Cerbos QUAD 10, User And Service Manual

Page 1: ...USER AND SERVICE MANUAL MODEL COMFORT PLUS PREMIUM QUAD 10 QUAD 15 QUAD 20 QUAD 25 QUAD 30 BTI Gumkowski Obornicka 71 62 002 Suchy las Poland ...

Page 2: ...g the boiler 5 1 Positioning the boiler 5 2 Fitting the burner to the boiler 5 3 Change of door assembly sides 5 4 Connection to the chimney system 5 5 Connecting to the CH and or HUW installation 5 6 Connecting to the electrical installation 6 Using the boiler 6 1 Filling and draining the boiler with water 6 2 Fuel requirements 6 3 Filling the hopper and feeder WZ WZO WZ gp WZO gp 6 4 Boiler star...

Page 3: ...other necessary information enabling safe and trouble free operation of the Compact pellet boiler The following instructions documents are enclosed with the boiler operating and installation manual ROTARY ROT POWER burner instruction manual by KIPI controller a touch panel brand PLUM 1 1 General description of the boiler The compact boiler is a water boiler for solid fuel pellets Possible heating ...

Page 4: ... water installations w10 Supply and return connectors W WZ WO WZO Connection to central heating and hot water installations w11 Water drain connection Draining the boiler water block z HOPPER z1 Front cover z2 Fuel feeder with gear motor Automatic fuel feeding z3 Fuel feeder spiro pipe Feeding fuel from the container to the burner z4 Fuel hopper hatch Filling the tank with fuel z5 Tray handles Rem...

Page 5: ...al and the compakt boiler meet the following standards and or directives PN EN 303 5 2012 Solid fuel heating boilers with manual and automatic fuel charging with a nominal power up to 500 kW MACHINERY DIRECTIVE 2006_42_EC 2 Building 2 1 Division into variants The compact water boiler is a device with a modular structure It consists of an exchanger a container and an automatic ash removal system Fi...

Page 6: ...Figure 3 Modular structure of the boiler The modular structure of the boiler enables its availability in several different variants Table II describes all the possible options available ...

Page 7: ...uctions contain the designations of the boiler variants eg WO WZO gp This means that a given chapter applies only to selected variants All other unmarked sections apply to all variants The pump group assembly replacing some of the boiler installation elements is available only for variants containing an integrated pellet container WZ and WZO Figure 4 and Figure 5 show a fragment of the boiler with...

Page 8: ...ter circuit through the exchanger The exchanger has the following features Exhaust fan creates negative pressure of exhaust gases in the exchanger This prevents unwanted smoke escaping through burner or boiler leaks and ensures a constant thrust value Three pass system the combustion chamber is the first line 1 Then the exhaust gases pass through the smoke tubes of the 2nd line 2 to the return cha...

Page 9: ...n chapter 5 4 3 Ash removal WO WZO WZO gp Most of the ash generated during the combustion process goes directly from the combustion chamber 1 to the ash removal spiral 2 This spiral is driven by a motor gear motor 3 The ash is forced through the ash removal pipe to the ash container 4 Figure 8 Ash removal principle 2 3 Division into power series The compact boiler is available for several differen...

Page 10: ...power series with the burner used Table III Boiler power types Boiler series of types Nominal capacity of the boiler Burner used 10 15 kW 10 5 kW 3 10 kW 15 kW 4 16 kW 20 25 kW 20 kW 5 20 kW 25 kW 6 26 kW 30 kW 30 kW 8 36 kW 3 Technical Specifications 3 1 Summary of overall dimensions ...

Page 11: ......

Page 12: ...1119 1194 1269 mm A4 1022 1097 1172 mm B 595 650 705 mm H1 1 637 692 747 mm H1 2 922 977 1032 mm H1 3 1324 1414 1504 mm H1 4 1609 1699 1789 mm H2 1 452 504 532 mm H2 2 737 789 817 mm H3 778 813 848 mm H4 606 641 676 mm Flue diameter φ 127 mm Tank capacity 155 195 240 l Fuel charging hole see draw Figure 27 width x length 406 x 555 456 x 610 506 x 665 mm x mm ...

Page 13: ... 52 7 C minimum power Flue gas mass flow nominal power 0 00847 0 0093 0 0115 0 0152 0 0178 kg s Flue gas mass flow minimum power 0 00403 0 0044 0 0057 0 0062 0 0073 kg s Water flow resistance nominal power 0 09 0 08 0 08 mbar Water flow resistance minimum power 0 05 0 01 0 01 Boiler class according to EN 303 5 2012 5 Continuous flammability nominal power 47 31 29 23 24 h Continuous flammability mi...

Page 14: ... the boiler The boiler is supplied by the manufacturer on a Euro pallet with standard dimensions of 1200x800 mm The boiler should be transported on a pallet to its destination and then removed from it Similarly if there is a need to transport the boiler to another place it should be placed and secured on a pallet adhering to the following guidelines Pay attention to the weight of the boiler was on...

Page 15: ...ner can be transported with forklift 4 2 Unloading from the pallet Steps when removing the boiler from the pallet 1 Cut the bandages and remove the mounting angles 2 Unwrap the cauldron from the foil 3 Dismantle the ash container 4 Hold the boiler from below with straps or rope ...

Page 16: ... 10 Removing the boiler from the pallet WO WZO WZO gp Figure 11 Removing the boiler from the pallet W WZ WZ gp WARNING Dismantle the ash pan before removing the boiler from the pallet 5 Installing the boiler ...

Page 17: ...during transport the plumbing system of central heating works correctly with no debris rust etc which could cause incorrect operation of the boiler eg increase resistance of flow of water in the boiler the chimney is provided with an insert made of stainless steel or the way and whether or not a valid string is there adequate ventilation in the boiler room in accordance with applicable standards w...

Page 18: ...ION All combustible materials pellet fuel and others should be kept at a safe distance from the boiler 5 2 Fitting the burner to the boiler The burner for the boiler can be mounted or dismounted using an allen key The figure below shows how to install the burner to the boiler Figure 13 Installing the burner ...

Page 19: ...nscrew the main screws hinge and remove the door 4 Unscrew the hinge bar 5 Unscrew the blanking screws 6 Door catch unscrew and disconnect the limit switch wires 7 Break a hole for a hook on the other side of the exchanger use appropriate tools for this 8 Screw back all parts symmetrically to the opposite side of the boiler in the reverse order Figure 14 Changing the door assembly sides 5 4 Discon...

Page 20: ...stant steel or appropriate ceramic materials if we are dealing with a traditional brick chimney an insulated stainless steel insert should be used From To ensure the sound he tightness and reduce the risk of efflorescence on walls condensation drain from the chimney should be provided WARNING The manufacturer is not responsible for any damage caused by plugging the boiler into an improperly adapte...

Page 21: ...to the chimney 5 5 Connecting to the heating system and or hot water system The boiler can work with a central heating CH installation and or a central utility water DHW installation Boiler conncetor see Figure 1 w9 w10 w11 should be connected to the water installation in accordance with the figures below ...

Page 22: ...ater and 3 4 inch DHW hot water b 3 4 inch Filling the boiler c 1 2 inch System return Cold water d 3 4 inch Supply from the installation hot water e 3 4 inch Water drain f 1 2 inch X1 165 193 220 mm X2 207 210 237 mm X3 70 mm X4 65 mm X5 45 mm X6 45 mm Y1 65 mm Y2 142 144 172 mm WARNING Between the boiler and the central heating system cut off valves should be installed allowing the boiler to be ...

Page 23: ... circulation closed system 1 boiler 2 DHW exchanger 3 central heating heaters 5 DHW circulation pump 5 central heating circulation pump 6 circulation pump 7 three way mixing valve 8 diaphragm expansion vessel Figure 20 Diagram of DHW and HW circulation closed system with a cooling coil 1 boiler 2 water exchanger 3 heaters HW 5 hot water circulation pump 5 circulating pump CH 6 circulation pump 7 t...

Page 24: ... CH circulation pump 6 circulation pump 7 three way mixing valve 8 expansion vessel 3 Connecting the boiler with a pump group WZ gp WZO gp Figure 22 The principle of operation of the pump group WZ gp WZO gp 1 Boiler 2 DHW 3 CH 4 Pump 5 Safety valve 6 Three way valve 7 Bypass 8 Manometer 9 Expansion vessel 10 Filling valve ...

Page 25: ...tallation WARNING Electrician qualifications up to 1kVA are required to connect the heating system devices pumps actuators pump groups solenoid valves WARNING SAFETY INFORMATION Before connecting the boiler make sure to that the boiler is disconnected from any source of voltage The boiler is powered by alternating current 230V 50Hz The installation should be connected to the controller located und...

Page 26: ...rcuit mixer 1 type CT4 WS weather temperature sensor type CT6 P RS temperature sensor of water returning to the boiler type CT4 FS feeder temperature sensor type CT4 OS optical flame brightness sensor BT CT4 FT boiler temperature sensor CT2S LN PE temperature sensor 230V mains supply CPU control STB to a input o safety temperature limiter FH main feeder CF burner blower fan VF exhaust fan SC burne...

Page 27: ...oiler e Cleaning the boiler 6 1 Filling and draining the boiler with water WARNING It is forbidden to fill the boiler with water or top it up with water while the boiler is in operation Allow the boiler to cool down before refilling water The boiler must be filled with water via the water drain socket see Figure 1 w11 In the case of the WZ gp or WZO gp variant it is allowed to fill the boiler with...

Page 28: ...ect sunlight 6 3 Filling the hooper and feeder WZ WZO WZ gp WZO gp WARNING Filling the feeder is necessary before the first start or when the pellet tank is empty and the burner is restarted Prepare the container and feeder for boiler operation 1 Fill the hopper with pellets as shown in the picture below Figure 27 Filling the hopper with pellets 1 opening of the hopper flap 2 bag with pellets 3 Ch...

Page 29: ...is best to place a container under the downpipe into which the pellets will fall Pay attention to the work of the auger it must work continuously 3 Carry out this feeder In the controller Main menu Boiler settings Power modulation Feeder Feeder efficiency test START The feeder test lasts 6 minutes during this time the auger feeds the pellets in a continuous operation mode Accordingly the parameter...

Page 30: ...r capacity than Table VIII Min Required feeder capacity for each burner power used in the boiler no burner power feeder efficiency 1 10 kW 4 kg h 2 16 kW 4 kg h 3 20 kW 5 kg h 4 26 kW 6 kg h 5 36 kW 8 kg h 6 4 Boiler start up and shutdown WARNING Do not start the boiler if it is not filled with water The manufacturer recommends that the first start up be performed by an Authorized Installer at the...

Page 31: ...N OFF To turn off the boiler Main screen ON OFF Then the boiler goes into the extinguishing mode In order to function properly when first starting a boiler it is advisable to perform measurement of exhaust emissions and the verification values of oxygen in flue gas by measuring apparatus 6 5 Modes of operation Boiler operation is possible only in automatic mode It provides several modes of operati...

Page 32: ...a brush and dustpan or a vacuum cleaner The manual presents cleaning of the boiler with a vacuum cleaner The tool attached to the boiler brush rod should be used when cleaning the smoke tubes Table X Summary of the frequency of cleaning of individual components No action Cleaning frequency 1 Ash tank WO WZO Depending on the quality and quantity of the burnt pellets once every 2 6 months 2 Flame tu...

Page 33: ...tical position Then unfasten the buckle 3 lift the cover 4 Empty the ash from the hopper by tilting it Figure 32 Emptying the ash container 2 Cleaning the smoke tubes and the front chamber 3 Cleaning the combustion chamber W WZ WZ gp ...

Page 34: ...4 Cleaning the back chamber including fan 5 Burner cleaning Detailed description in attached burner manual ...

Page 35: ...g the burner are included in the attached burner manual Use only fuels recommended by the manufacturer It is forbidden to burn materials not intended for this purpose Adequate fresh air must be provided 8 Security systems The hazards and safety assessment of the device were carried out in the risk assessment This information has been archived in the technical documentation of the device at the man...

Page 36: ...I List of common faults No Fault The cause of the fault How to remove the fault 1 The burner does not ignite Message Failed firing attempt No fuel in the container Refill the fuel in the container Perform the auger filling procedure point 6 2 Clear the error by pressing the knob Blockade of fuel feeding augers Remove the locking element Defective igniter Contact the manufacturer s service point Da...

Page 37: ...the cause of this error Delete the error by pressing the button in the controller housing 5 Alarm Damage to the boiler temperature sensor Boiler temperature sensor failure Contact the manufacturer s service point 6 The fan does not turn off when the burner is extinguished Photodiode damaged or dirty Clean the photo diode In the event of damage contact the manufacturer service point 7 Smoke burner ...

Page 38: ... Side MIRROR W17 Housing Top W18 Housing Pump group fastening W19 Burner W19 1 Burner power cable W19 2 Spiro tube Z1 Pellet feeder Z1 1 Pellet feeder gearmotor Z1 2 Feeder seal Z2 The hinges Z3 Gas shock absorber Z4 Housing Front tray Z5 Housing Side tray Z6 Housing MIRROR tray side Z7 Housing Hopper flap Z8 Housing Top of the tray Z9 Housing Rear tray Z10 EcoMax 860 controller panel O 1 Trolley ...