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Installation manual

pellet boiler

PK 10, PK 15 and PK 20

May 4, 2009

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Summary of Contents for PK 10

Page 1: ...Installation manual pellet boiler PK 10 PK 15 and PK 20 May 4 2009 ...

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: ...2 1 External conveyor screw 12 2 1 1 Rigid conveyor screw from the silo built by the building contractor 12 2 1 2 Flexible conveyor screw from pellet storage room 15 2 1 3 Flexible conveyor screw from bag silo 16 2 1 4 Storage tank with rigid conveyor screw 17 3 System proposals for the pellet boiler 18 3 1 PK2 system package pellet boiler with domestic water heater and buffer tank 18 3 2 PK3 syst...

Page 4: ...the remit of this directive and will therefore not be taken back by KÜNZEL Please take these components to the recycling depot We do not assume any liability for any malfunctions resulting from the use of non genuine KÜNZEL components This particularly applies to control units external materials handling equipment and fuel pipes from other manufacturers We also do not assume any liability for oper...

Page 5: ... operated with a flow line temperature of more than 100 C the boiler plant must be reported to the responsible trade supervisory centre in accordance with the German Ordinance on Steam Boilers The relevant standards and building authority regulations must be complied with Among other regulations the following apply the German Fire Code FeuVo the Federal Immission Control Ordinance BImSchV the VDE ...

Page 6: ... and left below the covering caps On the PK 10 and PK 20 the carry bushings are located at the front below the slanted cover panel and beneath covering caps Once the installation has been completed it should be ensured that the turbo gratings are correctly seated Illustrations on this subject can be found in the operating manual for the pellet boiler in the section entitled Maintenance and care fl...

Page 7: ... hood between washer and clip see pic below Figure 5 Sliding on the hood 1 5 Installation of the burner hood The pellet burner is supplied with the hood mounted For maintenance or cleaning purposes it can be necessary to remove the hood Before starting to do this disconnect the burner completely from the mains power supply When removing the hood proceed as follows Remove the discharge chute cover ...

Page 8: ...re sensible to move the cleaning lever to the left hand side of the boiler although it is only possible to do this on PK 10 and PK 20 boilers Figure 7 The cleaning lever Remove the red panel cover from the boiler and open the register cover located below it with an Allen key Release the screws marked with an arrow in the illustration and withdraw the shaft and handle from the boiler in a rightward...

Page 9: ... combustible components We recommend the use of insulated connectors The figures required for the chimney design calculations can be found in the technical data listed in section 4 on page 25 Calculated chimney diameters that are smaller than the flue gas branch of the boiler are not permissible Important Please note that the low exhaust temperatures occurring during prolonged operation may mean t...

Page 10: ... prevent the pellet boiler from corroding the boiler is operated with an elevated minimum temperature This is 50 C for systems without a buffer tank and 60 C for systems with a buffer tank For this reason a separate return flow temperature booster has to be fitted e g the Thermomix valve Part No 150218 from KÜNZEL Due to the elevated minimum temperatures the heating system must always be equipped ...

Page 11: ...s for the boiler thermostat and the temperature safety limiter are already installed beneath the cover panelling The boiler sensor for the differential temperature control unit must be inserted into a vacant immersion sleeve beneath the cover see fig On the PK 15 the immersion sleeves are below the panelling with the control panel These must be removed previously The screws can be accessed from th...

Page 12: ...etrimental to the combustion process and can lead to increased slagging in the burner 2 1 External conveyor screw 2 1 1 Rigid conveyor screw from the silo built by the building contractor This 3 metre long conveyor screw is supplied with a 240 V motor and is part of the product contents for the PK pellet boiler The conveyor screw is controlled directly by the pellet burner In order for the pellet ...

Page 13: ...air work However please note that the hose must be long enough to allow the burner door to swing open In order to ensure that the external pellet silo is emptied as well as possible position the input to the external conveyor screw in the centre and or at the lowest point of the external silo Please note that a storage room can never be emptied entirely because the pellets generally have an angle ...

Page 14: ... may not protrude from the pipe Figure 13 Outlet angle of the rigid conveyor screw The size of the hole in the wall depends on the wall thickness and the suspension angle For example a suspension angle of 50 and a wall thickness of 10 cm would require a hole height of 26 cm wall thickness cm tan50 14 cm the width remains unchanged at roughly 10 cm Please note Do not touch the conveyor screw when t...

Page 15: ... are to be used if a greater distance has to be bridged The minimum installation radius for the conveyor screw is 1 5 metres All of the curves followed by a conveyor screw must together have an angle of not more than 135 The maximum angle than can be achieved in one bend is 90 After this only one bend with an angle of not more than maximal 45 is permissible but this must be in the opposite directi...

Page 16: ...eaker 9 1 Stk various minor components Further accessories for the storage room 1 Filling connection kit part no 100065 consisting of 2 x Storz connections type ALU 2 x blind cover incl fittings 2 Filling and air bleeding connections 50 mm part no 100060 200 mm part no 100061 500 mm part no 100062 500 mm with earthing clamp part no 100067 1000 mm with earthing clamp part no 100063 3 Bend for filli...

Page 17: ... of the conveyor screw is not required The unit is installed directly onto the outlet of the bag silo using the installation instructions provided with the silo system 2 1 4 Storage tank with rigid conveyor screw Figure 17 Storage tank with rigid conveyor screw 17 ...

Page 18: ...r this system For this reason the Thermomix valve must be fitted Ensure that the boiler circulation pump 15 and the heating pump 18 are correctly matched to one another We recommend installing the Thermomix valve and the buffer tank so that they can be completely iso lated in order to simplify maintenance work Please read the operating and installation manuals for all of the units before installin...

Page 19: ...Figure 19 PK2 system package with hydraulic quick assembly wiring diagrams Wiring diagram Figure 20 Wiring diagram for PK2 system package with hydraulic quick assembly 19 ...

Page 20: ...ment a conventional heating system Ensure that the boiler circulation pump 15 and the heating pump 18 are correctly matched to one another We recommend installing the Thermomix valve and the buffer tank so that they can be completely iso lated in order to simplify maintenance work Please read the operating and installation manuals for all of the units before installing the system The electrical in...

Page 21: ...Figure 22 PK3 system package Wiring diagram Figure 23 Wiring diagram for PK3 system package 21 ...

Page 22: ...ultaneously serves as a return flow booster and a heating mixing valve and thus protects your boiler from corrosion The pellet boiler the domestic hot water tank and the 4 way mixing valve can also be regulated using the optional outside temperature control unit to be integrated in the pellet boiler Please read the operating and installation manuals for all of the units before installing the syste...

Page 23: ...cted to different positions in the layer storage tank This means that the pellet boiler cannot heat up the entire tank and the lower section of the layer storage tank therefore remains exclusively available for the use of solar energy The achieved solar yield therefore strongly depends on the return temperature of the heating system The colder the return temperature also during winter operation to...

Page 24: ...for outside temperature control unit 18 Heating pump 19 Heating system 20 Boiler charging pump 21 Check valve 22 Contact thermostat 23 Oil boiler base plinth 24 Intermediate feed pump 25 Gas hot water heater 26 Automix 27 Boiler thermostat 29 FO15 solid fuel boiler 30 Thermostat 1x changeover contact 31 Solar collector 32 PSW hygienic combination buffer tank 33 Solar domestic hot water storage tan...

Page 25: ...4 Technical data Figure 26 The PK pellet boiler Figure 27 Connecting dimensions 25 ...

Page 26: ...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 27: ...Figure 28 The pellet burner 4 1 Wiring diagrams 1 6 mm and 8 mm pellets that at least comply with DIN PLUS 2 100 mm for lateral cleaning lever 27 ...

Page 28: ...Figure 29 Wiring diagram for pellet boiler 28 ...

Page 29: ...Figure 30 Wiring diagram for PK 230V conveyor screw drive 29 ...

Page 30: ...Figure 31 Wiring diagram for PK 400V conveyor screw drive 30 ...

Page 31: ...Personal notes 31 ...

Page 32: ... ...

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