BURNiT WBS Active Pell Manual de usuario

Set pellet boiler with pellet burner

WBS Acve - Pell

Version i0.2.6

TECHNICAL PASSPORT

INSTALLATION and OPERATION MANUAL

FOR AUTHORIZED INSTALLER / SERVICE SHOP

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

TABLE OF CONTENTS

1. EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS ........................................................ 3

1.1. Explanaon of symbols .......................................................................................................... 3

1.2. Requirements to boiler installaon room .............................................................................. 3

1.2.1. Instrucons to boiler installer ............................................................................................. 3

1.2.2. Instrucons to installaon user .......................................................................................... 3

1.2.3. Minimum clearances for installaon and combusbility of construcon materials .............. 4

2. PRODUCT DESCRIPTION ............................................................................................................ 5

3. FUELS ........................................................................................................................................ 7

4. TRANSPORTATION OF THE BOILER AND BURNER ..................................................................... 8

5. DELIVERY OF THE BOILER AND BURNER.................................................................................... 9

6. INSTALLATION OF THE HEATING BOILER ................................................................................... 9

6.1. Requirements ........................................................................................................................ 9

6.2. Check door ghtness ........................................................................................................... 10

7. SETUP OF THE HEATING BOILER AND BURNER ...................................................................... 10

7.1. Connecng the boiler to a chimney .................................................................................... 10

7.2. Connecng the safety heat exchanger ................................................................................ 11

7.3. Connecng the boiler to the heang installaon ................................................................ 12

7.4. Connecon diagrams .......................................................................................................... 14

7.5. Pellet burner connecon to the fuel hopper and pellet auger ............................................ 18

7.6. Connecng the pellet burner to the mains power supply ................................................... 18

8. BURNER OPERATING ............................................................................................................. 21

8.1. Ignion ................................................................................................................................. 21

8.2. Burning ................................................................................................................................ 21

8.3. Automac cleaning system .................................................................................................. 21

8.4. Installer prescripons regarding burner servicing and maintenance ................................... 21

8.5. Important recommendaon for long-lasng and correct operaon of the burner............... 21

9. MAINTENANCE AND CLEANING OF THE BOILER ..................................................................... 22

10. OPERATION OF MICROPROCESSOR CONTROLER WHEN BURNING WOOD-PELLETS ........................ 24

10.1. Controller view. Explanaon of buons and indicators ..................................................... 24

10.2. User`s menu ...................................................................................................................... 27

10.3. Installer’s menu.................................................................................................................. 29

11. SETTING OUTPUT MODES OF OPERATION OF THE PELLET BURNER PELL ............................. 33

12. WARRANTY TERMS ............................................................................................................... 37

13. TECHNICAL PARAMETERS OF WBS ACTIVE - PELL ................................................................. 37

13.1. General features ................................................................................................................ 37

13.2. Technical parameters ......................................................................................................... 38

13.3. Elements of burner PELL .................................................................................................... 41

13.4. Technical parameters of fuel hopper FH 500-V2 ............................................................... 42

14. RECYCLING AND WASTE DISPOSAL ....................................................................................... 42

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

1. EXPLANATION OF SYMBOLS AND

SAFETY INSTRUCTIONS

1.1. Explanaon of symbols

CAUTION! –Important

recommendaon or warning

concerning safety condions during

installaon and operaon of the heang

boiler.

DANGER! – fault or improper use

may cause injury or be hazardous

to life of humans or animals.

FIRE HAZARD! – fault or improper

installaon and operaon may

cause re.

INFORMATION –Important

informaon on the proper operaon

of the product.

1.2. Requirements to boiler installaon

room

This manual contains important

informaon for the safe and correct

installaon, start-up and trouble-free

operaon and maintenance of the heang

boiler.

The heang boiler can be used for heang

rooms only in the manner described in

this manual.

Note of the boiler type data on the

factory rang label and the technical data

provided in chapter 13 in order to ensure

proper operaon of the product.

1.2.1. Instrucons to boiler installer

During installaon and operaon, the

country-specic requirements and

regulaons must be observed:

• local construcon regulaons on the

installaon, air supply and exhaust

gas extracon as well as chimney

connecon.

• regulaons and norms concerning the

ng of the heang installaon with

safety devices.

iUse only original BURNiT parts



DANGER of intoxicaon,

suocaon.

Inadequate inow of fresh air

to the boiler room may result in

dangerous leak of exhaust gases

during boiler operaon.

-Make sure the air inlets and

exhaust gas outlets are not

clogged or closed.

-If faults are not remedied

immediately, the boiler must

not be operated, and the user

must be provided with wrien

instrucons on the fault and the

hazard it entails.



DANGER of re when burning

ammable materials or liquids.

-Flammable materials/liquids

must not be le in close proximity

of the heang boiler.

-Instruct system user of the

allowed minimum clearances

from surrounding objects.

It is mandatory to assure a backup

power generator of corresponding

rated power! (see 13.2)

1.2.2. Instrucons to installaon user



DANGER of intoxicaon or

explosion

Toxic gases may be discharged

when burning waste, plascs,

liquids.

-Use only the fuels indicated in

this manual.

-In case of danger of explosion,

ignion or discharge of exhaust

gases in the room, stop the

heang boiler from operaon.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL



CAUTION! Danger of injury

/ damage of system due to

incompetent operaon.

- The heang boiler must be

serviced only by persons familiar

with the operaon manual.

- As a user, you are only allowed

to start the boiler up, adjust the

temperature of the boiler, shut

the boiler down and clean it.

- Unaended children must not be

allowed access to premises with

running pellet burner inside.

It is mandatory to assure a backup

power generator of corresponding

rated power! (see 13.2)

Safety rules for user operaon:

- Operate the heang boiler at a maximum

temperature of 80°C, and to that end

you must regularly inspect the boiler

room.

- Do not use ammable liquids for ignion

or increase of burner output.

- Collect ash in lid-covered reproof

containers.

- Clean the heang boiler surface using

non-ammable agents only.

- Do not place ammable objects onto the

heang boiler or in its proximity. (see

diagram 1 for the minimum clearances)

- Do not store ammable materials in the

boiler room.

1.2.3. Minimum clearances for

installaon and combusbility of

construcon materials

The applicable minimum clearances in

your country may dier from the ones

specied bellow. Please, consult your

installer.

The minimum distance from the heang

boiler or exhaust gas pipe to objects or

walls must be at least 200 mm.

For general safety consideraons, we

recommend that the boiler be placed on

a foundaon with height of 100 mm made

of class A material, see table 1.

Diagram 1

Recommended clearances between the

boiler and walls.

Table 1. Combusbility of construcon

materials

Class А -

non-

combusble

Stone, bricks, ceramic

les, baked clay, soluons,

plaster free of organic

addives.

Class B -

hard

combusble

Gypsum board panels,

basalt ber needled felt,

berglass board, AKUMIN,

Izomin, Rajolit, Lignos,

Velox, Heraklit.

Class С1/С2-

Medium

combusble

Wood beech, oak, Wood

sowood, layered wood

Class C3 -

easy

combusble

Asphalt, cardboard,

cellulose, tar, berboard,

cork, polyurethane,

polyethylene.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

2. PRODUCT DESCRIPTION

Set BURNiT WBS Active - Pell: tested

according to European standards

EN 303-5, class 5.

2.1. Descripon of WBS Acve

•Design. Boiler body is made of high-

quality boiler steel sheets with thickness

of 5 mm for the combuson chamber

and 3 mm for the water mantle.

•Ecient. The ue gas makes a three-pass

movement around three water-lled

barriers in the combuson chamber on

its way to the chimney. This way the

gas is cool when it leaves the boiler and

its energy has been transferred to the

water in the mantle. The water mantle

embraces the combuson chamber

in full to ulize the emied heat most

eciently. To keep from losing heat into

the ambience, the boiler is insulated on

the outside by 50 mm high-temperature

wool.

•Reliable and safe. The heat exchanging

tubular grill is protected by a replaceable

metal grate. A complex of safety devices

provide for the safety of the appliance.

• Cleaning door (combuson chamber)

• Dra regulang ap, mounted on ue

end

• Safety heat exchanger

2.2. Descripon of pellet burner

The BURNiT Pell pellet burner for hot

water boilers is designed to burn only and

exclusively wood pellets and it is intended

to heat up heang boilers. The built-in

control unit, automac cleaning system

and internal pellet auger ensure the

automated operaon of the burner and

opmal burning of the fuel.

Design.

The burner is made of high-quality

stainless steel able to withstand

temperatures of up to 1150°С. The burner

must be installed on a heang boiler.

The burner consists of two parts:

combuson chamber tube and

external tube with sheet metal mantle.

Longitudinally, under the housing, there

are blow chamber, fuel ignion heater,

fan and power supply. On the upper part

of the burner there is a feeder chute to

which the pellet auger is aached. The

housing of the burner has been designed

to meet all regulatory safety requirements

(no sharp or protruding elements) with

operang temperature not exceeding

50°C.

The combuson chamber consists of two

tubes:

Ember resistant steel tube inside the

burner with holes for air intake along

its enre length, opening for the hot air

from the fuel ignion heater, opening for

photosensor.

Outer stainless steel tube. Between the

two tubes there is a gap which provides

for free circulaon of the air necessary

both for cooling and oxygen supply into

the combuson chamber.

The feeder chute allows 360° rotaon

for its best convenient posioning when

connecng the pellet auger to the hopper.

• Built-in controller.

The main control unit, located in the

burner, manages the enre heang

process.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Diagram 2. Pellet burner Pell design

Controler funcons:

1) fully automated ignion and pellet

feed;

2) self-cleaning funcon (adjustable 1-6

mes over 24 hours at equal intervals),

programmable start me;

3) controls the operaon of the

circulaon pump of the central

heang;

4) opon for control by room thermostat;

5) mer;

6) controls the operaon of the pump of

the domesc hot water;

•Photo-sensor - monitors the power of

the burner ame

•Internal auger

•Dry contactless resistance heater

assuring ignion of fuel

•Innovave cleaning system of the

combuson chamber

•Air feed fan, step-regulated (0% to 100

%).

2.3. Burner safety devices

•Elbow-shape feeder chute. The

geometrical shape of burner feeder

chute prevents backre entry from

burner into pellet hopper.

•Thermostac protecon (80°С). The

thermostac protecon is ed on the

feeder chute. When the surface of the

feeder chute reaches 80°С, the control

stops the feeding of pellets into the

burner and signals for fault.

•Fuse. In case of electrical fault in the

system of the burner (short circuit, high

current, etc.), the overload is borne by

the electrical fuse ed on the main

control panel of the burner (10 А).

•Power interrupon. In case of power

interrupon, all parameter sengs are

stored in the memory of the controller.

Upon the subsequent restart of the

burner, the controller resumes the

execuon of the program from the point

when the power interrupon occurred.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

3. FUEL

All pellets are biomass manufactured

from common low-growing plants and

trees. The most common household type

pellets are made of sawdust and milled

wood chippings which are waste material

from wood used in the producon of logs,

furniture and other products. Wood is the

richest raw material which does not have

any impact on the producon costs of

food products or ethyl alcohol (ethanol).

The raw material is processed under high-

pressure and temperature and is pressed

to produce small-size cylindrical pellets.

The producon process may ulize so

wood material (such as sowood, pine),

hardwood (oak) as well as recycled waste

wood. Wood pellets are produced in

hammer mills or wood pellet plants.

Advantages of wood pellets:

Convenient storage. Pellet bags can be

stored on a small area in a dry garage,

basement, service room or shed.

Easy loading. In most cases the boiler

hopper needs loading only once a week –

this depends on the hopper capacity.

Beer control of fuel quanty. The small

size of the pellets allows for precise fuel

feeding. On the other hand, the supply

of air for reaching opmal combuson

eciency is easier to adjust since the

fuel quanty in the combuson chamber

remains constant and predictable.

Fuel eciency. High combuson eciency

is also determined by consistently low

moister content of pellets (consistently

under 10% as opposed to 20% to 60%

moisture content of the logs). Low

moisture content, controlled fuel

porons and precise air seng means

high combuson eciency and very low

carbon oxides in the ue gases.

When purchasing pellets, ask

for conformity declaration and

certificate issued by an accredited

laboratory and make sure the

fuel meets the requirements

indicated in the manual. If

you purchase large amount of

pellets (bulk supply for the entire

heating season for example), ask

your supplier to provde accurate

and true information about the

storage conditions.

We recommend to use pellet with size of

6 - 8mm. Density 600 - 750kg/m3 heang

value 4.7 - 5.5 kWh/kg. Ash content – less

than 1% and moisture content up to 8%,

EN ISO 17225-2:2014.

The opmal density of the pellets which

guarantees their quality is 605-700 kg per

cubic meter.

Pellet moisture content must not exceed

10%. Make sure you store your fuel in a

dry and well-venlated place.

The opmal pellet ash content is ≤ 1%.

This also provides for less frequent

cleaning intervals for the burner.

The table below contains the parameters

which we recommend that you take into

consideraon when choosing fuel for your

„Pell” burner.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

Table2. European Certification of Wood Pellets for Heating Purposes

Parameters Units ENplus-A1 ENplus-A2 EN-B

Diameter mm 6 (± 1)

8 (± 1)

6 (± 1)

8 (± 1)

6 (± 1)

8 (± 1)

Lenght mm 15 ≤ L ≤ 40 1) 15 ≤ L ≤ 40 1) 15 ≤ L ≤ 40 1)

Bulk dentsity kg / m2≥ 600 ≥ 600 ≥ 600

Caloric/heang value MJ / kg ≥ 16,5-19 ≥ 16,3-19 ≥ 16,0-19

Humidity /moisture Ма .-% ≤ 10 ≤ 10 ≤ 10

Dust Ма .-% ≤ 1 3) ≤ 1 3) ≤ 1 3)

Mechanical durability Ма .-% ≥ 97,5 4) ≥ 97,5 4) ≥ 96,5 4)

Ash Ма .-% 2) ≤ 0,7 ≤ 1,5 ≤ 3,5

Melng point of ash °C ≥ 1200 ≥ 1100 -

Chlorine content Ма .-% 2) ≤ 0,02 ≤ 0,02 ≤ 0,03

Sulfur content Ма .-% 2) ≤ 0,03 ≤ 0,03 ≤ 0,04

Nitrogen content Ма .-% 2) ≤ 0,3 ≤ 0,3 ≤ 1,0

Copper content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Chromium content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Arsenic content mg / kg 2) ≤ 1,0 ≤ 1,0 ≤ 1,0

Cadmium content mg / kg 2) ≤ 0,5 ≤ 0,5 ≤ 0,5

Mercury content mg / kg 2) ≤ 0,1 ≤ 0,1 ≤ 0,1

Plumbum content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Nickel content mg / kg 2) ≤ 10 ≤ 10 ≤ 10

Zinc content mg / kg 2) ≤ 100 ≤ 100 ≤ 100

1) Not more than 1% of the pellets may be longer than 40 mm, max. Length 45 mm;

2) Dry weight;

3) Particles <3.15 Mm, particulate matter, before handing over the goods;

4) Measurements with lignotester limit value ≥ 97,7% by weight.

4. TRANSPORTATION OF THE BOILER

AND BURNER

4.1. Transportation of the boiler

We recommend to transport the heang

boiler to the installaon site in its

packaging placed on the pallet. During

transport and installaon, depending on

the weight, suitable safety devices should

be used in accordance with Direcve

2006/42/EC.

When transporng items weighing more

than 30 kg, the use of pallet jack, fork

truck or other hoisng devices is a must.

The boiler is securely fastened with

fasteners to a wooden pallet.



Important: When installing the

boiler, the wooden pallet onto

which the boiler is placed must

be removed by unscrewing the

bolted connecons using at ring

wrench S13.

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

4.2. Transportation of the pellet and

auger.

It is mandatory for transportation to

place and secure the burner and auger

on a pallet.

- Dimensions of the packaging of the

burner: 450х350х750 mm;

- Dimensions of the packaging of the

auger: 260х120х1700 mm;

5. DELIVERY OF THE BOILER AND

BURNER

•Inspect the integrity of the packaging

upon delivery.

• Check whether all components have

been delivered to you.

1. Boiler scope of delivery includes:

1) Boiler body with boiler doors

2) Control unit

3) Safety valve 3 bar

4) Fire irons

5) Cleaning brush for ue pipes

6) Technical passport. Installaon and

operaon manual

7) Service booklet and Warranty card If

any of the above items are missing,

contact your supplier.

2. Burner consignment package includes:

1) Pellet Burner Pell with built-up Control

unit

2) Feeding chute

3) Fire irons

4) Auger

5) Technical passport. Installaon and

operaon manual

6) Service booklet and Warranty card

3. Fuel Hopper.

4. Mounng kit for parcular model

burner.

If you nd a missing component, contact

your provider.

6. INSTALLATION OF THE HEATING

BOILER



The assembly, installaon and

set-up of the boiler must be

performed by a technician

authorized for such operaons.

Installer must indicate to the user

of the installaon the minimum

clearances from ammable

materials and liquids.

6.1. Requirements:

- Boiler room must be frost-proof;

- Boiler room must allow for connuous

Table 3. Overall dimensions of model WBS Acve boiler

Model A,

mm B,

mm C,

mm D,

Weight,

Diagram 3. Overall dimensions of boiler

and pallet, model WBS Acve

WBS-A 20 650 1050 125 1475 255

WBS-A 25 650 1050 125 1475 300

WBS-A 30 650 1050 125 1475 322

WBS-A 40 750 1100 125 1475 362

WBS-A 50 750 1100 125 1475 392

WBS-A 70 810 1300 125 1620 466

WBS-A 90 810 1300 125 1620 508

WBS-A 110 880 1300 125 1620 531

TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

access of air necessary to maintain

combuson;

- Boilers must not be placed in inhabitable

rooms;

- All boiler rooms must have correctly

calculated vent depending on the boiler

output. The vent must be protected by

means of a net or grate.

The size of the vent is calculated according

to the formula:

А = 6,02*Q - where:

А – area of the vent in cm2,

Q – boiler output in kW

- Remove the packaging without pollung

the environment

- Observe building supervision

instrucons, in parcular the exisng

Ordinance on combuson devices and

storage of combuson materials, on

building requirements applicable to

installaon sites and on venlaon;

- The boiler must be placed on a

foundaon whose surface area is larger

than the base of the heang boiler

according to diagram 1;

- The boiler must be placed in a posion

which allows for the easiest possible

cleaning and servicing;

- Installaon must be carried out

according to installaon diagram 1

which shows the boiler housing;

- No objects made of ammable materials

or liquids may be placed on/near the

boiler;

6.2. Check door ghtness

Open boiler doors.

Place paper strips on the four sides of the

doors and close leaving part of the strips

protruding outside.

Pull the paper strips. If the strips tear

upon pulling, doors seal ghtly.



Cauon! Inadequate adjustment

of the hinges may result in air

being sucked in through the

doors and the boiler burning

uncontrollably.

7. SETUP OF THE HEATING BOILER

AND BURNER

7.1. Connecng the boiler to a chimney

Boiler-to-chimney connecon must

always comply with the exisng standards

and rules. The chimney must provide

sucient draught for evacuaon of the

smoke under any condions.

The proper funconing of the chimney

requires adequate sizing of the chimney

itself since the draught it produces aects

combuson, boiler’s output and life span.

The draught created by the chimney

is in funconal relaon to its cross-

secon, height and the roughness of its

interior walls. No other appliance may

be connected to the chimney serving the

boiler. Chimney diameter must not be

smaller than the ue outlet of the boiler.

Flue outlet must be connected to the

chimney opening. In terms of mechanical

properes, the ue outlet must be sturdy

and properly sealed (to avoid gas leak)

and allow for easy access for cleaning

on the inside. The inner secon of the

ue outlet must not be greater than the

eecve secon of the chimney and must

not narrow. Avoid using elbow joints.

The chimney cleaning opening has to be

in its lowest part. The chimney’s wall has

to be threeplied where the medium layer

is from mineral wool. The thickness of the

insulaon is not less than 30 mm when

the chimney is seng up inside the house

and the thickness is 50 mm, when the

seng up is outside.

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