/Translation from the Lithuanian language/

BIO 20

STEEL PELLET BOILER WITH BURNER AND AUTOMATIC

FUEL FEEDER

BIO 20 (POWER - 20kW) CONTROLLER ST-560

BOILER PASS, USER MANUAL, INSTALLATION, USAGE

AND MAINTENANCE

1. Introduction

UAB “Biokaitra” says thank you and congratulates you with your new purchase – the heating device. Your

purchased multifunctional boiler is fired with straw, wood sawdust and other agro-pellets.

The modern construction and the most advanced methods of steel manufacturing have allowed us to create a

cheap heat energy source for your home, commercial or agricultural buildings with the area of up to 240 m2.

While designing the Bio series boilers, we focused on satisfying your needs and paid attention to long term

observations and customer feedback. This allowed us to manufacture an easy-to-use boiler with the

efficiency ratio of 91.5 %.

Recommendations

Before use

- Please check the device and its contents.

- Please read the safe operation manual carefully.

- Before installation, it is necessary to familiarise with the boiler installation section carefully.

NOTES!

- During the transportation of boiler, it is necessary to take care of the protection of boiler and its

components from mechanical damage.

- Before installation the boiler has to be stored in a dry place.

- For connection of boiler to the power network, water supply system and chimney please refer to the valid

norms, requirements and the user manual.

- The manufacturer is not liable for any losses resulting from improper installation of the device.

- In case of emergency, it is necessary to contact the authorised service as soon as possible.

- Intervention of persons without an adequate qualification may result in the damage to the boiler.

- Use only genuine spare parts for the repair works.

- The boiler and the bunker frame are subject to 3 year warranty, provided that the annual inspection of

boiler is performed and the respective information is recorded in the warranty sheet. A warranty of one year

is provided to the moving parts that are subject to wearing, i.e. screw conveyor, motoreducers and motor,

ventilator, controller and insulation rope. The warranty does not apply to the boiler deflector!

- A warranty sheet and warranty conditions are enclosed to this manual.

Purpose of boiler with burner

- Bio boilers with automatic fuel feeder and burner are used for the combustion of straw, wood sawdust and

other agro-pellets of the diameter of 6-10 mm.

- Bio boilers are modern water heating boilers used for the production of heat and hot water (with bulk

household water heaters - boilers) used for heating residential and industrial buildings.

- Bio boilers are fitted with an automatic screw fuel feeder (conveyor), burner and fuel tank to store fuel for

several days upfront (3-7 days). Boiler’s screw fuel feeder, ventilator and circulatory pump are controlled by

modern automation. Fuel control system allows to program the combustion process according to the

maintenance conditions, weather and fuel quality.

- Bio boilers do not require constant combustion, because the fuel is dosed by the automatic screw conveyor,

whereas the burning takes place thanks to the ceramic heating element.

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Suitable fuel

Main fuel Straw pellets / wood sawdust pellets / sunflower husk pellets / peat pellets

Diameter of pellets: 6 - 10mm, length: diameter x4.

Calorific value 15 -18MJ

Moisture content: up to 12%

Ash content: up to 6%

Dust: up to 2% of the fuel mass

IMPORTANT! The boiler may only be used in a closed heating system with the expansion vessel.

Boiler specifications

1. Boiler construction

Boiler Bio is made of high-quality certified steel. The frame is made of the galvanised tip coated with a layer of

powder paint.

2. Composition

All boilers of Bio series made by Biokaitra consist of two individual active parts. The front part of frame is

occupied by the fire chamber, whereas the top and back parts of boiler frame contain a heat exchanger with the

water contour passing to the flue. The front part of boiler contains two doors: the upper - for burner and burning

chambers for visual inspection, the lower - bottom - for the removal of ashes. The opening on the top of boiler is

planned for the cleaning of heat exchanger which is hidden under the finishing.

3. Combustion In Bio boilers, the burning takes place in the burner to which the fuel is fed with the screw conveyor connecting

the fuel tank with burner. The fuel is loaded through the tank hatch with a lock.

IMPORTANT! When the boiler is operating, the tank should always be tightly closed.

Afterwards, the fuel is fed to the burner via screw conveyor powered by electric motor connected with

motoreducers. In the burner, the fuel is pushed to the top to form the hump. The burning takes place in the upper

part of the burner when the ventilator blows the air to the burner. The air passes to the heated pellets through the

burner channels via the ceramic heating elements and causes burning. From the burner the ashes fall

spontaneously to the box of ashes located at the bottom of boiler combustion chamber.

4. Water supply

The water is supplied to the boiler through the external screw connections G 1 ¼ “, the forced water discharge is

performed with ½” outlet located in the back bottom part of the boiler.

5. Boiler flue Flue socket of 150mm is installed in the back part of the boiler.

6. Protection against overheating

If the temperature in the boiler reaches 95°C, the emergency thermostat is activated, the fuel feed is

deactivated as well as air ventilator and the sound alarm is activated. The unblocking of the emergency

thermostat is performed manually – it is necessary to open the cap and to press the button under the cap.

Unblocking is possible when the water temperature in the boiler drops below 60°C. In case of unblocking of

the emergency thermostat, no sound alarm will be heard. When the boiler starts to operate again, it is

necessary to find out the reason of activation of emergency thermostat by continuing to monitor the work of

the device.

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The main boiler dimensions and technical characteristics

Boiler model BIO 20

Boiler type Automated central heating boiler

Power adjustment range, kW 6 - 20

Nominal power, kW (when burning pellets with the calorific value

of 4.2 kWh/kg) 20

Efficiency ratio working on nominal power, % 91.5

Exhaust fumes temperature °C 60 - 150

Heating area, m2 60 - 200

Used fuel Automated fuel feed: 6 - 10 mm straw, wood

and other agro-pellets

Chimney connection opening, mm ø 150

Fuel costs kg/h (Q min – Qn), when heating pellets of the calorific

value of 4.2 kWh/kg 1.5 – 5.5

Maximum working water pressure in a boiler 2 bar

Water volume in a boiler, l 63

Minimum boiler return water temperature during the operation, °C 60

Maximum permissible operating water temperature, °C 85

El. power, 230V/50Hz no more than, W 350

Maximum draught in the fire, Pa 25

Overall dimensions with

fuel tank, mm

Height 1350

Width 1150

Depth 980

Fuel tank capacity, l 220

Boiler’s weight, kg 380

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Bio boiler profile

4

INSULATION MATERIAL

CONTROL DESK

DEFLECTOR

INSULATION MATERIAL

BURNER

WATER CONTOUR

FLUE

BOX OF ASHES

Burner profile

20kW

Content

- boiler frame;

- fuel tank;

- fuel transporter with burner, fan, motoreducers and electric motor;

- boiler controller (automation);

- boiler pass, user manual and warranty sheets.

Boiler installation

- Boiler installation works must be performed by the authorised persons having the respective qualifications.

- It is necessary to prepare a project of the boiler-house where the boiler is to be installed according to the

effective laws and requirements in the Republic of Lithuania.

- The boiler must be installed pursuant to the effective requirements. The manufacturer assumes the liability

for direct and indirect losses that emerged in case of improper installation of the boiler.

Selection of boiler power

- Properly selected size of boiler, i.e. its thermal power, conditions the efficiency and effectiveness of the

boiler.

- The boiler shall be selected so that its heating power would meet the thermal losses of the object.

Boiler installation place

- The boiler shall be installed in a place the conditions of which meet the effective requirements.

- The smallest distance of the boiler contour from the walls is 300 mm. It is also necessary to leave a safe

distance from combustible materials, electricity and gas pipeline.

- It is recommended to store the boiler on a ground of non-combustible materials which is by 100 mm wider

than the contours of the boiler and 300 mm wider than the front part of the boiler. The height of the

foundation shall be approx. 100 mm.

IMPORTANT! The boiler-house shall be fitted with a gravitational ventilation and it is necessary to

ensure the passing of sufficient fresh air to the room of the boiler house to meet the costs of the certain

boiler, in view of its power. This pre-condition is necessary to ensure proper use of boiler and

security.

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Burner

Fan

Electric motor

Burner frame

Screw conveyor

Installation of boiler

- The boiler can be fitted only in the premises the conditions of which meet the requirements applicable to the

boiler houses.

- The outlets of the supplied and return water have an external screw G 1 ½“.

- The power supply of the heating network must be connected to the nozzle which is in the back upper part of

the boiler frame. The return of water from the network must be connected to the outlet that is located in the

back bottom part of boiler frame.

- The system must be fitted with the protective valve (diameter ½), which does not allow to exceed the

operating pressure more than 0.2 MPa (2.0 kgf/cm2) in the heating system. The operation of valve must be

periodically checked by turning the handle of the valve. The protective valve must be fitted on the piping of

the fed hot water.

Place of installation of the protective valve (example)

Heating

- In order to extend the service time of boiler Bio, it is recommended to keep a temperature of at least 65°C.

- The return temperature to boiler shall be at least 60oC in order to avoid condensation process and resin

liquefaction in the combustion chamber. This would allow to extend the period of use of boiler and to

improve its effectiveness.

- For proper adjustment of properly fed and return temperature, it is recommended to use 4-way manual or

electrified mixing valve with a gear.

- In order to ensure the highest efficiency, it is recommended to use the mixing valves in the heating system

as well.

- Clean soft water is recommended to be used for the heating medium. It is best to use special filters for the

preparation of water.

- Maximum permissible height of water pillar cannot exceed 20 m.

Connection to the flue

- The boilers in the central heating system should be connected into a separate flue channel.

- The works of connection to the flue must be performed by the persons with respective qualifications

according to the valid requirements.

- The flue section is selected according to the capacity of the boiler. It ensures effective and economic

performance of the boiler.

- It is recommended to install traction regulator valve in the flue.

Installation of boiler with equipment

The boiler is delivered in separate parts, i.e. the boiler, fuel transporter with burner, motoreducers and electric engine, fuel tank, ventilator, fuel control automation.

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Protective valve

Fed hot water from

boiler

Boiler assembly procedure

- Fuel transporter frame with burner is placed inside the boiler and fitted with screws to the boiler frame (the

place of connection of fuel transporter frame flange with boiler frame should be hermetic.

- Fuel tank is placed on and attached to the external fuel transporter frame flange part (the rubber insert is

placed between the flanges).

- Fuel control automation is connected together with the emergency thermostat (emergency thermostat

capillary is placed into a tube on the upper part of the boiler under the finish).

ATTENTION!!! All flange connections should be tightened and their tightness should be checked.

ATTENTION!!! The works of boiler automation equipment can be performed by an installer who has

a respective qualification. Complete information about the settings of automation equipment is

provided in Section 2 of this Manual (description of the controller).

Connection to the power network

For correct connection of boiler, it is necessary to plan and to install two electricity sockets to the boiler installation

place with earthing. Ventilator, automation equipment and fuel transporter engine with the entire boiler electric

equipment should be connected to an orderly power network that meets all the valid requirements. Electric socket with

earthing should be fitted in the same distance from the boiler so that in case of need it would be possible to disconnect

the boiler from the power network.

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I. Description of the device

ST-560 controller is used for boilers fired with CH pellets with a feeder and ventilator. Due to the advantageous

software, the controller performs many diverse functions:

Controls the burner

Controls the feeder

Controls air supply ventilator

Controls central heating pump – CH

Smoothly controls the mixing valve

Controls two additional valves (optionally by using additional module)

Adjusts DHW pump

Adjusts additional pump (additional pump: CH, DHW, circulator pump or base pump)

Floor heating

Weekly control

Interaction of two operation status regulators as well as controller that ensures RS communication.

Possibility to connect ST-65 GSM module allowing the user to adjust certain functions of the controller

by mobile phone

Possibility to connect ST-505 Ethernet module allowing the user to monitor and regulate certain controller

functions by internet

Possibility to connect two additional control modules (e.g.: ST-61 or ST-431N) – it helps to adjust two

additional valves.

II. Installation The controller must be installed by a qualified specialist.

WARNING

The risk of electric shock in case of touching the powered connections. Before working with a controller, make

sure to disconnect the power supply and avoid its disconnection.

III. How to use the controller? Phases of use

The user shall configure special CH boiler operation phases. Ignition and extinguishing – the multi-stage process

as described below. In case of proper ignition process, the controller is set at the operating or modulation mode –

subject to the usage algorithm chosen by the user – Fitter’s menu / Operation algorithm select.

Ignition The ignition procedure may be different subject to the chosen operation algorithm. This stage is activated by the

user in the main menu.

In case of selection of the ignition function, the following message is shown on the monitor: “Is there

sufficient fuel on the grating?”. The user confirms by moving to a next stage. In case of lack of fuel, the monitor

shows the command to fill the fuel manually in order to activate the feeder.

During the next stage, the controller turns on the heater and the fan – they remain turned on until the

increase in the temperature of flue gas.

Then they move to the next stage – deferral of ignition when the heater is turned off and the fan

functions for a pre-determined period of time (default parameter: 20 min.).

Next, the controller is set to the operation mode. If the controller cannot determine that flue gases

increased after 10 min., the heater is turned off and the fan functions for 5 min. only. It is then possible to

perform the next test - the heater was active on for 10 min.

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The fan operates for 5 min. The controller will try to ignite the boiler 3 times. In case of failure to start the boiler in all

attempts (the controller does not determine the flue gas temperature increase), the monitor shows the report of failure

to ignite.

Algorithm of the entire modulation operation In case of successful ignition, the controller is set to the modulation mode. It consists of five stages subject to the

operating temperature.

The following modulation stages are set one after another: 100%, 80%, 60%, 40% and 30% (the user sets the

specific parameters). The transfer from one stage to another is related to CH boiler temperature difference and pre-

determined value as stipulated below:

A- Pre-set temperature interval 100%

B- Pre-set temperature interval 80%

C- Pre-set temperature interval 60%

D- Pre-set temperature interval 40%

When the pre-set temperature is reached, the controller functions according to the 30% modulation of the stopping

mode parameter.

The user defines the operation duration, the feeder activation frequency and the blowing force for the

specific modulation stage (“Modulation settings” main menu).

In case of selection of 100%, 80%, 60% and 40% modulation, the user also configures “Range form set temp.”. The

parameter used to define the value when the controller moves to another modulation stage.

For example:

Pre-set CH boiler temperature: 60⁰C;

temperature setting interval 100%: 30⁰C;

temperature setting interval 80%: 25⁰C;

temperature setting interval 60%: 15⁰C;

temperature setting interval 40%: 10⁰C

Result: in case of successful ignition of boiler, the controller moves to the next modulation stages, when the CH

boiler temperature increases:

CH boiler temperature 30⁰C – transfer to 80% stage

CH boiler temperature 35⁰C – transfer to 60% stage

CH boiler temperature 45⁰C – transfer to 40% stage

CH boiler temperature 50⁰C – transfer to 30% stage

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When the pre-set temperature is reached, the controller functions according to the 30% modulation of the stopping

mode parameter.

Operation algorithm modulation 100%, 80%, 60%, 40%, 30% If the user selects specific CH boiler usage modulation parameters in the menu, the CH boiler operates according to

the parameters of the set modulation stage (feeding time, feeding pause, blowing force) and in case of achievement

of the pre-set temperature, according to the parameters of each modulation stage (support mode, number of cycles

on the support mode, fan support mode).

Extinguishing Extinguishing procedure does not depend on the selected functioning algorithm. This stage is activated by the user

in the controller’s main menu. When the extinguishing is activated, the heater and the fan are deactivated.

IV. Controller’s functions – Main Menu Due to various functions performed by the controller, the menu is classified into the main menu and maintenance

menu.

The main menu provides the basic options such as operation parameters, weekly control parameters, etc.

Main menu flow chart

• Main menu

• Ignition

• Filled fuel tank

• Temperature parameters

• Pre-set CH boiler temperature:

• CH boiler hysteresis

• Pre-set DHW temperature

• DHW hysteresis

• Pump starting temperature

• Manual ignition

• Modulation settings

• Modulation 30%

• Modulation 40%

• Modulation 60%

• Modulation 80%

• Modulation 100%

• Selection of fuel

• Straw pellets 1

• Straw pellets 2

• Wood pellets

• Manual mode

• Burner

• Blower

• Blower force

• Feeder

• CH pump

• DHW pump

• Auxiliary contact

• Installed valve 1

• Installed valve 2

• Weekly control

• Weekly control of CH boiler

• Weekly control of DHW boiler

• Operation modes

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• Domestic heating

• Water tank priority

• Parallel pumps

• Summer mode

• Floor heating

• Disinfection

• Screen settings

• Screen view

• Screen brightness

• Screen blinking

• Blinking time

• Software updates

• Metalworker’s menu

• Maintenance menu

• Language

• Software version

• Factory settings

V.a) Ignition The selection of this option starts the ignition process. Other stages are described in Section IV.

V.b) Filled fuel tank This function is applied when the fuel tank is fully filled to restore 100% fuel consumption percentage (the value is

shown on the right corner of the main screen below the stopwatch).

NOTE. Before using this function for the first time, it is necessary to calibrate the fuel feeder “Fitter’s

menu/Calibration”

V.c) Temperature parameters Press the “Temperature settings” icon to pre-set CH boiler and DHW tank temperature and hysteresis.

V.c.1) Pre-set CH boiler temperature: This option is used to pre-set CH boiler temperature. The setting interval reaches 65OC to 80OC (factory setting – CH

boiler manufacturer can change the settings interval).

V.c.2) CH boiler hysteresis This option is used to set the pre-determined CH temperature hysteresis. It is a difference of temperatures of support

mode entry and restoration maintenance mode (e.g. when the pre-determined temperature reaches 65ºC, hysteresis –

3ºC, because the support mode is entered under 60oC temperature when the operation mode return procedure is

performed under 62ºC).

V.c.3) Pre-set DHW temperature This function is used to pre-set water temperature. When the water in DHW tank reaches the pre-set temperature, the

controller disconnects the DHW pump. It is activated when the temperature drops below the pre-set DHW hysteresis

value (DHW sensor reading).

V.c.4) DHW hysteresis This option is used to set the hysteresis of pre-set water tank temperature.

It is a maximum difference between the pre-set temperature (desired DHW tank temperature) and operation

restoration temperature.

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E. g.: if the pre-set temperature reaches 55°C and the hysteresis value is 5°C, DHW pump is deactivated, when the

pre-set temperature of 55oC is reached and activated again when the temperature drops down to 50

oC.

V.c.5) Pump starting temperature This option is used to define CH pump and DHW pump starting temperature (the temperature is measured in the CH

boiler). When the temperature is lower, both pumps are inactive, when this temperature is higher, the pumps are

turned on and operate according to the selected operation mode (see Pump operation mode).

V.d) Manual ignition This function should be activated when CH boiler is used without fuel feed. When this mode is set, the feeder is

deactivated and ventilator operates according to the parameters set in the maintenance menu. This function is

planned for the firewood mode for 30kW and 50kW boilers.

V.e) Modulation settings Press this icon to configure the CH boiler operation parameters of specific modulation stage. The parameters should

be configured at the same stage (except for Range from set temp. parameter which is not applied when the

modulation reaches 30%).

V.e.1) Feeding time This parameter defines the feeder operation time having selected the specific modulation stage.

V.e.2) Temporary suspension of feed This parameter defines the duration of temporary stopping of feeder when a specific modulation stage is performed.

V.e.3) Blower force This parameter defines the force of the fan at the specific modulation stage.

V.e.5) Pre-set temperature interval

Note

This parameter does not apply in case of 30% modulation.

This parameter defines the time of passing to the next modulation stage (applied for CH boiler operation according to

the entire modulation algorithm). When CH boiler temperature reaches the pre-set value minus the pre-set

temperature interval value, the controller switches to the next modulation stage.

V.e.6) Support mode This parameter defines the feeder operation time on the support mode (i.e. when the pre-set temperature was

reached).

V.e.7) Number of support mode cycles This parameter defines the feeder actuation mode on the support mode. It is connected when the pre-set number of

fan operation cycles is reached. The number of cycles is set by the user.

V.e.8) Fan support mode This auxiliary mode is used to set the operating parameters of the fan on the support mode: duration of operation,

duration of temporary stopping and blowing power.

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V.f) Selection of fuel This option is used to select one of the following types of fuel: straw pellets 1, straw pellets 2 or wood pellets.

V.g) Manual mode The manual mode function is planned in the controller for more convenient operation of the device. Irrespective of

other devices, this function can be used to activate and deactivate each operated device. It is easy to check if the

device functions properly, i.e. burner, feeder, air blower (fan), CH pump, DHW pump, additional contact and valves

(valves can be opened or closed manually).

Furthermore, the user can regulate the speed of ventilator on the manual operation mode by using “blow force”

function.

V.h) Weekly control This function allows the user to program the weekly CH boiler operation schedule and to define the pre-set changes

of CH boiler and DHW temperature. The controller can be used to set three weekly control modes.

V.h.1) Weekly control of CH boiler Weekly control function allows the user to program the pre-set CH boiler temperature changes on specific hours and

days of the week.

In order to activate this function, please select Mode 1 or Mode 2. Detailed settings of each mode are available in the

auxiliary menu: “Set mode 1” and “Set mode 2”.

Having selected the necessary mode, in the main screen you will see the operating temperature deviation value

(below the pre-set CH temperature, contrary than with the advance setting button), which shows to the user that this

function has been activated.

How to change the weekly control settings? ST-560 controller allows the user to program the weekly control function on two modes: “MODE 1” – the user sets

temperature deviations for all days of the week individually; “MODE 2” – the user sets temperature deviations for all

business days (Monday - Friday) and for weekends (Saturday and Sunday) individually.

How to configure mode 1?

In order to configure mode 1, please select “Set mode 1” – the monitor shows the point of the specific days of the

week.

When the specific day of the week is selected, the screen shows the editing post - the upper row shows the current

deviation, the bottom row shows the time-period.

Please use and to change the time-period. In order to edit the value of deviation, use and .

In order to copy the parameter of the other time-period, please use .

When the temperature changes for the prepared specific day, please press “CONFIRM” icon – the screen will show

the screen allowing to copy the settings on other days.

For example:

Monday

Set: 300, temp. -100C (weekly control parameter – 100C) setting: 400,

temp. -100C (weekly control parameter – 100C) setting: 500 , temp. -100C

(weekly control parameter – 100C)

In this case, if the advance CH boiler setting temperature is 600C, from 300 to 600

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On Monday, the pre-set temperature drops down to 100C, for the temperature to reach 500C.

How to configure mode 2?

In order to configure mode 2, please select “Set mode 2” – the monitor shows the desk of two-days group –

Monday - Friday and Saturday - Sunday. Please choose the group you want to edit and follow the same procedure as

shown in Mode 1.

For example:

Monday- Friday

Set: 300, temp. -100C (weekly control parameter – 100C) setting: 400, temp.

-100C (weekly control parameter – 100C) setting: 500, temp. -100C (weekly

control parameter – 100C)

Saturday-Sunday

Set: 400, temp. 50C (weekly control parameter – +50C) setting: 500,

temp. 50C (weekly control parameter – +50C) setting: 600, temp. 50C

(weekly control parameter – +50C)

In such case, if the advance CH boiler setting temperature is 600C on each day of the week (Monday-Friday) from 300

to 600, the pre-set temperature drops by 100C, when the temperature reaches 500C. On the weekend from 400 to 700, the

pre-set CH boiler temperature increases by 50C, therefore, the temperature reaches 650C.

Note

For proper operation of the weekly control, it is necessary set the current time and day of the week in

technical maintenance menu >> “Time settings”.

Remove

This function allows the user to eliminate all weekly control settings.

V.h.2) Weekly control of DHW boiler This function allows the user to program everyday DHW temperature changes. Temperature deviation setting

interval +/-10⁰C. In order to configure DHW weekly control settings, please follow the steps indicated in CH boiler

weekly control manuals.

V.i) Operation modes The user can select one of the following modes:

V.i.1) Domestic heating When this function is selected, only the house is heated. CH pump is activated when the temperature exceeds the

pump activation threshold. In case of lower temperature, (minus 2oC – hysteresis), the pump is disconnected.

V.i.2) Water tank priority

By this mode, the water tank (DHW) pump is activated first and then it functions until the pre-set DHW temperature

is reached (the valve is closed in case of achievement of the maximum temperature and valve pumps are

disconnected). (Together with pumps - according to their settings).

The valves are functioning continuously until the temperature of the water tank drops below the pre-set

value minus hysteresis. Then the valve pumps are disconnected and the DHW pump is connected.

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V.i.3) Parallel pumps According to this mode, all connected pumps and valves are functioning at the same time. The valves support the

pre-set temperature and the water tank is heated until the pre-set temperature.

V.i.4) Summer mode When this mode is connected, CH valves are closed to prevent from additional heating of home. If the CH boiler

temperature is too high, the valve is opened at emergency mode (it is necessary to activate the reverse protection!).

When this mode is set, the water tank pump and base valves function according to the settings.

V.i.5) Floor heating This function is used to disconnect the control of underfloor heating system.

When this option is rejected, the control function closes all the valves attributed to this underground type (see valve

parameters technical maintenance menu). The default settings – function is activated.

V.i) Thermal disinfection Thermal disinfection covers DHW and can be activated only in the “Water tank priority” mode or “Parallel pump”

mode.

During this disinfection the water temperature in DHW chain reaches min. 60°C (necessary disinfection

temperature).

It is necessary to set DHW device when the thermal disinfection would be performed at least at 60°C (recommended

temperature: 70°C). Piping, reinforcement and technological DHW system design should meet the requirements.

DHW disinfection is aimed at removing Legionella pneumophila - bacteria that weakens the immunity system. Such

bacteria usually proliferates in hot water tanks (optimum temperature: 35°C), it usually happens in water tanks.

When this function is activated, the water boiler is heated until the pre-set temperature is reached. The temperature is

maintained throughout the entire disinfection time (e.g. 10 min.). The standard operation mode is restored.

Disinfection temperature should be reached within 60 min. from the start of activation (default parameter).

Otherwise, this function would be automatically disconnected.

Any changes of this system could be entered only at the time of technical maintenance.

V.j) Screen settings The main screen settings can be adjusted according to the needs of the user.

V.j.1) Screen view The user can change the main screen view by choosing the desk to show the current controller parameters.

V.j.2) Screen brightness This function is used to adjust the brightness of the screen in 10 - 100% interval.

V.j.3) Screen blinking This function can be used to regulate the brightness of empty screen in 0 – 50% interval.

V.j.4) Suppression time This function allows the user to set the screen suppression time.

V.k) Adjustment menu All settings in the adjustment menu are described in detail in the sections of this manual.

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V.l) Maintenance menu Access to the technical maintenance menu is restricted to the qualified personnel, therefore, it is protected with a

security code that can be provided by the technical maintenance company.

V.m) Language This function is used to select language.

V.n) Software version This function provides access to the controller’s software data.

V.o) Factory settings This function allows the user to restore factory settings saved by the manufacturer.

V. Controller functions - Adjustment menu Adjustment menu can be accessed by qualified personnel only. It is used to adjust the additional controller functions

such as CH boiler parameters, additional valves, additional pumps, etc. It also permits the user to achieve expanded

settings of basic functions (e.g. Parameters of installed valves).

Below is the simplified adjustment menu block diagram.

• Adjustment menu

• Operational algorithm option

• Full modulation

• Modulation 30%

• Modulation 40%

• Modulation 60%

• Modulation 80%

• Modulation 100%

• Buffer parameters

• Buffer

• OFF

• ON

• Pre-set temperature top

• Pre-set temperature bottom

• DHW function

• From the buffer

• From CH boiler

• Valve settings

• Installed valve 1

• Installed valve 2

• Valve 1

• Valve 2

• Auxiliary contact

• Device type

• CH pump

• DHW pump

• Circulator pump

• Floor pump

• Room regulator

• TECH RS regulator

• Standard regulator 1

• Standard regulator 2

• CH pump station regulator

• Time settings

• Clock settings

16

• Date settings

• Fuel level calibration

• Full tank

• Empty tank

• External temperature correction

• Correction values

• Average

• GSM module

• ON

• OFF

• Ethernet module

• ON

• OFF

• DHCP

• IP address

• IP mask

• Lock address

• DNS address

• Module version

• Restore module password

• Factory settings

VI.a) Operational algorithm option This function allows to choose the controller operation algorithm: full modulation or one of modulation stages.

Controller operation on each mode is described in detail in Section IV.

VI.b) Buffer parameters These parameters are used to regulate controller’s operation in the heating system with a buffer.

Buffer

When the buffer is activated (ON is selected) in the controller’s menu, CH pump is used as amortisation equipment

with two sensors: top (C1) and bottom (C2). The pump remains connected until the pre-set temperature bottom of the

buffer is reached. When the temperature drops below the pre-set temperature top, the pump is activated once again.

Pre-set temperature top

This function allows the user to set the pre-set buffer temperature top. When this value is reached, the pump is

disconnected (provided that pre-set buffer temperature bottom was reached.

Pre-set temperature bottom

This function allows the user to set pre-set buffer temperature bottom.

DHW function

If a buffer is installed in the heating system, it is necessary to indicated how to connect the water tank:

- From CH boiler - heating system where DHW tank is connected directly to CH boiler (separate chain).

- From buffer - heating system where the DHW tank is fitted to or connected to the buffer.

17

VI.c) Valve settings The module fitted in ST-560 controller regulating the mixing valve. For control valves (e.g. ST-431N), it is possible

to connect two additional modules. The interval of parameters allows the user to adjust the performance of the valve

according to the individual needs. When a specific valve is activated, the monitor shows additional menu where it is

possible to configure valve parameters.

The parameters of both installed valves and additional valve are similar as provided in the flowcharts:

• Installed valve

• ON

• Valve disconnected

• Pre-set valve temperature

• Opening time

• Type of valve

• CH

• floor

• Room regulator

• Control without room regulator

• RS regulator - reduction

• RS regulator - proportional

• Standard regulator

• Room reg. temperature is lower

• Room regulator CH pump

• Valve closing

• Air basis control

• Valve pump

• Always turned on

• Always turned off

• Turned on above the threshold valve

• Turn on the temperature

• Reverse flow protection

• ON

• OFF

• Minimum temperature

• CH boiler protection

• ON

• OFF

• Maximum temperature

• Opening direction

• Left

• Right

• Single stroke

• Minimum opening

• Proportionality coefficient

• CH sensor option

• CH sensor

• Additional sensor 1

• Calibration

• Measurement stopping

• Factory settings

• Additional valve 1, 2

• Registration

• Valve disconnected

• Pre-set valve temperature

18

• Opening time

• Type of valve

• CH

• floor

• Room regulator

• Control without room regulator

• RS regulator - reduction

• RS regulator - proportional

• Standard regulator

• Air basis control

• Valve pump

• Always turned on

• Always turned off

• Turned on above the threshold valve

• Turn on temperature

• Reverse flow protection

• ON

• OFF

• Minimum temperature

• Single stroke

• Minimum opening

• Proportionality coefficient

• CH sensor option

• CH sensor

• Additional sensor 1

• Sensor option

• Calibration

• Measurement stopping

• Factory settings

• Valve dismantlement

VI.c.1) Registration In case of additional valves, it is necessary to register the valve by entering the number of module (indicated on the

module frame, e.g.: ST-431N) in order to configure its parameters.

VI.c.2) Valve activation/deactivation This function allows the user to deactivate the control.

VI.c.3) Pre-set valve temperature This parameter defines the necessary temperature to be maintained by the valve. In case of proper operation, the

water temperature behind the valve comes closer to the pre-set value.

VI.c.4) Opening time This parameter defines the time necessary for the valve solenoid to open the valve in the 0% to 100% position. This

valve should be adjusted by the value according to solenoid nominal value.

VI.c.5) Type of valve With this parameter the user selects the type of controlled valve:

19

o “CH” - selected if the user wants to control CH chain temperature.

o “FLOOR” - selected if the user wants to control the temperature of underfloor heating chain. It protects the underfloor heating equipment from hazardous temperature. If the user chooses CH as the type of valve and connects it with the underfloor heating system, it can damage the fragile floor equipment.

VI.c.6) Room regulator This function allows the user to select and to set the room regulator operation that controls the valve.

o Control without room regulator

This option must be chosen if the user does not want the room regulator to influence the operation of the valve.

RS regulator - reduction

This option must be selected if the valve is controlled with room regulator with RS interface by reducing the pre-set

temperature with advance value. In case of selection of this function, the menu shows option: “Room reg. temp

lower”

o RS regulator - proportional

When this type of room regulator is selected, the valve is controlled according to Change of pre-set valve temp. and

Room temperature difference parameters (these parameters are shown in menu when this preparation is selected). By

activating this room temperature regulator, you can monitor the current temperature of CH boiler, water tank and

valves. The regulator must be connected to ST-650 controller RJ (telephone) socket by using 4-strand cable with

respective plugs (RS socket).

o TECH standard regulator

This option is selected if the valve is controlled by room regulator with RS interface. Regulator functions according

to the parameter set by Room reg. temp lower.

o Standard valve regulator

This option should be selected if the valve is controlled by the room regulator of two conditions (without RS

interface).

o Room reg. temperature lower

This function is activated only if TECH standard regulator or standard valve regulator is selected. The user defines

the valve temperature reduction value which is reduced when the room regulator reaches the pre-set temperature.

o Room temperature difference

Note

These parameters are related to RS regulator - proportional.

This setting is used to define the single change in the current room temperature (the precision is 0.1°C), when the

pre-set valve temperature is changed (the function is accessed only by TECH room regulator with RS interface).

For example:

Setting: room temperature 0.5ºC difference setting: change the pre-set valve temperature by 1ºC

20

Setting: pre-set valve temperature 40ºC

Setting: pre-set room regulator 23oC temperature

1st case. If the room temperature increases up to 23.5ºC (0.5ºC above the pre-set room temperature), the valve is

closed in such a scope that the pre-set value of valve reaches 39ºC (temp. reduction by 1ºC).

2nd case. If the room temperature drops down to 22ºC (1ºC below the pre-set room temperature), the valve is opened

in such a scope that the pre-set value of valve reaches 42ºC (temp. increase by 2ºC).

o Pre-set temperature change

Note

These parameters are related to RS regulator - proportional.

This parameter is used to set valve temperature degrees used to increase or decrease single change of room

temperature unit (see: Room temperature change). This function is activated with TECH room regulator and related

to room temperature difference parameter.

o Room regulator valve pump

When this function is selected, the valve pump is disconnected after the pre-set room regulator temperature is

reached.

o Valve closing

When this function is selected, the valve is closed after the pre-set room regulator temperature is reached.

VI.c.7) Air basis control

Air control function shall be activated, the external sensor shall be protected from sunlight or the effect of

weather conditions should be removed. When installed in a necessary place, it is necessary to turn on “weather

control” function in controller menu.

For proper functioning of valves, the user defines the pre-set temperature (behind the valve) in 4 interim external temperatures: -20ºC, -10ºC, 0ºC and 10ºC. The user chooses external temperature value with LEFT and RIGHT KEY and defines the pre-set temperature with

arrows UP and DOWN. The monitor the shows the heat curve.

Heat curve is a curve used to set the controller’s temperature according to the external temperature. In our controller,

this curve is related to four external temperatures.

The more the dots in the curve, the higher is the precision that ensures the flexibility. In our opinion, the four dots

curve provides a very good compromise, therefore, it is possible to set the curve form in a precise and easy manner.

VI.c.8) Valve pump

Valve pump This option allows the user to choose the pump operation mode:

“always ON” - the pump operates continuously despite the temperature;

“always OFF” - the pump is constantly disconnected and the regulator controls only the valves;

“ON above the threshold” – the pump operates on a higher than pre-set temperature. If the pump is

activated above the threshold temperature, the user must set pump activation threshold temperature.

21

VI.c.9) Reverse flow protection This function allows to set boiler protection parameters for the cool water not to return from the main circulator

piping that may result in the corrosion due to low temperature. The protection of this reverse flow is set by closing

the valve when the temperature is too low until the necessary temperature is reached in the boiler short circuit. After

activation the user sets the minimum acceptable reverse flow temperature.

VI.c.10) CH boiler protection

Note

This function is accessible when the valve is installed.

Protective function protects from excessive temperature formed in the CH boiler. The user sets the minimum

acceptable temperature of the return cycle. If the temperature increases dangerously, the valve is closed to cool down

the CH boiler. This function acts throughout the entire time.

VI.c.11) Opening direction

Note

This function is accessible when the valve is installed.

If after the connection of valve to the controller it appears to be connected in a reverse order, it is not necessary to

change the power cable. It is enough to change the opening direction of this parameter:

LEFT or RIGHT

VI.c.12) Single stroke It is a maximum single stroke (closing and opening) for one temperature sample to be performed with the valve. If

the temperature almost meets the set temperature, the stroke is calculated according to PROP_COEFF parameter

value. The lower the single stroke, the more precise is the setting of temperature. However, it takes longer to reach

the set temperature.

VI.c.13) Minimum opening The parameter indicates the lowest valve opening parameter. Due to this parameter, the valve can be opened only

minimally to support the lowest possible flow.

VI.c.14) Proportionality coefficient

Proportionality coefficient is applied to define valve stroke. The closer is the pre-set temperature, the lower is the

stroke. If the coefficient is very high, the valve takes less time for opening, but at the same time the opening is not

that precise. This formula is used to calculate the single opening percentage:

(PRE-SET_TEMP - SENSOR_TEMP) * (PROP_COEFF /10)

VI.c.15) CH sensor option This option is used to select the sensor used as CH sensor. It can be CH sensor or additional sensor (e.g. when a

buffer is used in the system).

22

VI.c.16) Sensor option

Note

The function is accessed only for the additional valve (the external module is necessary).

This option covers the reverse flow sensor and internal sensor. It allows the user to decide which sensor will be used

for data to be submitted to operate the additional valve (valve module sensors or main controller sensors).

VI.c.17) Calibration This function lets the user to calibrate the installed valve at any time. During this procedure, the valve is set in a safe

position - if the CH valve is opened, and the basic valve is closed.

VI.c.18) Measurement stopping This parameter sets water temperature measurement frequency (control) behind CH valve. If the sensor does not

show temperature change (deviation from pre-set value), the electric valve will be opened or closed in the set stroke

or returned to the initial temperature.

VI.c.19)Maximum surface temperature

Note

This option is accessible when the base valve is selected.

This function defines the maximum valve sensor temperature (if the base sensor is selected). When this temperature

is reached, the alarm is activated and the valve is closed.

VI.c.20) Factory settings

This function allows the user to restore the factory settings of the selected valve. The parameters of factory settings

do not change the selected valve type (CH or basic).

VI.c.21)Valve dismantlement

Note

The function is accessed only for the additional valve (the external module is necessary).

This option is used to dismantle the valve from controller’s memory. Valve dismantlement function

The valve is dismantled or the module is changed (it is necessary to register the new module).

VI.d) Auxiliary contact

This additional menu provides the parameters to calibrate the additional pump connected to the controller. When the

type of pump is selected, the monitor shows additional menu where it is possible to configure the parameters of the

additional valve. The following flowchart of CH boiler settings is provided:

• Auxiliary contact

• OFF

• CH pump

• Temperature threshold value

• Hysteresis

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• Sensor option

• DHW pump

• Temperature threshold value

• Hysteresis

• Pre-set temperature

• Maximum temperature

• Sensor 1 option

• Sensor 2 option

• Circulator pump

• Operation time

• Break duration

• Operation schedule

• Base pump

• Minimum temperature

• Maximum temperature

• Sensor 1 option

• Sensor 2 option

VI.d.1) CH pump When this option is selected, the additional pump is operated as CH pump. The pump is activated when sensor

temperature exceeds the threshold value of temperature. It is necessary to configure these parameters for this

function to act properly

o Temperature threshold value

This parameter defines the time of additional pump activation which is operated as CH pump. When the selected

sensor reaches this temperature, the pump is activated.

o Hysteresis

This parameter defines the hysteresis of threshold temperature of additional CH pump. It is the difference between

the threshold temperature and disconnection temperature. E.g.: when the threshold temperature reaches 40°C and

hysteresis 5°C. When the threshold temperature is reached, the CH pump is activated. It is deactivated when the

temperature drops down to 35°C).

o Sensor option

It allows the user to choose which sensor should provide data to activate the additional CH pump.

VI.d.2) DHW pump When this function is used, the additional pump is operated as CH pump. The pump is activated when sensor 1

temperature exceeds the threshold value of temperature. It remains activated until the temperature measured by

sensor 2 reaches the pre-set value. Furthermore, it is possible to set the alarm temperature with sensor 2. When this

value is reached, the emergency mode is turned on. It is necessary to configure the following parameters for the

proper functioning of DHW pump:

Temperature threshold value

This option is used to set DHW pump activation temperature (the temperature is measured with sensor 1 which

shows the temperature of the heat source - CH boiler). Below this temperature the pump is deactivated, when the

temperature is higher, it functions until the pre-set temperature is reached.

o Hysteresis

This option is used to set the pre-set temperature hysteresis.

In case this pre-set temperature is reached, the pump is deactivated. It is activated again when the sensor temperature

drops below the pre-set temperature minus hysteresis.

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E.g. if the advance temperature reaches 60oC, and the hysteresis value is 3°C, DHW pump is deactivated when the

pre-set 60oC temperature is reached and activated again, when the temperature drops down to 57

oC.

o Pre-set temperature

This option is used to pre-set the temperature of the device. When this temperature is reached, the device is

disconnected. The temperature is measured with sensor 2.

o Maximum temperature

This option is used to set the maximum temperature of sensor 1 (it measures the temperature of the heat source).

When the temperature is reached, the devices is activated despite the current temperature of sensor 2. It protects the

device from overheating.

o Sensor 1

This option is used to select sensor temperature to provide device operation data which is connected to the additional

contact - the source of heat (activation threshold).

o Sensor 2

This option is used to select sensor temperature to provide device operation data which is connected to the additional

contact - the source of heat (pre-set temperature).

VI.d.3) Circulator pump In case this option is selected, the additional pump is operated as circulator pump. The pump controls the valve

which mixes hot water circulating between CH boiler and DHW collection tanks. It is necessary to configure the

following parameters for proper functioning of the circulator pump:

o Operation time

This parameter defines pump operation duration.

o Stopping

This parameter indicates the frequency in which the circulator pump is activated during its operation.

o Operation schedule

The user may program the everyday schedule of pump operation and inaction in the precision of 30 min. The pump

is turned on in the frequency shown in “Pause time” parameter and remains active for the period of time set in the

“Operation time”. It is possible to copy the time setting.

VI.d.4) Base pump In case this option is selected, the additional pump is operated as the base pump. The operation is configured

according to the following parameters:

Minimum temperature

This parameter defines the activation temperature of base pump (temperature reading is provided in sensor 1). The

temperature is measured in CH boiler buffer.

Maximum temperature

This parameter defines the deactivation temperature of base pump (temperature reading is provided in sensor 2).

Sensor 1 option

This function is used to select the sensor providing the activation data of base pump (it includes the Minimum

temperature parameter).

Sensor 2 option

This function is used to select the sensor providing the activation data of base pump (it includes the Maximum

temperature parameter).

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VI.e) Room regulator This function allows to set the operating parameters of room regulator which is connected to the pellets-fired boiler

controller. It is necessary to launch room regulator which is connected by choosing the necessary room regulator

type. Up to three room regulators can be connected to the controller.

VI.e.1) TECH RS regulator Select this option if you want to connect room regulator with RS interface. Such regulator lets the user to review the

current CH boiler parameters and to change certain settings, e.g. advance CH boiler temperature, advance DHW

temperature.

VI.e.2) Standard regulator 1 / Standard regulator 2 Select this option if you connect the regulator of two technical conditions. Such regulator sends a signal to the main

controller and indicates whether the room temperature was achieved or not.

VI.e.3) Room regulator CH pump If this function is activated, the CH pump is deactivated when the room regulator sends a signal notifying about the

reached room temperature.

VI.f) Time settings This function is used to set the desired time. This setting is important for the weekly control in order for the device to

function properly.

VI.f.1) Clock settings This function is used to set the current time.

VI.f.2) Date settings This function is used to set the current date.

VI.g) Fuel level calibration After the proper performance of fuel level calibration, the user can review the current fuel level in the controller’s

screen. During the first step, the fuel is filled to the fuel tank and the option “Fuel tank full” is selected. The

controller remembers this level (100%).

When no fuel is left in the fuel tank after a certain period of time of CH boiler operation, the user shall

choose the option “Fuel tank empty”. This allows the fuel tank to be calibrated and the controller automatically

informs the user on the current fuel level. When the fuel level desk is chosen in the main screen, the monitor shows

the set amount of the remaining fuel (%) and the forecasted time for the consumption of fuel (days and hours).

Such calibration is usually performed once. When the fuel tank is filled again, it is enough to select option

“Fuel tank full” in the user menu.

VI.h) External temperature correction This function allows the calibration of the external sensor.

VI.i) GSM module

NOTE

This control type is applied in case of acquisition and connection of additional control module ST-65 which is not included in the standard controller set.

GSM module is a selected device which communicates with another controller and lets the user to control CH boiler

with a mobile phone (remotely). The user sends SMS each day when the alarm goes on. Furthermore, after sending

the text report, the user receives

26

a reply on the current temperature of all sensors. After the confirmation code is entered, it is also possible to

change the set temperature remotely.

The GSM module can function irrespective of the CH boiler controller. It contains two additional devices with

temperature sensors, one entered contact which is used at any configuration (contact closing/opening setting) and

one controlled output (e.g. the possibility to connect additional contact, to be used for the control of any electrical

circuit).

When any sensor reaches the maximum and minimum set temperature, the module automatically sends the SMS

message with such information.

A similar procedure is applied when opening or closing contact input which can be used as the ordinary property

protection mean.

If GSM module is planned in the ST-560 controller, it should be activated by choosing “ON option

(MENU>Fitter's menu>GSM Module>ON)”.

VI.j) Internet module

Note

This type of control is accessible when acquiring and connecting additional module ST-505 which is not included

in the standard set of controllers.

Internet module is a device allowing the user to control CH boiler remotely by internet or local network.

The user controls all CH boiler system devices in the home computer screen and each operating device is

illustrated in the scheme.

In addition to the possibility to review the temperature of each sensor, the user can change temperatures of

pumps and mixing valves.

Having activated the module and selected DHCP option, the controller automatically sends such

parameters to the IP address, IP mask, lock address and DNS address from the local network. If any problems

arise when sending the network parameters, they can be set manually. The procedure for the receipt of such

parameters is described in internet module manuals.

“Module password reset” function is applied when the user changes the default passwords in the login

page. If the user loses the new password, the default password may be restored by setting the module password

anew.

VI.k) Factory settings This function is used to restore factory settings.

VI. Protective equipment and alarms In order to ensure safe and smooth operation, the protective equipment is fitted in the regulator. In case of alarm,

the sound signal is activated and the monitor shows a respective message.

In order for the controller to function on the operating mode, press “MENU”. In case of “CH temperature too

high” alarm, it is necessary to wait until the temperature drops below the alarm temperature.

VII.a) Fire control During the CH boiler operation, the controller sets the loss of flame (due to fire sensor). If the loss of flame is set,

the controller moves to the second extinguishing stage (see Section IV) – please use the grating cleaning

indications. Then the ignition procedure is performed anew.

VII.b) Thermal CH boiler protection

The bimetal mini sensor is fitted in the controller (fitted next to the CH boiler temperature sensor) which

automatically disconnects the fan from the power network when the alarm temperature exceeds 90oC. It does not

allow the water to boil in the boiler.

27

Otherwise, the boiler would overheat and this would cause damage to the controller. When this protective

equipment is activated and the temperature drops down to the safe level, the sensor automatically turns off. In

case the sensor is damaged or overheated, the ventilator is also disconnected.

In case the CH boiler protective equipment is of a closed system type, the STB type temperature limiter is

used instead of bimetal mini sensor.

VI. C) Automatic sensor control In case of damage to one of the temperature sensors (CH, DHW or fuel tank), the alarm signal is activated and

the monitor informs about the failure, e.g.: “CH sensor damaged”. Both the feeder and the fan are deactivated.

The pump functions despite the current temperature.

If CH sensor or feeder sensor are damaged, the alarm is activated until the installation of a new sensor. If DHW

sensor is damaged, the alarm must be deactivated by pressing the “MENU” button – the controller restores the

operation with a single pump (CH). The new sensor has to be installed in order to use all the CH boiler operation

modes.

VII.d) CH boiler protection from the boiling water

This protection is applied only for the water boiler priority mode when the water tank is not sufficiently heated.

When the set water boiler temperature is 55OC, whereas the actual CH boiler temperature reaches 62OC (also

called the priority temperature), the controller disconnects the fan feeder. If the CH boiler temperature is

increasing and reaches 80OC, the CH pump is switched on. If the temperature increases further, the alarm is

activated under the 85OC temperature. It usually happens when the water boiler or the pump are damaged or in

case of improper installation of the sensor. When the temperature drops down at 60OC, the controller turns on the

fan and the feeder and operates on the set mode until the temperature of 62OC is reached.

VII.e) Temperature protection

The controller is characterised by additional protection against hazardously increasing temperature. If the alarm

temperature exceeds 83oC, the fan is deactivated and the pumps are activated to distribute hot water throughout

the entire equipment. When the temperature exceeds 85OC, the alarm is activated and the monitor shows the

following alarm message: “Temperature too high”

VII.f) Thermal CH boiler protection (STB) STB safety thermostat is installed in a closed CH system controller which protects the CH boiler from extensive

increase in the temperature. In case the pre-set “disconnection” value is exceeded (default value: 95oC), the

feeding circuit contacts of the fan are opened. The fan can be reactivated only manually after pressing the safety

thermostat “reset” button for the sensor to cool down.

VII. h) Fuse

The fuse WT 6.3A that protects the network is installed in the controller.

It is not possible to use a higher capacity fuse as this may lead to the damage of the controller.

VII. Maintenance and technical data

Before and during the heating season, it is necessary to check the technical condition of ST-560 controller

cables. The user also has to check if the controller is well installed and it must be clean. It is recommended to

measure the earthing parameters of engines (CH pump, DHW pump, fan and feeder).

28

TECHNICAL DATA

No Specification Unit

1 Supply voltage V 230V/50Hz +/-10%

2 Power consumption W 10

3 Ambient temperature OC 10÷50

4 Feeder output load A 2

5 Pump output load A 0.5

6 Fan output load A 0.6

7 Temperature measurement interval OC 0÷90

8 Measurement accuracy OC 1

9 Temperature parameter interval OC 45÷90

10 Sensor thermal resistance OC -25÷99

11 Fuse A 2x6.3

29

Principal scheme of the connection of controller’s regulated devices and sensors

1. Pellet boiler + radiators + boiler + floor heating

30

T4

FAUCET

PUMP

DIRT COLLECTOR

3-WAY VALVE

NON-RETURN VALVE

SAFETY GROUP

EXPANSION

VESSEL

Automatic mixing unit LK ARMTUR

810 or LADDOMAT 21

BOILER CONNECTION SCHEME

Before the boiler is started for the first time, it is necessary:

- to check if the heating system and devices are in compliance with the project;

- to check if the heating system and the boiler are filled with water and the air is discharged from the system; - to check if the heating system is hermetic; - to check the exhaust emissions channels; - to test the heating regulation;

- to familiarize the user with boiler manual and the terms of use; - to provide the date of initial putting into operation in the warranty sheet.

Use of boiler

Removal of ashes:

In view of the quality of used fuel, the ashes are removed in various periodicity, but sufficiently frequently for

the ashes not to reach the upper part of the burner. The ashes are usually eliminated when the boiler is not

operating and filled with fuel.

Note. Before starting to clean the boiler, it is recommended to wear gloves.

Cleaning of boiler and burner:

IMPORTANT! For the proper functioning of boiler, there should be no resin, volatile ashes or

soot on their internal walls. For this reason, it is necessary periodically but at least once in two

weeks to clean the boiler and the burner with the scraper and brush. Before cleaning the burner,

the boiler should be cooled down. In case the boiler is cooled down, it is necessary to remove the

pellets from the top part of the burner down to the elbow. After the removal of pellets, it is necessary to

clean the walls of burner carefully and to clean the air feed openings. When the cleaning is performed,

the burner can be removed from the boiler for easier cleaning.

If the diameter of the burner is significantly narrowed and a solid ring is formed (Example 1), the burner

requires cleaning.

Example 1

Example 2

31

Please use the hammer, scraper or other

tools to clean the burner and to eliminate

the formed ring and other dirt. For your

convenience, we recommend to remove

the burner from the boiler. This will

ensure easier cleaning process. Please

remove the accumulated ring by hitting

hard with the hammer and remove the

remaining dirt with a scraper or any

other abrasive tool. After cleaning, the

burner should look as in the picture

below (Example 2).

Maintenance

IMPORTANT! The boiler can be maintained by an adult only who has already familiarised with

its functions and the term of use. The person who performs the maintenance of the boiler shall follow the

boiler’s user manual, set the desired heating water temperature, stop the boiler and control its

operation. The person in charge of the maintenance of the boiler shall be familiarised with

boiler’s functions and the terms of use by the service employees when the boiler is installed and

ready for work. During the performance of such works, the children are prohibited from being near the

boiler. It is strictly forbidden to disturb the operating mode of the boiler if the device can cause a risk to

the health and life of persons who perform the maintenance of boiler or other persons. The boiler can be

used up to the highest water temperature of 85 °C.

Maintenance of boiler

At least once every 14 days it is necessary to check the condition of heated water in the boiler and in the entire

heating system (to check if there is no leakage and lack of water). If the water content is not sufficient in the heating system, it is necessary to fill it. After the end of the heating season, it is necessary to clean the boiler thoroughly and to replace the damaged parts. The average duration of the glass fibre sealing rope usage is 0.5 years (subject to the frequency of opening of doors). If the sealing rope is pressed and is not suitable to be used according to the purpose of use, it is possible to adjust the closing and hinges or to take out the rope from the grooves of doors, to rotate by 90° and to reinsert to the groove of the doors. It is only a temporary solution,

therefore, it may be necessary to replace the sealing rope immediately. At least twice a heating season, it is necessary to dismantle the ventilator and to clean the blade of

ventilator’s rotor. After the end of the heating season, it is necessary to perform the general thorough cleaning of the boiler. During the general cleaning, it is necessary to clean well the heat exchanger, burner, walls of the boiler, box of ashes by removing all ashes, soot and other dirt. In case of performance of the general cleaning, it

is recommended to cover the inside of the boiler with anti-corrosive material. The content of soot and volatile ashes depends on the quality of fuel and maintenance conditions. The soot and volatile ashes tend to accumulated more if the boiler is of higher capacity than necessary or the boiler is used under the temperature that is too low.

Replacement of door sealing rope

It is necessary to remove the sealing rope from the door notch and clean the notch. A new sealing rope is placed to the cleaned notch. The start of the rope is inserted to the horizontal notch of the doors. The rope is inserted to the notch of door perimeter manually or by gently hitting with a small hammer. The doors are then slightly

closed and the rope is pushed to the notch so that it could be easy to close the doors.

The Manufacturer:

UAB “Biokaitra”

Company number: 302482922 , VAT payer’s number: LT 100005239513

Laisvės pr. 3, LT-04215 Vilnius, Lithuania

Tel.: +370 5 219 56 13, fax: +370 5 278 49 15

E-mail: info@biokaitra.lt ,

Website: www.biokaitra.lt

32

Example of boiler specifications plate

33

Water boiler

“BIO 30”

Nominal power Qn 30 kW

Power - Qn 9-30 kW

Maximum permissible operating

water temperature, TS

85oC

Maximum permissible operating

pressure, PS

2 bar

Water tank 84l

Required electric power 200W

Electric connection 50Hz/220V

Date of manufacture 2013-03-25

Boiler class 5

Serial No 30UV11S8500001

Fuel class according to EN 303-

5:2012

C1

UAB “Biokaitra”

Šv. Stepono 27-28, LT-01312

Vilnius, Lithuania

DECLARATION OF CONFORMITY No BIOAD/14109-LT2

09.01.2014

Vilnius

We, UAB „Biokaitra“, company number 302482922, assume the responsibility and declare that the

following models of water boilers

BIO20

BIO30

BIO50

BIO95

are related to this declaration and are in compliance with the following provisions and the

requirements of standards:

- Pressure vessels technical regulation directive PED 97/23/EC

- Machine directive 2006/42/EC

- Directive on Electrical equipment designed for use with certain voltage limits 2006/95/EC

- Electromagnetic compatibility directive 2004/108/EC

- Heating boilers for solid fuels standard LST EN 303-5

UAB “Biokaitra”

General Director /Signature/ Židrūnas Mackevičius

/Seal:

The Republic of Lithuania

Vilnius

UAB “Biokaitra”/

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Please send the filled-out Warranty Certificate and copies of the Warranty Certificate Supplement to the

manufacturer by e-mail: info@biokaitra.lt or by fax: +370 5 2784915

WARRANTY CERTIFICATE

Product: Boiler BIO20, Serial No __________________________

The Manufacturer: UAB “Biokaitra”, Laisvės pr. 3, LT-04215 Vilnius, Lithuania.

This Warranty Certificate is adequate to the quality certificate

1. WARRANTY APPLICATION TERMS

- In case of sale, the Seller must familiarise the Buyer with the warranty application terms, to confirm the

warranty certificate and present the service manual.

- The manufacturer shall be liable under the warranty only if the failure originates as a result of causes

inherent to the device.

- The boiler with fuel feeder and burner must be installed and put into operation by an organisation certified

by the manufacturer.

- All putting into operation works and services of “Biokaitra” boilers shall be performed by the producer’s

authorised fitter or repair shop (all marks about the performed actions have to be included in the Warranty

Certificate Supplement). Otherwise, the warranty cases to be valid and no warranty-related claims are

accepted.

- The manufacturer shall have a right to choose between the elimination of failure and the replacement of

defected device with a technically fit one.

- The term of warranty is 36 months from the date of sale. The warranty is applied to all components of the

boiler except for the moving parts (screw conveyor, motoreducers, electric motor), controller and fast-

wearing elements (insulation ropes); these parts are subject to 12-month warranty from the date of sale.

- For the warranty to be valid, it is necessary to perform a warranty service after a year of operation. Such

inspection is performed for payment by an authorised repair shop.

- The warranty shall be valid only if the boiler’s model and place of installation are entered and all the

original seals of the seller and authorised fitting company or repair shop as well as the documents certifying

the fact of purchase are present.

2. THE WARRANTY SHALL NOT APPLY IN THE FOLLOWING CASES:

- the boiler’s Warranty Certificate and/or documents certifying the fact of purchase are lost;

- the requirements of the user manual are breached;

- in case of mechanical damage caused to the boiler, bunker, burner, controller, motor, transporter and

fan;

- the damage results from undue connection of boiler;

- no temperature control valve of three or four positions is installed in the system to ensure the

temperature returning to the boiler.

3. THE OWNER UNDERTAKES TO PAY FOR THE SPECIALIST’S VISIT IN THE FOLLOWING

CASES:

- the visit of the employee is not related to the failure of boiler;

- it is related to the causes stipulated in Item 2;

- by mutual agreement (by paying according to the price list approved by the company) for the

specialist’s performed works of putting into operation / fitting of the heating system.

I have familiarised myself with the terms and conditions of device connection and operation as well as

warranty service. I have been informed about the loss of entitlement to warranty service in case of installation

and operation of device without observing the requirements of this manual.

The Buyer

_______________________________________________________________________________

Please send the filled-out Warranty Certificate and copies of the Warranty Certificate Supplement to the

manufacturer by e-mail: info@biokaitra.lt or by fax: +370 5 2784915

35

Warranty Certificate Supplement

Boiler model: _____________________________________________

Controller model and serial number: ___________________________

Date of the original putting into operation: _______________________________________

System installer/person in charge of putting into operation

____________________________________________________________________ (First name, last name, company, signature, seal)

Place of installation (address)

_______________________________________________________________________

Item

No Date Description of performed works Conclusion

First name, last

name and signature

of the specialist

who performed the

works

36

Manufacturer’s copy

Please send the filled-out Warranty Certificate and copies of the Warranty Certificate Supplement to the

manufacturer by e-mail: info@biokaitra.lt or by fax: +370 5 2784915

WARRANTY CERTIFICATE

Product: Boiler BIO20, Serial No __________________________

The Manufacturer: UAB “Biokaitra”, Laisvės pr. 3, LT-04215 Vilnius, Lithuania.

This Warranty Certificate is adequate to the quality certificate.

4. WARRANTY APPLICATION TERMS

- In case of sale, the Seller must familiarise the Buyer with the warranty application terms, to confirm the

warranty certificate and present the service manual.

- The manufacturer shall be liable under the warranty only if the failure originates as a result of causes

inherent to the device.

- The boiler with fuel feeder and burner must be installed and put into operation by an organisation certified

by the manufacturer.

- All putting into operation works and services of “Biokaitra” boilers shall be performed by the

manufacturer’s authorised fitter or repair shop (all marks about the performed actions have to be included in

the Warranty Certificate Supplement). Otherwise, the warranty cases to be valid and no warranty-related

claims are accepted.

- The manufacturer shall have a right to choose between the elimination of failure and the replacement of

defected device with a technically fit one.

- The term of warranty is 36 months from the date of sale. The warranty is applied to all components of the

boiler except for the moving parts (screw conveyor, motoreducers, electric motor), controller and fast-

wearing elements (insulation ropes); these parts are subject to 12-month warranty from the date of sale. The

warranty does not apply to boiler deflector!

- For the warranty to be valid, it is necessary to perform a warranty service after a year of operation. Such

inspection is performed for payment by an authorised repair shop.

- The warranty shall be valid only if the boiler’s model and place of installation are entered and all the

original seals of the seller and authorised fitting company or repair shop as well as the documents certifying

the fact of purchase are present.

5. THE WARRANTY SHALL NOT APPLY IN THE FOLLOWING CASES:

- the boiler’s Warranty Certificate and/or documents certifying the fact of purchase are lost;

- the requirements of the user manual are breached;

- in case of mechanical damage caused to the boiler, bunker, burner, controller, motor, transporter and

fan;

- the damage results from undue connection of boiler;

- if the system has no installed thermal regulation valve of three or four positions;

6. THE OWNER UNDERTAKES TO PAY FOR THE SPECIALIST’S VISIT IN THE FOLLOWING

CASES:

- the visit of the employee is not related to the failure of boiler;

- it is related to the causes stipulated in Item 2;

- by mutual agreement (by paying according to the price list approved by the company) for the

specialist’s performed works of putting into operation / fitting of the heating system.

I have familiarised myself with the terms and conditions of device connection and operation as well as

warranty service. I have been informed about the loss of entitlement to warranty service in case of installation

and operation of device without observing the requirements of this manual.

The Buyer

_______________________________________________________________________________

Please send the filled-out Warranty Certificate and copies of the Warranty Certificate Supplement to the

manufacturer by e-mail: info@biokaitra.lt or by fax: +370 5 2784915

37

Manufacturer’s copy

Please send the filled-out Warranty Certificate and copies of the Warranty Certificate Supplement to the

manufacturer by e-mail: info@biokaitra.lt or by fax: +370 5 2784915

Warranty Certificate Supplement

Boiler model: _____________________________________________

Controller model and serial number: ___________________________

Date of the original putting into operation: _______________________________________

System installer/person in charge of putting into

operation____________________________________________________________________ (First name, last name, company, signature, seal)

Place of installation (address)

_______________________________________________________________________

Item

No Date Description of performed works Conclusion

First name, last

name and signature

of the specialist

who performed the

works

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Warranty Service Sheet

Boiler model:

___________________________________________________________________________________________

Company that performed installation / Fitter’s family name:

__________________________________________________________

Place of installation

(address):___________________________________________________________________

Repair No Repair

date

Failure Comments Signature and seal

of repair shop

representative

1.

2.

3.

4.

5.

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To Director of UAB “Biokaitra”

Warranty Service Application

Having familiarised with the pass and user manual of boiler “BIO - ______” (product No

______________________ _______) and having connected the boiler to the heating system and chimney

according to the requirements listed therein and I have the following claims:

1.______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

_______________________________________________________________________________________

Considering that it is related to the boiler’s defects, I hereby ask to send your representatives for the

inspection of connected boiler, determination and elimination of defects.

If the aforementioned defects of boiler result from improper connection or operation of boiler, I hereby

undertake to cover

the costs of arrival of your representatives: 0.50 EUR/km,

and time of each employee (including the driver) spent on the trip and at the place: 10.00 EUR/hour

If I fail to compensate the aforementioned costs within 7 calendar days, I hereby agree

for them to be recovered from me in accordance with the procedure established by the laws of the Republic of Lithuania.

Address:

First and last name:

Contact phone number:

Date of purchase of boiler:

Date of putting the boiler into operation:

Signature:

Note. Please send by the fax number indicated in technical pass or by e-mail info@biokaitra.lt

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NOTES

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