Verner G45 Specification sheet

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EXPERTONHEAT
ENISO9001:2008
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OPERATIONAND
INSTALLATIONMANUALFORTHE
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VERNERG45andGN45
Woodburning
gasificationboiler
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ProductNumber
b018.66654.250610
Issuedon:25.06.2010
Translatedon13.07.2013
SoleUKDistributor:
AshburnStoves
www.ashburnstoves.co.uk
08455390364
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CONTENTS
IMPORTANTINFORMATION...........................................................................................................3
INTRODUCTION...............................................................................................................................3
TECHNICALDESCRIPTION...............................................................................................................4
BOILERDETAILS...............................................................................................................................5
TECHNICALDETAILS........................................................................................................................6
BASICFUNCTIONALCOMPONENTS................................................................................................6
ASSEMBLYANDINSTALLATION......................................................................................................7
Location.......................................................................................................................................7
Hearth..........................................................................................................................................8
Combustionairsupply.................................................................................................................8
Connectiontothechimney.........................................................................................................8
Optionalflueexhauster.............................................................................................................10
Connectiontotheheatingsystem............................................................................................10
Openventedsystem..................................................................................................................11
Sealedsystem............................................................................................................................11
Optionalautomaticcoolingloopsystem...................................................................................11
Electricalconnections................................................................................................................13
TheR4/2regulatorterminalconnections.................................................................................14
OPERATIONINSTRUCTIONS..........................................................................................................14
Lightingtheboiler......................................................................................................................15
Stokingtheboiler.......................................................................................................................15
Combustioncontrol...................................................................................................................16
Outputcontrol...........................................................................................................................17
Ashremoval...............................................................................................................................17
Boilershutdown........................................................................................................................18
Fuel............................................................................................................................................18
THER4/2REGULATOR..................................................................................................................20
Frontpanel................................................................................................................................20
Regulatordescription................................................................................................................21
Descriptionofcontrols..............................................................................................................23
Regulatorsetup........................................................................................................................24
Descriptionoftheregulatorssensorsandtheirfunctions........................................................26
Regulatortechnicaldetails........................................................................................................26
InternalelectricalschematicoftheR4/2regulator..................................................................27
COMMISSIONING..........................................................................................................................28
MAINTENANCE..............................................................................................................................29
Usermaintenance......................................................................................................................29
Engineermaintenance...............................................................................................................30
BOILERREPAIRS............................................................................................................................32
Sensormalfunction....................................................................................................................32
ACCOMPANYINGDOCUMENTATIONANDACCESSORIES...........................................................33
DISPOSALOFPACKAGING............................................................................................................33
BOILERDISPOSALATTHEENDOFITSLIFE...................................................................................33
SAFETYINFORMATION.................................................................................................................33
BOILERCONNECTIONEXAMPLES.................................................................................................34
Heatstorewithback‐upgasboiler............................................................................................34
Heatstorewithback‐upelectricheating..................................................................................35
Heatstorewithpartialgravitysystem......................................................................................35
GUARANTEECONDITIONS............................................................................................................36
SERVICERECORD...........................................................................................................................38
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Dearcustomer,
Youhavebecometheownerofaproductfromourcompanyandforthatweappreciateitvery
much.YouhavejoinedthefamilyoftenthousandsofclientsofVERNERa.s.
Ourdesignersandproductionteamshaveworkedhardandbelievethatyouwillbepleased
withthisproduct.Yoursatisfactioncanbefurtherincreasedifyoutakethetimetofollowthe
instructionscontainedinthismanualandtakeourbusinesspartnersadvicethatare
experiencedwithourproducts.
Wewouldbepleasedtohearaboutyourexperiencesofthisproductandwouldliketothank
youinadvanceforanysuggestionsregardingthefuturedevelopmentofourproducts.
Wewishyoualotofsatisfaction  VERNERa.s.
IMPORTANTINFORMATION
READTHESEINSTRUCTIONSTHOROUGHLYBEFOREINSTALLING,OPERATINGORSERVICING
THISAPPLIANCE.FAILURETODOSOCOULDPUTLIVESATRISK!
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PleasenotethatitisalegalrequirementunderEnglandandWalesBuildingRegulations,and
theVERNERa.s.warrantysystem,thattheinstallationoftheboileriscarriedouteithertolocal
authoritybuildingcontrolapprovalorbyaCompetentPersonregisteredwithaGovernment
approvedCompetentPersonsScheme.HETASLtdoperatesuchaschemeandalistingoftheir
RegisteredCompetentPersonscanbefoundontheirwebsiteatwww.hetas.co.uk.
Thekeytosafeandefficientwoodburningisthroughcorrectinstallationandproperoperation
whichcanonlybeachievedbygoodplanning.Pleasereadthefollowinginstructionscarefullyto
getthebestfromyournewpurchase.
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TheG45GVandGN45boileristestedandapprovedforinstallationanduseto:‐
EN303‐5 Boilersforcentralheating–Part5:Boilersforcentralheating–solidfuel,with
manualorautomaticsupply,ratedheatingpowermax300kW(2000).
EN60335‐1 Safetyofelectricapplianceforhouseholdandforsimilarpurposes:part1–
Generalrequirements(1997).
EN50165 Electricalequipmentofnon‐electricappliancesforhouseholdandsimilar
purposes–Safetyrequirements(1999).
CEproductdesignationforelectricalappliancesoflowvoltageandforelectromagnetic
compatibility.
INTRODUCTION
Thisboilerisawoodfuelledgasificationboiler.TheGN45boilerbodyismadefrom4mmthick
class17gradestainlesssteeldesignedasafireboxwithtubularheatexchangershavinganinner
diameterof50mm.Theinternalpartsthatareincontactwithcondensationandcombustion
gassesarealsomadeofstainlesssteel.
Thewallsoftheboilerbodyaretwinwalledformingawaterjacket,theexternalskinisof4mm
thickclass11gradestainlesssteel.Theboilerbodyiscoveredwith40mmthickcompressed
mineralfibreinsulationandapaintedsteelcasing.
TheG45GVissimilarbutisfabricatedfrom6and8mmsteelboilerplate.
Thebottomoftheboilerisinsulatedwith40mmthickceramicbricksandalayerofmineral
fibre.Thefuelchamberis545mmlong,440mmwideand790mmhigh.Thecombustion
chamberislinedwithceramicinsulationpanels.

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Theheatingwaterconnectionsare2"BSPwithasinglereturnconnectionattherearofthe
boilerandthetwoflowconnectionseithersidetowardsthetopoftheboiler.
Theboilerdoorsareequippedwithhightemperaturefibreropeseals.Thedoorgasketsand
othermaterialsoftheboilerdonotcontainasbestosorotherharmfulsubstances.
Flueconnectionissituatedintheupperpartoftherearboilerwallinwhichisfittedasteel
pocketforthecombustiongastemperaturesensor.
Mainssupplyisprovidedviaathreecoreflexiblecable.
Theboilerisequippedwithdualoverheatprotection:
1.Byelectronicregulation.
2.Byanindependentemergencythermostat.
Theboilerisdesignedforcontinuousoperationasthemainheatsourcefordwellingspaces,
houses,cottages,industrialbuildings,farmhousesandsimilarbuildingswithaheatlossupto
45kWandassupplementaryheatingforapplicationswithaheatlossover45kW.
Longburningtimes,greateroutputadjustabilityandlowoperationandmaintenance
requirementsallowforveryeasyandcomfortableoperation.Itshighefficiencyguaranteesa
verylowrunningandenvironmentalcost.
Modernhomeshavesuperiorlevelsofinsulationandarefarmoreenergyefficientwhich
makeshomeseasiertoheatandretainheatmuchbetter.Vernerwoodburningappliancesare
carefullydesignedsothattheywillfunctioncorrectlyinmodernenergyefficienthomes.The
moreenergyefficientahouseis,thelessfuelisrequiredtoheatit,meaninglessimpactonthe
environment.
Superiordesignandthehighqualityofconstructionguaranteealonglifespanforyour
investment.
Themanufacturerreservestherighttomaketechnicalchangesandmodificationsinthecourse
ofproductimprovementandinnovation.
TECHNICALDESCRIPTION
TheVERNERG45GVandGN45boilerisbasedontheprincipleoftwostagecombustionwhere
woodfuelisfirstlyburnedinthefuelchamberandthegasproduceddrawnthroughanozzle
whereitismixedwithforcedairwheresecondarycombustion(gasification)takesplace.
Duringoperationprimarycombustion(orgasification)takesplaceinthebottompartofthefuel
chamber(1).Heatfromthisprimarycombustionheatistransferredthroughthewallsofthe
fuelchamberintothewaterjackettopreheattheincomingheatingwater.Theburningwood
gasflowsthroughtheslotsinthebottomofthefuelchamberintothenozzle(2),where
secondaryairismixedwithit.Thissecondaryairandwoodgasmixtureresultinsecondary
combustiontakingplaceinthecombustionchamber(3).Hotgasesflowintothetubularheat
exchanger(5),wheretheytransferheattothealreadypreheatedwater.Aftercoolingthegas
movesintothechimneyviatheflueconnection(7).
Non‐combustiblewaste(ash)ismovedbytheburninggasintothecombustionchamberfrom
whereitiscollectedforremoval.Airforcombustionissuppliedbythecombustionfan(9),
whosespeediscontrolledbytheelectronicregulatoraccordingtotheactualoutput
requirement(outgoingwatertemperaturefromtheboiler)oraccordingtotheoutgoing
temperatureoffluegasfromtheboiler.
Theboilerisequippedwithanelectronicregulatorandnon‐electricoverheatthermostatwhich
willshuttheboilerdownshouldthewatertemperatureexceed95oC.
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BOILERDETAILS
  SectionalsideviewRearview
 
Frontview Sideview
1. Fuelchamber2. Nozzle
3. Combustionchamber4. Sideandrearcombustionchamberinsulationpanels
5. Heatexchanger6. Boilerbody
7. Flueconnection8. Chimneydamper
9. Combustionfan10. Primary airregulation
11. Secondaryairregulation12. Upper (stoking)door
13. Lower(cleanout)door14. Heating wateroutlet(flow)
15. Heatingwaterinlet(return)16. Coldfeedanddraintapconnection
17. Damperlever18. Heatexchangercleaningcover
19. Anti‐smokeplate20. Boilerregulator (controlpanel)
21. Leftsidecover 22. Rightsidecover
23. Rearcover 24. Frontcover
25. Upperdoorcasing 26. Bottomdoorcasing
27. Regulatorcasing 28. Top casing
29. Combustionchamberbottom insulationpanel 30. Chamotbrick
31. Combustionfaninletregulator32. Coolingloop(Optional)
33. Transportandhandlingfeet 34. Fluegastemperaturesensor
35. Turbulators36. Dampercleaningcover

6|Page
TECHNICALDETAILS
Totalratedthermaloutput45kW
Efficiency 87%
Outputmodulation50–100%
Fuelconsumptionatratedoutput 13.5kg/hour
Burningdurationoffullfuelloadatratedoutput 5hours
Dimensionofstokingopening240x430mm
Fuelchambercapacity 180litres
Boilerhydraulicresistanceat70/90oC20Pa
Combustiongastemperatureintochimney(at30kWoutput) 200oC
Minimumwaterreturntemperature60oC
Waterconnections2”BSP
TotalweightG45GV/GN45 630/570kg
Watercapacityofboiler 92litres
Maximumoperationalpressure 3bar
Supplyvoltage(formainsadapter12V‐1A) 230V/50Hz
Maximumelectricalinput70W
ElectricalprotectionIP21
Maximumnoiselevel54dB
Minimumchimneydraught 15Pa
Minimumfluesize180mm
Minimumrecommendedflueheight5m
Combustiongasmassflowrateatoutputof45kW0,030kg/s
Combustiongasmassflowrateatoutputof22kW0,015kg/s
Fuels woodlogs,briquettesandchipsupto20%moisture
BASICFUNCTIONALCOMPONENTS
Fuelchamber(1):servesasafuelreservoir.Duringprimarycombustionthefuelisgasifiedand
warmsinletwater.
Combustionchamber(3):secondarycombustionoccurshereandatthesametimethenon‐
combustiblewaste(ash)isdepositedhere.
Heatexchanger(5):transfersburntgasheattopreheatedwater.
Damper(8):directscombustiongasdirectlyintothefluefromthefuelchamberduringstoking
andlighting.
Combustionfan(9):suppliestheairnecessaryforcombustionintheboiler,theairissplitinto
primaryandsecondaryair.
‐  Primary(main)air–flowsbetweenupperdoor(12)andanti‐smokeplate(19)intothe
feedingchamber(1),whereitsupportsprimaryfuelcombustion.
‐Secondaryair–flowsintothenozzle(2),whereitismixedwithwoodgas.
Builtintotheairsupplysystemisabackflowpreventionvalvethatprotectsthefanfromthe
posibilityofburnbackorflashoverandclosestheairsupplyintotheboileratshutdown.
Anti‐smokeplate(19):reducesthestokingareaopeningsothatexcessivesmokedoesntenter
theboilerroomduringstokingtheboiler.
Boilerregulator(20):controlstheboileroperationbyregulatingthecombustionfanspeedand
controlingthecombustionandefficiencybasedontheoutgoingwatertemperatureand
outgoingfluegastemperature.Itcontrolsthesystem(Heating)pumpandthepumpinthe
boiler(shunt)circuit.

7|Page
Turbulators(35):increasetheeficiencyoftheheatexchangerbyinducingswirlontheflue
gasses.Itisimperativethatgoodqualityfuelisusedinconjuctionwithturbulatorsaspoor
qualitycombustionwillpotentiallyblocktheheatexchanger.
ASSEMBLYANDINSTALLATION
Theboilerinstallationmusttobecarriedoutincompliancewiththisoperatingandinstallation
manual.
InallcasestheinstallationmustcomplywithcurrentBuildingRegulations,LocalAuthority
Byelawsandotherspecificationsorregulationsastheyaffecttheinstallationofthestove.
ItshouldbenotedthattheBuildingRegulationsrequirementsmaybemetbyadoptingthe
relevantrecommendationsgiveninBritishStandardsBS8303,BSEN15287‐1:2007asan
alternativemeanstoachievinganequivalentlevelofperformancetothatobtainedfollowing
theguidancegiveninApprovedDocumentJ.
Shouldanyconflictapplybetweentheseinstructionsandtheoriginalmanufacturers
instructionsthenthemoststringentadvicemustapply.
Beforeboilerinstallation,theinstallershouldcheckthattheinformationontheboilerdata
platecorrespondswiththeoperationandinstallationmanualandtheapplianceissuitablefor
theintendeduse.Acheckshouldalsobemadefordamagedandmissingpartswhichshouldbe
notifiedtothesupplierbeforeinstallation.
Buildingregulationsrequirethatwheneveraneworreplacementfixedsolidfuelor
wood/biomassapplianceisinstalledinadwellingacarbonmonoxidealarmmustbefittedin
thesameroomastheappliance.Furtherguidanceontheinstallationofthecarbonmonoxide
alarmisavailableinBSEN50292:2002andfromthealarmmanufacturer’sinstructions.
Provisionofanalarmmustnotbeconsideredasubstituteforeitherinstallingtheappliance
correctlyorensuringregularservicingandmaintenanceoftheapplianceandchimney
system.
Location
Thisboilershouldnotbeinstalledinthelivingareasofadwelling.Itshouldnotbeinstalled
externallyotherthaninsideapurposebuiltbuilding.
Minimuminstallationandserviceclearances
800mmtothefront
100mmtothesides(increasedto650mmtothesidewhereacoolingloopisinstalled)
100mmtotherear
1000mmabovethetopcover
Minimumdistancesfromcombustiblesurfaces
400mmtothefront
400mmtothesides
400mmtotherear
400mmabovethetopcover
Clearancestocombustiblesurfacescanbereducedinsomecircumstances.ConsultDocumentJ
oftheBuildingRegulations.
Theboilerandfluemustbeinstalledtoallowaccessforcleaning.Itisnecessarytoremovethe
topcovertocleanandmaintaintheheatexchangeranddamper.

8|Page
Hearth
Theboilerdoesnotrequireaconstructionalhearth.Howevertocomplywithbuilding
regulationsitmustbelocatedonanon‐flammableflatandlevelhearthofminimum12mm
thickness.Thehearthtemperaturedoesnotexceed100oC.Thehearthmustextendaminimum
of300mminfrontand150mmtoeachsideoftheappliance.Theinstallermustensurethatthe
flooronwhichtheboileristobemountedhassufficientcarryingcapacity.
Combustionairsupply
Theboilertakescombustionairfromtheroominwhichitisinstalled.Toperformefficiently
andsafelythisappliancerequiresacombustionairventilatorfittingdirectlytooutsideair.
BuildingregulationsApprovedDocumentJhavedifferentrequirementsfordwellings
constructedpriorto2008.
Totalfreeairdirectfromoutside
Constructionpriorto200822000mm2
Constructionin2008orafter24750mm2

Thecombustionairventilatorshouldbelocatedinaplacewhereitisunlikelytobeblockedby
theenduser.Itispreferabletoplacetheventinapositionsoasnottocausedraughtsor
nuisance.Ventsmustbeofthenon‐closingtypeandmustnotcontainaflyscreen.
Ifitisfoundduringoperationthattheboilersmokesexcessivelywhilststoking,ensurethatthe
flueisuptotemperatureandthedamperisoperated.Ifexcessivesmokingcontinues,then
openawindowinthesameroomastheboiler.Shouldthesmokingreduceorbeeliminated,
extrapermanentventilationshouldbefittedtotheroom.
Iftheboilerisoperatedtogetherwithanotherapplianceinthesameroomrequiringanair
supply,theairrequirementcalculationshouldbecarriedoutassumingbothappliancesare
operatingatmaximumoutput.
Avoidfittingtheboilerinthesameroomsasamechanicalextractorfan.
Connectiontothechimney
Amajorcauseofchimneyrelatedfiresisfailuretomaintainnecessaryclearances(airspaces)
tocombustiblematerials.Itisoftheutmostimportancethatthechimneyisinstalledonlyin
accordancewiththechimneymanufacturer'sguidelinesandBuildingRegulations.
Toreachtheappliance'sratedoutput,chimneydraughtmustbeaminimumof15Pa.However,
gooddraughtisdesirablebecauseitpreventssmokespillingintotheroomduringstoking.
Shouldexcessivedraughtbeencounteredthenafluedraughtstabilisercanbeinstalled
howeverthiswilleffectcombustionairrequirements,pleaseconsultApprovedDocumentJ.
Allpartsoftheflueandchimneymustbemadeofapprovednon‐combustiblematerials.Any
fluepipeorchimneyinstalledinareasexposedtocoldmustbeinsulated.Theminimum
allowabletemperatureofcombustiongasonemetrebelowtheoutletofthechimneyis90oC.
Thehighefficiencyoftheapplianceresultsinfluegastemperaturesofbelow220oC.Iftheflue
gasistoremainbuoyantthetemperatureinthefluemustbekeptrelativelyhighinorderto
providegoodapplianceperformance.
Thechimneythattheapplianceisconnectedtomustserveonlyoneappliance.

9|Page
Singlewallflueconnectionpipesarenotsuitableforconnectiontothisapplianceunless
connectingdirectlytoaninsulatedmetalflueliner.
Achimneyheightof5metresshouldprovidesufficientdraught.Itshouldhaveanapproved
termination.
Masonrychimneys
Masonrychimneysmustbelined.Thechimneyshouldbeofsoundconstructionandswept
beforefittingaliner.
Metalliners
Linersshouldbeofanapprovedtypeforusewithsolidfuel.Theannularspacebetweenthe
linerandmasonryshouldbefilledwithaninsulationmaterialorthelinerwrappedwith
proprietaryinsulationpriortoinstallation.
Pre‐fabricatedmetalchimneys
Attentionmustbegiventochoosingthecorrecttypeofchimneysuitableforsolidfuel.Itmust
beinsulatedtwinwallpipeofstainlesssteelconstruction.
Suitabilityandinstallationdetailsshouldbesoughtfromthechimneymanufacturerand
BuildingRegulations.
Theweightofthechimneymustnotbesupportedbytheappliance.Theconstructionofthe
chimneyshouldbesuchthatitisself‐supporting.

Chimneytermination

Chimneymanufacturers'guidanceandBuilding
RegulationsdocumentJshouldbeadheredto
whendesigningthefluesystemandin
particulartheterminationwhichhasamajor
impactonthesuccessfulfunctionofthe
chimney.
 


Pointwherefluepassesthrough
weathersurface(notes1,2)Clearancestoflueoutlet
AAtorwithin600mmoftheridgeAtleast600mmabovetheridge
BElsewhereonaroof
(whetherpitchedorflat)
Atleast2300mmhorizontallyfromthe
nearestpointontheweathersurfaceand:
Atleast1000mmabovethehighestpointof
intersectionofthechimneyandtheweather
surface;or
Atleastashighastheridge
C
Below(onapitchedroof)or
within2300mmhorizontallyto
anopenablerooflight,dormer
windoworotheropening(note
3)
Atleast1000mmabovethetopoftheopening
D
Within2300mmofanadjoining
oradjacentbuilding,whetheror
notbeyondtheboundary(note
3)
Atleast600mmaboveanypartofthe
adjacentbuildingwithin2300mm
Notes
Theweathersurfaceisthebuildingexternalsurface,suchasitsroof,tilesorexternalwalls
Aflatroofhasapitchlessthan10o
TheclearancegivenforAorB,asappropriate,willalsoapply
Averticalfluefixedtoanoutsidewallshouldbetreatedasequivalenttoaninsideflue
emergingatthenearestedgefromtheroof
AdjacentBuilding
Flueoutletpositionsforsolidfuelappliances
Datumfor
horizontal
measurements
Datumfor
vertical
measurements
150mm
max
Thedatumfor vertical
measurementsisthe
pointofdischargeof
theflue,or150mm
abovetheinsulation,
whicheveristhelower
Regulatedbuilding

10|Page
Optionalflueexhauster
TheoptionalflueexhausterVS5isdesignedforchimneydraughtsupportduringlightingand
stokingoftheboiler.Itissituatedontheboilerflueoutletandisthenconnectedtothe
chimney.Withtheboileratoperatingtemperatureandtheflueexhausternotrunningthe
minimumfluedraughtof15Paisstillrequired.
Theusageoftheflueexhausterhasthefollowingadvantages:
Reductionofsmokingduringstoking
Reductionofdustduringdeashingandboilercleaning.
Theflueexhaustercomprisesaflueexhaustertimercontrolboxandthefanunit.Theyare
connectedtogetherviaacableandcomecompletewithafour‐poleplugwhichconnectstothe
boilerinterface.Theconnectorscannotbeinterchangedwithanyotherboilerconnectorandso
theflueexhaustercannotbeconnectedincorrectly.Thefanisstartedbypressingthebuttonon
thecontrolpanelfortwoseconds.Theflueexhausterrunsfor3minutes,andthenitstopsand
waitsforthenextbuttonpressfromtheoperator.
Iftheboileroverheatsandtheoverheatthermostatoperates;thisfancannotbestartedup
untiltheoperatormanuallyresetsthethermostat.
Boileroperationwithanopendampermustbelimitedtothetimenecessaryfortheboilerto
lightandheatuporwhilststoking.Thefluegastemperaturecannotexceed420°Cin
permanentoperationand600°Cinshort‐timeoperation.
Connectiontotheheatingsystem
Therelevantstandardshavetobeconsideredattheprojectdesignstageandsatisfiedwhen
theheatingsystemisinstalled.
Examplesofconnectingtheboilerintotheheatingsystemareshownattheendofthismanual.
Theboilerisdesignedforconnectionintoasystemwhichiseitheropenventedorsealed
systemwithamaximumworkingpressureof3bar.
Theboilerinlet(return)fromtheheatingsystemisconnectedtothelowersingle2“BSP
connection.Thelower½”BSPconnectioncanbefittedwithadrainvalveorcoldfeed.The
boileroutlet(flow)intotheheatingsystemcanbefromeitherofthetwoupper2“BSP
connections.Theotherconnectioncanbeblankedoff.
Theinlet(return)watertemperaturemustnotbebelow60oC.Asuitablethermostaticmixing
valve,e.g.RegomatorThermovar,mustbefittedtoprovidebackendprotection.Manual
mixingvalvesarenotsuitable.Failuretocomplywiththisrequirementmayinvalidateyour
guarantee.


Regomat65W
    Thermovar65


Theboilercanonlybeconnecteddirectlytotheheatingsystemifprovisionismadetoprevent
shortcyclingoftheboiler,howeveritisstronglyrecommendedthataheatstoreisfittedto
storesurplusheatedwaterandevenoutthedemandplacedontheboiler.Inthiscasethe
heatingsystemflowandreturnareconnectedtotheheatstore.
Ifthereisapossibilityoftheappliancefreezingitisacceptabletoaddsuitablecentralheating
antifreeze,e.g.FernoxAlphi11.

11|Page
Itisrecommendedtofitallradiatorswiththermostaticvalves(otherthanonheatleakcircuits).
Inthiscaseanautomaticbypassvalveshouldalsobefittedtotheheatingsystemtomaintain
pumpcirculationshouldtheradiatorsallclose.
Theboilershouldbeinstalledtoallowfortheinspection,serviceandreplacementof
connectionsandcomponentsandmusthaveadraintapfitted.
Thesystemcanbedesignedandinstalledtodissipateheatedboilerwaterviaagravityheat
leakcircuitiftheelectricpowershouldfailduringboileroperation.Provisionforthiscanbe
througheithergravityheatingorhotwatercircuitstotallingaminimum50%nominalboiler
heatoutput.Ifthissystemdesignisnotpossiblethentheautomaticcoolingloopsystemmust
beused.
Thesizeofpipeworkforgravityandpumpedcircuitsshouldbeselectedinaccordancewith
BuildingRegulationsandapprovedcodesofpractice.Whendesigningagravitycircuitthe
centreoftheheatexchangershouldbetakentobe800mmabovetheboilerbase.
Aboilerandheatingsystemhastobeprotectedfromoverheating.Thatcanbeachievedas
follows:
1. Byfittinganautomaticcoolingloopsystem.
2. Bydesigningapumpedsystemwithpartialgravitycirculationbranch.
Openventedsystem
Thistypeofsystemmustincludeasuitablysizedfeedandexpansiontank.Werecommended
thatametalheadertankfittedwithametalfloatandballtapisused.Thefeedandexpansion
pipesmustrisecontinuouslyfromtheboilertothefeedandexpansiontank.Thefeedand
expansiontankandassociatedpipeworkshouldbeprotectedfromfreezing.Inthecaseof
pumpfailuretheexcessheatisdissipatedbythesystemwaterboilingandventingintothefeed
andexpansiontank.
Sealedsystem
Thistypeofsystemmustincludeanexpansionvesselandpressurereliefvalve.Thepressure
reliefvalve,ratedat3bar,mustbefittedontoboileroutlet(flow)pipewithin1metreofthe
outletoftheappliancesheatexchanger.Thepipeworkfromtheheatexchangeroutletmust
risetothepressurereliefvalve.ExpansionvesselsshouldbesizedtoBS7074‐1:1989butasa
ruleofthumbshouldnotbelessthan7%ofthetotalheatingsystemwatervolume.
Wheninstallingtheboilertoasealedsystemtheautomaticcoolingloopsystemmustbe
installedineverycase.
Optionalautomaticcoolingloopsystem
Theoptionalcoolingloopmustbefittedwheninstallingontoasealedsystemoronanopen
ventedsystemwithoutasuitablegravityheatleakcircuit.Thecoolingloopisadevicewhich
allowscoldwatertorunindirectlythroughtheboilersheatexchangertocooltheboilerswater
viaheattransfershouldtheboileroverheat.
Wheninstallingtheboilertoasealedsystemtheautomaticcoolingloopsystemmustbe
installedintotheflangeonthetoplefthandsideoftheboiler.Thecoolingloopiscapableof
watertowatertransferof45kWwithatemperaturedifference(t)of85oC(boilerwaterat
100oCandincomingwaterat15oC)attherequiredflowrate.
Theautomaticcoolingloopmustbeconnectedviaathermostaticsafetyvalvetoacoldwater
mainwithaminimuminputpressureof2bar.Thewatersupplypipeworkmustnotbevalved
otherthanatthemaincoldwaterstoptaptothebuilding.Thewatersupplymustnotbe
dependentonanelectricalpowersupplysuchasahomepressurisationunitorborehole.

12|Page
Shouldtheapplianceoverheatthethermostaticsafetyvalvewilloperateattemperatures
above95oCandallowcoldwatertoflowthroughthecoolinglooptocooltheheatexchanger.
SuitablethermostaticsafetyvalvesaretheHoneywellT131orWattsSTS20(notsupplied).The
sensorpocketforthethermostaticsafetyvalvemustbefittedintothe½”BSPconnectioninthe
heatexchanger(seediagram)andthesensormustbeguardedagainstaccidentalremoval.


HoneywellTS131


Thewaterconnectionfromthethermostaticsafetyvalvecanbetoeitherofthecoolingloop
heatexchanger¾”BSPconnectionsandtheoutlettowasteisconnectedintotheother.(Either
canbeusedforinletorforoutlet).Plasticpipesarenotsuitable,metalpipesshouldbeused.
Werecommendthatatestmeasurementoftheflowofcoolingwaterismadeincaseofit
beingrequiredinanemergency.Theflowcanbemeasuredbyoperatingthethermostatic
safetyvalvestestfunctionandrunningthewaterintoacontainerforoneminute.Theflow
shouldbeaminimumof10litresperminutewhenthethermostaticvalveisfullyopen


13|Page
Electricalconnections
Introduction
Onlyaregisteredcompetentelectricianshouldconnectthisboilertoapowersupplyand
externalcontrols.CompetentelectriciansworkinaccordancetoBS7671andaremembersofa
registrationbodysuchastheNICEICwhocanbecontactedherehttp://www.niceic.com/
ATTENTION!Isolatethemainselectricitysupplybeforestartinganyworkandobserveallsafety
precautiuons.
ATTENTION!Whenconnectingcablestotheregulatorensurethatnocablepeicesfallinsideas
theycouldcauseashortcircuit.
Electricalconnection
Theboilerisdesignedtobeconnectedtoa230V/50Hzsupplyandmustbefusedat3A.
Electricalconnectionmustbemadeviaafuseddoublepoleisolationswitchwithaminimum
3mmcontactseperationofallpoles.Thisappliancemustbeearthed.
Theconnectionofthecirculatingpumpsalongwithtimeandtemperaturecontrolmustbein
accordancewiththismanual.
Externalcontrolsconnection
Anytimeclock,programmableroomthermostatorroomthermostatwithvoltfree
independentswitchingcontactscanbeconnecteddirectlytotheR4/2regulatorusingterminals
7and8.Theconductorpolarityisnotimportant.
Connectinganexternalcontrolwhichgivesaswitched230vfeedwillseriouslydamagethe
regulator.
Shouldtheheatingsystemcontainanexternalcontrolwhichprovidesa230vswitchedoutputit
canbeconnectedtotheregulatorviatheendswitchofamotorisedvalveorviaarelay.
Theterminalshaveasafelowvoltageof12Vwhichenablesconnectionstobemadeviaa2
corecable.Asonlyon‐offinformationistransmittedthenthecablelengthisonlylimitedbya
maximumresistanceof100ohmsasitswitchesaverylowcurrentinternalrelay.
Whentheregulatorissetforoperationwiththeboilerinstandbymodetheexternalcontrols
mustnotbesettoswitchinshorterintervalsthan30minutes.
Whensetforoperationwiththeboilerinsystempumpswitchoffmodetheregulatoris
incapableofswitchingthesystempumpmoreoftenthanoncein20seconds.


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230VSupply
connector
Pumps
connector
Flueexhauster
connector
Boilerelectricalconnectors
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TheR4/2regulatorterminalconnections
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OPERATIONINSTRUCTIONS
Toensurethesafeandefficientuseoftheapplianceitmustbeoperatedinaccordancewith
theinstructionssetoutinthisoperationmanual.
Theboilermustbeoperatedonlybyadults.Theboilermustbetendedandrefuelled
periodically.
Theboilergetshotduringoperationandcautionshouldbeusedwhenoperatingthedamper
control.Aheatresistantgloveissuppliedandshouldbeusedwhenoperatingthestokingdoor
andcleanoutdoor.
Anymaterialswhichmaygiveoffcombustiblegas(solvents,gluesandpaint,etc.)shouldnotbe
broughtintothebuildingwhilsttheboilerislitasthereisariskoffireorexplosion.Theboiler
mustbeextinguishedbeforethisriskdevelops.
Burningwasteintheboilerisprohibited.Onlythespecifiedfuelshouldbeused.Liquidfuels
mustnotbeused.
Combustiblematerialsarenotbeputontheapplianceorplacedcloserthanthedimensions
specifiedinthesection“Location”earlierinthisdocument.
Theappliancecannotbeoverloadedwithfuel;howeverfuelshouldnothinderclosingthedoor.
Theboilermustnotbeoperatedwithoutbeingconnectedtoaheatingsystemfullofwater.
Ifitissuspectedthatanypartofthesystemisfrozen,donotoperatetheboiler.
Theboilermustnotbeoperatedwithitsstokingorcleanoutdoorsopenedexceptwhilst
stokingandlighting.
Iftheboilerhasnotbeenoperatedforalongtime,itsflueandchimneymustbechecked
beforelightingtoensuretherearenoblockages.
Nounauthorisedmodificationsshouldbemadetotheboiler.

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Lightingtheboiler
Checkbeforelighting:
1. Checkthatthesystemisfullofwater.
2. Checkthatthelower(13)andupperdoors(12)closeproperly.
3. Checkthatthefuelchamber(1)isclearandthenozzle(2)isunobstructed.
4. Checkthatthecombustionchamber(3)isclearandtheinsulationpanelsareinplace.
5. Turnontheboilerswitch,(1)page24,ensuringthedisplayshowstheboiler
temperature.Checktheoperationofthecirculatingpumpsiffitted.
6. Turntheswitchbackoffagain.
Tolighttheboiler:
1. Opendamperbypushinginitslever(17).
2. Setthecontrolofthemainairregulator(10)intotheopenpositionbyslidingthe
controltowardstheboiler.
3. Setthefireinthefuelchamber(1)bylayingseveralsmallpiecesofwoodontopofa
layerofwoodshavingsorkindlingwithscreweduppaper.
4. Addmoresmalllogsandclosetheupperdoor.Openslightlythelowerdoor.
5. Allowtheboilertoburnfor5‐10minutesusingonlythenaturalchimneydraught.Close
thebottomdoor(13)andturntheboiler´smainswitchon.Combustioninthefuel
chamberisnowsupportedbythefan.Closethedamperbypullingthecontrol(17).A
characteristicquietwhistleshouldbeheardafterashortwhileindicatingsuccessful
ignition.Allowtheboilertorunforafurther10–15minutes
6. Slowlyopenthelowerdoor;youshouldseeflamesemergingfromthefuelchamber.If
noflameisevidentthenozzlemaybeblockedandmanualclearingwillberequiredafter
firstopeningthedamper.Oncecleared,closethedamperandflamesshouldemerge
throughthenozzle.
7. Oncethecombustioninthecombustionchamberisstabletheprimaryaircontrolcanbe
setasnormal.
Theinitialfuelvolumeusedtolighttheboilershouldnotbetoolargeasthelargerthefuel
loadused,thelongerittakesforcorrectignitiontoestablish.
ATTENTION:Combustibleliquidsmustnotbeusedtolighttheboiler.Theboilermustnotbe
usedwithdoorsopenduringnormaloperation.Itisprohibitedtostorecombustibleobjects
closetotheboiler.Theashmustbeputintoanon‐combustiblebinwithcover.
Stokingtheboiler
Itisbesttostoke(i.e.feedtheboiler)whentheflamesdisappearandthereisjustaglowing
emberlayerremaining.
1. Turntheregulatoroffwhichstopsthefan(unlessfittedwithoptionalflueexhauster
whichshouldbeturnedon).
2. Opendamperbypushinginitslever(17).
3. Slightlyopentheupperdoortoallowthefuelchambertoventilate.Slowlyopenthe
doorfullyandoperatetheanti‐smokeplate.
4. Addfuel.Shouldsmokespillintotheroom,closetheanti‐smokeplateandcontinue
fillingwithfueluntilfull.

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5. Closetheupperdoor.
6. Turnontheregulator(unlessfittedwithoptionalflueexhauster).
7. Closethedamper.
Ifexcessivesmokingoccursduringstoking,weadviseyoutocheckifthereisenoughair
suppliedtotheroomandthatanyairventsarenotobstructed.Tryopeningawindowordoor
whilststokingandifthishelpstheproblemthenyoumayneedextracombustionventilation.
ATTENTION:Initiallightingmaycausepaintandoilsusedinmanufacturetoemitfumes.
Combustioncontrol
Duringoperationitisnecessarytomakesurethatcombustionisrunningoptimally.Efficiencyis
reducedbyimperfectcombustionandasaresulthighamountsofharmfulsubstances
(hydrocarbons,especiallytar)occurthatcauseairpollutionandclogtheboilerandflue.
Combustionqualityisnotonlydeterminedbythefueltypeandmoisture;itcanbesignificantly
influencedbythemethodoffuelstokingandoutputregulation.
Itisnecessarytopayextraattentionduringthetransitionalperiods(autumnandspring)when
theboileroperatesmoreofteninstandbymode.Standbyshouldonlyoccuraftertwohours
fromstokingattheearliest.Duringtheseperiodsthefuelloadsshouldbesmallersothatthe
stokingintervalsarebetween8‐12hours.
Combustionqualitycanbecheckedbylookinginthecombustionchamber.Cleanflamewithout
smokemeansqualitycombustion.Asootyflameshowsthattheburningprocessisimperfect
forsomereasonandinthiscaseitisnecessarytoincreasetheamountofsecondaryairby
adjustingthecontrol(11)inwards.
Airregulationdetails:
SECONDARY (ADDITI-
ONAL) AIR
max min
max min
PRIMARY (MAIN) AIR

Therecommendedstandardmanufacturerset‐upistopulloutthesecondaryaircontrolabout
20mmoutwardsfromthemaximumopenedposition.Moresecondaryairwillberequired
whenburningqualityhardwood,woodenbriquettesorsmallerfuelandlesssecondaryair
volumeisrequiredforsoftwoodandpoorqualityfuel.Therecommendedstandard
manufacturerset‐upfortheprimarycontrolistopullthecontroloutabout25mmfromthe

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maximumopenposition.Whenthemaximumboilerpoweroutputisrequired,itisnecessaryto
openitatmaximum.
ATTENTION:Duringcombustionfanoperationthebottomdoorcanonlybeopenedifstrictly
necessaryandthenfortheshortestpossibletime.Hotgasseswillbeexhaustedandcan
causedamage.
Outputcontrol
Theregulatorcontrolsthecombustionfanspeedduringoperationtocontroltheoutgoing
watertemperaturecorrespondingtoheatvaluesetontheregulator(65‐90°C).Iftheoutput
requiredbytheheatingsystemislessthantheboileroutputduringcontinuousoperationthe
regulatorshutsthecombustionfanoffandtheboilerswitchestothestand‐bymode.In
standbymodetheventilatoroutputandoperationindicatorlightsarenoton.Theboiler
standbylastsuntiltheoutgoingwatertemperaturefromtheboilerdrops7°Cundertheset
outputtemperaturewhentheboilerautomaticallyrevertstonormaloperation.
Thetimeandtemperaturecontroloftheboilercanbeprovidedbyconnectingathermostat
andprogrammerdirectlytotheregulator.
Theboileroutputcanbeinfluencedbyadjustingthecontroloftheprimaryairregulation(10).
Whenusingdifficulttoburnfuelsuchaslesswellseasonedorlargerlogsthensetthecontrolto
open.
Theboileroperationandcombustioniscontrolledaccordingtotheoutgoingcombustiongas
temperature.Theboilerisequippedwiththefluegastemperaturesensor(34)situatedinthe
flueconnector(7).Thefluegastemperatureismeasuredcontinuouslythroughouttheboiler
operation.Ifthemaximumsettemperatureisreached,theregulatorreducestheairfor
combustion,reducingtheboilerheatoutput,andthereforetheburningrateofthefuelfora
shorttime.Bymeansofthisregulationthefuelburnsinthefuelchamberequallywithinstoking
cyclesandthefueldoesnotburnoutcompletelyensuringchimneytemperaturelossisreduced
andtheboilerandcombustionefficiencyisincreased.
Whentheheatexchangerbecomescoatedwithdirt,thetemperatureoftheoutgoing
combustiongasisincreased,thecombustionairisreduced,theboilerheatoutputreducesand
theboilermustbecleaned.Themaximumcombustiongastemperaturecanbesetinthe
regulatorasdescribedlaterinthismanual.
Itispossibletoset:
Maximumcombustiongastemperature 270°C
Temperaturefortheratedboilercapacity 220°C
Temperatureforthereducedboileroutput 180‐200°C
Thevaluesaresetforlumpwoodcombustionwithmoistureupto20%.Thevaluesshouldnot
besetlowerthan180°C.Donotoperatetheboilerattoolowanoutput–thiscausessootingof
thefuelandcombustionchambers,heatexchangerandchimney.Theoptimalboileroutputis
intherangeof50‐100%.
Ashremoval
Theashfromthecombustionchamber(3)isremovedwhenthedepositreachesathicknessof
morethan5cm.Theperiodbetweencleaningdependsontheoperationofboilerandthefuel
used.
Theashfromthebottomofthefeedingchamber(1)mustberemovedifthecoatofash
reaches8cm.Theashisscrapedthroughtheslotinthebottomintothecombustionchamber
fromwhereitissubsequentlyremoved.

18|Page
Itisrequiredtoemptytheashalsofromtheareasbesidethecombustionchamberandunder
theheatexchanger.
Theashisremovedfromtheareaunderthetubularexchangerbyusingtheashscraper.There
isaholeintherearwallofthecombustionchamberforthispurposeaccessedbyremovingthe
chamotbrick(30).Aftercleaningreplacethisbrickattherearwallofthecombustionchamber.
Boilershutdown
Duringboilershutdownforlongerperiods,itisnecessarytoremovetheashfromtheboiler
andtoventilatetheboilerproperlysoanycondensationmoisturedoesn’tcollectonthe
internalboilerswalls.
Atboilershutdownduringsummerdonotunplugboilermainssupply.Itissufficienttoswitch
offtheboilerusingthecontrolswitchontheregulator.Incaseoflongtermmainssupply
interruptionthebackupbatteriesintheswitchingclockcanbedamaged.
Fuel
Hardwoodandsoftwoodlogsandchipsup50cmlongandadiameterupto20cmwitha
maximummoisturecontentof20%maybeusedinthisboiler.Commerciallyavailablewood
briquettesmayalsobeused.Thisboilerisnotsuitableforburningwoodproductscontaining
paint,varnishorglueswhichcoulddamagetheboilerandflue.
Theheatproducedfromallkindsofwoodisroughlythesame(approx.15MJper1kgofdry
wood).Hardwood(withhigherdensity)ismoresuitableiflongerburningtimesarerequired.
However,hardwoodusuallyburnspoorlyandsolargerlogsmustbesplit.Softwood(with
lowerdensity)burnsmoreeasily,soitispossibletoburnlarger,un‐splitlogs.
Burninggreenormoistwoodisnotrecommended.Apartfromvoidingthewarrantyofthe
appliance,theeffectiveheatingvalueisreducedwhenthewoodisun‐driedandthisbecomes
evidentinincreasedwoodconsumption.Inaddition,fluegasescarrymoremoisturewhich
resultsintheproductionofcondensationandpoorcombustion.Boilerandfluelifewillbe
reduced.Smokeemissionsarealsoincreasedcausingtheflueandinternalcomponentsofthe
appliancetobecomeblockedwithtarandcreosotewhichcanfuelachimneyfire.
Woodwillnaturallydryovertimeifcorrectlystoredoutsideinapurposemadelogstoreor
coveredwithawaterproofcoverleavingspaceforaircirculation.Logsshouldbecuttolength
andsplitbeforestoringwhichwillaidairdrying.Soft‐woodsplitlogsshouldbereadytoburn
after1‐2years,andhardwoodafter2‐3years.
Ifwoodissourcedfromalocallogsupplierforimmediateusethencareshouldbetakenin
confirmingthemoisturecontentofthefuelbeforedelivery.Anyprofessionallogsupplierwill
beabletoanswerthisquestionbutifanydoubtexiststhenamoisturemetercanbeusedto
checkthemoisturecontentbeforedeliveryisaccepted.
Theheatingvalueofwoodenbriquettesisapproximately17MJper1kg.Largebriquettes
mouldedbyhighpressurearemostsuitable.Smallerbriquettesorbriquettespressedbylow
pressurearelesssuitable.(Thesefallapartintheboilerafterashorttime).
ATTENTION:Plasticsandanysyntheticmaterialshouldnotbeburnedintheboiler.During
theircombustiondangerousgasesareproduced.Theyaffectheattransfer,causesurface
corrosionandreducethelifeoftheboilerandchimneyunit.Theyalsoaffecthealthand
contaminatetheatmosphere.

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Averagedensitiesofwood(inkg/m3ofdrywood).
Sycamore500Hornbeam 680 Alder 520
Fir500Ash670 Spruce 450
Birch630Maple 660 Poplar 450
Beech670Chestnut 560 Willow 440
Oak690Larch590 Elm 570

Thespecificweightofstackedwoodpercubicmetreis0.6to0.8timeslessthanthespecificweight
ofsolidwood.


Source:ForestryCommision.
Source:ForestryCommision.