Topling BTA350 User manual

BTA User Guide
Topling Prnjavor Page 1
PRIVATE COMPANY FOR PRODUCTION,
SERVICES AND TRADE
TOPLING d.o.o. PRNJAVOR
BOSNIA AND HERZEGOVINA
www.topling.com
[e-mail]
USER GUIDE
Hot Water Pellet Boiler
BTA

BTA User Guide
Topling Prnjavor Page 2
CONTENTS
1. Notes on this user guide
1.1. Introduction 5
1.2. Glossary 6
2. Safety tips
2.1. Proper use 7
2.2. Present risks 8
2.3. Used warning and safety signs 9
2.4. Duty - be informed 10
3. Description and purpose of boiler
3.1. Summary 11
3.2. Technical data 13
4. Boiler room and the storage of fuel
4.1. Boiler room 31
4.2 The storage of fuel 34
4.3. Pellet quality requirements 36
5. Boiler installation
5.1. Boiler connection to central heating system 38
5.2. Instruction for automated control of boiler.....................45
6. Boiler maintenance
6.1. Frequency of cleaning and maintenance 57
7. Warranty
7.1. Period of warranty 66
7.2. Terms of warranty 66
7.3. When the guarantee is not recognised 66
8. Addendum 1
9.1. Boiler Feed Water 67
9. Addendum 2
10.1. Wiring Diagram 69

BTA User Guide
Topling Prnjavor Page 3
I PREFACE
NOTE: YOU MUST READ THIS USER GUIDE BEFORE TURNING
ON THE SYSTEM AND YOU MUST COMPLY WITH THIS
USER GUIDE.
The aim of this User Guide is to make you completely acquainted with our
system. Instructions for installation and use of the delivered system are given in this
User Guide.
Please comply with this User Guide and this system will always function at your
pleasure.
KEEP THIS USER GUIDE FOR LONG-TERM USE AND IN AN
ACCESSIBLE PLACE FOR FURTHER REFERENCE.
Please feel free to contact us if we can provide you with any further information
Topling d.o.o. –Prnjavor
Address: Topling d.o.o.
Magistralni put bb 78430 Prnjavor
Bosnia and Herzegovina
Tel./fax [phone]
00387 51 645 200
00387 51 645 300
00387 51 645 400
E-mail [email protected]
www.topling.com

BTA User Guide
Topling Prnjavor Page 4
II OPERATOR
NOTE: You must read this User Guide for use of the system
and comply with the safety and exploitation
instructions.
The operator of the system must have degree of vocational education –technical
course. The operator must be trained by the producer for operating the system and
safety requirements. When the boiler is commissioned by the authorized person, in the
same time the operator appointed by the buyer is trained. After the training is finished
the Record on successfully completed training is signed.
When a customer wants to change the system operator, he/she is obliged to inform
the producers about it and arrange the training of a new operator. In the case of non-
compliance with this obligation, the producer does not bear any responsibility for any
possible damages which occurred in connection with an untrained operator.

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1.NOTESONTHISUSERGUIDE
1.1Introductory
notes
EASYANDSAFEUSE
READUSERGUIDE
TECHNICALCHANGES
COPYRIGHT
This guide contain significant information for appropriate and
safe use of hot water boiler type BTA. If you follow these
Instructions, you can avoid risky situations, reduce maintenance
costs, avoid failure, provide reliability and prolong boiler life.
This User guide must be read and applied by anyone using the
boiler type BTA.
We keep developing and enhancing our boilers. All information
regarding this Guide that are related to the boiler type BTA are
correct at themoment of print out.
Before the use, all details mentioned herein concerning
standards and legislation must be checked and compared to
standards and legislation applied in the location where the boiler
is to be installed.
We reserve the right to make changes on the boilers that would
differ in technical data and drawings herein.
Written approval of Topling d.o.o. to copy, store in electronic
form, transfer information in electronic format, photography,
translation of this manual in whole or in part is required.

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Topling Prnjavor Page 6
1.2Glossary
Table1 –Explanationof terms
Term
Explanation
Engine gear
The part of system intended for moving pellet screw conveyor.
Screw conveyor
Serves for the transport of pellet from storage to firebox.
Automatic cleaning
Part of program intended for cleaning firebox just before
damping down a fire.
Display
Display of central unit for furnace operating control
BTA
Boiler intended for burning of pellet
Central Unit
Electric controller for managing boiler operation
Pellet
Type of solid fuel made of sawdust previously dried, then pressed
and in such mannermaking acylindrical form with 6 mm diameter
and 20-50mm length.
PP set
System for preventing fire in pellet reservoir. It is activated if
temperature in pellet feeder pipe exceeds 95˚C.
Pellet Storage
Reservoir for storing a pellet that is transported to firebox by screw
conveyor.
Probe
Serves for detecting certainparameters (temperature, feeder
level, etc.) and forwards them to the central unit for further
processing.

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2.SAFETYINSTRUTIONS
2.1.Properuse
MAINPRINCIPLES MAINPRINCIPLESOFSYSTEMCONSTRUCTION
The boiler is made in accordance with the known principles of
safe use. Improper use may cause harm, injury or even death
to those who do not comply with safety guidelines as well as to
third parties, which may result in damage to the boiler, and
damage to other resources in the immediate environment
Specialized person who made the boiler installation and
commissioning should demonstrate you how to use it.
Use boiler only when it is completely in order. Use it the right
way and for the purpose for which it is intended, always taking
care of your own safety and the safety of others and the safety
of property. Constantly comply with this User Guide.
Any defect which may impair safety must be immediately
removed.
USEOFBOILER
RELIABLE ANDUNRELIABLEUSE
The boiler is designed to burn pellet.
Use of any other fuel is not allowed. The manufacturer is not
liable for any damages resulting from improper use. In case of
improper use the responsibility is borne by the one who used
boiler improperly.
As a user, you can enter or alter the operating parameters
within the limits prescribed by these instructions. Entering any
other value of the operating parameters that are not listed in
this leaflet, can lead to errors in the functioning of the system

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ALLOWEDFUEL
Only pellet that is made from sawdust is allowed to burn.
Pellet is cylindrically pressed into cylindrical shapes. It is made
from wood residues generated in wood processing. Pellet must
have a standard diameter and length. Chips from which the real
pellet is made, are pressed under high pressure and must have
a low percentage of humidity.
RECOMMENDED
CHARACTERISTICSOFPELET Topling’ recommends pellet of 6 mm diameter and a 10-30 mm
length. Quality and geometric characteristics of pellets are
prescribed by the German Standard DIN 51731 or Austrian
Standard ONORM 7135
Pay special attention to the quality of pellet, both when
ordering and admission.
Use pellet that meets the standards of DIN or ONORM.
For additional information regarding the pellet, see Section
3.4. Requirements regarding fuel quality in chapter "3
Functional Description"
2.2Alwayspresentrisks
Despite of all precautions, the below given risks should be always considered:
Attention!
High temperature surfaces.
Contact with such surfaces may cause burns.
Waitfor the boilerto cool to touch these uninsulated surfaces.
Warning!
Danger of choking carbon monoxide.
When boiler is used, carbon monoxide can be emitted through
openings in the boiler.
Do not leave boiler doors open more than required

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2.3 Used warning and safety signs
The below listed warning and safety signs are used in the User
Guide:
Danger!
Danger from electrical current.
Work on devices marked with this symbol is only
allowed for the qualified persons.
Warning
Work in areas that are marked with this symbol could
result in serious injury or create serious damage.
Attention
Possible hand injury.
Work in areas marked with this symbol can lead to
hand injuries.
Attention
High temperature surfaces.
Work in areas marked with this symbol can lead to
burns.
Attention
Flammable.
Work in areas marked with this symbol can lead to
fire.
Attention
Dangerof freezing.
Work in areas marked with this symbol can lead to
freezing.
Notes on proper disposal.
Additional information for the operator.

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2.4Duty-beinformed
READING
USERGUIDE Anyone who intends to use the boiler is required to read and understand
this manual, and special attention must be paid to the Chapter 2, Safety
instructions. This especially refers to those who only occasionally use the
boiler, for example, only when cleaning or other tasks related to the
maintenance of the boiler.
This manual must be constantly ''at hand'' where the boiler is installed.
Particular attention should be paid to the standards applicable
to the place where the boiler is in

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3. DESCRIPTION AND PURPOSE
3.1. Summary
Boiler BTA has modern construction and design, and is made of quality certified materials.
Construction of the boiler is in the compliance with European Directives:
2006/42/EC, PED 97/23/EC, LVD 2006/95/EC, EMC 2004/108/EC
and European Standards:
EN ISO 12100:2012, EN 10204:2004, EN ISO 7000:2012, EN 12953-1:2002, EN 12953-2:2002 ,
EN 12953-3:2002 , EN 12953-4:2002, EN 12953-5:2002 ,EN 12953-6:2012,
EN 12953-8:2001, EN 12953-9:2007, EN 12953-10:2003, EN 12953-11:2003,
EN 287-1:2011, EN ISO 15614-1:2004+A1:2008,EN 60204-1:2006, EN 61000-6-3:2006
Boiler testing was done according to mentioned standards and meets all requirements for
connection to the central heating system.
Hot water boiler is designed for heating of small residential units, family houses, shops and small
manufacturing units.
Automatic operation of the boiler provides the user with an enviable comfort considering that you
need to take into account only the charge of pellet reservoir, which makes it suitable for
widespread use.
Pellet is an environmentally clean fuel produced from sawdust. Sawdust is initially dried and then
pressed under high pressure. The final product is fuel of exceptional calorific power and pure
composition with no chemical additives. The percentage of ash in the combustion of pellets is
very low and amounts to 1%.
Calorific power of pellet is about 18000 kJ/kg , which means that 2 kgs of pellet
corresponds to 1l of heating oil.
From a functional point of view the pellet boiler is not behind the oil or gas heating systems, while
in fuel consumption it is significantly more cost-effective.
Compared to boilers with heating oil the savings with pellet boilers is up to three times. Pellet is
renewable, which means that, as such, is environmentally friendly.
Pellet tank is an integral part of the boiler plant and needs to be recharged as needed.
The firebox and convective part of boiler are made of quality sheet metal by welding
technology. The boiler is well insulated with hard-pressed mineral wool in a quality tin plating.
Assembly and commissioning of the furnace are simple, and the connectors are standard. Boiler
is tested for water resistance. Allowable working pressure is 2.5 bar.

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EC-DECLARATION OF CONFORMITY
In accordance EN45014:1998
We .................…………………….... : TOPLING
ul. Magistralni put bb
78430 Prnjavor
Bosna i Hercegovina
We state with personal responsibility that the product:
Mark........ .................................... : boiler BTA
Type / Model.. .............................. : BTA350, BTA450, BTA550, BTA750, BTA1000,
BTA1200, BTA1500, BTA2000
Year of production ...................... : 2013
On wich this declaration is stuck on, in accordance with the following normative documents :
In accordance with EC-Directives : EC-Directive –Machine safety 2006/42/EC
EC- Directive-Equipment under pressure 97/23/EC
EC Directive-Low voltage 2006/95/EC
EC Directive-electromagnetic compatibility 2004/108/EC
Applied standards, especially:
EN ISO 12100:2012, EN ISO 7000:2012, EN 12953-1:2002, EN 12953-2:2002 , EN 12953-
3:2002 , EN 12953-4:2002, EN 12953-5:2002 ,EN 12953-6:2012,
EN 12953-8:2001, EN 12953-9:2007, EN 12953-10:2003, EN 12953-11:2003,
EN 60204-1:2006, EN 61000-6-3:2006
And other standards :
EN 287-1: 2011, EN 15614-1; EN 10204:2004; EN ISO 7000 :2012;
Applyed procedure for declaration of conformity: Modul B1
Emission limits according (class):
Issue certicates: EC Control type-Certificat br. ______________________
Accredit laboratory: TÜV Thüringen e. V. Service-Center Südthüringen
Industriestr. 13 98544 Zella-Mehlis
We hereby state that the above mentioned product in its concept and way of production, is in
accordance with the safety and protection norms which are in accordance with the above
mentioned directives and standards.
Also, all drive conditions and conditions of use are in accordance with the attached instructions
for use and technical documentation.
If only one change of the product is done, which has not been agreed with us, this
declaration automaticly loses its validyt.
Surname, name and title of signatory :
Prnjavor Živanić Radislav bach.eng.manager
................................................ ....................................................
Place and date signature, seal

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3.2. Technical Description
Hot Water Boiler BTA is made of quality boiler steel plate with welding technology with
connection to external pellet burner. The boiler is completely covered by sheet plate.
External pellet burner is an device in which pellet burning process takes place so that
already formed hot gas stream comes to the firebox. Burner has cylindrical shape with
tangentially positioned channel through which fuel is dosed. The burner is insulated with a thick
layer of concrete for thermal insulation and it has connections for air inlet and the outlet of
combustion products towards the boiler. Centrifugal fan is mounted on the burner, which has a
role to accelerate the combustion process and routing - flowing of gases to the boiler and
chimney
Storage with feeder consists of storage, screw convenor and rotary feeder. Screw convenor
and rotary feeder are driven by electric motor and gear.
.
Multi Cyclone separates large particles from the flue gases, in order to reduce environmental
pollution and to prevent the release of sparks that could cause a fire. Flue gas fan through the
flue pipe transports flue gases to the chimney.
Counter controller automatically leads the combustion process regarding the lower and
upper fixed point of boiler water temperature.
The chimney must be properly selected. Proper chimney dimensioning is a precondition for
safe boiler operation and heating efficiency. At the bottom of the chimney there is a door for
cleaning. The interior chimney dimensions depend on the chimney height and the power of hot
water boiler.
For proper boiler operation it is necessary to provide a minimum airflow in the chimney which
is achieved by suitable section and chimney height.
Boiler installation is correctly calculated by the designer and expertly performed to achieve
maximum efficiency and to avoid malfunctions and unwanted consequences.
The system is easy for servicing, maintenance and cleaning. Combustion process is very
good, so the contamination of exchange surfaces is minimal, and layers of ashes can be simply
removed.
Cleaning equipment is delivered together with this system by the producer.

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Figure 1 . Boiler room with two system units and external silo

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A
F
C
E
B
Figure 2. Boiler dimensions with pellet burner

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Table 2. Technical characteristics
Power (kW)
350
450
550
750
1000
1200
1500
2000
h(%)
92-95
92-95
92-95
92-95
92-95
92-95
92-95
92-95
Flue gas
temperature (˚C)
max.190
max.190
max.190
max.190
max.190
max.190
max.190
max.190
Noise (dB)
78
78
78
78
78
78
78
78
El. power (kW)
9(1)
9(1)
9(1)
11(1)
11(1)
11(1)
13(1)
13(1)
Boiler weight (kg)
5320
6120
6320
6610
7420
7920
8350
8910
Burner weight
(kg)
2950
3150
3450
3785
3850
4050
4240
4500
Amount of water
in boiler(l)
2550
2950
3550
4040
4530
4760
5135
5320
A (mm)
5300
5400
5933
6260
6460
6970
7176
7370
B (mm)
2500
2500
2500
2500
2500
2500
2500
2730
C (mm)
1502
1602
1702
1802
1802
1902
1902
1902
D (mm)
1500
1500
1500
1500
1500
1500
1500
1500
E (mm)
1400
1400
1465
1473
1473
1573
1573
1673
F (mm)
3540
3740
3940
4140
4340
4540
4746
4946
Chimney height
(mm)
8000
10000
10000
10000
10000
12000
12000
14000
Chimney
diameter (mm)
400
450
500
550
600
600
600
600
Maximal working
water pressure
(bar)
2.5
2.5
2.5
2.5
2.5
2.5
2.5
2.5
Maximal water
temperature (0C)
90
90
90
90
90
90
90
90
Test pressure
(bar)
5
5
5
5
5
5
5
5
Flue gas fan
(type)
LM33
LM33
LM39
LM39
Ekovent
C4-62
No4.5
Ekovent
C4-62
No4.5
Ekovent
C4-62
No4.5
Ekovent
C4-62
No4.5
Fuel consumption
(kg/h)
70
90
100
150
200
240
300
500
Pressure drop
from water side
(mbar)
165
180
200
270
310
335
375
415
Pressure drop
from flue side
(mbar)
2.0
2.2
2.5
3.0
3.3
3.7
4.1
4.3
Starting line
90/70(DN)
80
80
100
125
125
125
150
150
Return line
90/70(DN)
80
80
100
125
125
125
150
150
Safety line (DN)
50
50
50
65
65
65
65
80
(1)-note
Electrical power is given for the standard dosing system with one screw conveyor . In
the case of more complex systems when the dosing silo is away from the rotary feeder so the
transportation is performed with multiple screw conveyers, electrical power should be increased
by the number of screw conveyers x1.5kW.

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cold cooling water
to heating system
from heating system
1. boiler
2. three way mixing valve
3. circulation pump
4. shut off valve
5. safety valve
6. ball check valve
7. expansion vesel
8. pipe for charging and discharging
9. thermometer
10.manometer
11.boiler thermal protection
drain
Figure 2a. (scheme of connecting boiler to the system)
The central heating system, in the vicinity of boiler, must be equipped with
pressure gauge to show the pressure of water in the boiler. (Fig.2a, poz.10)
The central heating system, in the vicinity of boiler, must be equipped with
thermometer to show the temperature of boiler water. (Fig.2a, poz.9)
Softened water is recommended for filling the boiler from the system.
Circulation pump is put into operation only when the heating system is filled with water. What
must be taken into account is that the system is vented.
The central heating system, in the vicinity of boiler, must be equipped with safety
valve to prevent the increasing of water pressure . (Fig.2a, poz.5) . The safety valve must
be set to 2.5 bar.
The safety valve is not supply with the boiler and must be installed in the central
heating system.
Safety valves are used for controlling pressure on boilers in heating systems and generaly
in all systems feeded by water or mixtures of water and vector liquids (glycol, for example). When
calibrated pressure is reached, the valve opens and, by means of the discharge to atmosphere,
prevents the pressure of the system from reaching levels which would be dengerous for the boiler

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and the components of the system itself. The discharge pressure of the valve is calibrated by the
manufacturer, and no change of this calibration is possible if the valve itself is no broken. The
safety valve must be installed in line with flow direction indicated by the arrow on the valve body.
Before the first firing, it is necessary to check whether the chamotte is properly placed in
the furnace and check that the transportation and installation of the boiler has not caused
movement of refractory bricks.
When connecting the furnace and chimney, the flue pipe should be placed horizontally or
vertically. All connections must be well sealed.
Risk of boiler overheating
When wooden logs or coal are used as a fuel, there is a risk of overheating in case of
interruption of power supply ( in that case the circulation pump stop working)
Remedy - battery backup supply for circulating pump or
- safe remuval of residual heat as describe in figure below
to heating system
from heating system
drain
cold cooling water
temperature relief valve
Figure 2b. Installation of temperature relief valve
The temperature relief valve is used to ensure safety in heating system using solid fuel.
The temperature relief valve is set to 950C . When the setting temperature is reached, the cold
cooling water inlet to the boiler and the overheated boiler hot water is drained and pass to the

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heating system simultaneously until the temperature drops below the trigger value. When the
setting value is reached, the inlet cold cooling water and discharge apertures are close
simultaneously.
Note-As usual, the arrow on the valve body indicates the cold water supply pipe inlet
point. The valve may be installed verticaly or horizontaly, but the discharge must always be facing
downwards. It must not be install upside down. The valve should be installed at the uppermost
point of the boiler.
When pellet is used as fuel, there is a risk of overheating also.
Remedy
The boiler BTA is equipped with safety thermostat, which in case of water
temperature excess above 950C, interrupt the power supply of regulator. In that case the
dosing system stops, and pellet is not enter into the boiler.
Connecting the control panel of boiler to the network
When installing the boiler, power supply cord must be connected to the boiler. The power supply
is single-phase 220 V, 50 Hz. Installation must be performed by an expert because there is a
danger of electrical shock.
Before putting into operation the work You must check:
- the pressure in the boiler and installation,
- whether complete installation is properly vented,
- whether boiler cables do not rely on the warm (hot) portions of the boiler or the cables are not
physically damaged,
- before feeding pellets into the reservoire, check that there are no mechanical hard objects that
could impede the work of the screw conveyor.
In a closed heating system the installation of a certified expansion vessel (figure 2a,
poz.7) is requred to avoid hydraulic shock. Locking element must not be installed between
the safety valve, expansion vessel and boiler. Expansion vessel is not supply with the
boiler and must be installed in the central heating system.
Water temperature in boiler may not fall below 550C not to cause condansate.
In the event of severe winter weather and low temperature, and when the boiler is not used it is
necessary to drain waiter from the system or fill it with antifreeze liquid.

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Flue gas fans
Figure 3 –Flue gas fan type LM
Table 3. LM Flue gas fan dimensions
Table 4. LM Flue gas fan characteristic
Motor
Flow: Qv= m3/h
Type
Mark
kW
o/min
660
720
840
960
1080
1200
1320
1500
1920
2160
2400
2700
3000
3300
3600
4200
4800
5400
6000
6600
7200
8400
dB(A)
LM 28
80B-4
0,75
1375
38
40
42
44
45
47
48
52
52
50
45
40
56
LM 33
90S-4
1,1
1410
58
59
60
60
61
62
63
68
70
73
73
72
70
66
56
61
LM 39
112M-4
4
1420
84
85
86
89
90
93
95
98
101
103
110
115
118
118
118
115
113
73
LM 25
80A-4
0,55
1375
35
36
38
40
40
41
40
40
32
51
Presure drop (mm H2O)