THERMOSTAHL PELLET COMPACT PLC 25 Installation And User Manual

Pellet boiler. pellet compact plc series

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PELLET BOILER
PELLET COMPACT PLC
INSTALLATION AND USER MANUAL
VERSION:
2.2
UPDATE:
20.08.2017

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Summary of Contents for THERMOSTAHL PELLET COMPACT PLC 25

  • Page 1 PELLET BOILER PELLET COMPACT PLC INSTALLATION AND USER MANUAL VERSION: UPDATE: 20.08.2017...
  • Page 2 Contents GENERAL INFORMATION ................... 3 1.1. Proper use of the appliance ................3 1.2. Safety warnings ....................3 1.3. Data label ......................3 1.4. Document information ..................3 TECHNICAL FEATURES AND DIMENSIONS ............4 2.1. Technical features ..................... 4 2.2. Function principle ....................
  • Page 3: General Information

    The appliance is designed for use in pumped hot water central heating systems. Any other use is considered improper and is prohibited. THERMOSTAHL declines any responsibility for damages or injuries caused by improper use; in this case the risk is completely at the user’s responsibility.
  • Page 4: Technical Features And Dimensions

    TECHNICAL FEATURES AND DIMENSIONS 2. TECHNICAL FEATURES AND DIMENSIONS 2.1. Technical features The boiler is made of steel, with horizontal construction, fire-tube type. The heat transfer from the exhaust gases towards the water is done primarily by thermal radiation in the first two passes, and in the third is done by thermal conduction.
  • Page 5: Dimensions

    TECHNICAL FEATURES AND DIMENSIONS 2.3. Dimensions T1-T2 TYPE inch inch inch PLC 25 1270 1500 1100 1 ½” ½” ½” PLC 35 1270 1500 1200 1 ½” ½” ½” PLC 50 1350 1500 1260 2” ½” ¾” PLC 80 1455 1055 1050 1500...
  • Page 6: Fuel

    TECHNICAL FEATURES AND DIMENSIONS 2.4. Fuel The PLC series is designed for pellet as fuel, with use of an automatic pellet burner. As fuel, it is recommended to use only premium quality wood pellet 6-8 mm diameter. Pellet of lower quality or agropellets can only be used if approved by the pellet burner manufacturer.
  • Page 7: Boiler Mounting

    BOILER MOUNTING INSTALLATION 3. BOILER MOUNTING 3.1. Transportation and delivery The boiler is delivered on wood pallet, well positioned with metal plates. Remove them carefully by unscrewing the screws holding them in place. The loading and unloading of the boiler must be performed with a forklift or a crane. A special hook is provided on the upper part of the boiler for lifting.
  • Page 8: Boiler Room

    BOILER MOUNTING INSTALLATION 3.2. Boiler room 3.2.1. General requirements The boiler must be installed in a special and separate room. This room must be chosen so that it offers easy access for fuel transport, air supply and exhaust gas evacuation. The doors of the boiler room must be metallic, open outwards, and have at least 0,9 m width.
  • Page 9: Chimney

    BOILER MOUNTING INSTALLATION 3.3. Chimney The chimney installation must supply sufficient draught, air tightness and protection against condensation. The appropriate chimney installation is very important for the boiler’s efficient and safe function! The chimney must be positioned if possible in the interior of the building. It must be vertical, with no changes in the direction.
  • Page 10: Mounting The Burner

    BOILER MOUNTING INSTALLATION 3.4. Mounting the burner The burner is mounted on the flange provided on the door of the boiler. First install the insulation cord and then fix the burner on the flange with the four screws provided, as shown on Fig 5. Pay attention so that the burner furnace is correctly positioned in the fire chamber and the door opens normally.
  • Page 11: Installation

    INSTALLATION 4. INSTALLATION 4.1. Hydraulic connections The boiler is intended for connection with a closed expansion vessel network. The boiler is intended for maximum working temperature 90 C and maximum pressure 3 bar. The expansion vessel must be connected on the return line. The discharge valve be connected through a pipe to the drainage.
  • Page 12: Connection Diagrams

    INSTALLATION Do not fill the system at the working pressure! When the boiler will be heated, the water pressure will raise. Filling pressure must be at least 1 bar lower than working pressure! 4.4. Connection diagrams 4.4.1. Installation as single heating source Legend PLC boiler Closed expansion vessel...
  • Page 13 INSTALLATION 4.4.2. Installation with buffer tank Legend PLC boiler Closed expansion vessel Safety kit 4+5. Recirculation pump and 3-way thermostatic valve Filter “Y” Chemical phosphate filter Automatic water filling valve Mechanical filter with nylon “Ny” Buffer tank-heat storage Dual safety valve pressure/temperature Circulation pump for heating &...
  • Page 14 INSTALLATION 4.4.3. Installation with an alternative heat source Legend PLC boiler 2+3. Alternative oil/gas boiler and burner Closed expansion vessel Safety kit 6+7. Recirculation pump and 3-way thermostatic valve Filter “Y” 3-way valve with servomotor Buffer tank-heat storage Dual safety valve pressure/temperature Sanitary hot water boiler Mechanical filter with nylon “Ny”...
  • Page 15: Electrical Connections

    The main electrical supply of the boiler must be connected to an independent safety of max 16A. The boiler room lighting must be on a separate circuit. THERMOSTAHL is not responsible for accidents or malfunctions caused by wrong or bad electrical connections.
  • Page 16: Controller

    CONTROLLER 6. Controller 6.1. General description Description:  Diodes signalizing the status of outputs and the working mode of the driver,  LCD screen used for communication between the device and the user,  Buttons steering the driver's work. 6.2. Description of buttons Button Function Changes the burner's working mode –...
  • Page 17: Operation Functions

    CONTROLLER 6.3. Operation functions After switching the burner on, it is appeared on the LCD screen the program's logo defining the type of the driver and the version of the current software While activating, the burner carries out a test of the connected sensors. In case of one lacking, on the screen appears an appropriate message (---).
  • Page 18: Menu Parameters

    CONTROLLER FUNCTION'S NAME DESCRIPTION OF FUNCTIONS STOP Burner stopped. Filling the feeder. FEEDER FILLING Filling stops automatically after about 10 minutes. The burner is on Ignition process, which mean that has fed with ignition dose IGNITION of pellet, the heating element (igniter) and the air fan are working. The mode would be automatically changed after detecting a flame by the sensor.
  • Page 19 CONTROLLER WUW BUFFER SETTINGS (B) FUNCTION FUNCTION SETTING SETTING MANUFACTURER NAME UNIT RANGE SETTING WUW BUFFER ºC 20 - 80 TEMPERATUR WUW SURPLUS ºC 5 - 20 TEMPERATURE Yes/No PRIORITY BURNER SETTINGS (C) FUNCTION FUNCTION SETTING SETTING MANUFACTURER NAME UNIT RANGE SETTING BURNER POWER...
  • Page 20: Boiler Start-Up

    BOILER START-UP 7. BOILER START-UP 7.1. Initial lighting checks Before you start the boiler, make the following checks:  Check that all the hydraulic connections and make sure they are tight. Make sure there is no leakage or moisture on the pipes or other equipment. ...
  • Page 21: Fuel Loading

    BOILER START-UP 7.3. Fuel loading The fuel must be loaded in the fuel tank and is then supplied to the pellet burner through the pellet feeder. This is controlled directly by the pellet burner. The first time the burner is started, the pellet feeder must be filled completely. This can take up to 15 minutes, depending the length of the feeder and the rotation speed of the motor.
  • Page 22: Checks To Carry After Initial Start-Up

    BOILER START-UP 4. In “Automatic mode”, starts the operation of the burner. 5. When the photo sensors detects fire, then the burner starts its “Work” by increasing its power gradually to the power it has been set (i.e 30kW) 6. When the boiler's water temperature reaches the desired temperature “HEATING WATER TEMPERATURE “, the the power of the burner goes down ta 3kW (Maintain mode) 7.
  • Page 23: Service And Maintenance

    SERVICE AND MAINTENANCE 8. SERVICE AND MAINTENANCE 8.1. Cleaning the boiler Pellet boilers require regular cleaning in order to function properly and efficient. The boiler is equipped with three cleaning tools appropriate for the cleaning procedure of the boiler, as shown in Fig 6.
  • Page 24: Cleaning The Chimney Box

    SERVICE AND MAINTENANCE 8.2. Cleaning the chimney box To ensure efficient and safe function of the boiler, you must clean the chimney box from ash residues at least every 3 months. The ash box is equipped with a cleaning door for this purpose, as shown in Fig 8. In order to open the door, unscrew the wing nuts, remove the washers and springs that keep it in place.
  • Page 25: Maintenance Intervals

    SERVICE AND MAINTENANCE 8.4. Maintenance intervals 8.4.1. Daily maintenance The pressure of the network must be daily verified to be within the allowed limits. Make sure that all the safety devices and pumps function properly. 8.4.2. Weekly maintenance The pellet burner must be cleaned according to the manufacturer’s instructions, usually recommended once a week.
  • Page 26: Maintenance After Long Stop

    SERVICE AND MAINTENANCE 8.6. Maintenance after long stop It is necessary to perform a general maintenance and cleaning of the boiler after the heating season. Clean thoroughly all the surfaces of the boiler as described in the corresponding paragraph. Also clean the chimney box, and all the chimney parts where ash might be deposited. After cleaning all the ash, empty the ash box and leave the boiler clean for the next winter season.
  • Page 27: Troubleshooting

    TROUBLESHOOTING 9. TROUBLESHOOTING Indication Description Solution 1. The driver starts up relevant emergency procedures for every sensor in order to prevent the CH:!!!! Malfunction water boiler from working beyond the safe range for the WUW:!!!!!! temperature sensors installation of the central heating STOP 2.
  • Page 28: Ce Declaration Of Conformity

    CE DECLARATION OF CONFORMITY (conform cu ANEXA VII din Directiva Europeană 97/23/EC) (in compliance with the Annex VII of the European Directive 97/23/EC) THERMOSTAHL ROMANIA SRL Producător / The Manufacturer’s name Adresa producătorului / Manufacturer’s address: Str. Drumul Osiei 57-59, sector 6, București, România PRIN PREZENTA, DECLARĂ...
  • Page 29 THERMOSTAHL ROMANIA SISTEME TERMICE S.R.L. DRUMUL OSIEI 57-59, sector 6 Bucureşti 062395, România www.thermostahl.ro...

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