperature will drop under 90
C. After the temperature drops press the reset button of the safety thermostat in order for the
system to restart working..
e). The ON-OFF button is used for electric feeding of the panel. It is used by the operator for
maintenance and repairs of the boiler.
g) the witness lamps are lit during burner or pump operation.
f) the instrument probes must be well fitted inside the sheath and have a safety clip. Install the
extra length of the capillary tubes on the insulation on the boiler body and do not bend the
capillary (they can be damaged)
When installing a burner it is compulsory that the mounting and connecting of the burner to
the control panel to be made by an authorized installation company. The operation of the
burner and its signals are described in its technical book. An authorised electrician must make
the electric conexion to the control panel by the drawing provided.
7.2 Electric installation
An authorized electrician according with the valid rules EN 60529 and EN 60335-1, and the
protection rules IP 40 and IP 44 must realize the electric installation. the electric installation of
the boiler consists on an general electric panel placed on the wall which distributes the
electric power needed.
This must be waterproof, and the wires must be insulated. The light and the light switch
should be on a separate circuit. The light lamps must be placed on the ceiling and waterproof.
The wires must be protected until maximum 16 A.

7.3 Installation drawing of a Pellet star boiler in a boiler room:
Connection with indirect heated storage
Installation drawing of a Pellet Star with water storage tank for domestic hot water
1.
Boiler
2.
Closed type expansion tank
3.
3 bar safety set (safety valve, automatic air vent, manometer)
4+5.
Circulator and 3 way safety valve
6.
Y-type strainer
7.
Filter
8.
Automatic feeling with manometer
9.
Filter
10.
Indirect heated storage with one serpentine
11.
Safety valve
12.
3-way diversion valve
13.
Radiators – Heating installation
RS
Ball valve
CS
Check valve
RG
Drain tap
TC
Room thermostat
MC
Control panel
SB
Boiler sensor

Connection with buffer tank
Installation drawing of a Pellet Star with buffer tank
1.
Boiler
2.
Closed type expansion tank
3.
3 bar safety set (safety valve, automatic air vent, manometer)
4+5.
Circulator and 3 way safety valve
6.
Y-type strainer
7.
Filter
8.
Automatic feeling with manometer
9.
Filter
10.
Buffer tank
11.
TP safety valve
12.
Heating and DHW Circulator
13.
3-way diversion valve
14.
Indirect heated storage with one serpentine
15.
Safety valve
16.
Radiators –Heating installation
RS
Ball valve
CS
Check valve
RG
Drain tap
TC
Room thermostat
MC
Control panel
SB
Boiler sensor

Connection with second boiler
Installation drawing of a Pellet Star with second boiler
8. GENERAL MAINTENANCE INSTRUCTIONS
According the regulations DIN 4575 and 4756 the boiler needs periodic cleaning (if necessary
even daily) by qualified personnel to ensure an economic and ecologic operation.
The boiler needs a maintenance cleaning at the end of winter season. A special care needs to
be taking with the smoke tubes cleaning, for avoiding deposits of lime and salt that may
destroy them. The burnt residues must be removed.
Ifacorrectmaintenanceisn’tdoneproperlythenproblemswouldarisesuchas:
Efficiency decrease
Increase of fuel consumption
Increase of burnt gas temperature
Soot sediment
Decreased draught
1.
Boiler
2+3.
Oil boiler and oil burner
4.
Closed type expansion tank
5.
3 bar safety set (safety valve, automatic air vent, manometer)
6+7.
Circulator and 3 way safety valve
8.
Y-type strainer
9.
3 way mixing valve
10.
Buffer tank
11.
TP safety valve
12.
ΜπόϊλερπαραγωγήςΖΝΧμεμίασερπαντίνα
13.
Filter
14.
Filter
15.
Automatic feeling with manometer
16.
Heating and DHW Circulator
17.
3-way diversion valve
18.
Boiler safety valve
19.
Radiators –Heating installation
RS
Ball valve
CS
Check valve
RG
Drain tap
TC
Room thermostat
MC
Control panel
SB
Boiler sensor

Maintenance operations:
- Dismantling and cleaning of the burner.
- Opening of the door.
- Dismantling of the turbulators from the smoke tubes and cleaning them with a
special brush.
- Cleaning of the fire chamber with a special poker.
- Cleaning the ash.
- Checking the ceramic braids from the door and replacing them if damaged.
- Checking the refractory material of the door.
- Safety valves must be checked and replaced if damaged.
- Checking of water supply.
- Checking of the filter of the water supply.
- Checking and cleaning the glass from the eye slit.
PELLETSTAR boiler can be equipped at request with different type of flanges, for operations
with different type of burners:
- Flange for pellet burner type PELLTECH
- Flange for diesel burner (request)
- Flange for gas burner (request)
Back fire Protection Systems.
The feeding hose is made by a silicone material and on the intake pipe there is a safety
thermostat that will cut the power and stop the pellet feeding and burning.
When it is activated then after the thermostat cools down, you have to reset it by pressing the
reset button so that the burner may start working again. But first you have to remove what
caused the alarm.
9. TROUBLESHOOTING
Inthefollowingtableyou’llfindtheactionsyoumusttakewhenaproblemshouldarise.Inthe
left column you may find the problem and in the right the solution for it.
Lack of electric power
(the water in the boiler
is boiling)
In case the boiler produces also hot sanitary water open a tap of
hot water to reduce the temperature in the boiler.
Lack of electric power
at the control panel.
Check if the connections between the control panel and the
power source are correct and in good condition.
Check if the safety thermostat for backfire did not switched off.
You have to shut off the power and to reset the thermostat
manually, (danger for electric shock)
Thepumpdoesn’t
start
Check if the connections between the pump, the sensor and
the control panel are correct and in good condition.
Check if the pump is not jammed; in this case switch off the
power, open the pump lid and unlock manually with a screwdriver
Check if the temperature probe in the boiler is well
positioned and if it is not rusted or deteriorated.
The warm water
doesn’treachthe
radiators
Check if the valves from the radiators are open and if there
is no air trapped in the installation (vent it off)
Check the hydraulic connections to be correct.
Check if the pump is working.
The boiler has smoke
leaks
Checkifthechimneydoesn’thaveexcessivesootlayers
Check the chimney tightness
Check if the chimney is in good condition
Checkthepelletsquality(theyshouldn’tbewet).

Excessive layers of
soot are on the fire
chamber walls
Checkthepelletsquality(theyshouldn’tbewet)theymay
jam the feeding system
Do not use pellets made from different products such as
furniture industry made with glue or other kind of adhesives,
because they produce a lot of soot and will obturated very quickly
the smoke tubes increasing the cleaning frequency from once a
week to 1-2 times a day
Clean the burner (the mobile tray) because ash has
accumulated inside of it and the air is allowed to enter the burner so
there will be no fire.
Fire is weak and the
pellets are below the
air holes in the burner
Increase the feeding time from the timer until the pellets
level in the burner reaches the superior level in the burner tray.
Watch it for a time so that the level will not be too high and
unburnt pellets may result.
The eye slit glass gets
excessively dirty
Check if there is not too much soot on the smoke tubes,
which can cause a smoke stop in the fire chamber, stop the pellets
feeding and clean the turbulators and the smoke tubes with the
cleaning brush.
Hot sanitary water
with insufficient
temperature
Increase the temperature of the pump thermostat and then
check at the tap
Check that the flame to be always lively
Eventual problems of hydraulic installation (check the pump
that pumps hot water into the sanitary water-accumulating tank).
Smoke inside the silo
There is a problem with the chimney:
The turbulators were not cleaned and the smoke tubes
diameter is obturated. If the turbulators are damaged they need
replacement;
The elbows and the T pipes of the chimney need to be
cleaned.