INSTALLATION AND USER GUIDE PELLET BOILER COMPACT 35 translation of original instructions EN
TABLE OF CONTENTS TABLE OF CONTENTS....................................................................................... II INTRODUCTION .............................................................................................. 1 1-WARNINGS AND WARRANTY TERMS. . ............................................................. 2 2-INSTALLATION INSTRUCTIONS...................................................................... 7 3-DRAWINGS AND TECHNICAL SPECIFICATIONS. . ....................................
INTRODUCTION DDear Customer, Our boilers are designed and built in compliance with the European standard EN 303-5 (manual or automatic loading solid fuel boilers). They also meet the essential requirements of directive 2006/95/EC (Low Voltage) and directive 2004/108/EC (Electromagnetic Compatibility). To get the best performance out of your boiler, we suggest you read the instructions in this manual carefully before starting it up for the first time.
1-WARNINGS AND WARRANTY TERMS SAFETY PRECAUTIONS • • • • • • • • • • • • • • • • • • • 2 • Installation, electrical connection, function test and maintenance must only be carried out by authorised and qualified personnel. Install the product in accordance with all local and national legislation and regulations in force in the region or state. Only use the fuel recommended by the manufacturer. The product must not be used as an incinerator. It is strictly forbidden to use liquid fuel.
1-WARNINGS AND WARRANTY TERMS INFORMATION: Please contact the retailer or qualified personnel authorised by the company to resolve a problem. • You must only use the fuel specified by the manufacturer. • Check and clean the smoke extraction pipes regularly (connection to the chimney). • Always keep the cover of the fuel hopper closed. • Store this installation and use manual with care as it must accompany the product for the duration of its useful life.
1-WARNINGS AND WARRANTY TERMS EXCLUSIONS The guarantee does not cover malfunctions and/or damage to the appliance that arise due to the following causes: • Damage caused during transportation or relocation • all parts that develop faults due to negligence or improper use, incorrect maintenance, installation that does not comply with the manufacturer’s instructions (always refer to the installation and use manual provided with the appliance) • incorrect dimensioning with regards to the use or faults in the
1-WARNINGS AND WARRANTY TERMS SPARE PARTS In the event of a malfunction, consult the retailer who will forward the call to the Technical Assistance Service. Use only original spare parts. The retailer or service centre can provide all necessary information regarding spare parts. We do not recommend waiting for the parts to be worn before having them replaced. It is important to perform regular maintenance.
1-WARNINGS AND WARRANTY TERMS RULES FOR INSTALLATION The product is a boiler that uses wood pellets. Below is a list of European regulations regarding the installation of the product: EN 303-5:2012: Solid fuel boilers, with manual or automatic loading, nominal thermal power of 500 kW - Terminology, requisites, tests and marking. EN 12828 Heating systems design. Electrical systems with rated voltage not exceeding 1000 V AC and 1500 V DC.
2-INSTALLATION INSTRUCTIONS The instructions in this chapter refer explicitly to the Italian installation regulation UNI 10683. In any case, always observe the domestic regulations in force. PELLETS Wood pellets are manufactured by hot-extruding compressed sawdust which is produced during the working of natural dried wood. The compactness of the material is guaranteed by the lignin contained in the wood itself and allows pellets to be produced without glue or binders.
2-INSTALLATION INSTRUCTIONS PRECAUTIONS REGARDING INSTALLATION IMPORTANT! Product installation and assembly must be carried out by qualified personnel. The product must be installed in a suitable place that allows easy access for it to be opened regularly and for routine maintenance to be performed. The installation area must be: • suitable to enable the appliance to operate correctly. • Equipped with an adequate smoke extraction system. • Equipped with adequate ventilation from outside.
2-INSTALLATION INSTRUCTIONS POSITIONING AND RESTRICTIONS In the case of simultaneous installation with other heating appliances, provide appropriate air inlets for each one (according to the instructions of each product).
2-INSTALLATION INSTRUCTIONS FOREWORD This chapter on the Smoke Flue has been produced in reference to the prescriptions of European regulations (EN13384 - EN1443 - EN1856 - EN1457). The chapter provides indications for installing an efficient and correct smoke flue but is under no circumstances to substitute the regulations in force, which the qualified technician must be in possession of.
2-INSTALLATION INSTRUCTIONS TECHNICAL CHARACTERISTICS Flues serving a pellet/wood fuelled appliance must meet the following requirements: • made of materials that are sufficiently resistant to mechanical stress, heat, the action of the products of combustion and their vapours.
2-INSTALLATION INSTRUCTIONS ROOF AT 30° A = MIN. 1.30 metres B = DISTANCE > 1.50 metres C = DISTANCE < 1.50 metres D = 0.50 metres ABOVE HIGHEST POINT E = 0.80 metres F = REFLUX ZONE B C D A E 30° F FIGURE 4 ROOF AT 45° A = MIN. 2.00 metres B = DISTANCE > 1.30 metres C = DISTANCE < 1.30 metres D = 0.50 metres ABOVE HIGHEST POINT E = 1.50 metres F = REFLUX ZONE B C D A E 45° F FIGURE 5 ROOF AT 60° A = MIN. 2.60 metres B = DISTANCE > 1.20 metres C = DISTANCE < 1.20 metres D = 0.
2-INSTALLATION INSTRUCTIONS DIMENSIONING The drop in pressure (draft) of a flue depends on its height. Check the drop in pressure with the values indicated in the technical characteristics. The minimum height of the chimney is 3.5 meters. The interior cross-section of the flue can be circular (best variation), square or rectangular (the ratio between the interior sides must be ≤1.5) with the sides joined with a minimum radius of 20 mm. The dimension of the cross-section must be a minimum Ø150mm.
2-INSTALLATION INSTRUCTIONS MAINTENANCE The flue must be kept clean, since the deposit of soot or unburned oils reduces the cross-section reducing the draft and thus compromising the efficient functioning of the heater and, if large build-ups accumulate, can catch fire. The flue and chimney must be cleaned and checked by a qualified chimney sweep at least once a year. Once the maintenance has been performed, request a written declaration that the device is safe.
2-INSTALLATION INSTRUCTIONS CONNECTION TO FLUE The connection between the flue and the appliance must be via a smoke duct that conforms with EN 1856-2. The connecting section must extend no more than 4 m horizontally, with a maximum incline of 3% and containing a maximum of 3 90% bends (accessible for inspection - do not count the T joint at the appliance outlet). The diameter of the smoke duct must be equal to or greater than that of the outlet of the appliance (Ø 100 mm).
2-INSTALLATION INSTRUCTIONS EXAMPLES OF CORRECT INSTALLATION 1 U F E V I 1. Installation of Ø150mm flue with hole for the passage of the tube increased by: minimum 100 mm around the tube if next to non flammable parts such as cement, brick, etc.; or minimum 300 mm around the tube (or as prescribed by data tags) if next to flammable parts such as wood etc. In both cases, install suitable insulation between the flue and the ceiling.
3-DRAWINGS AND TECHNICAL SPECIFICATIONS DRAWINGS AND CHARACTERISTICS COMPACT 35 HYDRO DIMENSIONS (in cm) Technical Dept.
3-DRAWINGS AND TECHNICAL SPECIFICATIONS TECHNICAL CHARACTERISTICS COMPACT 35 HYDRO Product class (EN 303-5:2012) 5 Nominal thermal power to firebox 34,5 kW (29670 kcal/h) (Max) nominal output power: 32,0 kW (27520 kcal/h) Minimum output power 8,1 kW (6966 kcal/h) Efficiency at Max 92,8% Efficiency at Min 90,0% Temperature of exhaust smoke at Max 140°C Temperature of exhaust smoke at Min 60,5°C Maximum temperature that can be set 80°C Maximum operating temperature 95°C Particulate/OGC /
3-DRAWINGS AND TECHNICAL SPECIFICATIONS Residual head We recommend in particular to check the data tags of the flue for the safety distances that must be respected in presence of combustible materials and the type of insulating material to be used. These indications must be followed rigorously to avoid serious harm to personnel and surrounding infrastructure. 600 500 A 400 300 200 100 0 0 500 1000 1500 2000 B A = Residual Head (mbar) B = Load (l/h) Technical Dept.
4-INSTALLATION AND ASSEMBLY PREPARATION AND UNPACKING The Compact boiler is supplied complete with all its electrical and mechanical components and factory-tested: Open the package and remove the two screws between the bracket and the boiler and the two screws that fasten the bracket to the pallet. Set the boiler in the pre-selected place, making sure this complies with the requirements. The boiler body or unit must always be kept in a vertical position when handled and moved by using carts only.
4-INSTALLATION AND ASSEMBLY The end user is responsible for product storage, disposal or possible recycling in compliance with the relative applicable laws. Position the product without its cladding and connect it to the chimney. Once the connections are complete, assemble the cladding. Adjust the 4 feet (J) to level the stove so that the smoke exhaust and the pipe are coaxial.
4-INSTALLATION AND ASSEMBLY REQUIREMENTS FOR SYSTEM INSTALLATION • • • • the minimum distance in front of the product to allow for cleaning, maintenance, etc.
5-PLUMBING CONNECTION PLUMBING CONNECTION IMPORTANT: The connections depend on the type of hydraulic kit installed and on the type of System Configuration. IMPORTANT! If installation of the product involves interaction with another, pre-existing system complete with heating equipment (gas boiler, methane boiler, diesel boiler, etc.), contact qualified personnel, who subsequently will be responsible for conformity of the system in compliance with the applicable law in force.
5-PLUMBING CONNECTION FILLING THE SYSTEM Fill the system slowly to allow air bubbles to pass through the vent holes of the heating system. For closed circuit heating systems, the filling pressure of the system at cold and the pre-inflation pressure of the expansion tank must be the same. • In open vessel heating systems, direct contact between circulating liquid and air is allowed. During the heating season, the user must check the circulating water level in the expansion tank regularly.
5-PLUMBING CONNECTION To fill the system, the hydraulic kit (optional) is fitted with a tap, with a check valve, to load the heating system manually. During this operation, any air in the system is released via the air valve located in the upper part of the boiler. To ensure the valve vents, it is advisable to loosen the side cap (see figure) The filling pressure of the system WHEN COLD must be 1 bar. Upon completion of this filling operation, always close the loading tap.
6 - ELECTRICAL CONNECTIONS GENERAL PRECAUTIONS Electrical safety of the system is ensured only when it is properly connected to an efficient earthing system made in compliance with the safety standards in force: gas, water or heating systems pipes are not suitable as earth connections.
7 - INITIAL START-UP BEFORE START-UP GENERAL PRECAUTIONS Remove all components that could burn from the brazier (manual, various adhesive labels and any polystyrene). Check that the brazier is positioned correctly and rests properly on the base. After a long period of inactivity, remove any pellets left in the hopper (using a vacuum cleaner with a long pipe ), as they could have absorbed moisture, thereby altering their original characteristics and no longer being suitable for combustion.
7 - INITIAL START-UP The boiler will be subject to expansion and contraction during the start-up and cooling phases, therefore slight creaking noises may be heard. This is absolutely normal as the structure is made of laminated steel and must not be considered a defect. It is extremely important to make sure the boiler is not immediately overheated and the temperature is increased gradually, initially using low power.
7 - INITIAL START-UP LOADING THE PELLETS Pellets loading can be either manual or automatic. When empty the hopper can contain 150 litres i.e. roughly 100 kg of pellets. Manual Loading: • Open the upper door of the boiler directly and pour in the pellets. Automatic Loading (to be combined with the remote 100/200 or 400 kg hopper - optional - see accessories): • Remove the round plate from the door, cut the insulation and insert the hopper pipe. Subsequently load from the optional hopper.
8 - MENU ITEMS AND OPERATION CONTROL PANEL DISPLAY Menu items 2 7 1 3 4 5 6 KEY 1. Boiler lighting/shutdown 2. Scrolling of programming menu to decrease. 3. Menu 4. Scrolling of programming menu to increase. 5. Decrease set temperature/programming functions. 6. Increase set temperature/programming functions. 7. Display. MAIN MENU It is accessed by pressing key 3 (menu).
8 - MENU ITEMS AND OPERATION PROGRAMMED MODE SETTING (TIMER) - Main menu Setting the current day and time is essential for the proper operation of the timer. There are six TIMER programmes, for each one the user can decide the start-up and shutdown time as well as the day of the week in which it is active.
8 - MENU ITEMS AND OPERATION NOTES FOR TIMER OPERATION • Start-up with the timer always takes place with the last temperature and ventilation settings (or with default 20°C and V3 settings in the event they have never been changed). • Start-up time ranges from 00:00 a 23:50 • If the shutdown time is not already memorised, it proposes a start-up time in + 10 minutes.
8 - MENU ITEMS AND OPERATION SETTINGS MENU The SETTINGS menu allows to act on the boiler operating mode: a. Language. b. Cleaning (displayed only when the boiler is switched off). c. Feed screw loading (displayed only when the boiler is switched off). d. Tones. e. External thermostat (activation). f. Auto Eco (activation). g. Eco-Shutdown T (default 10 minutes). h. pump on T (default 50°C). i. Auxiliary boiler (default active). j. Pellet recipe. k. Smoke rpm % ventilation. l.
8 - MENU ITEMS AND OPERATION c - Feed screw loading Allows to fill the pellets loading system. It can only be activated with the boiler switched off, it displays an 180" countdown after which the feed screw stops automatically, as when exiting the menu. To select "Feed screw loading" (only when the boiler is switched off) act as follows: • Press the “menu” button. • Scroll to "Settings" using the arrows • Press "menu" to confirm. • Scroll to "Feed screw loading" using the arrows. • Press "menu" to confirm.
8 - MENU ITEMS AND OPERATION g - Eco Shutdown t To select the Eco - shutdown t function act as follows: • Press the “menu” button. • Scroll to "Settings" using the arrows • Press "menu" to confirm. • Scroll to "Eco - shutdown t" using the arrows. • Press "menu" to confirm. • Enter the minutes with the + - keys. • Press "menu" to confirm and "esc" to exit. AUTO ECO MODE Auto-Eco mode changes the behaviour of the boiler in automatic mode, i.e.
8 - MENU ITEMS AND OPERATION i - Auxiliary boiler One must install an additional module (optional) to enable start-up of an auxiliary boiler in the event the boiler is switched off or in alarm conditions. By default this function is deactivated, if needed activate it to access the settings menu. l - Pellet Recipe This function is for adapting the boiler to the pellets that are being used.
8 - MENU ITEMS AND OPERATION n - Maximum power (only for expert users) It allows to set the maximum flame limit at which the boiler can operate to reach the set temperature target. To change the power act as follows: • Press the “menu” button. • Scroll to "Settings" using the arrows • Press "menu" to confirm. • Scroll to "Maximum power" using the arrows. • Press "menu" to confirm.
8 - MENU ITEMS AND OPERATION q - System configuration To change the system configuration act as follows: • Press the “menu” button. • Scroll to "Settings" using the arrows • Press "menu" to confirm. • Scroll to "System configuration" using the arrows. • Press "menu" to confirm. • Change the configuration from 01 to 05 with the + - keys • Press "menu" to confirm and "esc" to exit.
8 - MENU ITEMS AND OPERATION SYSTEM CONFIGURATIONS Upon installation, the product must be set according to the type of system, selecting the appropriate parameter in the "SETTINGS" menu. The possible configurations are 5, as described below: Configuration Description 1 Room temperature management via the boiler probe or by enabling the external room thermostat. 2 2.
8 - MENU ITEMS AND OPERATION CONFIGURATION 2.1 (FACTORY SETTING) 5 4 5 2 6 3 7 1 CONFIGURATION 2.
8 - MENU ITEMS AND OPERATION CONFIGURATION 3 5 4 5 6 8 11 12 9 2 3 7 1 CONFIGURATION 4 5 5 4 4 13 11 6 17 15 2 3 1 Technical Dept.
8 - MENU ITEMS AND OPERATION CONFIGURATION 5 5 5 4 4 13 11 2 16 3 1 1 COMPACT 2 HEATING DELIVERY 3 HEATING RETURN 4 ZONE VALVES 5 HEATING BODIES 6 DOMESTIC HOT WATER 7 COLD DOMESTIC WATER 8 DOMESTIC WATER BOILER 9 DIVERTER VALVE 10 BOILER THERMOSTAT 11 THERMOSTATIC MIXING VALVE 12 DOMESTIC WATER 10 kΩ β3434 NTC PROBE 13 HEATING PUFFER 14 HEATING SYSTEM CIRCULATOR 15 PUFFER THERMOSTAT 16 PUFFER 10 kΩ β3434 NTC PROBE 17 SAFETY VALVE 42 14 7 6
8 - MENU ITEMS AND OPERATION OPERATING MODE Flame modulation is managed according to the "System configuration" of the room probe placed on the rear of the appliance (see drawing), by the external thermostat, by the boiler water temperature or by the NTC probes. ELECTRICAL CONNECTIONS TERMINAL BLOCK CONTACTS POS.1-2 EXTERNAL THERMOSTAT/PUFFER THERMOSTAT POS.8 THREE-WAY VALVE NEUTRAL POS.3-4 PUFFER/BOILER PROBE POS.9 THREE-WAY VALVE NEUTRAL (domestic) POS.5 EARTHING POS.
8 - MENU ITEMS AND OPERATION IMPORTANT! Set up all of the electrical and hydraulic connections to the hydraulic kit, purchased separately, following the instructions of the dedicated manual. START-UP Press key 1 (esc) to begin start-up, the control panel displays ON with a flashing flame. When the flame stops flashing the boiler has reached the "power output" operating mode.
9-SAFETY DEVICES AND ALARMS SAFETY DEVICES The product is supplied with the following safety devices PRESSURE SWITCH Monitors pressure in the smoke duct. It is designed to shut down the pellets feed screw in the event of an obstructed flue or significant back-pressure. (wind) SMOKE TEMPERATURE PROBE Detects the temperature of the smoke, thereby enabling start-up or stopping the product when the temperature drops below the preset value.
9-SAFETY DEVICES AND ALARMS TAMPERING WITH THE SAFETY DEVICES IS PROHIBITED If the product is NOT used as described in this instruction manual, the manufacturer declines all liability for any damage caused to persons and property.
9-SAFETY DEVICES AND ALARMS ALARM ALERTS Whenever an operating condition other than that designed for the regular operation of the boiler occurs, there is an alarm condition. The control panel gives information on the reason of the alarm in progress. A sound signal is not envisioned for alarms A01-A02 only so to not disturb the user in the event of pellets running out in the hopper during the night. Panel alert A01 A02 A03 Thermostat alarms A04 A05 Type of problem Solution The fire does not ignite.
9-SAFETY DEVICES AND ALARMS NORMAL SHUTDOWN (on the panel: OFF with flashing flame) If the shutdown key is pressed or if there is an alarm signal, the boiler goes into the thermal shutdown phase which entails the automatic execution of the following stages: • It stops pellets loading • The room fan (if provided) maintains the set speed until the smoke T reaches 100°C, then it automatically sets itself at the minimum speed until it reaches the shutdown temperature • The smoke fan sets itself at maximum spee
9-SAFETY DEVICES AND ALARMS Safety thermostat - Alarm A03 This type of alarm occurs when the water temperature in the boiler exceeds 95°C. The boilers contain a safety thermostat that prevents the water in the boiler from boiling. The safety thermostat in the boilers must be reset manually. This is done by pressing the small button between the two sockets (see below).
10-MAINTENANCE AND CLEANING DAILY OR WEEKLY CLEANING PERFORMED BY THE USER BEFORE EACH START-UP Clean the ash and any deposits in the brazier that could clog the air passage holes. If the pellets in the hopper finish, unburned pellets may accumulate in the brazier. Always empty the residue in the brazier before starting-up. REMEMBER THAT ONLY A CORRECTLY POSITIONED AND CLEAN BRAZIER CAN GUARANTEE START-UP AND OPTIMAL OPERATION OF YOUR PELLET BOILER.
10-MAINTENANCE AND CLEANING CLEAN THE EXCHANGER AND THE UNDERGRATE SPACE EVERY 2/3 DAYS Cleaning the exchanger and the undergrate space is a simple operation but very important for always maintaining performance as declared.
10-MAINTENANCE AND CLEANING PERIODIC CLEANING PERFORMED BY A QUALIFIED TECHNICIAN CLEANING THE EXCHANGER AND PIPE UNIT CLEANING THE UPPER COMPARTMENT When the boiler is cool, lift the front cover “I”; unscrew the screws on the rod “D” to clean the pipe unit and take out the two beams “A”. Now take off the cover “B”. Then, take off screws “V” (two on the right and two on the left) that hold the turbulators to the boiler.
10-MAINTENANCE AND CLEANING ATTENTION: It is advisable to carry out the cleaning of the upper exchanger at the end of the season by an authorised technician in order to also replace the gasket located below plug “B”. CLEANING THE LOWER COMPARTMENT Lower lever “E” and extract pan “F”, take out pans “H”. Remove the ash from all pans and if needed use a vacuum cleaner to remove any other ash or soot that has built-up under the drawer. Remove brazier “G” and clean it every 2/3 days.
10-MAINTENANCE AND CLEANING END-OF-SEASON SHUTDOWN At the end of season, before shutting down the boiler, we recommend completely removing pellets from the hopper with the use of a vacuum cleaner with an extension. The service fuse may have to be replaced if the control panel display does not go on when the product is re-started upon pressing the main switch on the rear of the boiler. On the rear of the boiler there is a fuse compartment which is located underneath the supply socket.
10-MAINTENANCE AND CLEANING PARTS/INTERVAL 2-3 DAYS Clean the brazier.
11-PROBLEMS/CAUSES/SOLUTIONS CHECKING THE INTERNAL COMPONENTS ATTENTION: GUIDE FOR THE EXCLUSIVE USE OF THE SPECIALISED TECHNICIAN. ATTENTION: All repairs must be carried out exclusively by a specialised technician, with the boiler switched off and the plug disconnected. The operations marked in bold type must be carried out by specialised personnel. The manufacturer declines all liability and warranty terms expire if this condition is not complied with.
11-PROBLEMS/CAUSES/SOLUTIONS ANOMALY POSSIBLE CAUSES The boiler runs for a few minutes and Start-up phase is not completed then switches off Temporary power cut Clogged smoke duct SOLUTIONS Repeat start-up Wait for the automatic restart Clean the smoke duct Faulty or malfunctioning temperature Check and replace the probes probes Faulty spark plug Pellets accumulate in the brazier, the Insufficient combustion air glass of the door gets dirty and the flame is weak Check the spark plug and replace it, if
11-PROBLEMS/CAUSES/SOLUTIONS The boiler does not start No power supply Check that the plug is inserted and the main switch is in the “I” position. Pellet probe blocked Unblock it by acting on the rear thermostat, if it happens again contact the service centre. Blown fuse Replace the fuse. Pressure switch faulty (block alert) Water pressure low in boiler Clogged smoke exhaust or smoke duct Clean the smoke exhaust and/or the smoke duct.
12-WIRING DIAGRAM MOTHERBOARD WIRING KEY 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. FUSE 14. BOARD PHASE 15. BOARD NEUTRAL 16. SMOKE EXPULSION FAN 17. ROOM FAN 18. PELLETS SAFETY THERMOSTAT 19. WATER TEMPERATURE OVERLOAD PROTECTOR SPARK PLUG 20. CONNECT TO THE WATER PRESSURE SWITCH OF THE 21. HYDRAULIC KIT (OPTIONAL) 22. AIR PRESSURE SWITCH 23. AUXILIARY BOILER CONNECTION (TERMINAL BLOCK) 24. FEED SCREW 25.
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