Centrometal PelTec 12 Technical Instructions

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Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: +385 40 372 600, fax: +385 40 372 611

ENG

for installation, use and maintenance

of hot water boiler

and installation of additional equipment

THE FIRST START-UP MUST BE DONE BY AUTHORIZED PERSON,

OTHERWISE PRODUCT WARRANTY IS NOT VALID.

TU-PLT/PLT-L-12-96-10-2021-ENG

HEATING TECHNIQUE

TECHNICAL INSTRUCTIONS

PelTec-lambda 12-96

PelTec 12-48

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Page 1 HEATING TECHNIQUE Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: +385 40 372 600, fax: +385 40 372 611 TECHNICAL INSTRUCTIONS for installation, use and maintenance of hot water boiler and installation of additional equipment THE FIRST START-UP MUST BE DONE BY AUTHORIZED PERSON, OTHERWISE PRODUCT WARRANTY IS NOT VALID.
Page 2: Technical Data
(output is directed sideways) **** PM = particulate matter, OGC = organic gaseous compounds, CO = carbon monoxide, NOx = nitrogen oxides Contact details: Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia Technical instructions PelTec-lambda...
Page 3 Technical data 12 kW 18 kW 24 kW 31/36 kW 48 kW Dimensions of the boiler to enter the room Width (G) Depth (H) Height (I) 1560 1275 1340 1340 1490 Min. room height for turbulators removing (J) 1900 1700 1700 1700 2000...
Page 4 Technical data 69 kW 96 kW Dimensions of the boiler to enter the room Width (G) 1220 1245 Depth (H) Height (I) 1550 (+30 mm)* 1530 (+30 mm)* Min. room height for turbulators removing (J) 2050 (+30 mm)* 2050 (+30 mm)* * height can be adjusted +30 mm from this dimension 69/96 kW 69/96 kW...
Page 5 Dimensions and basic parts of the boiler Back view - PelTec / PelTec-lambda 12-48 SG ¹ SG ¹ PelTec / PelTec / Peltec-lambda Peltec-lambda SG ¹ SG ¹ PelTec / PelTec / Peltec-lambda Peltec-lambda 24-36 FC PE Back view - PelTec-lambda 69/96 SG ¹...
Page 6: Additional Equipment
Basic parts and sensors 1 - Boiler sensor ( 6 - Flue gas sensor (Pt 1000) 11 - Return ﬂow sensor ( 7 - Fan speed sensor sensor (NTC 5k) 3 - Pressure switch tube bimetal sensor 12 - Lambda probe 4 - Photocell 9 - Pellet level in the tank 13 - Outdoor sensor (NTC 5k)
Page 7: Safety Precautions
Introduction, boiler description, safety precautions, important informations 1.0. INTRODUCTION The PelTec / PelTec-lambda has a modern construction and design and is made out of the controlled materials of high quality, welded with most modern technology and is approved and tested under EN 303 - 5 norm and fulfil all special request for the connection on the installation of a central heating system.
Page 8 Status of delivery 1.4. STATUS OF DELIVERY 1.4. STATUS OF DELIVERY 1.4. STATUS OF DELIVERY Equipment is delivered seperately: 1. Boiler with planking and thermal insulation With inbuilt and pre-wired: - color touch screen display control unit - boiler temperature sensor - NTC 5K - PVC l=1000 (12041) - flue gas temperature sensor - PT 1000 - Teflon l=1700 (62330) Additional parts, sensors and connectors in basic delivery: - lambda probe (only for PelTec-lambda 69/96)
Page 9: Pump Group
Connect the pump cable with connector to the back of the control box. Mandatory set the 3-speed pump on the speed 3 or max. power for HE pumps. Socket for temp. sensor PelTec 12-48 Socket...
Page 10: Pellet Tank
Positions of mounted components Pellet level in the tank sensor - mount this sensor on the back side inside of the pellet tank. First set the plastic glass distance for sensor. After that, put the sensor on this glass. Attach the sensor and the plastic distance with 4 screws supplied.
Page 11: Mounting Parts
Mounting parts 1.5. MOUNTING COMPONENTS For ease of handling, transport and import of boiler, PelTec / PelTec-lambda is delivered in parts that need be mounted on the boiler when the boiler is in the boiler room. These parts need to be installed on the boiler: - mount on the back of boiler, is obligatory to use the flange gaskets fan, fastened using M8 bolts and nuts.
Page 12 Grate cleaning 1.5.1. MOUNTING MECHANISM FOR GRATE CLEANING 1. Remove the three screws (A), from cover (B) of the grate cleaning mechanism and remove cover carefully . 2. Remove the two screws (C) and just slightly loosen screws (D) as shown in picture below. Carefully attach grate cleaning mechanism to loose screws (D), then fasten with screws (C) and tighten the screws (D).
Page 13 Grate cleaning 3. Set the screw (E) into the jagged track (F), set the nut on the screw and tighten. Free space (G) is required for the proper functioning of the mechanism. 4. Connect the connectors (H) so they have a good contact. Carefully set the cover and tighten with the screws (A).
Page 14 Setting photocell on the work position 1.5.2. SETTING PHOTOCELL TO THE WORK POSITION Before first startup, be sure to set the photocell to the position as on the figures below, otherwise the boiler will not work properly! The photocell should not be set too deep or too shallow in the box. Because of this, there is an limiter by which correct photocell dept is set.
Page 15 Installation of the handle on the casing cover door 1.5.3. INSTALLATION OF THE HANDLE ON THE CASING COVER DOOR Status of delivery (24-48kW) Technical instructions PelTec-lambda...
Page 16: Safety Elements
Safety elements, fuel 1.6. SAFETY ELEMENTS Boiler have a few safety elements: - Bimetal thermostat - built on the burner pellet feeding tube. If the bimetal set temperature (80°C) is exceeded, pellet feeding is stopped, the boiler stops working and the E8, E8-1 or E8-2 and "Pellet supply tube temperature too high"...
Page 17 Boiler positioning 2.0. BOILER POSITIONING AND ASSEMBLY Boiler positioning, assembly and building in must be performed by a qualified person. We recommend that boiler is placed on a concrete base with height of 50 to 100 mm above the floor. Boiler room must be frost- proof and well ventilated.
Page 18: Connection To The Chimney
Connection to the chimney 3.0. CONNECTION TO THE CHIMNEY Properly dimensioned and built chimney is the main condition for safe and economical functioning of the boiler. The thermal insulation of the chimney has to be done properly, it has to be absolutely gas-proof and smooth. On its lower part there has to be built in the opening for cleaning with the door.
Page 19 Installation of the connection flue gas tube thermal insulation 3.1. INSTALLATION OF THE CONNECTION FLUE GAS TUBE (BETWEEN FAN AND CHIMNEY) THERMAL INSULATION a) A </= 1200 b) A > 1200 EXAMPLE 1 1200 mm 1200 mm A-1200 max. 160 mm (15 x) 1200 mm EXAMPLE 2...
Page 20: Installation
Installation, connection to central heating system 4.0. INSTALLATION All local regulations, including those referring to national and European standards need to be complied with when installing the appliance. 4.1. CONNECTION TO CENTRAL HEATING SYSTEM All installation work must be made in accordance with valid national and European standards. Boiler PelTec / PelTec-lambda can be built in closed and open central heating systems.
Page 21 Configuration DHW, DHC NOTE: - at PelTec-lambda 69/96 boilers at schemes 10, 11 and 15 CM2K obligatory must be installed for boiler to work for heating (this boilers starts/stops according to the heating demand, they can’t work according hydraulic crossover temp.) - at scheme 15 without CM2K boiler can work only according DHW demand.
Page 22 Configuration DHC || DHW, BUF Required sensors: - return flow temp. sensor Scheme 3. Configuration DHC || DHW - main flow temp. sensor - DHW sensor 1 - Boiler PelTec / PelTec-lambda 7 - DHW tank 2 - Air self-venting group 2,5 bar 8 - DHW tank sensor 3 - Motor 4-ways mixing valve 9 - Heating circuit...
Page 23 Configuration DHW || BUF, BUF -- IHC Required sensors: - return flow temp. sensor Scheme 5. Configuration DHW || BUF - DHW tank sensor - Acc. (buffer) tank sensor (upper) - Acc. (buffer) tank sensor (lower) 1 - Boiler PelTec / PelTec-lambda 7 - DHW tank sensor 2 - Air self-venting group 2,5 bar 8 - "CAS"...
Page 24 Configuration DHW || BUF -- IHC, BUF -- DHW Required sensors: - return flow temp. sensor Scheme 7. Configuration DHW || BUF -- IHC - DHW tank sensor - acc. (buffer) tank sensor (upper) - acc. (buffer) tank sensor (lower) 1 - Boiler PelTec / PelTec-lambda 9 - Accumulation (buffer) tank sensor (upper) 2 - Air self-venting group 2,5 bar...
Page 25 Configuration BUF -- IHC || DHW, CRO Scheme 9. Configuration BUF -- IHC || DHW Required sensors: - return flow temp. sensor - DHW tank sensor - acc. (buffer) tank sensor (upper) - acc. (buffer) tank sensor (lower) 1 - Boiler PelTec / PelTec-lambda 8 - Accumulation (buffer) tank sensor (lower) 2 - Air self-venting group 2,5 bar 9 - DHW tank...
Page 26 Configuration CRO / BUF, DHC || DHW (2) NOTE: USED ONLY IN CASCADES AND EXTERNAL CONTROL Scheme 11. Configuration CRO / BUF Version 2: (Display shows 2 temperatures (eg. accumulation tank) AT 69/96 BOILER ONLY OPTION Version 1: (display shows 1 temperature, eg hydraulic crossover) NOT POSSIBLE AT 69/96 boiler 1 - Boiler PelTec / PelTec-lambda 6a - Hydraulic crossover / 6b - Accumulation tank...
Page 27 Configuration DHC x2, BUF--IHCx2 Scheme 13. Configuration DHC x2 2. Heating circuit 1. Heating circuit Required sensors: - return flow temp. sensor - main flow temperature sensor 1 - Boiler PelTec / PelTec-lambda 8 - 3-way manual mixing valve 1.circuit 2 - Air self-venting group 2,5 bar 9 - Heating circuit 2 3 - Motor 4-ways mixing valve...
Page 28 4-WAY MIXING VALVE CONNECTIONS: LEGEND: 1 - boiler main ﬂow 2 - main ﬂow to the installation 3 - return ﬂow from the installation 4 - boiler return ﬂow PelTec 12 PelTec 18-36 PelTec 48 PelTec-lambda 12 PelTec-lambda 18-36 PelTec-lambda 48...
Page 29 Thermal safety protection connection 4.2. THERMAL SAFETY PROTECTION INSTALLATION (only 69 and 96 kW) Boilers PelTec-lambda 69 and 96 obligatory must have thermal protection installed. They have factory installed thermal protection exchanger which must be connected to the water supply throught the thermal protection valve (delivered with the boiler, must be installed by installer).
Page 30: Electrical Connections
Electrical connections 5.0. ELECTRICAL CONNECTIONS All electrical works must be performed by a certified professional in accordance with valid national and European standards. If the supply cord is damaged, it must be replaced by the manufacturer, its service agent or similarly qualified persons in order to avoid a hazard. A device for switching of all power supply poles must be installed in electrical installation in accordance with the national regulations on electrical installations.
Page 31 Fuses 5.1. FUSES The 23029XXXXXXX main PCB or the BIOPELTEC-D-G (23029XXXXXXX "G") main PCB can be installed. Main PCB: 23029XXXXXXX label board: 23029XXXXXXX Mark: F3 Mark: F2 mark: F1 3,15 A, M 1,6 A, M 3,15 A, M Lambda board Main PCB: BIOPELTEC-D-G (23029XXXXXXX "G") (only PelTec-lambda) label board:...
Page 32 Fuses Main PCB: 23029XXXXXXX MARK FUSE DEVICES - outputs P1, P2, P3 3,15 A, M - regulation (power supply) - all other devices who are not on the F1 and F3 (output P4, motor mechanism for the grating self-cleaning, pellet conveyor 1,6 A, M motor, ﬂue gas tube cleaning motor, mixing valve motor...)
Page 33 Electrical scheme (PelTec 12-48) 5.2. ELECTRICAL SCHEME INSTALLATION - MAIN PCB - 23029XXXXXXX 5.2.a ELECTRICAL SCHEME INSTALLATION - PelTec 12-48 TO 5 Technical instructions PelTec-lambda...
Page 34 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 35 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 36 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 37 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 38 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 39 Electrical scheme (PelTec-lambda 12-48) 5.2.b SPAJANJE NA ELEKTRIČNU INSTALACIJU - PelTec-lambda 12-48 TO 5 Technical instructions PelTec-lambda...
Page 40 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 41 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 42 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 43 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 44 Electrical scheme (PelTec-lambda 69/96) 5.2.c ELECTRICAL SCHEME INSTALLATION - PelTec-lambda 69/96 TO 5 Technical instructions PelTec-lambda...
Page 45 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 46 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 47 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 48 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 49 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 50 Electrical scheme (PelTec 12-48) 5.3. ELECTRICAL SCHEME INSTALLATION - MAIN PCB - 23029XXXXXXX "G" 5.3.a ELECTRICAL SCHEME INSTALLATION - PelTec 12-48 TO 5 Technical instructions PelTec-lambda...
Page 51 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 52 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 53 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 54 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 55 Electrical scheme (PelTec 12-48) Technical instructions PelTec-lambda...
Page 56 Electrical scheme (PelTec-lambda 12-48) 5.3.b ELECTRICAL SCHEME INSTALLATION - PelTec-lambda 12-48 TO 5 Technical instructions PelTec-lambda...
Page 57 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 58 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 59 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 60 Electrical scheme (PelTec-lambda 12-48) Technical instructions PelTec-lambda...
Page 61 Electrical scheme (PelTec-lambda 69/96) 5.3.c ELECTRICAL SCHEME INSTALLATION - PelTec-lambda 69/96 TO 5 Technical instructions PelTec-lambda...
Page 62 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 63 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 64 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 65 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 66 Electrical scheme (PelTec-lambda 69/96) Technical instructions PelTec-lambda...
Page 67: Operating The System
Operating the system, safety, startup 6.0. OPERATING THE SYSTEM Boiler must not be used in flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety.
Page 68 - Close all doors leading to the living space Flue gas can lead to life-threating poisoning! Picture 9. PelTec / PelTec-lambda boiler doors Flue gas tubes door Flue gas tubes door (PelTec 12-48) (PelTec 69-96) Upper boiler door Turbulators of ﬂue gas tubes...
Page 69: Cleaning And Maintenance
Cleaning and maintenance 7.0. CLEANING AND MAINTENANCE Every millimeter of soot on the exchange surfaces and in the flues means about 5 % more fuel consumption. A clean boiler saves fuel and protects the environment. Save fuel – always clean the boiler in good time! PROTECTIVE GLOVES ARE OBLIGATORY!! Boiler type Description...
Page 70: Cleaning Intervals
Cleaning intervals Cleaning interval Boiler type Description At least once per year Cleaning of exchanging surfaces (This procedure is very simple and is 12-96 kW (above the burner) recommends even more often) Claning of exchanging surfaces (above the burner) 1. Maintenance Man.
Page 71 Cleaning intervals Cleaning interval Boiler type Description Cleaning of exchanging surfaces At least once per year 12 kW (around the entire boiler) 1. Maintenance Man. Boiler Cleaning Man. Boiler Cleaning 2000 Filling feeder screw Airvent Metal tube 1. Press ''Maintenance'' on the regulation and then ''Cleaning the boiler''. 2.
Page 72 Cleaning intervals Cleaning interval Boiler type Description Cleaning of exchanging surfaces At least once per year 69/96 kW (around the entire boiler) 1. Maintenance Man. Boiler Cleaning Man. Boiler Cleaning 2000 Filling feeder screw Airvent 1. Press ''Maintenance'' on the regulation and then ''Cleaning the boiler''. 2.
Page 73 Cleaning and maintenance New photocell cleaning interval Description Boiler type At least once a year (or if you have problems Photocell cleaning 12-96 kW with the ignition) Dirty photocell which can result Valid photocell error in ignition or flame dissapear error Carefully remove the photocell from the box and then gently with a cotton swab clean the body and lens of photocell.
Page 74 Cleaning and maintenance 7.1.1. EXTRACTION OF TURBULATORS - PelTec/PelTec-lambda 12-48 6.a i 6.b Only in case all turbulators can’t be removed together (step 6) 1 - Remove the casing cover. 2 - Unscrew the 4 srews and remove the flue ducts door. 3,4 - Unscrew the 2 srews and lift turbulators (first pass) with bracket as shown in picture.
Page 75 Cleaning and maintenance 7.1.2. EXTRACTION OF TURBULATORS - PelTec-lambda 69/96 PROTECTIVE GLOVES ARE OBLIGATORY! 6.a i 6.b Only in case all turbulators can’t be removed together (step 6) Technical instructions PelTec-lambda...
Page 76 Extraction of helical metal plate from second pass turbulators Remove the casing cover. Unscrew the 8 srews and remove 2 flue ducts door. 3, 4 - Unscrew the 2 screws and lift turbulators (first pass) with bracket as shown in picture. Unscrew the 2 screws from carrier on second pass.
Page 77 Replacement of the electric heater - only PelTec/PelTec-lambda 12-48 7.3. REPLACEMENT OF THE ELECTRIC HEATER - only PelTec/PelTec-lambda 12-48 7.3.1. REPLACEMENT OF THE EL. HEATER WITH NEW EL. HEATER DIAMETER Ø35mm Heater clamp for heater diameter Ø35mm The heater holder (Heater holder is identical with heaters diameter Ø20mm and Ø35mm)
Page 78 Replacement of the electric heater - only PelTec/PelTec-lambda 12-48 3. Unscrew the two screws and remove the heater clamp. Insert the new el. heater, turn it so that the shaft at the front part of the el heater is turned vertically (see detail C) and gently attach it to the heater holder (Still not fully tightened).
Page 79 Replacement of the electric heater - only PelTec/PelTec-lambda 12-48 7.3.2. REPLACEMENT OF THE EL.HEATER WITH NEW EL. HEATER DIAMETER Ø20mm The upper part of the heater clamp diameter Ø20mm The lower part of the heater clamp diameter Ø20mm The heater holder (Heater holder is identical with heaters diameter Ø20mm and Ø35mm)
Page 80 Replacement of the electric heater - only PelTec/PelTec-lambda 12-48 3. Unscrew the two screws and remove the heater clamp. Insert the new el. heater, turn it so that the shafts at the front part of the el heater are turned vertically (see detail C) and gently attach it to the heater holder (Still not fully tightened).
Page 81 Replacement of the electric heater - only PelTec-lambda 69/96 only PelTec-lambda 69/96 7.3.3. REPLACEMENT OF THE EL.HEATER - Electric heater with a diameter of Ø 20 mm 1. Disconnect the wires of the electric heater power supply from the terminal block (Detail A). Terminal block is located on the right boiler side, behind lower pellet tank door.
Page 82 Installation of 4-way mixing valve actuator (only PelTec-lambda 69/96) INSTALLATION OF ACTUATOR (IF THE BOILER WORKED) If the boiler worked, actuator of the 4-way mixing valve can be removed only when the boiler is in OFF mode (not working). When boiler is in OFF mode, from ’’Manual test’’ menu press ’’Close valve’’ button and wait until valve closes completely (until valve actuator stops).
Page 83 Installation of 4-way mixing valve actuator (only PelTec-lambda 69/96) Flow to the Valve is 100% closed installation Return from Flow from installation the boiler Return to the boiler Valve is 50% opened/closed Flow to the installation Flow from Return from the boiler installation Return to...
Page 84: Pump Setting
Pump setting PUMP SETTING - GRUNDFOS UPM3 HYBRID (PelTec/PelTec-lambda 12-48) Pump is factory preset to constant curve, curve 4. This setting can be checked by short press of the button (after short press for 2 seconds pump setting is displayed). Factory setting LEDS are displayed below (LED 1 = green, LED 2 = yellow, LED 3 = yellow, LED 4 = oﬀ, LED 5 = yellow).
Page 85 Pump setting Toggling the settings of UPM3 When you switch on the circulator, it runs with the factory pre-setting or the last setting. The display shows the current operation status. 1. Press the button to switch to the setting view. The LEDs show the current setting for 2 seconds. 2.
Page 86 Company assumes no responsibility for possible inaccuracies in this book originated typographical errors or rewriting, all the pictures and diagrams are principal and it is necessary to adjust each actual situation on the field, in any case the company reserves the right to enter their own products such modifications as considered necessary. Centrometal d.o.o. Glavna 12, 40306 Macinec, Croatia central tel: +385 40 372 600, fax: +385 40 372 611 service tel: +385 40 372 622, fax: +385 40 372 621 www.centrometal.hr...

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