kunzel PK 10, Operating Manual

Page 1: ...Operating manual Pellet boiler PK 10 and PK 20 October 6 2010 ...

Page 2: ...tents of this manual before installing and operating the boiler Be sure to also comply with the regional regulatory provisions they may differ in full or in part from the requirements named in this manual In this case the regulator requirements always have precedence The master chimney sweep responsible for your region can always provide information The company KÜNZEL would like to thank you for y...

Page 3: ...t into service for first time 15 5 1 Settings on the boiler 15 5 2 Settings on the burner 15 5 3 Setting the output setting 15 5 4 Starting the burner for the first time after the unit is installed 16 5 5 Setting the draft 17 5 6 Emissions measurement 17 5 7 Setting the excess air 17 6 Daily heating 18 6 1 Switching on the burner 18 6 2 Switching off the burner 18 6 3 Manual ignition 19 7 Filling ...

Page 4: ...ker 24 9 3 2 Cleaning of the conveyor screw 24 9 3 3 Thermomix valve 24 10 What to do in the event of a malfunction 25 10 1 Causes and remedial actions 25 10 2 Resetting the automatic circuit breaker 28 10 3 Resetting the temperature safety limiter 28 10 4 Setting the chamber full sensor 28 11 Technical data 30 11 1 Wiring diagrams 32 4 ...

Page 5: ... 6mm or 8mm The pellets must comply with the DIN Plus standard or the PVA standard Austrian Pellet Association The fine fraction proportion of pellets with a length of less than 10mm is not permitted to exceed 8 in the pellet bunker The powder density must be less than 0 75kg dm3 Other fuels in particular pellets that contain recycled materials may not be used The specified cleaning interval appli...

Page 6: ...er switch is not sufficient because this action switches off all of the monitoring equipment as well Please read section 8 on page 20 to learn more about this 2 Installation When operating a KÜNZEL pellet boiler it is recommended to always fit a buffer tank with a capacity of about 500 l to the system Fitting a buffer tank to the system extends the length of the burner run times which markedly red...

Page 7: ... flue draft insufficient Should this occur the control lamp will switch to yellow and thereby show that the burner is in emergency operation mode The display unit will then alternately show the above fault message and the fault message reduced output If the problem cannot be handled by reducing the output of the burner and dangerous temperatures occur at the sensors the burner will be switched off...

Page 8: ...fails to take place once again the burner is switched off Figure 2 Pellet boiler The burner output depends on the output setting It can be set in the menu of the burner control unit in 1 kW steps between the minimum permissible output and the maximum permissible output If the burner is equipped with the optional auxiliary sensor the output setting is set automatically The maximum and minimum setti...

Page 9: ...ght or calorific value the corresponding values for volumetric weight and calorific value must be adjusted to compensate for differences in heating per formance and combustion values However this is generally only the case when 8 mm pellets are used instead of 6 mm pellets standard Using good quality pellets ensures a high degree of operational safety and efficiency Figure 3 Moveable grate The pat...

Page 10: ...4 2 Differential temperature control unit Figure 6 The differential temperature control unit The differential temperature control unit is required so that the pellet boiler can be operated in conjunc tion with a buffer tank It monitors the filling and emptying of the buffer tank and controls the boiler circulation pump and the burner This ensures that the pellet boiler is not switched on too often...

Page 11: ...s 70 C The buffer tank is now completely filled 3 The pumps runs When the temperature T1 is higher than the set temperature T1 boiler is warm When the temperature T1 is higher than the set temperature T2 storage tank is colder than boiler 4 The pump stops When the temperature T1 is more than 3 C below the set value T1 after run period of 3 minutes When the temperature T2 is higher than the tempera...

Page 12: ...The menu system of the KÜNZEL pellet boiler includes two menu levels i e a user menu and a service menu The status of the user menu appears when the unit is started up PLEASE NOTE The status is automatically reset if no switch is pressed for five minutes Stop Start Press the On Off button All processes in the burner are interrupted total stop when this switch is pressed If it is pressed again the ...

Page 13: ... power supply breakdown Manual ignition This feature can be used to ignite the burner manually if the igniter is defective The burner then runs in ember conservation mode This is an emergency feature and should only be used under such circumstances End operation This feature switches the burner off properly It no longer responds to the boiler control unit and remains off The burner can be restarte...

Page 14: ...ted 49 Reduction If the temperature in the discharge chute reaches this value the burner limit will attempt to prevent it increasing any further by reducing the output The control lamp turns red The message flue draft low appears in the display Clean the boiler and the exhaust system 56 Standby Maximum period for which the burner will run in ember conservation maximum duration 1 00 h mode without ...

Page 15: ...u You can use the and the to move about within the menu tree Press the menu button if you want to change a value The value will start to blink You can now change the value using the and buttons To save your changes keep the menu button depressed for more than 3 seconds Please note ONLY change the values specified in the table Changing other values can lead to seri ous operational malfunctions If y...

Page 16: ...nce to fill the filling spout with pellets up to the chamber full sensor For more information about this please read the item manual ext pellet feed mechanism in sect 5 Once the filling spout has been filled the chamber full sensor reacts and switches the conveyor screw off The external conveyor screw can also be operated manually The manual feeding of pellets is only possible when the unit has be...

Page 17: ...ler and then measure the CO2 and CO values with an exhaust gas sensor that is suitable for wood pellets The following guidelines apply At minimum boiler output the average O2 content of the exhaust gas should be between 9 and 12 while at maximum boiler output it should be between 6 and 10 At maximum boiler output the average CO content of the exhaust gas should be less than 400 ppm 13 O2 and at mi...

Page 18: ...n the burner it must be completely disconnected from the mains power supply To do this disconnect the burner plug Immediate power down The pellet feed mechanism and the fan are stopped The remaining pellets stay in the brazier and burn out there Press the ON OFF button The display show the message switched off manually All of the burner s functions are switched off This condition is described as t...

Page 19: ...tion system is normally set to Autostart upon start up The display will show the message switched off manually The manual feeding of pellets is only possible when the unit has been stopped Now press the menu button repeatedly until the message manual pellet feed mechanism appears Keep the button depressed and let the motor run for between 35 and 40 seconds Open the boiler door The burner swings ou...

Page 20: ...e agreement with your heating specialist 9 1 Monthly cleaning routine 9 1 1 Using the cleaning lever There is a cleaning lever on the side of the boiler that activates the cleaning mechanism inside the boiler Cleaning the flue gas ducts markedly increases the heat transfer characteristics and therefore the effi ciency of the boiler It is therefore a good idea to operate this lever as often as prac...

Page 21: ...three seconds The burner will now perform a burn out procedure with subsequent ash removal Wait a sufficiently long period until the components have cooled to a temperature at which they can be handled The wearing of protective gloves is recommended for the following tasks The components in the com bustion chamber are dirty and under some circumstances could still be hot Figure 9 The brazier 21 ...

Page 22: ... 2 Interim bunker if present The pellet interim bunker should be completely emptied for cleaning every half year Any automatic filling system must be switched off Any wood dust and other pollutants accumulated in the pellet bunker should be removed 9 2 3 Dosage screw auger Figure 11 Release lid of downpipe Disconnect the mains power supply using the mains power switch and remove the plugged con ne...

Page 23: ...es place at the start of the heating season Actuate the lever located on the right hand side of the boiler several times Then remove the red panel cover from the boiler and open the register cover with an Allen key The flue gas ducts are now open to inspection In order to be able to clean the flue gas ducts the turbo gratings must first be removed The turbo gratings are very dirty and the wearing ...

Page 24: ... Accessing the interior of the conveyor screw involves a great deal of work For this reason it is only to be checked in the event of malfunctions Before commencing with any work on the unit ensure the mains power supply is disconnected and remove the plugged connectors from the drive motor There is a risk of injury Now remove any deposited and encrusted materials 9 3 3 Thermomix valve The KÜNZEL T...

Page 25: ...t Overheating in burner due to insufficient draft in the boiler Check exhaust draft Clean boiler and flue gas ducts Check chimney and have it cleaned if necessary The control lamp is glowing red FAULT external the pellet feed has been interrupted The conveyor screw is not getting any material Check whether the bunker is filled Exclude the possibility of cavities or craters having formed in the pel...

Page 26: ...ignition system does not work Remove the lodged pellets from the brazier Please contact the manufacturer if this malfunction re occurs The control lamp is glowing red FAULT ignition the flame sensor has tripped ignition has not taken place Igniter defective There are too few pellets in the brazier Before starting the unit check whether there are pellets in the dosage screw auger The pellets have t...

Page 27: ... serviced at the earliest opportunity cleaned and examined Reset the maintenance interval by calling up item 59 in the service menu and then press the menu button for three seconds The boiler output is too low The selected output setting is too low Poor pellet quality Require your pellet supplier to provide a quality certificate for the supplied pellets Negative pressure in the boiler is either to...

Page 28: ...ation It must then be reset Switch off burner The main switch must be switched on so that the burner is supplied with power Release the downpipe hose and remove it from the burner inlet Use your finger to test whether the LED on the sensor glows when your finger comes to between 8 mm and 9 mm as shown in the figure below Use a small terminal screwdriver to unscrew the protective cover in order to ...

Page 29: ...PLEASE NOTE The adjustment screw is delicate and will only have to be turned a few degrees to achieve the required adjustment Do not twist it excessively hard against the end stops 29 ...

Page 30: ...11 Technical data Figure 13 The PK pellet boiler Figure 14 Connecting dimensions 30 ...

Page 31: ...ated load kg s 0 009 0 0135 0 018 Exhaust temperature oC 130 130 130 CO2 12 12 12 Exhaust gas connection diameter mm 110 110 130 Efficiency 90 2 91 92 3 Electrical supply 230V AC 10A 50Hz Burner 80W 230V 50Hz Fuses 6A automatic circuit breaker 6A high speed fuse for the heating coil External conveyor screw single phase 230V AC 50 Hz 250W 2 4A capacitor 14 µ F three phase motor should be used for c...

Page 32: ...Figure 15 The pellet burner 11 1 Wiring diagrams 1 6 mm and 8 mm pellets that at least comply with DIN PLUS 2 100 mm for lateral cleaning lever 32 ...

Page 33: ...Figure 16 Wiring diagram for pellet boiler 33 ...

Page 34: ...Figure 17 Wiring diagram for PK 230V conveyor screw drive 34 ...

Page 35: ...Figure 18 Wiring diagram for PK 400V conveyor screw drive 35 ...

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