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45-010 (3) 127 COMBS RD-MASS AUDUBON-PYMCHON MEADOW RD BP-2016-1052 GIS#: COMMONWEALTH OF MASSACHUSETTS Ma -Block: 45-010 CITY OF NORTHAMPTON Lot: -001 PERSONS CONTRACTING WITH UNREGISTERED CONTRACTORS Permit: Buildinq DO NOT HAVE ACCESS TO THE GUARANTY FUND (MGL c.142A) Category: BOILER BUILDING PERMIT Permit# BP-2016-1052 Project# JS-2016-001785 Est. Cost: $26039.00 Fee: $198.00 PERMISSION IS HEREBY GRANTED TO: Const. Class: Contractor: License: Use Group: SANDRI ENERGY LLC 103814 Lot Size(sq.ft.): 14226696.00 Owner: MASSACHUSETTS AUDUBON SOCIETY INC Zoning: Applicant: SANDRI ENERGY LLC AT. 127 COMBS RD - MASS AUDUBON - PYMCHON MEADOW RD Applicant Address: Phone: Insurance: P O BOX 1578 (413) 772-21210 Workers Compensation GREENFIELDMA01302-1578 ISSUED ON:3/1/2016 0:00:00 TO PERFORM THE FOLLOWING WORK.-INSTALL PELLET BOILER POST THIS CARD SO IT IS VISIBLE FROM THE STREET Inspector of Plumbing Inspector of Wiring D.P.W. Building Inspector Underground: Service: Meter: Footings: Rough: Rough: House# Foundation: Driveway Final: Final: Final: Rough Frame: Gas: Fire Department Fireplace/Chimney: Rough: Oil: Insulation: Final: Smoke: Final: THIS PERMIT MAY BE REVOKED BY THE CITY OF NORTHAMPTON UPON VIOLATION OF ANY OF ITS RULES AND REGULATIONS. Certificate of Occupancy Signature: FeeType: Date Paid: Amount; Building 3/1/2016 0:00:00 $198.00 212 Main Street, Phone(413)587-1240,Fax: (413)587-1272 Louis Hasbrouck—Building Commissioner File#BP-2016-1052 APPLICANT/CONTACT PERSON SANDRI ENERGY LLC ADDRESS/PHONE P O BOX 1578 GREENFIELD01302-1578(413)772-2121 O PROPERTY LOCATION 127 COMBS RD-MASS AUDUBON-PYMCHON MEADOW RD MAP 45 PARCEL 010 001 ZONE THIS SECTION FOR OFFICIAL USE ONLY: PERMIT APPLICATION CHECKLIST ENCLOSED REQUIRED DATE ZONING FORM FILLED OUT -41044)04 --agaa Fee Paid /777% Jf1 Building Permit Filled out Fee Paid Typeof Construction: INSTALL PELLET BOILER New Construction Non Structural interior renovations Addition to Existing Accessory Structure Building Plans Included: Owner/Statement or License 103814 3 sets of Plans/Plot Plan THE FOLLOWING ACTION HAS BEEN TAKEN ON THIS APPLICATION BASED ON INFO ATION PRESENTED: '' Approved Additional permits required(see below) PLANNING BOARD PERMIT REQUIRED UNDER:§ Intermediate Project: Site Plan AND/OR Special Permit With Site Plan Major Project: Site Plan AND/OR Special Permit With Site Plan ZONING BOARD PERMIT REQUIRED UNDER: § Finding Special Permit Variance* Received&Recorded at Registry of Deeds Proof Enclosed Other Permits Required: Curb Cut from DPW Water Availability Sewer Availability Septic Approval Board of Health _Well Water Potability Board of Health Permit from Conservation Commission Permit from CB Architecture Committee Permit from Elm Street Commission Permit DPW Storm Water Management D olit' De Signature of Building O icia Date Note: Issuance of a Zoning permit does not relieve a applicant's burden to comply with all zoning requirements and obtain all required permits from Board of Health,Conservation Commission,Department of public works and other applicable permit granting authorities. * Variances are granted only to those applicants who meet the strict standards of MGL 40A. Contact Office of Planning& Development for more information. Version 1.7 Commercial-Buildin Permit May 15,2000 Department use only Zt7� ZOO C1 of Northampton Status of Permit: Bu ding Department Curb Cut/Driveway Permit 2 2 Main Street Sewer/Septic Availability Room 100 Water/Well Availability_ Northampton, MA 01060 Two Sets of Structural Plans,__,,, phone 413-587-1240 Fax 413-587-1272 Plot/Site Plans I Other Specify_ APPLICATION TO CONSTRUCT,REPAIR,RENOVATE,CHANGE THE USE OR OCCUPANCY OF,OR DEMOLISH ANY BUILDING OTHER THAN A ONE OR TWO FAMILY DWELLING SECTION 11 -SITE INFORMATION 1.1 Pro arty Address: This section to t)e completed by office 127Combs Road \rA Map Lot 10 Unit Northampton,MA.01060 Zone Overlay District Elm St.District co District SECTION 2-PROPERTY OWNERSHIPIAUTHORIZED AGENT 2.1 Owner otRecord: Mass Audubon Society 208 South Great Road,Lincoln,MA.01773 Name(Print) Current Mailing Address: (781)259-2101 Signature Telephone 2.2 Authorized A-qLt. Sandri Energy,LLC Thom 3urden 400 Chapman Street,Greenfield, MA. 01301 Name(Print) Qxrerd Mailing Address: (41 3)772-2121 L Signature Telephone SECTION 3-ESTIMATED CONSTRUCTION COSTS Item Estimated Cost(Dollars)to be Official Use Only completed by permit applicant 1. Building (a)Building Permit Fee 2. Electrical (b)(b)Estimated Total Cost of $28,239.00 Construction from(6) 3. Plumbing $1,100.0() Building Permit Fee 4, Mechanical(HVAC) $26,039.00 $198.00 5. Fire Protection 6, Total=(1 +2+3+4+5) Check Number This Section For Official Use Only .. ..................... Building Permit Number Date Issued Signature: -du—iid-in—q"C'o-mm—issk--mir—nspector of Buildings Date Version 1.7 Commercial Building Permit May 15,2000 SECTION 10-STRUCTURAL PEER REVIEW(780 CMR 110.11) Independent Structural Engineering Structural Peer Review Required -Yes 0 No lu SECTION 11 -OWNER AUTHORIZATION-TO BE COMPLETED WHEN OWNERS AGENT OR CONTRACTOR APPLIES FOR BUILDING PERMIT 41 r. vii v s of ''v(" as Owner of the subject property hereby authorize Sandri Energy, LLC Thom Burden to act%,+- y behay,in all pa�ters dative to work authorized by this building permit application. 02/19/2016 Signature of OUr Date J Thom Burden, Sandri Energy, LLC as Owner/Authorized Agent hereby declare that the statements and information on the foregoing application are true and accurate,to the best of my knowledge and belief. Signed under the pains and penalties of perjury H.Thomas 1.11110" Print N re 02/19/2016 Signature of Owner/Agent Date SECTION 12-CONSTRUCTION SERVICES 10.1 Licensed Construction$4pqrvisor: Not Applicable [3 ._ Name of License Holder. Dennis Goshea CS-106814 License Number 13 French King Highway,Gill MA, 01354 07/09/2016 Address Expiration Date (413) 772-2121 Signature Telephone SECTION 13-WORKERS'COMPENSATION INSURANCE AFFIDAVIT(M.G.L.c.162,§25C(6)) Workers Compensation Insurance affidavit must be completed and submitted with this application. Failure to provide this affidavit will result in the denial of the issuance of the building permit, Signed Affidavit Attached Yes No 0 Versionl.7 Commercial Building Permit May 15,2000 SECTION 4-CONSTRUCTION SERVICES FOR PROJECTS LESS THAN 35,000 CUBIC FEET OF ENCLOSED SPACE Interior Alterations ❑ Existing Wall Signs ❑ Demolition❑ Repairs❑ Additions ❑ Accessory Building❑ Exterior Alteration ❑ Existing Ground Sign❑ New Signs❑ Roofing❑ Change of Use❑ Other El Brief Description Removal of existing oil boiler, Installation of pellet boiler, thermal storage tank, and pellet Of Proposed Work: flexilo storage. Venting thru existing Stainless Steel liner, single fuel only. SECTION 5-USE GROUP AND CONSTRUCTION TYPE USE GROUP(Check as applicable) CONSTRUCTION TYPE A Assembly ❑ A-1 ❑ A-2 ❑ A-3 ❑ 1A ❑ A-4 ElA-5 El1 B El B Business ❑ 2A ElE Educational ❑ 26 I ❑ F Factory ❑ F-1 ❑ F-2 ❑ 2C ❑ H High Hazard ❑ 3A ❑ I Institutional ❑ 1-1 ❑ 1-2 ❑ 1-3 ❑ 36 M Mercantile 114 El R Residential ❑ R-1 ❑ R-2 ❑ R-3 ❑ 5A ❑ S Storage ❑ S-1 ❑ S-2 ❑ 56 ❑ U Utility ❑ Specify: M Mixed Use ❑ Specify: S Special Use ❑ Specify: COMPLETE THIS SECTION IF EXISTING BUILDING UNDERGOING RENOVATIONS,ADDITIONS AND/OR CHANGE IN USE Existing Use Group: Proposed Use Group: Existing Hazard Index 780 CMR 34): Proposed Hazard Index 780 CMR 34): SECTION 6 BUILDING HEIGHT AND AREA BUILDING AREA EXISTING PROPOSED NEW CONSTRUCTION OFFICE USE ONLY Floor Area per Floor(sf) 1 St 1 St 2nd 2nd 3rd 3rd 4th 4th Total Area(so Total Proposed New Construction(sf) Total Height(ft) Total Height ft 7.Water Supply(M.G.L.c.40,§54) 7.1 Flood Zone Information: 7.3 Sewage Disposal System: Public ❑ Private ❑ Zone Outside Flood Zone❑ Municipal ❑ On site disposal system❑ Versionl.7 Commercial Building Permit May 15,2000 8. NORTHAMPTON ZONING Existing Proposed Required by Zoning This column to be filled in by Building Department Lot Size Frontage Setbacks Front Side L: R: L:. R: Rear Building Height Bldg. Square Footage % Open Space Footage % (Lot area minus bldg&paved parking) #of Parking Spaces Fill: volume&Location A. Has a Special Permit/Variance/Finding ever been issued for/on the site? NO © DON'T KNOW 0 YES 0 IF YES, date issued: IF YES: Was the permit recorded at the Registry of Deeds? NO 0 DON'T KNOW 0 YES 0 IF YES: enter Book Page and/or Document# B. Does the site contain a brook, body of water or wetlands? NO 0 DON'T KNOW 0 YES IF YES, has a permit been or need to be obtained from the Conservation Commission? Needs to be obtained © Obtained 0 , Date Issued: C. Do any signs exist on the property? YES 0 NO 0 IF YES, describe size, type and location: D. Are there any proposed changes to or additions of signs intended for the property? YES Q NO IF YES, describe size, type and location: E. Will the construction activity disturb(clearing,grading,excavation, or filling)over 1 acre or is it part of a common plan that will disturb over 1 acre? YES O NO IF YES,then a Northampton Storm Water Management Permit from the DPW is required. Version 1.7 Commercial Building Permit May 15,2000 SECTION 10-STRUCTURAL PEER REVIEW(780 CMR 110.11) Independent Structural Engineering Structural Peer Review Required Yes Q No SECTION 11 -OWNER AUTHORIZATION -TO BE COMPLETED WHEN OWNERS AGENT OR CONTRACTOR APPLIES FOR BUILDING PERMIT 1, as Owner of the subject property hereby authorize Sandri Energy, LLC Thom Burden to act on my behalf, in all matters relative to work authorized by this building permit application. 02/19/2016 Signature of Owner Date Thom Burden, Sandri Energy, LLC as Owner/Authorized Agent hereby declare that the statements and information on the foregoing application are true and accurate,to the best of my knowledge and belief. Signed under the pains and penalties of perjury. H. Thomas urd Print N e 02/19/2016 Signature of Owner/Agent Date SECTION 12-CONSTRUCTION SERVICES 10.1 Licensed Construction Supervisor: Not Applicable ❑ Name of License Holder: Dennis GOshea CS-106814 License Number 13 French King Highway, Gill MA. 01354 07/09/2016 Ad ress Expiration Date (413) 772-2121 Signature Telephone SECTION 13-WORKERS'COMPENSATION INSURANCE AFFIDAVIT(M.G.L.c.152,§25C(6)) Workers Compensation Insurance affidavit must be completed and submitted with this application. Failure to provide this affidavit will result in the denial of the issuance of the building permit. Signed Affidavit Attached Yes G) No Version 1.7 Commercial Building Permit May 15,2000 SECTION 9-PROFESSIONAL DESIGN AND CONSTRUCTION SERVICES-FOR BUILDINGS AND STRUCTURES SUBJECT TO CONSTRUCTION CONTROL PURSUANT TO 780 CMR 116(CONTAINING MORE THAN 36,000 C.F.OF ENCLOSED SPACE) 9.1 Registered Architect: Not Applicable El Name(Registrant): Registration Number Address Expiration Date Signature Telephone 9.2 Registered Professional Engineer(s): Name Area of Responsibility Address Registration Number Signature Telephone Expiration Date Name Area of Responsibility Address Registration Number Signature Telephone Expiration Date Name Area of Responsibility Address Registration Number Signature Telephone Expiration Date Name Area of Responsibility Address Registration Number Signature Telephone Expiration Date 9.3 General Contractor Company Name: Not Applicable El Responsible In Charge of Construction Address Signature Telephone The Commonwealth of Massachusetts Department of Industrial Accidents Office of Investigations 600 Washington Street Boston,MA 02111 www.mass.gov/dia Workers' Compensation Insurance Affidavit: Builders/Contractors/Electricians/Plumbers Applicant Information Please Print Legibly Name (Business/Organization/Individual): SANDRI ENERGy Address: 400 CHAPMAN STREET City/State/Zip: GgFFNFIELD, MA 013Q1 Phone#: 413-772-2121 Are you an employer?Check the appropriate box: Type of project(required): 1.(R 1 am a employer with 100 . 4. ❑ I am a general contractor and I -"� � have hired the sub-contractors 6. ❑New construction(full and/or part-time). 2.❑ I am a sole proprietor or partner- Iisted on the attached sheet. 7. ❑ Remodeling ship and have no employees These sub-contractors have 8. Demolition working for me in any capacity. employees and have workers' 9 ❑Building addition [No workers' comp.insurance comp.insurance.t required.] 5. M We are a corporation and its 10.❑Electrical repairs or additions 3.❑ I am a homeowner doing all work officers have exercised their 11.M Plumbing repairs or additions myself. [No workers' comp. right of exemption per MGL 12 ❑Roof repairs insurance required.]t c. 152, §1(4),and we have no employees. [No workers' 13.❑Other comp,insurance required.] *Any applicant that checks box#1 must also fill out the section below showing their workers'compensation policy information. t Homeowners who submit this affidavit indicating they are doing all work and then hire outside contractors must submit a new affidavit indicating such. tContractors that check this box must attached an additional sheet showing the name of the sub-contractors and state whether or not those entities have employees. If the sub-contractors have employees,they must provide their workers'comp.policy number. I am an employer that is providing workers'compensation insurance for my employees. Below is the policy and job site information. Insurance Company Name: Hnl C,FRL I AMFRICA Policy#or Self-ins.Lic.#: Fl GC ()nn 182215 Expiration Date: 7/31/2016 Job Site Address: Ic CSS AG9,TMTVT4A � City/State/Zip: 01 O Q a Attach a copy of the workers' compensation policy declaration page(showing the policy number and expiration date). Failure to secure coverage as required under Section 25A of MGL c. 152 can lead to the imposition of criminal penalties of a fine up to$1,500.00 and/or one-year imprisonment,as well as civil penalties in the form of a STOP WORK ORDER and a fine of up to$250.00 a day against the violator Be advised that a copy of this statement may be forwarded to the Office of Investigations of the DIA for' surance geverage verification. I do hereby certun a is d penaltie of perjury that the information provided above is true and correct. Si nature: /1- Date: 1;)-'�ky (10 Phone Official use only. Do not write in this area,to be completed by city or town official City or Town: PermitlLicense# Issuing Authority(circle one): 1.Board of Health 2.Building Department 3.City/Town Clerk 4. Electrical Inspector 5.Plumbing Inspector 6.Other Contact Person: Phone#: City of Northampton 212 Main Street, Northampton, MA 01060 Solid Waste Disposal Affidavit In accordance of the provisions of MGL c 40, S54, I acknowledge that as a condition of the building permit all debris resulting from the construction activity governed by this Building Permit shall be disposed of in a properly licensed solid waste disposal facility, as defined by MGL c 111, S 150A. Address of the work: 03 The debris will be transported by: SP4D�Ci► The debris will be received by: Building permit number: Name of Permit Applicant Date Signature of Permit Applicant City of Northampton Mail-Re: 127 Combs Road-Audubon https://mail.google.com/mail/u/0/?ui=2&ik=39211afc3d&view=pt&se... ` City Of Xortlumwim Charles Miller<cmiller@northamptonma.gov> Re: 127 Combs Road - Audubon 1 message Thom Burden <tburden@sandri.com> Mon, Feb 29, 2016 at 3:50 PM To: Charles Miller <cmiller@northamptonma.gov> Hi Charles, The Okofen Unit that we are installing is the PES 20. 20 Kw (68,000 Btu) max output. The ASTM standard you show here is a standard for pellet stoves, or room heaters. This is a boiler, central heating, providing energy for the house as a standard fossil fuel boiler would do. This system is UL listed, (UL 2523) and the test report numbers etc are on page 5 of the owners manual. I can send just that information if you like. The chimney that is installed currently does meet the boiler manufacturers spec, we will be adding black smoke pipe to access the existing stainless. I hope this will answer the questions, Thank you for your time, Thom On Mon, Feb 29, 2016 at 3:30 PM, Charles Miller <cmiller@northamptonma.gov> wrote: Hi, Which unit is being used for this application? Do you have anything that shows that this unit meets ASTM E 1509 standard per M904.1? Does the existing chimney meet the manufacture's requirement for this unit? Thanks, Chuck Miller Assistant Building Commissioner City of Northampton Town of Williamsburg In 1931, not long before he died, Thomas Edison told his friends Henry Ford and Harvey Firestone: "I'd put arty money on the sun and solar enemy. What a source of power!I hope we don't have to wait until oil and coal run out before we tackle that. Thom Burden NFI Certified Pellet Specialist Sandri Energy, LLC Tel: 413.223.1117 Cell: 413.364.3217 Email: tburden@sandri.com http://www.sand ri.com/renewableenergy/ 1 of2 3/1/2016 10:30 AM W11ESYS MAINE ENERGY SYSTEMS Maine Energy Systems' OkoFEN 36 KW, 48KW and 56KW boilers have met very stringent proposed EPA emission standards The US Environmental Protection Agency has proposed rules to take effect on December 16, 2010, which would hold heating and process boilers as "area sources of hazardous air pollutants" to extremely stringent emissions standards in commercial, industrial, and institutional application. Average CO emissions for biomass fueled boilers must be at, or below, 100 ppm @ 7% 02, and particulate emissions must be at, or below, 0.03 /b/MMBTU. The proposed rules are receiving substantial critical review and response from the industry. Comments are focusing on issues ranging from data sample selection, to data collection methods, to surrogacy assumptions with various fuel types, to assumptions about the practical availability of control technologies to achieve the proposed emissions levels. It is not clear at this time whether or not the rules will be promulgated as proposed. Maine Energy Systems' 36 KW (123,00013TU), 48KW (164,00013TU), and 56KW (191,00013TU) OkoFEN pellet-fired boiler systems have met the proposed standards of 100 ppm CO at 7% 02 and particulate emissions 50.03 Ib/MMBTU in a certified testing laboratory setting. This compliance is reported in independent product testing completed at the laboratories of Francisco Josephinum Wieselberg, BLT. CO testing yielded the following results averaged over the full test duration: Carbon monoxide ppm 76.6 (average) Dust emissions and Organic Carbon emissions were determined at Nominal and Minimum output levels and reported in mg/MJ. Both emissions sources were used in weighted average computations performed in Ib/MMBTU by the Maine Department of Environmental Protection. The weighting valued the higher emission Minimum output values at 90% and the lower emission Nominal output values at 10%. The average particulate emission, reported with the same significance as that used in the proposed rules, follows: Average Annual Particulate Matter Emission 0.03 Ib/MMBtu heat output The OkoFEN 36 KW, 48KW and 56KW pellet-fired boiler systems have met, or exceeded, proposed EPA standards for biomass fired boilers in a laboratory installation. If enacted, EPA proposed standards would require onsite verification of compliance. Please read carefully prior to installing and servicing. SAVE THESE INSTRUCTIONS Ins , t 11atio M n I Pellet heating with vacuum ${` suction system, type }3 AutoPellet° ' ' PES 10 — 32kr v; N FA_V2.03 4 AutoPelletTOUCH USA PE 199 USA 2.0 Title: Installation Manual AutoPellet'PES 10—32 Article number: PE 199 USA 2.0 Version valid 03/2015 from: Approved: Wohlinger Christian Author & Manufacturer MAINE ENERGY SYSTEMS LLC 8 Airport Road — P.O. Box 547 Bethel Maine 04217 E-Mail: info@maineenergysystems.com © MAINE ENERGY SYSTEMS LLC www.maineenergysystems.com Subject to modifcations Contents I Dear Customer -----------------------------------------------' 5 2 Use only for the purpose intended ------------------------------------�5 3 Types ofsafety warning sign----------------------------------------7 4 VVarnimgsandsa[etyinstnuctions-- ------------------------------� 4.1 Basic safety instructions ----'- ------------------------------------ 8 42 Warning signs ------� --------------------------------------------� O 4.3 What todoinanemergency ---� emergency............................. ......................................................................................... 5 PrerequisitesfurinstaUingapeUetboi|er---------------------------' ll 5] Guidelines and standards for installing a pellet boiler —� ----------------------------------------------------' ll 5.2 Boiler room 11 53 F|uegassystem ----- ________________________________________-- 12 5.4 Safety systems ----� ----------------------------------------' 14 E5 |nstaUstiunwith anexisting boiler ---' -------------------------------------l5 6 Product description ---------------------------------------' lG 5] ThepoUetboi|ec ----' ------------------------------------------ 17 52 Pellet suction system ----� ------------------------------------------ 79 62] Assembly ofthe vacuumsystem �� ------------------------------' 19 63 Storage systems -- ---------------------------------------------- 2l 63J F|exi|otextile tank ---------------------------------------- 2l 7 BringingthepeUetboi|erintotheboi|erruono---------------------------- 22 7l Transport —� --------------------------------------------' 22 72 Notes cmbringing the unit into the building � _________________________. 22 T3 Flooring ------� � ---------------------------------------------' 26 74 Casing parts ----� -----------------------------------------. 27 75 Removing the casing the' _____________________-------. 28 7E1 Dismantling the burner casing.................................................................................................... 28 7.5.2 Dismantling the hopper.............................................................................................................. 29 7.5.3 Dismantling the burner ------------------------------------ 30 7.5.4 Dismantling the boiler door ----------------------------------'32 7.5.5 Dismantling the boiler casing..... ............................................................................................... 33 8 External de-ashing/automatic ash compaction system---------------. 35 8] Description ofde'ashingsys em ------ ^ --------------------------------. 35 Ei2 |nstaUingthe de'ashingsys em ----- ^ ------------------------------------' 36 8.3] B�nginginand instaUing6e-ashingsystem onthe base plate----------------'36 822 |nstaUingthe ash auge��ttingthe sub'assemWyand mounting the doorplate-------� 37 82I |nsLaUin� theburnersi�ecasingwi�hcu�'outande|ectica| connection � / -----------. I8 82.4 Assembling the pellet boiler and activating the ash box...........................................................3y 9 Connectingupthohydronics------------------- --------------- 9] Hydronic connecting diagrams ----' '~ --------------------------------------'4l 10 Connecting tothe power supply................................................................................ ----� 42 l(l7 Termina| box ----- _________________________________________---- 42 7O]7 Wiring terminal —' � _________________________ 42 lO2 Plugs onthe boiler control unit --------� _______________________________ 45 l(l3 Cable routing ------- ----------------------------------------. . 47 10.4 Wiring diagrams -----' _____________________________________. 50 10.5 Fuses- boi|ercontnd|er -------' ----------------------------------- 54 10.5 Operating the AutoPeUet ...................................................................................... ll Startingupfwrthefinsttinne----------------------------------- ll] Adjusting ----�~~ -^ ----------------------------------------- S5 ll]] Installing the tuMbu|atooand closure Plugs --------------------------' 5S 12 Appendix ------------------------------------------. 57 l2] Check|istforcheckin0theheatngsys�em --- ' ------------------------ 57 l��2 Appendix8ofCAN/CS�rB365-B365 --------� ---------------------------' 59 l2.3 Modifyingtheburner ------- _______________________________________--. 60 123J 0smandingthecasing. huppe/ combustioncharnber|id.Mametub�andburner---. 60 � --------- l2�3�2 Modifytheburnerun�he|� --' ----------------------. 61 l2�� Modifying� � -------------------- 62 Installation Manual AutnPeUeC`IDES lO-32 Contents 12.3.4 Changing the direction of rotation of the cleaning motor.......................................................63 12.3.5 Modifying and re-assembling the cleaning system ..................................................................63 12.4 Parts list.....................................................................................................................................................65 12.4.1 Pellematic PES 10-20 34,000-68,300 BTU/hr.......................................................................65 12.4.2 Pellematic PES 25-32/Boiler 85,300-109,500 BTU/hr........................................................69 12.5 Technical data............................................................................................................................................73 12.6 Pellet boiler cautionary markings ..............................................................................................................77 Installation Manual AutoPellet'PES 10—32 Dear Customer 5 1 Dear Customer Maine Energy Systems specializes in wood pellet heating, our company enjoys an exclusive license from OkoFEN to manufacture AutoPellet boilers here in the USA. We represent expertise, innovation and quality. We are delighted that you have decided to purchase our product. • This instruction manual is intended to help you operate the product safely, properly and economically. • Please read this instruction manual completely and take note of the safety warnings. • Keep all documentation supplied with this unit in a safe place for future reference. Please pass on the documentation to the new user if you decide to part with the unit at a later date. • Installation and first start up must be carried out by an installer certified by Maine Energy Systems. • Please contact your authorised dealer if you have any questions. We place great importance on the development of new products. Our R&D department continues to question accepted solutions and works continually on new improvements. That is how we maintain our technological lead. We have already received several awards for our products in Austria and abroad. Our products fulfil European and USA requirements regarding quality, efficiency and emissions. Tested& Portland Listed By Oregon USA C xf US OMNI-Test Laboratories,inc. Report No.0444PBO04S Installation Manual AutoPellet'PES 10—32 Use only for the purpose intended 2 Use only for the purpose intended The pellet boiler is designed to heat water for central or other indirect heating systems and hot water supply for buildings. It is not permissible to use the pellet boiler for any other purpose. Reasonable foreseeable inadvertent uses for the pellet boiler are not known. The boiler fulfils the requirements of UL 2523-2013 and CSA B366.1-2011. PE 199 USA 2.0 Types of safety warning sign 7 3 Types of safety warning sign The warning signs use the following symbols and text. Types of safety warning sign 1. Risk of injury NOTICE 2. Consequences of risk Damage to property 2 Heating only with pellets complying with the 3. Avoiding risk standard. 3 1. Risk of injury: Danger- indicates a situation that could lead to death or life- threatning injury. Warning - indicates a situation that could lead life-threatning or serious injury. Caution - indicates a situation that could lead to injury. UTION Note- indicates a situation that could lead to property damage. 2. Consequences of risk Effects and consequences resulting from incorrect operation. 3.Avoiding risk Observing safety instructions ensures that the heating system is operated safely. Installation Manual AutoPellet*PES 10—32 Warnings and safety instructions 4 Warnings and safety instructions Observing safety instructions ensures that the heating system is operated safely. 4.1 Basic safety instructions • Never get yourself into danger;give your own safety the utmost priority. • Keep children away from the boiler room and storage room. • Observe all safety warnings on the boiler and in this user manual. • Observe all instructions relating to maintenance,servicing and cleaning. • The pellet heating system may only be installed and started up for the first time by an authorised installer. Professional installation and start up is the prerequisite for safe and economical operation. • Never make any changes to the heating system or flue gas system. • Never close or remove safety valves. 4.2 Warning signs 7Pkofoning at the pellet boiler is supplied with suffi- stion air. The openings in the combustion air inlet must never be partially or completely closed. Ventilation systems, central vacuum cleaning systems, extractor fans,air conditioning systems,flue gas blowers,dryers,fuel storage ventilation fans or similar equipment must never be allowed to draw air from the boiler room and cause a drop in pressure. The boiler must be connected tight to the chimney using a flue gas tube. Clean the chimney and the flue gas tube at regular intervals. The boiler room and pellet storage room must be suffi- ciently supplied with air and ventilated. Before entering the storage room it must be ventilated with sufficient air and the heating system switched off Risk of electric shock 0nlan authorised installer may connect the pellet boi- ler to the power supply. Always disconnect/de-energize the power supply be- fore working on the boiler. 7R-iskxplosion BURN GARBAGE,GASOLINE, NAPHTHA, EN- GINE OIL, OR OTHER INAPPROPRIATE MATERIALS. DO NOT USE CHEMICALS OR FLUIDS TO START THE FIRE. Switch off the heating system before filling the storage room. PE 199 USA 2.0 Warning signs 9 � , 7onot ire tore any flammable materials in the boiler room. ang out any washing in the boiler room. Do not operate with fuel loading or ash removal doors open. _ i Risk of burns Do not touch the flue gas connector or flue gas pipe. Do not reach into the ash chamber. Use gloves to empty ash box if boiler not equipped with automatic ash compression Do not clean the boiler until it has been allowed to cool down. CAUTION HOT SURFACES Keep children away. Do not touch during operation. Do not operate if maximum draft as listed on boiler nameplate is exceeded. Doing so can allow non-controlled combustion. CAUTION Risk of cut injuries due to sharp edges. Use gloves for performing all work on the boiler. Damage to property The pellet boiler is suitable only for pellets which comply with PFI premium or EnPlus-Al pellets specifications. The use of any other fuel voids your warranty and can cause damage to the pellet boiler and chimney. Damage to property Do not use the heating system if it,or any of its compo- nents,come into contact with water. If water damage occurs,check the heating system by an authorized service technician and replace damaged parts. Ftl cover plates,enclosures, and guards must be main- ined in place at all times, except during maintenance and servicing. Installation Manual AutoPellet'PES 10—32 What to do in an emergency 4.3 What to do in an emergency 7isvk0 o life r get yourself into danger;give your own7safety tmost priority. What to do in the event of a fire • Switch off the heating system. • Call your local fire department and or 911. • Use approved fire extinguishers (fire protection class ABC). What to do if you smell smoke • Switch off the heating system. • Close the doors leading to living areas. • Ventilate the central heating room. PE 199 USA 2.0 Prerequisites for installing a pellet boiler 11 5 Prerequisites for installing a pellet boiler You must fulfil the following conditions before operating a fully automatic pellet boiler. 5.1 Guidelines and standards for installing a pellet boiler Overview of standards and guidelines applying to the installation of a pellet boiler. Check whether you need to obtain planning permission or approval from the authorities for installing a new heating system or changing your existing system. Installation must meet all requirements for pellet fired heat- ing systems in your specific location. 5.2 Boiler room The pellet boiler is installed in the boiler room. 1. Safety instructions for the boiler room Risk of fire Do not store flammable materials or liquids in the vici- nity of the pellet boiler. Do not permit unauthorised persons to enter the boiler room- Keep children away. Do not operate with fuel loading or ash removal doors open. 2. Air supply and ventilation of boiler room The boiler room must be fitted with air supply and ventilation openings(at least 31 inch 2/200cmz),In any case you must comply with the state and local regulations 3. Combustion air supply The pellet boiler needs a supply of combustion air. The supply of combustion air can: a. take place using one or more air supply and ventilation openings in total min.31 inch2. b. or through a special air supply line directly from outside,where the diameter of the air supply line must be at least 4 inch/100mm in for type PE(S)12- PE(S) 32.Ambient air independent operation of PES 36-56 types is also available on request. In any case, properly sized room ventilation is still re- quired to allow your barometric draft controller to function properly. Never operate the pellet boiler if the air intake openings are partially or completely closed. Contaminated combustion air can cause damage to the pellet boiler. Never store of use cleaning deter- gents containing chlorine, nitrobenzene or halogen in the room where the heating system is installed, if combustion air is drawn directly from the room. It is recommended that no washing or drying of laundry is done in the boiler room or where the boiler may draw air from. Do not hang out washing in the boiler room. Prevent dust from collecting at the combustion air intake to the pellet boiler. 4. Damage due to frost and humid air The boiler room must be frost-proof to ensure trouble-free operation of the heating system. The tempera- ture of the boiler room must not fall below 37°F and must not exceed 90°F. The air humidity in the boiler room must not exceed 70%. 5. Danger for animals Make sure that household pets and other small animals cannot enter the boiler room. Fit mesh over any openings. 6. Flooding Installation Manual AutoPellet'PES 10—32 Flue gas system If there is a risk of flooding, switch off the pellet boiler and disconnect from the power supply before water enters the boiler room.You must have all components that come into contact with water replaced, before you start up the pellet boiler again. 5.3 Flue gas system The flue gas system consists of a chimney and a flue gas tube.The flue gas tube connects the pellet heating system to the chimney.The chimney leads the flue gas from the pellet heating system out into the open. 1. Design of the chimney The dimensions and design of the chimney is very important.The chimney must be able to ensure suffi- cient draft to safely draw away the flue gas regardless of the status of the boiler. Low flue gas tempera- tures can cause sooting and moisture damage on chimneys that are not insulated. For this reason moisture-resistant chimneys(stainless steel or ceramic)should be used.An existing chimney that is not damp-resistant needs to be rennovated before use. Follow guidelines below: Boiler size PE(S)12-20 PE(S)25-32 PE(S)36-56 Flue gas tube diameter(at boiler) inch/mm 5/130 or 6/150 6/150 7/180 Flue gas temp./rated power OF 320 320 360 Flue gas temp./partial load °F 212 212 230 Min.draft-full load/part load in/wc -0.04/-0.02 Chimney size Min. Height bin x 6in 17ft lin x lin 16ft 8in x 8in 16ft 6in round 19ft 7in round 17ft Recommended and UL-103HT approved chimney materials are: a. Selkirk sure temp b. Supervent(JSC) c. Security chimneys(secure temp ASHT) Use flue gas pipe from chimney to boiler as required by your local code. CAUTION Unregulated combustion Please observe that combustion air openings and flue pipes are not reduced in size or closed. Make end user aware of these guidelines and their potential danger. Clean the chimney and the flue gas tube at regular intervals. Check if the draft inducer is clean and in a good condition. 2. Flue gas temperature The flue gas temperatures are approximately the same for all Autopellet boilers covered in this manual. The dewpoint of flue gas with wood pellets(max.10%water content)is approx.120°F. PE 199 USA 2.0 Flue gas system 13 It is possible to increase the flue gas temperature to prevent condensation inside the chimney and avoid damage due to damp. Only authorised installers may increase the flue gas temperature. Note: The increase in flue gas temperature results in reduced efficiency and thus increases fuel consumption. 3. Negative pressure of the chimney The boiler must be connected to a chimney or a vertical venting system that is capable of handling and producing a negative breeching pressure of-0.4 "WC. Use a draft gauge to verify the indicated draft va- lue,adjust barometric damper as required. Drill a small hole in the connection pipe at about tin/50mm from the boiler flue outlet and use this hole as your measuring point. Chimney draft The suction effect of the chimney draft must extend all the way to the boiler flue pipe connection.The maximum flow rate that can be drawn through the chimney limits the maximum performance of the chim- ney connection. The boiler performance must be reduced if the chimney does not possess the necessary cross-section. This may only be performend by authorised personnel. 4. Power venter AutoPellet boilers are approved by the manufacturer for installation with the Field Controls SWGAF power venter which is approved for wood pellet burning appliances. Boilers installed with SWGAF power venters must follow all manufacturer's installa- tions and must comply with all applicable codes from agencies having authority over the installation. 5. Cleaning Clean the flue gas tube and chimney regularly. Solid fuel burning appliances need to be cleaned fre- quently because soot,creosote,and ash may accumulate. The hotter the fire,the less creosote is depos- ited. Cleaning intervals can vary in warm periods due to this and become more frequent. Risk of chimney fire Creosote-formation and need for removal:Low flue gas temperature can cause creosote. Creosote can con- dense in a relatively cool chimney. As a result,creosote residue accumulates on the flue lining. If ignited, this creosote will create an extremely hot fire.The chimney and the chimney connector should be inspected at least twice monthly during the heating season to determine if a creosote buildup has occurred. If creosote has accu- mulated it should be removed to reduce the risk of a chimney fire. Oxidation of chimney Do not use metal brushes to clean chimneys made of stainless steel. Your state and local regulations must be observed. Installation Manual AutoPellet'PES 10—32 Safety systems 5.4 Safety systems The following safety measures are the prerequisite for safe operation of your system. Emergency stop switch Every heating system must be able to be switched off with an Emergency Stop switch. The Emergency Stop switch must be outside of the boiler room. Safety valve The hydronic system must be equipped with a safety valve. This valve opens before the pressure inside the heating system increases to max. 43 P.S.I..The safety valve must be in- stalled at the highest point of the boiler,must not be locked and must be within 3.28 ft/ 39.37 inch/lm of the boiler.A 30 Ib/sq in relief value is supplied with each boiler. Safety temperature sensor The pellet boiler is equipped with a safety temperature sensor.This is located on the pellet boiler. If the boiler temperature exceeds 230°F then the heating system switches off. Low water cut off The hydronic system must be equipped with a low water cut off. If the water level falls be- low a certain level,the low water cut off switches off the heating system. Initial start-up The initial start-up of each AutoPellet boiler must be performed by an authorized installer. PE 199 USA 2.0 Installation with an existing boiler 15 5.5 Installation with an existing boiler Autopellet boilers are not to be connected to a chimney flue serving another appliance. However,when all State and local codes allow for the sharing of chimney flues,the Autopellet boilers and another appliance burning pellets or a different fuel can be operated simultaneously while connected to a single existing chim- ney or flue gas system providing the following conditions are met: • All state and local codes permit the specific installation • All appliances are installed in accordance with the manufacturer's installation specifications or if lacking manufacturers specifications,the appliance in question is installed in a manner commonly recognized as safe and correct for the application and circumstances • The chimney or flue gas system must be able to handle the combustion products of either appliance and both appliances when operated simultaneously Avoid clearance issues that can make servicing difficult: Be sure to follow suggested clearances when installing the Au- topellet boiler with an existing boiler to be sure that service and cleaning can be performed adequately. CAUTION Avoid code violations: When connecting to or with an existing boiler,contact the authority having jurisdiction to be sure the type of installation planned is allowed. Document the type of boiler that the Autopellet is connected to or with. Pellet boiler: Make and Model number: Existing boiler: Make and Model number: A 11, reia Possible escape of flue gas: Do not connect this unit to a chimney flue serving another appli- ance unless multiple appliances into a single flue is authorized by all authorities having jurisdiction. Installation Manual AutoPellet"PES 10—32 Product description 6 Product description The description of the product is intended to provide an overview of the components that make up a pellet heating system,the parts of the pellet boiler and advice on where you can find more information. The pellet heating system consists of 3 components 1 Pellet boiler 2 Conveyor system 3 Storage system-textile tank Pellet boiler with textile tank fit'' 2 I 3 i .. ��W�..�is The concept features different sizes of design and type for each component. These are compatible and designed to match. PE 199 USA 2.0 The pellet boiler 6.1 The pellet boiler The pellet boiler is equipped with an automatic cleaning system,an ash box with ash compression system and an integrated return water temperature control.The installed programmable logic controller system en- ables fully automatic operation and highest efficiency.We offer an optional automatic de-ashing system for the highest level of cleanliness and comfort. Pellematic types and power ratings We offer the Pellet boiler with the following power ratings: Suction-feed systems:41,000;51,000; 68,300;85,300;109,500;123,000;164,000 and 191,000 BTU/hr All sizes/outputs of the Autopellet boiler are available with external automatic ash compression system. Note: Refer to the data plate for the power rating of your Pellematic.The data plate is located on the rear side of the Pellematic. Here you will find the type designation, manufacturer's seri- al number and year of build. Key components of the Pellematic �J 2 O® 5 n J 3 I� 4 l 1 Boiler(heat exchanger) 2 Vac Hopper/Day tank 3 Burner 4 External automatic ash compression system 5 Boiler controller Installation Manual AutoPellet" PES 10—32 The pellet boiler e 8 5 4 I I 3 I I II 2 o _ 9 .o 0 10 15 14 13 12 11 1 Burner plate 9 Fire protection- ball valve 2 Flame tube 10 Burner fan 3 Heat exchanger 11 External ash box 4 Boiler water 12 Burner auger 5 Boiler insulation 13 Electronic ignition 6 Combustion chamber 14 De-ashing system cover 7 Suction turbine 15 Ash chamber/Fire chamber 8 Vac hopper/Day tank PE 199 USA 2.0 Pellet suction system 19 6.2 Pellet suction system The pellet suction system consists of a pellet line,an air line and a suction turbine.The suction turbine in the hopper conveys pellets in the pellet line from the storage room or textile tank to the hopper. Key components of pellet suction system 1 Pellet hose Hose from textile tank to the hopper. 2 Air hose Hosee from the suction turbine to the textile tank. 3 Suction turbine Located above the hopper underneath the AutoPellet burner casing. 4 Suction switch Located underneath the textile tank. Pellet boiler FIeXILO textile tank 2 3 1 1 2 4 ~ 6.2.1 Assembly of the vacuumsystem The pellet hose and the air hose are flexible spiral hoses made out of plastic.A copper braid avoids the static loading of the spiral hose. To avoid damage to the spiral hose,you must observe the following assembly guidelines: Bending radius The hose should be led as briefly as possible and with a few curves as necessarily. Bend- ing radius may never be smaller than 12inch. Upward Max difference in height=236inch gradients Note:A difference in height of up to 118inch can be overcome at one time. Larger differ- ences in height must by interrupted with a 4 foot horizontal run of the pellet hose. Impact The spiral hose can be mounted up to 236inch exactly straight. In such cases however, it protection is very important to create a slight"S" in the pellet piping before a sharp curve to slow down the pellets to prevent hose damage. Installation in When installing pellet lines underground remember! The pellet lines are not designed for the soil and direct burial and require protection from being crushed or chewed by varmints. openings: Protective piping should be minimum 4 inch and sealed at each end. There should be no bends greater than 15 degrees in the underground sections of the pellet hose. Tightness To avoid problems with your pellet lines, it is important to have all hose connections se- cured completely air tight with hose clamps. Static The hoses are provided with a copper braid,those the hose keeps antistatic. In order to neutralization ensure the function of the anti-statics,those copper braid must be attached at each end to the existing grounding become. Fire protection At a wall break-through to the heating room must be installed a fire protection seal in the pellet-and the air hose. Installation Manual AutoPellet PES 10—32 Assembly of the vacuumsystem Crossing The pellet hose and the air hose should cross each other as few times as possible. Length of the spiral hose The maximum total length of the spiral hose is 130 feet. The maximum for pellet hose and air hose are each 60 feet. Assembly Use securing clips and carrying bowls. O O O 0 ® 0 *Pay attention to the defined distances! 1 2 3 1 Hose min.l2in f 2 Clip N 3 Carrying bowl E 8x Note: Impact protection by swirling of the pellets. PE 199 USA 2.0 Storage systems 21 Connection of the pellet and air hose to the suction turbine O O O • O O 0 0 • I a 6.3 Storage systems For storing pellets we offer a FleXILO textile tank. FIeXILO textile tanks can be located inside the boiler room, storage room or protected from wet and sun outside. Damage to property and loss of warranty The use of an AutoPellet boiler with a storage or con- veyor system from another manufacturer is not permis- sible and will result in voiding your warranty along with undependable operation. 6.3.1 Flexilo textile tank Maine Energy Systems offers various sizes and types of fabric tanks. The fabric tank supplied may vary from the example shown above. Please refer to the installation instructions supplied for the fabric tank. Note also the instructions on setting up and filling. Installation Manual AutoPellet"PES 10—32 Bringing the pellet boiler into the boiler room 7 Bringing the pellet boiler into the boiler room This section describes the prerequisites as well as the working sequence required. 1. Transport 2. Notes on bringing the unit into the building 3. Casing parts 4. Dismantling the casing parts 7.1 Transport We supply the pellet boiler on a pallet.The pellet boiler is ready to be connected. The control unit for the boiler controller and the operating drvice is integrated into the control panel. If it is not possible to bring the boiler into the building at ground level,then you can remove the casing,the burner,the hopper and the boiler controller.This will reduce the weight of the unit and make it easier to carry. i Contamination and corrosion Make sure that the pellet boiler is located under a roof if it needs to be stored outside before it is transported/ brought into the building. It is also necessary to trans- port the boiler in a closed in truck or trailer. Boilers transported otherwise will lose their warranty. 7.2 Notes on bringing the unit into the building Before bringing the unit into the building,check the dimensions of all doors to ensure that the boiler has suffi- cient clearance and can be set up properly. Minimum door width-max.unit dimension PE, PES 10,12,15,20 27,5 inch PE, PES 25,32 29,75 inch PES 36,48,56 31,2 inch Boiler dimensions 1. - , F R ® + H ----- E A C ® IT 1— T .I PE 199 USA 2.0 Notes on bringing the unit into the building 23 --- ------- Boiler size PE(S)12 PE(S) PE(S) PE(S) PE(S) PE(S) PE(S) PE(S) is 20 25 32 36 48 56 B- Overall inch 44112 441/2 441/2 463/4 463/4 51 51 51 width of pellet boiler C-Width of inch 271/2 271/2 271/2 293/4 293/4 34 34 34 boiler casing H- Height of inch 43 43 43 51 51 61 61 61 boiler casing D- Height of inch 55 55 55 63 63 73 73 73 pellet suction system F- Height of inch 12 12 12 12 12 12 12 12 suction filling unit I T- Depth of inch 32 32 32 341/4 341/4 39 39 39 boiler casing V- Depth of inch 20 20 20 20 20 20 20 20 burner casing E- Flue gas inch 251/2 251/2 251/2 331/4 331/4 41 41 41 tube connection height A- Height of su- inch 353/4 3S3/4 3S3/4 433/4 433/4 52 52 52 ply/return R- Diameter of inch 5or6 5or6 5 or,6 6 6 7 7 7 flue gas tube Installation Manual AutoPellet,'PES 10—32 Notes on bringing the unit into the building Approximate boiler Weight Boiler size PE(S) PE(S) PE(S) PE(S) PE(S) PE(S) PE(S) PE(S) 12 15 20 25 32 36 48 56 Weight of boiler packaged on Lb 858 858 858 1003 1003 1430 1430 1430 pallet with wooden frame Weight of boiler with casing, Lb 533 542 551 696 705 1327 1336 1344 hopper and burner Weight of boiler without casing, Lb 1 529 1 529 529 664 664 930 930 930 hopper and burner Minimum clearances suggested for proper cleaning and maintenance Note: To install the heating system properly and ensure economical operation,you need to make sure that mini- mum clearance dimensions indicated below are observed when setting up the boiler.In addition,make sure that all code requirements at the installation location are complied with relating to the minimum clearances. a Minimum clearance to the edge of inch 18 removable top cover of the boiler. For flue pipe clearance, refer to applicable codes. b Min.clearance of side of boiler inch 3 C Min. clearance of front of boiler inch 28 d Min. clearance to housing - burner nch 12 side. a e Min. ceiling height inch 73 And the distance from ceiling to top of boiler must be enough to remove all covers. Note: Place the boiler according to the minimum clear- ances to the flue pipe connection point as defined in NFPA 31,or if NFPA is not recognized,then the code pertinent to the installation location. Make sure that you also comply with local legal regulations. For clearances required for floor protection,see fol- lowing page. PE 199 USA 2.0 Notes on bringing the unit into the building 25 Placement of rubber plates 4x Loss of warranty! The boiler must be placed on the supplied rubber plates. Failure to do this may allow corrosion and will void the warranty of the boiler vessel. Installation Manual AutoPellet�PES 10—32 W Flooring 7.3 Flooring The boiler room floor must be flat and level and must be able to support boiler gross weight.The floor must comply with the requirements of NFPA 31. Generally the boiler should be placed on non-combustible floors. However,a shielding material can be placed underneath the boiler and the chimney connector in the case of a combustible floor like shown on the follow- ing drawing. 1 Boiler base plate 2 Spacer E 3 Shielding material N Un O � 2 The spacer must be able to support the weight of the boiler and has to be non combustable. The shielding material must be equivalent to a YZin/13mm micro board with a K-value of 0.49(W/m K)(R-value of 1.02 Km2/W)or greater. For more information contact Maine Energy Systems. A 7Riskire: combustible flooring needs to extend out to te cearances shown on the chart below. Minimum clearances of shielding material required for floor protection Min.clearance of the shielding material inch 17 from the boiler back- Note also the local x restrictions in your area(a) Min. clearance of the shielding material inch 8 from the boilers left side panel (b) Min.clearance of the shielding material inch 27 f' from the boilers front panel (c) Min.clearance of the shielding material inch 12 from the boilers right side panel (d) PE 199 USA 2.0 Casing parts 27 7.4 Casing parts The boiler is protected by a casing on all sides.The casing parts prevent contact with hot, moving and live components. They give the pellet boilers a unique appearance. 10 9 1 11 2 0 br 8 D, 6 b 5 3 4 1 Boiler casing cover 7 Boiler side panel with opening 2 Boiler rear panel 8 Burner side panel (same as 11) 3 Boiler side panel without 9 Burner lug without opening opening 4 Boiler door panel (semi-circle) 10 Burner cover suction system 5 Boiler front panel (semi-circle) 11 Burner side panel (same as 8) 6 Boiler front panel (straight) Installation Manual AutoPellet'PES 10—32 Removing the casing,the hopper and the burner 7.5 Removing the casing, the hopper and the burner Dismantle the pellet boiler as far as necessary if site conditions require,so that the unit can be brought safely into the building. The complete dismantling of all components described here is divided into the following sections: 1. Dismantling the burner casing 2. Dismantling the hopper 3. Dismantling the burner 4. Dismantling the boiler door S. Dismantling the boiler casing 7.5.1 Dismantling the burner casing O O O CA � 3 PE 199 USA 2.0 Dismantling the hopper 29 7.5.2 Dismantling the hopper O O O V .q: a O O © I •� 00 00 0 0 00 00 00= 00 =0= =0 00 00 Installation Manual AutoPellW PES 10—32 Dismantling the burner 7.5.3 Dismantling the burner O e%4 x- 2 3 4 2xM4 S O w M i 5 6 a 7 •� o 1 8 4xM10 PE 199 USA 2.0 Dismantling the burner 31 7'Behind ctric shock boiler front panel isthe energized control . nnect main power before removing the front panel. r Damage of property Remove disconnect all of the electric cables that con- nect the burner assembly to the controller(at the con- troller end) before removing the burner. Multi segmented burner plate There are 2 mounting variations: With burner plate cleaning system: Bolts loosened Without Burner plate cleaning system: Bolts tightened Damage to property Damage to property The safety screws for rotating the Multi segmen- The safety screws for rotating the Multi segmen- ted burner plate must be loosened/removed ted burner plate may not be loosened/removed when exchanging the Multi segmented burner when mounting. plate. Installation Manual AutoPellet"PES 10—32 Dismantling the boiler door 7.5.4 Dismantling the boiler door PE 199 USA 2.0 Dismantling the boiler casing 33 7.5.5 Dismantling the boiler casing O NETZ KF Installation Manual Auto Pel PIES 10—32 Dismantling the boiler casing O O O M6 1 ® M6 M © O O • Sam- Vo pam. V © y' •�©� e .I M6� M64 PE 199 USA 2.0 External de-ashing/automatic ash compaction system 3S 8 External de-ashing / automatic ash compaction system We offer an automatic external de-ashing system. 1. Description of de-ashing system 2. How the de-ashing system works 3. Installating the de-ashing system 4. Emptying the de-ashing system 8.1 Description of de-ashing system The de-ashing system compresses the ash and conveys it from the ash chamber into the ash box. The ash box enables the ash to be easily disposed off without creating dust. 1 2 3 4 �T' �® 7 6 5 1 Turnstile with agitator, door plate and 5 mounting bolts Ash container 2 Ash box with single-hand lever 6 Sub-assembly with extractor auger and cable 3 Mounting frame 7 Extended nuts to secure the sub-assembly 4 Cable duct with mounting bolts 8 1 pack of bio-bags Note: All components for the de-ashing system are packaged in a separate box which is shipped together with the boiler. Open the box and check that all parts are available before starting work. Installation Manual AutoPellet*PES 10—32 Installing the de-ashing system 8.2 Installing the de-ashing system We recommend installing the de-ashing system after the boiler has been brought in, but before the boiler casing is fitted.The de-ashing system has to be installed before the burner casing is assembled. Installation of the de-ashing system is divided into the following steps: 1. Bringing in and installing the de-aching system on the base plate 2. Installing the de-ashing auger,fitting the sub-assembly and mounting the doorplate 3. Installing the burner side casing with cut-out and electrical connection 4. Assembling the pellet boiler and activating the ash box 8.2.1 Bringing in and installing de-ashing system on the base plate 0 0 a o 0 oa 0 Note: 5: Replace the screw with the base in a horizontal position. PE 199 USA 2.0 Installing the ash auger,fitting the sub-assembly and mounting the door plate 37 8.2.2 Installing the ash auger, fitting the sub-assembly and mounting the door plate 0 10 11 1 12 13 14 0�e7�S_ Ir 0 15 � 16 17 vi I Note: Do not tighten the screws firmly(picture 7).Tighten the screws firmly only after working step in picture 11. The ash auger engage with the gear must be so that the agitator moves freely. Installation Manual AutoPellet"PES 10—32 7 13 Installing the burner side casing with cut-out and electrical connection 8.2.3 Installing the burner side casing with cut-out and electrical connection 18 19 20 WUA i 21 0 o � 0 8 0 J ® -P�m Cn 0 w ® wD O N ® N< r � LO LO W i Q d d i LO LON i i i 0 PE 199 USA 2.0 Assembling the pellet boiler and activating the ash box 39 8.2.4 Assembling the pellet boiler and activating the ash box 22 23 � 24 *06 ioIsm, 25 26 27 2. 3 l 0 Note: Refer to the section on bringing the pellet boiler into the boiler room for detailed instructions on assem- bling the hopper, burner and casing components. Activating the ash box 1. Switch the boiler ON 2. In the menu Pellematic,after entering the code,you can activate the function Ashbox. 3. Set up the number from Oto 1 4. Ash box is now active Installation Manual AutoPellet*PES 10—32 41 , Connecting up the hydronics 9 Connecting up the hydronics The hydronic connections are located on the rear side of the boiler. Risk of explosion The boiler can only be connected and operated after the hydronic system is complete, with all safeties and purged of air. Water damage,damage to pellet boiler The hydronic system can only be installed by an experienced heating professional. Check the entire installation for leaks before firing the boiler. 1. Return water temperature control The device to increase the return temperature is already integrated into the boiler.You do not need to make any adjustments to this. 2. Hydronic schematics If you have questions about piping a heating system, refer to the our hydronic schematics when connecting the boiler. Our hydronic schematics are available from your sales partner or from our website. 3. Connections The connections between the pellet boiler and the hydronic system must be disconnectable. 4. Drain connection When you install the pellet boiler, remove the plug from the drain connection(4)and fit a 1/2"diameter shut-off valve. 5. Thermometer connection Installing a thermometer at location(3) (submersion sleeve 3.94 in long)enables you to measure the temperature of the return water after the return water temperature control. Whether this is installed or not,after setting up the pellet boiler you need to remove the cap and fit a 1/2" diameter closure plug at location(3). 1 2 MAIM 3 4 1 Flow out 3 Thermometer connection 2 Flow return 4 Drain connection PE 199 USA 2.0 Hydronic connecting diagrams 41 9.1 Hydronic connecting diagrams AutoPellet and existing gas or oil fired boiler, modified "primary- secondary"allows heat to come from ei- ther source without external changes. Individual heating circuits/Zones Each boiler operates it's own injection a circulator. s Individual zone circulators provide zone flows and loop flow passing the "close spaced Ts". Installation Manual AutoPellet PES 10—32 „a Connecting to the power supply 10 Connecting to the power supply 10.1 Terminal box The terminal box serves as the connection point for the power supply, low water cut off, circulator pump, cold start contacts, bus connection, power vent,and outdoor sensor if used. There is also a low power 220 volt connection point. 1.......Terminal box e e 10.1.1 Wiring diagram -terminal box The wiring diagrams for the terminal box provide detailed technical information for professionals and are packed within the terminal box along with other helpful schematics for interconnecting the boiler with circu- lator controls. 7Risk I A Ulm:4lectric shock uthorised installer may connect the pellet boi- eroe power supply. Always disconnect/de-energize the power supply be- fore working on the boiler. General information for the electrician • USA and Canada 208 to 240 VAC, single phase, 60 Hz,15 amp dedicated circuit.To operate the boiler dur- ing prolonged power failures,the heating system, including controls and circulators, must be conected to a generator which produces clean, true 60 cycle power. Minimum suggested generator size,2500W. • Lightening protection:As there is no possible complete protection against lightening,we suggest installing a voltage spike suppression system for the building where the boiler is located or in the same panel as the boiler is powered from. • Electrical connection: USA and Canada 208 to 240 VAC,single phase, 60 Hz,15 amp dedicated circuit. PE 199 USA 2.0 Wiring diagram-terminal box 43 —---------- Wiring Plan Terminal Specification I Hot wire Ll-Power supply 208 VAC 2 Hot wire L2-Power supply 208 VAC 3 Neutral wire-Power supply 208 VAC :!: Ground wire-Power supply 4 Hot wire-Boiler contact 5 Hot wire-Boiler contact 6 Hot wire-Domestic hot water pump 7 Neutral wire-Domestic hot water pump y Ground wire-Domestic hot water pump 8 Hot wire-Boiler controlled pump 9 Neutral wire-Boiler controlled pump Ground wire-Boiler controlled pump 10 Hot wire-Power supply-Low water Cut-Off' 11 Hot wire-Burner circuit-Low water Cut-Off 12 Neutral wire- Low water Cut-Off _±: Ground wire-Low water Cut-Off 13 Hot wire Ll-Power supply 14 Hot wire L2-Power supply :!- Ground wire-Power supply IS Hot wire-Power vent-Safety close contact 16 Hot wire-Power vent-Safety close contact :L- Ground wire-Power vent 17 Hot wire-Power vent-Power supply 110VAC 18 Neutral wire- Power vent-Power supply 110VAC Ground wire-Power vent-Power supply 110VAC 19 Hot wire Ll- Delivery motor 20 Hot wire L2-Delivery motor-Suction system 21 Hot wire L3-Delivery motor-Suction system Ground wire-Delivery motor-Suction system 22 Neutral wire-Delivery motor-Suction system 23 Hot wire-Level detection system 24 Hot wire-Level detection system 2S Hot wire-Level detection system 26 Hot wire-Outdoor sensor 27 1 Hot wire-Outdoor sensor 24V 24V GIND GND A A 0 B I shield 1Shield Installation Manual AutoPellet'PES 10—32 m WIRING DIAGRAM - Terminal box _ _ __ _ _ __ _ _ _ _ _ _ _ _ _ _ _ _ _ _ - - - - — oovoi unrt - 208 VAC iMust npt b.pWpatl n If 24 VDC t✓ '.. s I mere a no Pawar va,ot uaadl — D ws — N P52 -51 Summa+/wmtar swnrh ( O Mairt ((Nat,nstabad wean tlN:vYrad witna s.v,tch ,Paa+�ron��natmr c�nnero=N�.r-rt I !baa -xI %2 X3 X4 XS X6 X7 I - I I 115 VAC Relais 230 VAC Relais 115 VAC Relais 230 VAC Relais 115 VAC Relais FAD water filling level Cut Off-Boiler Ff 14I 1 - _ X2 X, YYYYY 1"' 'd I � 208 VAC 110 VAC 110 VAC 130 VAC 208 VAC 110 VAC 110 VAC 208 VAC 24 VDC PT1000 24 VDC Power supply Boiler contact and Boiler controlled pump Low water Power supply Power Vent Power Vent Delivery motor Level Outdoor BUS Domestic hot water Cutoff max.2A Safety close Power supply Suction system detection sensor Pump•Switch on Y PP y max.4A system pump(max.2A) temperatures 140'f contact max.2A I(Not used when ( max.2A N delivered with a IPelletronic 1 O X (heating controller)I ! Plugs on the boiler control unit 45 10.2 Plugs on the boiler control unit The designation of the plugs must correspond with the labeling of plug-in positions. Designation of plug-in position Voltage Name of sensors,motors and pumps XIA 32GNDI 24 Volt Operating display XIB 32GNDI 24 Volt Heating/zone controller X2 54 24 Volt Power supply display R1 4645 24 Volt Not used R2 4443 24 Volt Not used AF 4241 24 Volt Not used KF 89 24 Volt Boiler sensor UP 234 24 Volt Negative draft measuring AE2 567 24 Volt Level detection system AE1 1098 24 Volt Not used FRT 1213 24 Volt Combustion chamber temperature sensor RGF 1415 24 Volt Flue gas temperature sensor(optional) PWM 1617 24 Volt PWM for speed controlled high-efficiency pump Analog IN 1819 24 Volt Not used BRI 78 24 Volt Burner/"cold start"contact AK 1112 24 Volt Existing boiler(optional) ESAV 32 33 34 24 Volt Ash box RPM feedback DE 37 36 35 24 Volt Not used DE 2 40 39 38 24 Volt Not used KAPZW 26 25 24 24 Volt Capacitive sensor- hopper KAPRA 543 24 Volt Capacitive sensor- burner BSK 654321 24 Volt Ball valve/Flame return gate X21 PE L N 236 Volt Power supply VAK 50 PE 49 2 &,Yolt, Vacuum turbine ZUEND N PE 22 1 36 Volt Ignition AV 52 PE 51 2310-V61t Motor ashbox RES2 53 PE 54 230,Volt Not used MA 48 PE 47 2ni Volt Magnetic valve(Cleaning nozzle, heat exchanger) RM 15 PE N 236 jolt Motor for boiler flame tube cleaning device SM 1920 230,VoJt Relay fault signal(optional) SZ 17 PE N 230 Volt Flue gas fan UW 13 PE N 236 Volt Boiler controlled pump STB 17 PE 19 230 Volt Safety temperature/Over-temp sensor NOT 4341 230 Volt Connection to low water protection J Emergency stop heating RAI N PE 141516 1230 Volt Fuel transport system REST 50 PE 49 1 236V' O'It Motor hopper- IDES 36-56 only ------- --- Installation Manual AutoPellet"PES 10—32 Plugs on the boiler control unit ZW N PE 26 25 24 0 Voit Vibration motor ES 1 2 3 N PE 6C V1 '. Burner motor LUFT N PE 11 Burner fan PE 199 USA 2.0 Cable routing 47 10,3K~abUe routing Reroute cables after dismantling the casing orother system components. Risk of electric shock Switch off the system before performing work on the Note the following points toensure the cables are routed securely: Cables must not berouted: ^ over moving parts ~ over hot parts ^ over sharp edges Cables must be: ~ routed inthe cable ducts provided ^ through cable|eadthroughs ~ tied together ~ secured with cable ties atthe points provided ^ Power cables must be routed in the right-hand duct and sensor cables must be routed in the left-hand duct. IRi W shock sk of electric is of I ctric heck cables for damage.. eplace any cables that are damaged. Damage to the boiler controller Before fitting the casing components,make sure that all cables are connected to the correct points on the con- troller! Failure to do so can lead to damage to the con- troller,and such damage is not covered by warranty! Installation Manual AutoPeUet'PES lO-32 Cable routing KF UP o • o uJ 0 FRT ES AVW' AV 0 0 o KAPZW PE 199 USA 2.0 I I I�1 O t 1 I I "��=i�j `�-„„%►�/��%' �� _�� VIII_ , •r ti OT <• I � o I I I Wiring diagrams 10.4 Wiring diagrams The wiring diagrams for the boiler control unit provide detailed technical information for electricians. 70ectric shock n authorised installer may connect the pellet boi- ertothe power supply. Isolate the entire heating system from the power supply before starting work on the pellet boiler. N N I LL. '-T O O Q O O 0' L .o I Z CE N N O N O H N a" Nin N r LL M Eeqctn O (0 U = a`� Z CD � C) CL 't N CO O W 0) O 1 O n Z Q O. 1 5 OD I O , Q - - J CO Q _N C O >+ N Q D- :3 O LO qt CD cv N W C0 E'0C: N ¢� > (na o N o a M C m � N 0 rn(D m.S X Z C o ' ` C M = CD M O O = U a z ` M o C Q N C _ '4-- T Cc CO LL. 0D N X Z N a Y d7 N O_ in :O r O :5 m YL N N PE 199 USA 2.0 24V PWM Analog IN BR1 AK ESAV DE1 DE2 KAPZW KAPRA B$f( 16 17 18 19 8 7 12 11 34 33 32 5 36 37 338 39 40 2 5261 3 4 5 1 2 3 4 516 Z ', Q i !1J i Not used Not used Not used N - I 14 14 + y y IzavoCl I — — liow I M - - - - - - - - - - PWM for speed Burner/"cold Existing boilers Ash box RPM Capacitive sensor- Capacitive sensor- Ball valve/Flame controlled high- start"contact feedback hopper burner return ate efficiency pump g i i ;y iL 0 3 C C 0 M w o ! I I w N i Ul M RA RES1 ZW ES LUFT 115V- N O 141151161 150 O 1491 N 18 126125124 1 1 12131 N 18 6 O N 11 240V C D i N O i 23ovAC�Mi— M 1~ 230VAC M 1~ M 1~ 50W AC M 1~ max.4A max.2A 230VAC max. 2A 230VAC max. 2A 85W max.2A Fuel transport Motor hopper— Vibration motor Burner motor- Burner fan system PES 36-56 (optional) Auger system only with vibration motor SM SZ UW STB FNO7T 1920 17O N 13O N 17019 4143 M1~ M1~ 230VAC 230VAC Relay fault signal50W max. 2A max.2 A Safety temperature Connection to low sensor 230VAC water protection / Flue gas fan Boiler controlled pump Emergency stop heating is ' v Q 3 X2 RES2 VAK ZUEND AV MA RM 115V- S L N 5049 N (D 22 521 (D 151 54 O 53 48 (D 47 15 240V L1 3 Not used Power supply 230VAC 230VAC 230VAC 230VAC 230VAC max. 2A 250W max. 2A Boiler controller max. 2A 25W max. 2A max. 2A Vacuum turbine Magnetic valve Ignition Motor ashbox Motor for boiler flame tube cleaning device CU 0 1 Fuses- boiler controller 10.5 Fuses - boiler controller The control unit is protected against short circuits by fuses which are in the control panel (under the front boiler panel).There are also fuses in the terminal box at the rear of the boiler. At the rear panel,there are 4 fuses.Two 6.3 amp for outputs there,and two 10 amp also for the main controller. Damage of property Should it become necessary to replace a fuse, it is criti- cally important to replace the fuse only with a fuse hav- ing the same exact ratings. 0 ' m LUJ a OO O O °' a0 O Q OO 10 10 OO Inn .: an M n0�� THE 0 PUT z 1 Fl: Fuse T8A 2 F2: Fuse T10A 10.6 Operating the AutoPellet The operation of the system is described in the manual for the End User. PE 199 USA 2.0 Starting up for the first time 55 11 Starting up for the first time After bringing in the boiler,connecting up the hydronics and power supply,the unit can be started up for the first time. Air tight property of combustion chamber To ensure correct combustion and overall operation,all fittings to the combustion chamber must be correctly assembled to be completely air-tight. Note: The boiler may only be commissioned(first start-up) by an authorized installer. Before starting up the pellet boiler,the following settings must be made in the sequence specified below: 1. Adjust power rating 2. Settings in the boiler control unit 3. Output test-test all motors 4. Settings in heating controller(if installed) S. Start the pellet boiler Use the checklist enclosed to document the start-up procedure. Property damage The allowed temperature of the boiler controller is 40 to 122°F. 11.1 Adjusting power rating On Autopellet boilers the effective heat exchanger area can be changed within a finite range. This involves opening or closing the heat exchanger tubes.The output power of the boiler is adjusted with this change in conjunction with a parameter change within the controller. If the condition as shipped is different from the power rating required,then the service technician must adjust the power rating, including the correct setting of the heat exchanger area, before starting up for the first time. 11.1.1 Installing the turbulators and closure plugs The heat exchanger in the pellet boiler has between 12 and 36 heat exchanger tubes, depending on the size of the boiler. Springs are installed inside the heat exchanger tubes to clean the tubes as well as act as turbulators. Increasing the boiler power rating 1. Remove the closure plugs from the ends of the heat exchanger tubes. 2. Insert the turbulators supplied into the heat exchanger tubes. 3. Hook the turbulators onto the ring of the cleaning system. Reducing the boiler power rating 1. Unhook the turbulators from the ring of the cleaning system. 2. Remove the cleaning springs/turbulators from the heat exchanger tubes. 3. Close off the heat exchanger tubes using the closure plugs supplied. Installation Manual AutoPellet�PES 10—32 Installing the turbulators and closure plugs Number of cleaning springs(tubulators)to be removed/installed: Final boiler power No.of Full power setting of No.of setting springs boiler springs 41,000 BTU/h 10 68,300 BTU/h 16 Remove 6 turbulators 51,000 BTU/h 12 68,300 BTU/h 16 Remove 4 turbulators 68,300 BTU/h 16 68,300 BTU/h 16 No adjustment required 85,300 BTU/h 16 109,500 BTU/h 20 Remove 4 turbulators 109,500 BTU/h 20 109,500 BTU/h 20 No adjustment required 123,000 BTU/h 30 191,000 BTU/h 36 Remove 6 turbulators 164,000 BTU/h 32 191,000 BTU/h 36 Remove 2 turbulators 191,000 BTU/h 36 191,000 BTU/h 36 No adjustment required 68,300 BTU/hr 51,000 BTU/hr 41,000 BTU/hr eyae e (De e ) e e e e e 4 tubes closed 6 tubes closed 109,500 BTU/hr 85,300 BTU/hr e ) e ) e m e m I ID 4 tubes closed 191,000 BTU/hr 164,000 BTU/hr 123,000BTU/hr e w e 4 tubes closed 6 tubes closed PE 199 USA 2.0 Appendix 57 12 Appendix 12.1 Checklist for checking the heating system The checklist is intended to help authorised specialists perform and document a comprehensive check on the heating system. Name and adress of the customer Heating device Name: Type of boiler: Street: Rated power: Place: Year of build: Name and adress of installer Manufacturer's serial number: Name: Type of heating controller: Street: Type of accumulator: Place: Solar device: Damage to property Use the checklist to check the heating system before starting up for the first time, CHECKLIST _ Yes I Comment Textile tank Textile tank Are the tie members installed? Are all legs straightened vertical? Is the slot for the emercency gate valve closed with an ad- Delivery unit hesive tape? Filling coupling Are the filling couplings correctly installed? Are the plugs at the filling couplings? Are the safety labels placed?(Caution-Switch off the heat- ing systembefore entering) Are the couplings correctly grounded? Is the storage room/building properly ventilated with mini- Ventilation mum 27 square inches to the outside? Is the label"Wood pellets storage room" placed on the door Caution label to the storage room? Check the electrical connection of the vibration motor and Vibration plate the capacitive sensor If auger delivery system is installed Drive unit Is the direction of rotation correct? Is a clemounting possible? Spiral hose Is the pitch to the burner>45'? Sound insulation Is the rock wool insulation fix at the wall pass through? Pellet boiler Installation Manual AutoPeilet�IDES 10—32 Checklist for checking the heating system Adjusting power rating Is the power rating corrrectly adjusted? Burner plate Is the screw fixing the burner plate,tightened? Flame tube Is the flame tube placed correctly? Combustion cham- Are the adjusting screws for the increasing of the flue gas ber cover temperature adjusted correctly? Is a chimney draft regulator, barometric damper Flue gas connection implemented? Make-up air/ ventilation Does the boiler room have required make-up air? Nameplate Is the nameplate placed on the boiler? Electric installation and regulation Power supply Check the electrical connection?(terminal box) Check the ratings of the fuses. Settings-Boiler con- Are the settings of the boiler control unit according to the trol unit installation manual? Settings-Heating Set the parameters,the heating circuit program and do- controller(if used) mestic hot water program. Boiler sensor Securing location and connection Hydronic Connection Circuit pumps Check the switch on temperature(min.140°F)for boiler controlled pump(Parameter P 281). Low Water Cut Off Is a low water cut off installed?(terminal box) Test low water device Boiler connection Is the pellet boiler correctly connected Is the hydronic system free of air? Is the system filled up with water? Check the pressure. Safety systems Fire protection - ball Check the function? valve Check the installation and explain the function. Safety temp.sensor Securing location and connection Negativ draft control Check the function. Safety valve Is a safety valve installed? Emergency stop switch Is there an emergency stop switch? Fire extinguisher Is there a fire extinguisher? Instruction Explanation of functions, malfunctions and maintenance to Heating-up the customer. Heating controller Explanation of the heating controller. PE 199 USA 2.0 Appendix GofCAN/CSAB365 M91 59 Explanation of the operating and maintenance regulations Operating manual to the customer. Maintenance contract Notice to the legal regulations" Date' Signature author|oiedinstaller: Signature customer: The customer confirmes that the installer has shown how to operate the boiler,empty the ash box and how to tell if the storage room or F|eX!L0 is requiring more pellets aswell as the need tuempty the sto- rage unit yearly. 12,2 Appendix G of CAN/CSA-B365—M91 Functioning ofsafety and operating controls This Annex is not a mandatory part of this Standard,but is written in mandatory language to accommodate its adaption byanyone wishing tndnso. The safety and operating controls shall function within the limits specified by the manufacturer for the type ofequipment.The following test shall beperformed: l Check the operation nfthe automatic fuel feeding interrupt device ateach entrance tothe 800rspace within which the fuel-feeding device is installed. 2. Check that when the low water level control on steam and hot water boilers is operated to indicate a low water level,the automatic fuel-feed isinterrupted. 3. Check that when the excessive pressure control onsteam and hot water boilers isoperated asinanex- cessive p/esounesituetion'theautomaticfue}-feed is interrupted. 4. Check that when the excessive water temperature control on steam and hot water boilers is operated to indicate excessive water temperature,the automatic fuel-feed is interrupted and, if appropiate,that one ormore zone control valves open, S. Check that if the temperature exceeds 200'F in a furnace supply plenum on hot air furnaces,the auto- maticfue|-feedisinterrupted. 6. Check that if there is a failure of the fan providing combustion air,the automatic fuel-feed is interrupted. 7. Check that if there is a failure of the combustion air supply control mechanism to remain fully open,the automaticfue|-feed is interrupted. 8. Check that when the hot water circulating pump manual disconnect switch is opened,the automatic fuel- feedisinterrupted. Q. Check that if there is a shutdown or failure of the mechanical flue-gas exhauster,the automatic fuel-feed is interrupted. lO. Check that if there is a failure in the flue gas flow, the automatic fuel-feed is interrupted,or the combus- tionairsupp|yisshutoffinnnanuaUyfueUedapphances. ll. Check for the proper operation of the minimum fire maintenance controls and system or, if applicable,of the automatic ignition system. 12. Check for the proper operation of the controls used for normal automatic fuel-feeding. 13. Check the operation of any other controls supplied on the appliance by the manufacturer,or required by the authority having jurisdiction. Installation Manual AutoPeUet�PES lO-32 6 Modifying the burner 12.3 Modifying the burner The pellet boiler is configured symmetrically. If required,you can remove the burner from the right-hand side (as shipped)and reinstall it on the left. 1. Dismantle the casing, hopper,combustion chamber lid,flame tube, burner and burner plug. 2. Modify the burner on the left. 3. Modify the cleaning system motor and off-set disc. 4. Change the direction of rotation of the cleaning motor. 5. Modify and re-assemble the cleaning system. 6. Route cables through cutouts to the boiler controller and connect up the plug. 12.3.1 Dismantling the casing, hopper,combustion chamber lid,flame tube, and burner ©6 r 1 Q• a a 4xM10 PE 199 USA 2.0 Modify the burner on the left 61 12.3.2 Modify the burner on the left 10 11 12 .VQ4 o O 3 .Qs 4 4xM10 13 14 15 j 0 0 16 17 a 0 v 4xM 10 Note:. Do not tighten too firm,otherwise the dummy cover could become leakly. Installation Manual AutoPellet'PES 10—32 r; Modifying the cleaning system motor and off-set disc 12.3.3 Modifying the cleaning system motor and off-set disc • • • 0 O ® Il' O 40 06 6 Note: Figure 6:Glue and tighten the hex-socket nut to secure the off-set disc. PE 199 USA 2.0 Changing the direction of rotation of the cleaning motor 63 12.3.4 Changing the direction of rotation of the cleaning motor O O 0 0 00 ol 0 o 0 Q ® 0 • O o • 12.3.5 Modifying and re-assembling the cleaning system Setting up the cleaning system: • Switch on the pellet boiler. Output • Select"Output test"of the boiler controller for Pellernalic the boiler cleaning motor. 42 MA • Push the lever mechanism of the cleaning sys- tem against the cleaning shaft. Off • Press the clip on the cleaning shaft against the off-set disc and switch on the cleaning motor. • As soon as the off-set disc causes the clip to kinton spring back,switch off the motor and tighten the shaft clamp as tight as possible. Off • Use a lock nut to secure the shaft mounting. Fine adjustment: • If the cleaning system does not lift high enough: loosen the mounting angle, push forward in the slots and tighten again. • If the cleaning system stops at the limit bolt: loosen the mounting angle, push back in the slots and tighten again. Note: The motor mounting must not be able to move and the motor must rotate easily. Installation Manual AutoPellet*PES 10—32 Modifying and re-assembling the cleaning system O � O . o at 4x o �0 Q► 0 � � '0 10 0 PE 199 USA 2.0 Parts list 65 12.4 Parts list 12.4.1 Pellernatic PES 10-20 34,000-68,300 BTU/hr Pos. Article number Pos. Article number Pos. Article number 1 PE114 26 PE120(B, G, R) 49 PE143 2 PE119 27 121159 50 PE129 2 PE119B 28 PE121(13,G, R) 51 1 121049/121126 2 PE119G 29 E1412 52 PE103 2 PE119R 29a PE564 53 PE142 3 PE200 29b E1411 54 E1054 4 PElS6 29c E1330 54a E1186 5 J PE289 29d E1238 55 121169 6 PE215 29e E1073 56 121168 7 121259 30 on request 57 PE281 8 PE429 31 PE191 58 B103 9 121347 32 on request 58a PE277S 10 1121082/121037 33 PE160 59 PE133 11 PE131 34 PE176 60 PE475 12 PE212 35 on request 61 121380 13 PE174 36 121039 62 PEASCH RE- I-I 24155/24157/121198 14 121373 37 PE416/PE413 63 24315 15 on request 38 121410 64 PE 467/121327 16 121034 39 121042 65 PE 192 17 121381 40 121379 66 24169 18 041876 41 121083/121029 67 PE260 19 PE185 42 PE188 68 j PE419 20 121109/121255 43 PE115 69 1 PE330 21 PE123 44 PE117.1 69a PE135 22 121123 45 PE117 69b PE139 23 B0020 B0020BR 46 PE209 69c PE136 24 PE116 47 PE258 f 69d I PE134 25 PE118 48 E1001A Installation Manual AutoPellet"PES 10—32 r; Pellematic PES 10-20 34,000-68,300 BTU/hr 1 56 10 2 •55 64 60 57 3 0 67 9 52 51 54 7 8 5 - 53 50 13 - 49 14 15 16 18 11 17 48 �47 � 12 � 19 45 59 58 20 2 46 4 22 0 44 3 M 21 ------------- 65 5 42 38 D 63 36 ----------------- 66 35 ' 27 40 39 41 1 34 33 9 26 � 32 ----------------, 31 43 69 30 8 68 s 62 PE 199 USA 2.0 Pellematic PES 10-20 34,000-68,300 BTU/hr 67 B0020/B0020 BRE B0020 Burner without capacitive sensor,WITHOUT Burner plate clean- ing system B0020BR- Burner without capacitive sensor,WITH Burner plate cleaning E system 1 121041 19 121196 37 121041 2 121058 20 B172 38 B147 3 8150 21 121197 39 121082 4 121039 22 121023 40 B152 5 121038 23 B130 41 B144 6 121011 24 121041 42 B136 7 121195 25 121037 43 E1413E 8 121051 26 121079 44 B225 9 B179 27 E1030/E1002.1 44a B101 10 121082/1121037 28 121166 45 121034/121082 11 B129 29 121039 46 121034/121037/121082 12 121075 30 121038 47 B181 13 121193 31 B113 48 E1204/E1002.1 14 121194 32 E1059 49 B182 15 121192 33 E1004 50 B183 16 121010 34 B105 51 B184 17 121083/121029 35 E1005 52 B196 18 1 121039/121038 36 B202 53 121361 139 40 41 43 44 42 ,t; *• _ 37 38 34 0 53 45 36 25 33 49 35 23 52 32 51 13 12 14 17 50 46 10 11 d 1 ® 47 5 45 a ° 21 24 2627 3 0 20 48 2 8 16 18 29 31 1 15 8 6 7 9 19 30 Installation Manual AutoPellet,PES 10—32 6G3 Pellematic PES 10-20 34,000-68,300 BTU/hr 041876- Hopper 1 E1138 7 E1368 2 121114 8 041870 3 121010 9 E1205 4 041070 10 041869 5 041071 11 041868 6 121122 9 0 a' ,o 11 o 4 65 PEASCHLI -Ash box PEASCHRE-Ash box 44 � T,-.jr,ZJ 1 2a 3 3 2b 2c a 1 PE442 3 PE373 PE436 2a PE440 4 PE453 121296 2b PE439 PE347 PE292 PE 199 USA 2.0 Pel|enriatic PES 2S'32/Boiler 85,3O0-lOS.5O0BTU/hr 69 12.4'2 PeUKematic PIES 25 -32 Boiler 85,300-109,500 BTU/hr Pos. Article number Pos. Article number Pos. Article number 3 PE205 28 PE121B 51 121050/121126 7 1212S9 29a PES64 54a E1186 8 PE430 29b E1411 55 121169 9 . 121347 29c E1330 56 1121168 10 PE244 29d E1238 57 PE281 11 PE131 29e E1073 58 B104 12 PE213 30 on request 58a PE277S 14 121373 32 121378 60 PE476 15 PE244.1 33 PE160 61 121380 16 121034 34 PE176 62 PEASCH RE- LI 241SS/24157/121198 17 121381 35 on request 63 2431S 18 041886 36 121039 64 PE 467/121327 20 121109 38 121410 66 24169 20 1212SS 39 121042 67 PE260 21 PE183 40 121379 68 PE419 22 121123 41 121083/121029 69 PE331 Installation Manual AutoPeUet*IDES lO-32 r Pellematic PES 25- 32/Boiler 85,300-109,500 BTU/hr 1 10 56 57 2 60 55 � � 0 64 3 lj �U � t �► 4 Pit o 9 10 52 5153 54 .•64 7 8 15 61 50 a 14 3 cam' 18 16 11 17 49 47 g 12 19 48 58a 45 58 24 0 59 .0 46 65 2 44 0 0 1 29d 29e 29c �29a .b 5 63 38 4066 36 35 4241 37 39 9 26 ----- -------2sb 34 32 33 31 68 43 30 28 B 62 - PE 199 USA 2.0 Pellematic PES 25-32/Boiler 85,300-109,500 BTU/hr 71 80030/B0030 BRE B0030 Burner without capacitive sensor,WITHOUT burner plate clean- ing system B0030BRE Burner without capacitive sensor,WITH burner plate cleaning system 1 121041 19 121196 37 B148 2 121058 20 B172 38 121082 3 8150 21 121197 39 B152 4 121039 22 121023 40 B144 5 121038 23 B131 41 B132 6 121011 24 121041 42 E1413E 7 121195 25 121037 43 8226E 8 121051 26 121079 44 121284 9 B179 27 E1030/E1002.1 45 121034/121082 10 121082/121037 28 121166 46 121034/121037/121082 11 B129 29 121039 47 B181 12 121075 30 121038 48 E1204/E 1304 13 121193 31 B113 49 B182 14 121194 32 E1004 50 B183 15 121192 33 B105 51 B184 16 121010 34 E1005 52 B197 17 121083/121029 35 B202 53 121361 18 121039/121038 36 121041 41 37 39 42 34 40 43 38 44 53 45 49 35 36 33 22 23 25 5 12 14 17 51 13 32 p 50 46 11 ® 47 10 26 a 4 5 0 4 7 3 a 20 21 45 48 a 18 29 31 2 1 15 16 8 8 i 19 6 7 9 30 Installation Manual AutoPellet®PES 10—32 Pellematic PES 25-32/Boiler 85,300-109,500 BTU/hr 041886- Hopper 1 E1138 7 E1368 2 121114 8 041600 3 121010 9 E1205 4 041070 10 041869 5 041071 11 041868 6 121122 a t 9 6 ° ° ql ,a 11 8 o a C3 4 6 5 PEASCHLI PEASCHRE , _ 2 3 3 2 1 PE442 3 PE373 PE436 2a PE440 4 PE453 121296 2b PE439 PE347 PE292 PE 199 USA 2.0 Technical data 73 12.5 Technical data Boiler-Type PE(S) PE(S) PE(S) PE(S) II PES PES PES 12 15 20 25 32 36 48 56 Boiler-rated BTU/hr 41,000 51,000 68,300 85,300 109,500 123,000 164,000 191,000 power kW 12 is 20 25 32 36 48 56 Boiler-partial BTU/hr 11.601 17.061 20,473 27.297 34.121 37.534 51.182 58,006 load kW 3,4 5 6 8 10 11 is 17 Measurements Width-total(B) Inch 441/2 44112 441/2 463/4 463/4 51 51 51 mm 1.130 1.130 1,130 1,186 1.186 1.297 1.297 1.297 Width-boiler Inch 271/2 271/2 27112 293/4 293/4 34 34 34 (C) mm 700 700 700 756 756 . 862 862 862 Height- boiler Inch 43 43 43 51 51 61 61 61 (H) mm 1.100 1.100 1.100 1,300 1,300 1.555 1.555 1,555 Height-vacuum Inch 55 55 55 63 63 73 73 73 system execu- mm 1,400 1,400 1.400 1.600 1.600 1.855 1.855 1.855 tion (D) I I Height-filling Inch 12 12 12 12 12 12 12 12 unit(F) mm 300 300 300 300 300 300 300 300 Depth-boiler Inch 32 32 32 341/4 341/4 39 39 39 (T) mm 814 814 814 870 870 990 990 990 Depth -burner Inch 20 20 20 20 20 20 20 20 casing (V) mm 508 508 508 508 508 508 508 508 Flow/return- Inch I 1 1 5/4 5/4 2 2 2 dimensions Flow/return- Inch 3S3/4 3S3/4 3S3/4 433/4 433/4 52 52 52 height of con- mm 905 905 905 1.110 1,110 1.320 1.320 1.320 nection (A) Flue size- Inch 5 5 5 6 6 7 7 7 diameter mm 130 130 130 JISO 150 180 1180 180 Flue- height of Inch 251/2 25I/2 251/2 331/4 331/4 41 1 41 41 connection(E) mm 645 64S 645 844 844 1.040 11.040 1,040 Overall Weight Lb 631 631 631 756 756 1.120 1.120 1.120 kg 286 286 286 343 343 508 508 508 Boiler Body Lb 529 529 529 664 664 1930 930 930 Weight kg 240 240 240 301 301 422 422 422 Efficiency rated % 85,4 85,6 85'5 84,9 84,5 85,3 85,4 85,9 power Efficiency partial % 85,1 84,3 84,2 84,2 84,3 84,1 84,1 84,1 power Water capacity Gal 15,0 15,0 15,0 23,6 23,6 130,6 130,6 130,6 1 166,0 66,0 . 66,0 1 104,0 104,0 1135,0 1135,0 1135,0 Flue gas area Installation Manual AutoPellet�PES 10-32 Technical data Boiler-Type PE(S) IPE(S) PE(S) PE(S) PE(S) PES IDES IDES 12 15 20 25 32 36 48 56 Fire vault OF 1652-2012 temperature Oc 900-1100 Fire vault Inch WC -0.14 pressure mbar -.35 Flue gas tem- OF 320 perature rated Oc 160 power(Flue gas temperature can be adjusted) Flue gas tem- OF 212 perature partial Oc 100 load (Flue gas temperature can be adjusted) Flue gas inertia Lb/hr 49,60 62,17 82,89 99,43 115,96 149,25 198,85 231,92 current rated power kg/h 22.50 28,20 37,60 45,10 52,60 67,70 90,20 105,20 Flue gas inertia Lb/hr 14,11 20,72 24,91 29,76 35,71 45,64 62,17 70,33 current partial load kg/h 6,40 9,40 11,30 13,50 16,20 20,70 28,20 31,90 Flue gas volume Cft/hr 918 1.232 1.642 1.971 2.627 2,956 3.941 4.598 rated power M 3/h 26 3S 47 56 74 84 112 130 Flue gas volume Cft/hr 240 353 424 509 607 777 1.059 1.204 partial load at flue gas rn'/h 7 10 12 14 17 22 30 34 temperature Chimney according to chimney calculation diameter Chimney steel or ceramic lined,withstand humidity construction Electrical USA and 208 to 240 VAC,single phase,60 Hz,15 amp dedicated circuit, connection _TCanada Water area Water resistance In WC 38,22 60,22 88,32 114,02 150,95 15,62 20,84 24,29 at 10K mbar 95,20 150,00 220,00 284,00 376,00 38,90 51,90 60,50 Water resistance In WC 9,72 15,26 22,08 28,91 38,14 4,18 5,58 6,50 at 20K mbar 24,20 38,00 55,00 72,00 95,00 10,40 13,90 16,20 Boiler OF 149-194 temperature Oc 65-90 Boiler input tem- OF 131 perature Oc 55 minimum Operating pres- psi 50 sure maximum bar 3 Test pressure psi 67 bar 4,60 PE 199 USA 2.0 Technical data 75 Boiler-Type PE(S) PE(S) PE(S) PE(S) PE(S) PES PES PES 12 15 20 25 32 36 48 56 Flue gas volume Cft/hr 1.010,0 1.327,8 1.7 72,8 2.231,9 2.874,6 3.217,2 4.262,5 4.944,1 rated power at flue gas m3/h 28,6 37,6 50,2 63,2 81,4 91,1 120,7 140,0 temperature Flue gas volume Cft/hr 243,7 384,9 459,1 614,5 769,9 847,6 1.165,4 1.313,7 partial load at flue gas m3/h 6,9 10,9 13,0 17,4 21,8 24,0 33,0 37,2 temperature Fuel USA According to PFI Premium Standards or EnPlus-Al pellets Europe According to EN14961-2 Standards(Al Class) Colorific value BTU/Ibs >7.200 MJ/kg >16,5 Bulk density Lb/cft >40,00 kg/m3 >600 Water content Mass% <10 Ash content Mass% <1 Lenght Inch 11/4-11/2 mm 3,15-40 Diameter Inch 1/4-5/16 mm 6,00-8,00 Fine material Mass% <0.5 Mass% <1% Ash melting OF >2.200 point OC >1.200 Contents USA untreated wood Europe stemwood or chemically untreated wood Components Internal ash pan Gal 5,68 6,81 - volume lb 25 30 - External ash box Gal 4,54 5,675 volume lb 20 25 Main Drive W 40 Drive Motor W 250/370 Suction Turbine W 1200 Combustion Air W 83 Blower Suction Fan W 32 Blower Electrical W 250 Ignition Cleaning Motor W 40 Installation Manual AutoPelletO PES 10—32 Technical data Boiler-Type PE(S) PE(S) PE(S) PE(S) PE(S) PES PES PES 12 15 20 25 32 36 48 56 Motor External W 40 Ash Box Fire protection W 5 motor The data are values of the test measurement and can vary from locally measured values WB Federal Institute of Agricultural Engineering Wieselburg Address:A-3250 Wieselburg, Rottenhauserstraf3e 1;Tel.: +43-7416-52175-0 Note: Test reports are available PE 199 USA 2.0 Pellet boiler cautionary markings 77 12.6 Pellet boiler cautionary markings Labeling 60x30 THE CONTAINER CAN BE BEFORE OPENING TO START THE SYSTEM TAKEN DOWN ONLY BY TURN OFF THE PRESS THE LOOSENING THE YELLOW MAIN SWITCH GREEN ON/OFF BUTTON LOCKING SCREW l�3 CAUTION & CA TION & CAUTION DO NOT ALTER THIS POWER SOURCE NOT POWER ORGINATED FROM EQUIPMENT IN ANY WAY CONTROLLED BY SUCTION A SOURCE OF POWER TURBINES MAIN OTHER THAN THIS MOTOR DISCONNECT Q CAUTION 4& CA TION 4& CAUTION DO NOT REMOVE THE SNAP FOR USE WITH WOOD VACUUM SUCTION SYSTEMS; RING! PELLET FUEL ONLY REMOVE THE PROTECTIVE CAP FROM THE BALL VALVE Labeling 99x34 CZ Eel ' CONTACT LOCAL BUILDING OR TO AVOID INJURY FROM MOVING PARTS, FIRE OFFICIALS ABOUT SHUT OFF THE MAIN CONTROLLER RESTRICTIONS AND INSTALLATION BEFORE REMOVING THIS COVER INSPECTION IN YOUR AREA It I'I ti Q► CAUTION KEEP VIEWING AND ASH REMOVAL DO NOT CONNECT THIS UNIT TO A DOORS TIGHTLY CLOSED DURING CHIMNEY FUEL SERVING ANOTHER OPERATION! APPLIANCE. SEE LOCAL RESTRICTIONS! 4& CAUTION FORWARD INSTALL AND USE ONLY IN ACCORDANCE WITH INSTALLATION- WATER QUALITY ACC.TO VDI 2035 STANDARD AND OPERATING INSTRUCTIONS! (THE MEDIUM HAS TO BE FREE FROM AIR AND MUD) REFER TO OWNERS MANUAL =- " = RETURN MOVING PARTS CAUSE INJURYI WATER QUALITY ACC.TO VDI 2035 STANDARD DO NOT OPERATE WITH REMOVED (THE MEDIUM HAS TO BE FREE FROM AIR AND MUD) COVERING! Installation Manual AutoPellet*PES 10—32 7r Pellet boiler cautionary markings Labeling 105x74 IN THE CASE OF A"RUN-AWAY" FIRE: ACAUTION NEVER PUT YOUR SELF AT RISK OF HOT SURFACES FATAL INJURY. YOUR SAFETY MUST ALWAYS TAKE HIGHEST PRIORITY! • DO NOT TOUCH DURING OPERATION! • KEEP CHILDREN AWAY SWITCH OFF THE HEATING SYSTEM • KEEP CLOTHING AND COMBUSTIBLE MATERIALS AWAY FROM MARKED EXIT THE BUILDING AND CALL YOUR CLEARANCES. SERVICE CONTRACTOR AND LOCAL ' MAXIMUM DRAFT MARKED FIRE DEPARTMENT ON NAMEPLATE : CAUTION IN THE CASE OF A CONNECTING BOILER RISK OF FIRE! CONTACT A SERVICE TECHNICIAN FOR DO NOT OPERATE WHILE FLUE DRAFT COMPLIANCE INFORMATION BEFORE EXCEEDS-.11 INCHES WC! CONNECTING! DO NOT OPERATE WITH DOORS OPEN! MAY BE CONNECTED TO AN EXISTING DO NOT STORE FUEL OR OTHER BOILER SYSTEM COMBUSTIBLE MATERIAL WITHIN MARKED INSTALLATION CLEARANCES! THE FOLLOWING UNIT IS APPROVED FOR INSPECT AND CLEAN FLUE AND CHIMNEY CONNECTING WITH THE AUTOPELLET SYSTEM: REGULARLY! • DO NOT USE CHEMICALS TO START UNIT FIRING MODEL NUMBER CONNECTED UNIT: DO NOT BURN GARBAGE,GASOLINE,FUEL OILS ITEM NUMBER CONNECTED UNIT: OR OTHER FLAMMABLE LIQUIDS OR MATERIALS ACAUTION HOT SURFACES AND MOVING UNSAFE TO ADJUST FLUE DRAFT HIGHER PARTS MAY CAUSE INJURY! THAN .11 INCHES WATER COLUMN • MIN DRAFT @ LOW FIRE -.02 INCHES WC RISK OF FIRE OR EXPLOSION—DO NOT • MIN DRAFT @ HIGH FIRE -.04 INCHES WC BURN GARBAGE, GASOLINE, FUEL OILS . MAX DRAFT -.11 INCHES WC OR OTHER FLAMMABLE LIQUIDS OR MATERIALS nS CAUTION LOSS OF ELECTRICAL POWER THE HEAT EXCHANGER, FLUE PIPE AND NO DANGER CHIMNEY MUST BE CLEANED REGURARLY PELLET BOILER COOLS DOWN TO REMOVE ACCUMULATED CREOSOTE AND AUTOMATICALLY ASH, ENSURE THAT THE HEAT EXCHANGER, FLUE PIPE,AND CHIMNEY ARE CLEANED AT THE END OF THE HEATING SEASON TO MINIMIZE INSPECT AND CLEAN CORROSION DURING THE SUMMER MONTHS, THE APPLIANCE FLUE PIPE AND CHIMNEY MUST EXHAUST VENTING BE IN GOOD THESE INSTRUCTIONS ALSO APPLY TO A SYSTEM FREQUENTLY DRAFT INDUCER IF USED. PE 199 USA 2.0 Author & MaMWfactWyeF MAINE ENERGY SYSTEMS LLC 8Airport Road— P.O. Box S47Bethel Maine 04217 E-Mail:(nho@rnainepnergysysternszorn MAINE ENERGY SYSTEMS LLC vvvvw.nna|neenergysystenns.conn Subject tonnodifca|ions Inst;lll !mf on � manual H Co'mpact FIeXILO storage tank ENGLISH - USA PE274 USA 2.2 Title: Installation manual FIeXILO storage tank Article number: PE274 USA 2.2 Versio: 2.2 Version valid from: 0512012 Author: MAINE ENERGY SYSTEMS LLC 8 Airport Road — P.O. Box 547 Bethel Maine 04217 e-mail: info@maineenergysystems.com web: www.maineenergysystems.com Q MAINE ENERGY SYSTEMS LLC Subject to modifications Contents 1 Dear Customer............................................................................................................................................... 4 2 Intended use................................................................................................................................................... 5 3 Types of safety warning sign.......................................................................................................................... 6 4 Preconditions for FIeXILO storage tanks........................................................................................................ 7 4.1 The installation room............. 7 ......................................................................................................................... 4.2 Outdoor installation—FleXILO storage tank..................................................................................................... 12 4.3 Storage material—pellets............................................................................................................................... 13 5 Assembly of FIeXILO H storage tank .............................................................................................................14 5.1 Parts list—FIeXILO H storage tank................................................. 14 5.2 Assembly—FleXILO H............................................................ 5.3 Installation of the dispensing unit.................................................... 16 ............ 19 6 Assembly in small rooms...............................................................................................................................22 7 Assembly of FIeXILO Compact storage tank..................................................................................................25 7.1 Parts list—FleXILO Compact storage tank......................................................................................................26 7.2 Assembly—FIeXILO Compact........................................................................................................................28 8 Assembly of the filling system.......................................................................................................................38 9 Final inspection..............................................................................................................................................43 10 Filling of the storage tank.............................................................................................................................44 PE274 USA 2.2 Installation manual FIeXILO storage tank Dear Custonier Dear Customer We are specialist in pellet heating,licensed by 6koFEN Expertise,innovation and quality from a single source. It is based on our tradition that we take on future challenges. We are delighted that also you have decided to purchase our product. • This instruction manual is intended to help you operate the product safely, properly and economically. • Please read this instruction manual right through and take note of the safety warnings. • Keep all documentation supplied with this unit in a safe place for future reference. Please pass on the documentation to the new user if you decide to part with the unit at a later date. • During installation and/or first start up the service engineer must carry out the following work. • The installation has to be performed by a qualified installer. • Please contact your authorised dealer if you have any questions. We place great importance on the development of new products. Our R&D department continues to question accepted solutions and works continually on new improvements. That is how we maintain our technological lead. We have already received several awards for our products in Austria and abroad. Our products fulfil European and USA requirements regarding quality, efficiency and emissions. Ttsled Portland Oregon USA C us OPANI-Te5t Laboratories.Inc. Installation manual FIeXIL0 storage tank PE274 USA 2.2 Intended use 2 Intended use The FIeXILO storage tank is designed for the storage of pellets for heating systems in detached and semi-detached houses or commercial buildings. Use of the FIeXILO storage tank for other purposes is not permitted. No reasonably foreseeable forms of misuse of the FleXILO storage tank are known. The following Austrian standards, guidelines and specifications have been applied: Standards Designation ONORM M7137 Wood pellets-Requirements for pellet storage at retail PE274 USA 2.2 Installation manual FleXILO storage tank y d s of safety warrflj" sign 3 Types of safety warning sign The warning signs use the following symbols and text. Types of safety warning sign 1. Risk of injury NOTICE 1 2. Consequences of risk Damage to property 2 Heating only with pellets complying with the 3. Avoiding risk standard. 1. Risk of injury: Danger-indicates a situation that could lead to death or DANGER life-threatning injury. Warning - indicates a situation that could lead life-threatning or serious injury. Caution-indicates a situation that could lead to injury. CAUTION Note- indicates a situation that could lead to property damage. 2. Consequences of risk Effects and consequences resulting from incorrect operation. 3. Avoiding risk Observing safety instructions ensures that the heating system is operated safely. Installation manual FleXILO storage tank PE274 USA 2.2 Preconditions for ReXILO storage tanks 4 Preconditions for ReXILO storage tanks The following conditions must be observed for the installation of a FIeXILO storage tank. 4.1 The installation room 1. Room size 2. Room characteristics 3. Room ventilation 4. Fire protection 4.1.1 Room size The necessary room size differs, depending on the type and size of the FIeXILO storage tank. Add the following installation dimensions of the storage tank type and thus calculate the minimum size of your installation room. FleXILO and FleXILO PLUS Installation dimensions Length On the filling system side: . /width FleXILO Plus + 12in On the sides without filling system: FleXILO Plus + 3in Height FleXILO H Minimum room height=7.1ft Room height for the maximum filling volume=7.9ft FleXILO Plus N Minimum room height=6ft Room height for the maximum filling volume=6.9ft ,t Length /width Rr Height z A � r � �111t+ : ft -- — _ 97 CCrt 3. PE274 USA 2.2 Installation manual FIeXILO storage tank Preconditions for HeXILO storagetanks These dimensions apply for internal filler couplings. For individual solutions with reduced space requirements, please contact your OkoFEN dealer. The size of the different storage tank types can be found in the following table. Storage tank type Length Width Height Filling capacity FIeXILO ft ft ft tn.sh. S110 H 3.61 3.61 4.43 0.5 S160 H 5.58 5.58 6.5 2.2 -2.8 S190 H 6.69 6.69 6.5 3.1 - 3.5 S220 H 7.55 7.55 6.5 3.4 - 4 5260 H 8.46 8.46 6.5 4.4 - 5.1 S2216 H 5.58 7.55 6.5 3.0 - 3.4 S2219 H 6.69 7.55 6.5 3.3 - 3.7 S2619 H 6.69 8.46 6.5 3.0 - 4.0 S2622 H 7.55 8.46 6.5 4.0 - 4.6 FIeX1LO COMPACT N ft It ft tn.sh. KGT1814 N 6.04 4.72 6.5 2.0 - 2.4 KGT2614 N 8.46 4.72 6.5 3.1 - 3.6 KGT2618 N 8.46 6.04 6.5 4.1 - 4.7 KGT2620 N 8.46 6.69 6.5 4.6 - 5.5 KGT2626 N 5.46 5.46 6.5 6.1 --7.2 The filling capacity depends on the room height and the burn density, at max. filling capacity a min. room height of 7.9 ft is required for H and Compact tanks: _', special sizes of FleXILOs on request Installation manual FleXILO storage tank PE274 USA 2.2 Preconditions 1 IL storage n • 4.1.2 Room characteristics • The installation room must have a level floor. Minor differences in height can be compensated with underlay material (e.g. wooden or metal plates). • The floor carrying capacity must correspond to a point load of 4409 lbs. • Damp cellar walls do not represent an obstacle to the installation of the storage tank. The fabric of the tank must not, however, touch the walls—observe the minimum clearances. • The installation room must protect the storage tank from direct sunlight. • The installation room must not have any sharp or pointed objects or installations that could damage the fabric of the storage tank. FIeXILO FIeXILO COMPACT II i I I i r I "i II PE274 USA 2.2 Installation manual FIeXILO storage tank Preconditions r HeMLO storage tanks 4.1.3 Room ventilation The room in which a storage tank is installed(= installation room)must always have a ventilation opening to the outside of at least 170 cm2. The air blown in during filling must be able to escape freely to the atmosphere so that no pressure is built up in the installation room. 9.84in 92.52in 5.91in c at least 11.81 in rn Airation at least 26.85in2 Flexi tank S190 Filling couplin d=3.94in ST GE ROOM 6 CD F C C_ LOO r- r � M I+ FITTING OF THE FILLER COUPLING—EXAMPLES: Filler coupling in the next room: Only closed filler couplings WITHOUT ventilation opening may be used. The next room must have a separate _ Afration ventilation opening to the outside. Airtight lid at least CELLER ROOM STORAGE ROOM Installation manual FIeXILO storage tank PE274 USA 2.2 Preconditions for FleXILO storage Filler coupling in the heating afa room: The fitting of caps with ventilation „ function is forbidden. CAUTION_ For fire protection Airationnin got lid > Ajr ton at least 31 in' at least 26.35in'11t reasons, approved fire plugs with aluminium blind cover must be used. In such cases, plastic caps are note BOILER ROOM = STORAGE ROOM k admissible. A separate ventilation opening to the outside is necessary. �u s Filler coupling outdoors- storage tank in the tank room: The tank room must have a separatery ventilation opening to the outside of i —--� at least 26.35in 2. Airanon at least 26.35in' Even if the filler coupling is located Filling coupling outdoors, there must be an additional ventilation opening to the CELLAR ROOM STORAGE ROOM outside of at least 26.35in z so that no ,�,,, �>, - pressure is built up in the tank room. '" r:e ra x Filler coupling outdoors- storage tank in the heating room: If the storage tank is installed " together with the boiler in the heating roam, ventilation is already Airanon at least 4` assured by the ventilation opening 26.35in' Filling coupling of the heating room required by law. U ry' f� r q. 4.1.4 Fire protection The fire protection requirements for the installation room of a FIeXILO storage tank are country-specific. The latest applicable regulations in the respective country must always be observed. The construction work must conform to the respective fire protection guidelines before the start of commissioning. PE274 USA 2.2 Installation manual FIeXILO storage tank Preconditions for ReXILID storage tanks 4.2 Outdoor installation — FleXILO storage tank Storage tanks can also be installed outdoors. In this case the storage tank has to be protected from rain and direct sunlight. A roof and a housing therefore have to be built. Furthermore, concrete foundations to spread the load are necessary with outdoor installation. Foundation An individual 50 cm x 50 cm frostproof foundation per upright is required to spread the load. The uprights must be anchored to the concrete foundation to withstand wind loads. Roof beam construction and housing OkoFEN offers an upright extension for attachment of the roof construction. It serves as the base for a lean-to roof. The supporting system of the storage tank serves at the same time as substructure for the housing. All other construction timbers and boardings must be provided on site. M8x70 No. Part Quantity Illustration Article No. 1 Upright extension 4 S140 2 Frame bolt 24 121067 M8x70 3 Washers M8 24 121038 4 Spacer Screw 0.8in 24 160221 Installation manual FleXILO storage tank PE274 USA 2.2 Preconditions for ReXILO storage tanks 4.3 Storage material — pellets The ReXILO storage tank is suitable exclusively for the storage of wood pellets. Wood pellets are small rolls made from natural wood (dry wood shavings or sawdust)compacted under high pressure with extremely little moisture and very high calorific value. 4.3.1 Specification for high quality pellets as PFI (Pellet Fuel Institut) Calorific value min. 7200 BTU/lbs Bulk density min, 40 Lb/cft Water content max. 10% Ash content max. 1.0% Ash melting point at least 2192°F Length max. 1.5 inch/40 mm Diameter 1/4"—5/16"/6—8mm Fine material max. 0.5 % Contents 100% untreated natural wood The pellet boiler is suitable only for pellets of natural wood that comply with PFI premium specifications. Using non-pelletised fuels or pellets that are not manufactured from natural wood will lead to the warranty becoming void and will cause damage to the pellet boiler and the chimney. For more information on fuels, please visit our website at: www.meco—pelletheating.com f PE274 USA 2.2 Installation manual FIeXILO storage tank Assembly ' . storage tank J Assembly of FleXILO H storage tank The FIeXILO H storage tank is the simplest and least expensive form of storage tank. The tank is made from high-quality polyester fabric, is dust-tight but permeable to air,is permanently anti-static and easy to install. FIeXILO H is available in a wide variety of special sizes. OkoFEN storage tanks are only available in conjunction with a boiler installation. 5.1 Parts list — FleXILO H storage tank NOW Before starting assembly, check that the delivery is complete against the parts list. No. Part Quantity Illustration Article No. 1 Storage tank 1 SP160H- - ' SP 280H 2 Assembly film / S110 3 Upright 4 S100H 4 Damp room shoes 4 � 5101 Installation manual FIeXILO storage tank PE274 USA 2.2 Assembly of FleXILO H storage tank No. Part Quantity Illustration Article No. 5 Transverse member 4 GT160HV2 KT200 GT220HV2 KT260 GT280HV2 6 Struts 16 SR160HV2 KSR200 SR220HV2 KSR260 (8 for S 160) SR280HV2 7 Transverse member bracket 4 K121 8 Filling unit with hose clamp 1 -2 S106HK 3.54in—4.33in depending on size and arrangement 9 Filling instructions 1 PE489 10 Dispensing unit 1 5104 11 Bolt set 1 S103HV2 Tank with auger delivery system 12 Delivery auger 1 r ST 178 ST 220 ST 260 ST 3006 ST330G Tank with vacuum suction system 13 Suction switch 1 SWS-M PE274 USA 2.2 Installation manual FfeXILO storage tank Assembly of FleXILO H storage tank 5.2 Assembly — FleXILO H Assembly of the storage tank frame MMMCMM� Damage to the fabric Valid for all bolted connectionsThe bolt head must be on the inside, the nut with washer on the outside of the storage tank frame. 0 ee e � � o "�� M8x25 O ` c 0 � c �c 0 c �? o � c- O3 '� � 0 M8x120 Picture 1: not required for S160 Not*; Use the self-locking nuts for the through bolts. Installation manual FleXILO storage tank PE274 USA 2.2 Assembly of FleXILO H storage tank M8x35 0 saw N The transverse member bracket must be fastened to the outside of the uprights. Spread out the assembly film before you place the storage tank on the floor. It protects the fabric from soiling and damage. IA DANGER- Crushing Faults or incomplete installation of the struts can cause the storage tank to collapse. PE274 USA 2.2 Installation ymanual FIeXILO storage tank Preparation of the storage tank The sack(=fabric)of the storage tank is packed in a cardboard box. The box also includes an assembly film. Damage to the fabric Do not use a knife or other pointed objects to open the packaging. 1. Spread out the assembly film in the middle of the installation room. The assembly film helps to keep the fabric clean. Do not walk on the assembly film with shoes. 2. Position the storage tank in the middle of the tank frame. Unpack the tank and spread it out. 3. Turn the storage tank until the lifting straps are at the top and the delivery opening (= large central opening)is on the underside. 4. Turn the storage tank until the filler openings are pointing towards where the filling system is to be installed. Threading in the transverse members and hooking in the storage tank. El 12 13 $x SPAX 6x45 Installation manual FIeXILO storage tank PE274 USA 2.2 Assembly IL 5.3 Installation of the dispensing unit The dispensing unit on the FIeXILO H storage tank consists of the connector with retaining ring and an emergency slide valve. Install the dispensing unit on the delivery funnel of the storage tank. O O 3 0 0 W 0 � o 0 0 a ® O 5.3.1 Connection to the auger delivery system The auger delivery system is connected to the dispensing unit by means of a pipe clamp. O � 3 PE274 USA 2.2 Installation manual FIeXILO storage tank Assembly 5.3.2 Connection to the vacuum suction system Connection of the suction switch to the dispensing unit using a pipe clamp. O 0 O Connection and earthing of the pellet and air line to the suction switch. O O O V I� I Installation manual FleXILO storage tank r � PE274 USA 2.2 Assembly of FIeXILO H storage tan k Connection of the room delivery motor to the CMP boiler controller at slot RA o 0 ! ! A- 0 a RA a dab Connection of the room delivery motor to the boiler controller at slot RA s 0 e t RA installation manual FIeXILO storage tank PE274 USA 2.2 Assembly oornv 6 Assembly in small rooms The storage tank frame(uprights with damp room shoes and rubber underlays,struts and transverse member brackets) is assembled in the installation room. After assembly, move the frame into the correct position in the installation room. Pay attention to the correct position of the filler opening. 1. Turn the storage tank from the initial position 90° to the left. 2. Pull the storage tank together to the minimum width of the door opening. 3. Push the transverse members into the carrying loops. 4. Turn the storage tank with the transverse members back into the initial position. 0) a 2 a Ib a 1 — a � — a — b a — ( — a 1 — a 1 4 a a 1 d d b b 1 1 a — — a a _.— va 1 �4 e 1 t e � \ e Installation manual FleXil_O storage tank PE274 USA 2.2 Assembly in gall rooms 5. Pull the storage tank with the transverse members apart. 6. Hook the two transverse members into the transverse member bracket. 7. Pull the storage tank together along the transverse members to the width of the door opening. 8. Push the transverse members into the opposite carrying loops. Ia b a a a 1 t i 1 T— a — a i a — b a -- — b 1 � i� 1 — a i — a I 1 I a e e PE274 USA 2.2 Installation manual FIeXILO storage tank Assembly in smalf ms ol'--,--,—,-,--,--,"',-"",-----"---------"""--,---,-----,--"----- 9. Pull the storage tank with the transverse members apart. 10. Nook the two transverse members into the transverse member bracket. a 10 a a 'i b a ^ b .•— —•— — a — a 1 4 a a Installation manual FIeXILO storage tank PE274 USA 2.2 Assembly f F1eX1_11LO Compact storage tank 7 Assembly of FleXILO Compact storage tank The FIeXILO Compact storage tank with tension springs allows maximum use to be made of the space available. The tank is made from high-quality polyester fabric, is dust-tight but permeable to air, is permanently anti-static and easy to install. The fabric lies on the bottom of the tank. An auger delivery system serves as dispensing unit. The lateral suspension from springs allows the tank to be emptied completely. OkoFEN storage tanks are only available in conjunction with a boiler installation. 1814 2614, 2618 2620 2626 Installation manual FIeXiLO storage tan PE274 USA 2.2 Assembly of ; LO Compact storage tank 7.1 Parts list — FleXILO Compact storage tank tote: Before starting assembly,check that the delivery is complete against the parts list. No. Part Quantity Illustration Article No. 1 Storage tank 1 7`' KS1814 ry KS2614 KS2618 KS2620 ti! KS2626 2 Upright 4 S100H 3 Damp room shoes 4 5101 in K116 integr. 4 Transverse meber filling side 2 \ KT140H2O (1 for N) ..� KT180H2O \`\ KT20OH2O KT260H2O 4 Transverse member filling 1 (only for N) KT140H2OB side \\ KT180H2OB Execution N \\�� KT20OH2OB �\\ KT260H2OB 5 Transverse member spring 2 KT 180 side 1 KT260 6 Beam filling side(bottom) 2 KT140U KT18OU KT2000 KT260U 7 Struts 16 KSR140V2 KSR180V2 KSR200V2 KSR260V2 8 Transverse member bracket 4 K121 9 Filling unit with hose clamp 1 S106HK 3.54in-4.33in 0 0 9 Filling unit execution N 1 S106HKN 10 Filling instructions 1 PE489 � AAYTYnIOM I hh Installation manual FIeXiLO storage tank PE274 USA 2.2 Assembly of FleXILO Compact storage tank No. Part Quantity Illustration Article No, 11 Connecting flange, rear I K122 12 Pressure relief fitting 1 K104 not with KGT1814 13 Pressure relief bracket I K107 K108 14 Spring tube 6 K131 K132 K133 K134 15 Tension springs 4-1814 K113 6—2614,2618 8-2620 10-2626 16 Caps for tension springs 2 per tension K119 spring 17 Retainer belt 8-1814 K114 10-2614,2618 16-2620 18-2626 18 Spring belt 4-1814 K115 6—2614,2618 8-2620 10-2626 19 Small pads 1 K116V2 Compact storage tank 20 T-piece 1 K125 21 Delivery auger 2 FSV140M+ (1 for 1814) FS100 (FS160M) 22 Tube 1 K126 Auger guide K129 23 Motor unit 1 K118 PE274 USA 2.2 Installation manual FleXILO storage tank Assembly of HeXILO Compact storage tank 7.2 Assembly - FleXILO Compact Assembly of the storage tank frame Damage to the fabric Valid for all bolted connections The bolt head must be fitted on the inside, the nut with washer on the outside of the storage tank frame. O OP 9 � MW5) O vd/4 O3 S O � M8®20 • Use the self-locking nuts for the through bolts. Installation manual FleXILO storage tank PE274 USA 2.2 ------ Assembly t storage tank M8x30 O O� I o . ■ 8x SPAX 6x45 * Execution N see next page PE 274 USA 2.2 Installation manual FIeXILO storage tank Assembly of HeXILO Compact storage, tank IL Lei 7Faulty ng or incomplete installation of the struts can cause the tank to colla se. Execution N ®� ®L r9 LIJ Installation manual FIeXILO storage tank � �� PE274 USA 2.2 Assembly of ReXILO Compact storage tank Assembly of the delivery system 10 4 43 � Q) M10x7 M8 11 12 *Figure 12-14: Not required with KGT 1814 PE274 USA 2.2 Installation manual FieXILO storage tank Assembly act storage tank 15 lin 16 17 18 M 10x7 19 M8x12 0 M8x20 Installation manual FIeXILO storage tank .,,r.. aPE274 USA 2.2 Assembly of ReXILO Compact storage tan Insertion of the delivery system into the storage tank 20 21 00 0 0 0 0 o � 0 0 0 O O O O 4.1-5.4in 22 0 0 00 a 0 0 0 0 0 0 O O O O 3.5-4.3in picture 21/22 Close off the storage tank opening for the delivery auger • Pull the storage tank opening over the connecting flange. • Fasten the storage tank to the connecting flange using straps. • Close off the storage tank at the connecting flange using a pipe clamp. PE274 USA 2.2 Installation manual FleXILO storage tank Assembly e Compact story t tank Attaching the storage tank on the filling side and opposite side • Hook 2-5(depending on the size)retainer belts over the transverse members on the filling side. • Pull the storage tank to the required height on the filling side. • Thread a spring tube(a)alternately through the lifting straps of the storage tank and the loops of the retain • Repeat the whole procedure on the opposite side. er belts(b). 23 b 0 Installation manual FIeXILO storage tank PE274 USA 2.2 Assembly of FleXILO Compact storage tank Attaching the lateral spring tubes with the springs • Hook 2-5 (depending on the size)retainer belts(b)over the lateral transverse members. • Pull the storage tank to the required height on the filling side. • Thread a spring tube(a)alternately through the lifting straps of the storage tank and the loops of the retainer belts(b). • Thread 2-5 tension springs(c)into the spring pockets and hook the springs to the loops of the retainer belts(b). • Thread the spring tube(a)alternately through the lifting straps of the storage tank and the loops of the spring belts(d). • Hook the tension springs (c) into the spring belts (d). Repeat the whole procedure on the opposite side. 25 26 d d dapnob 27 28 b � r d PE274 USA 2.2 Installation manual FleXILO storage tank Assembly of HeXILO Compact storage tank 29 30 q sqt tB 6 SPAX 4x50 31 32 ra SPAX 6x45 33 34 SPAX 6x45 Installation manual FIeXILO storage tank x PE274 USA 2.2 RAssembly of FleXlLOact storage tank Installation of the drive unit 36 ® 37 0 ® o 38 0 0 Connection and earthing of the pellet and air line to the T-piece O O O 4 9 8 PE274 USA 2.2 � Installation manual FIeXILO storage tank _M Assembly of the filling system 8 Assembly of the filling system The filling system is the same on all storage tank types. It consists of filling nozzle with bracket and coupling with blind cover. Installation of the filling nozzle Depending on the storage tank type and position of the filling connection, one or two filling nozzles are installed. silo S2216 KGT 1814(N) S160 rFT�i�� Sigo S2219 KGT 2614(N) S220 S2619 KGT 2618(N) S 260 S2622 KGT 2620(N) 7KGT 2626(N) The height of the filling nozzle provides an optimum filling level of the storage tank. Lift the filling nozzle to approx. 5 cm from the underside of the ceiling of the installation room. The bracket of the filling nozzle, however, must not be lifted to higher than the underside of the storage tank transverse member. Damage to the fabric Valid for all bolted connectionsThe bolt head must be on the inside, the nut with washer on the outside of the storage tank frame. Installation manual FIeXILO storage tank PE274 USA 2.2 w. nMAssembly of the fillingsystem Standard it GJ d6 5 min.10cm 9 D o aa Seam of the filler opening /� b Bracket of the filling nozzle —b b Tearing of the storage tank The storage tank opening must be fixed as closed as I i possible to the bracket of the filling nozzle. The seam of the filler openinq must not hang over the filling nozzle. PE274 USA 2.2 Installation manual FleXILO storage tank Assembly of the filling system Execution N—low ceiling hight 1 2 Q o 0 ' 8X-AW ' . SPAX . 6x45 4 o° o ° 0 9 O O 4 0 o 0 Installation manual FleXILO storage tank PE274 USA 2.2 Assembly of the filling system Installation of an extended filling system In cases where the filler coupling is not accessible for filling, further elbows and pipes have to be linked together with connecting clamps until a filler coupling accessible from the outside can be installed. a 2 3 4 0 o i � tib 5 7 PE274 USA 2.2 � Installation manual FleXIL.O storage tank Assembly of the filling system Earthing of the storage tank The filler coupling must be earthed. The bracket of the filling nozzle has a connection for the earthing. Installation of the instruction sign Attach the instruction sign visibly to the filler Fix the instruction plate directly to filling couplings of the OkoFEN FleXtLO textile tank! coupling. Manufacturer OkoFEN Fohichunigis-and Entwicklungs Ges,m.b.H G"em"oen,I A 4133 Njedlerkrmpel Type Fli textile tank for pellet storing Year of build: 2010 fining volume 6 ATTENTION • VENTILATE THE STORAGE ROOM OF the OkoFEN FleXILO textile tank BEFORE ENTERING. • TO STAY BELOW OR IN THE NEAR OF the OkoFEN ReXlL0 textile tank is PROHIBITED. • STORAGEOF ANY MATERIAL BELOW OR IN THE NEAR OF the FLEXI tank is PROHIBITED. DO NOT CHANGE THE FILLING COUPLINGS. OPERATING PROCEDURE I SWITCH OFF THE HEATING SYSTEM 2 NEVER EXCEED THE MAXIMUM FILLING VOLUME(see above). I SLOWING AIR WILL ESCAPE NATURALLY. The blown air filters through the textile tank, 4 MAXIMUM FILLING PRESSURE:1,5 bar, Is the Filling hose shorter than 5m:max,filing pressure 0.5 bar. as 5 FIT THE COUPLINGS PROPERLY with 2 wrenches. 6 INFLATE THE FLEXI TANK 1 min with -- AIR(max_1,5 bar pressure) 7, FILL THE FLEXI TANK WITH PELLETS. 8 FLEXITANKS WITH 2 COUPLINGS: 1 Fill through nozzle I to high press beam level.(Nozzle 2 ca, 2 Fill through nozzle 2 to maximum level,(Noule I capped!) 3 F, through nozzle I to maximum level.(Nozzle 2 capped!)Icy 6koFE—N PELLET HEATING Installation manual FleXII-0 storage tank PE274 USA 2.2 Final inspection�� d� 0�~ U ~ �� ° KD��. inspection Material damage Before commissioning and the first filling of the storage tank, a detailed inspection of the installation room and the storaqe tank must be carried out. Check: In the installation room ~ Are the ventilation openings ioplace? ~ Are the filler couplings open orclosed? ° Have the fire protection regulations been observed? ^ Has the alignment ofthe uprights and transverse members been checked with o spirit level? Onthe storage tank ^ Have the damp room shoes and rubber underlays been installed? ~ Have all the bolts ofthe storage tank frame been tightened correctly? ~ Have all the bolts been inserted with the bolt heads onthe inside towards the fabric Uoprevent damage tothe tank fabric? , Have all struts been correctly installed and the bolts tightened? ~ |othe whole storage tank frame stable? ^ Are the lifting straps ofthe storage tank inthe middle? ~ Are the lifting straps of the storage tank straight(without creases)so that there are no point loads on the storage tank? Point loads can cause the fabric to move so that the dust-tightness of the tank can no longer be assured. ^ Are the not used filler openings of the storage tank securely closed? ~ |sthe filler nozzle correctly fastened buthe filler pipe bymeans ofahose clamp? ~ Is the auger delivery system or suction system correctly fastened to the dispensing unit by means of a hose clamp? ^ |uthe dispensing unit correctly positioned inthe middle? 17 L U, ^ |othe filling instruction sign installed onthe filler coupling? KGT ^ Are the tension springs guided through the flaps and suspended correctly? ^ Are the spring tubes mounted centrally? ^ |nthe zipper closed completely? PE274 USA 2.2 |notmUoUon manual F|eX|L[} storage bank Filling the storage tank 10 Filling of the storage tank Number of filling nozzles Depending on the size of the storage tank or on the possibility of positioning the filling unit, 1 or 2 filling units are installed to allow optimum use to be made of the tank volume. silo S2216 KGT 1814 (N) S160 S2219 KGT 2614 (N) S190 S2619 KGT 2618 (N) S 220 S2622 KGT 2620 (N) S 260 KGT 2626 (N) Guidelines and preconditions for filling the storage tank • Observe the instruction sheet on the storage tank. • Ventilate the installation room well before entering. • Inspect the proper condition of the installation room and the storage tank. 40* The storage of any materials under or in the vicinity of the storage tank is forbidden. • Check the positions of the openings in the installation room. • Do not make any modifications to the filling device. • Exhausting of the filling air is not necessary. • Never stand in the immediate vicinity of the storage tank. • Never exceed the maximum gross weight(see below or observe the instruction sign"Filling of the storage tank"). • Maximum filling pressure=21.7psi. If the filling line is less than 16ft: Maximum filling pressure=7.2psi. Filling of the storage tank 1. Switch off the pellet heating system. 2. Connect the hose coupler correctly with 2 coupler keys. 3. Check that all other filler couplings are closed. 4. Inflate the storage tank for 1 minutes with max. 21.7psi. 5. Fill the storage tank. With 2 filler couplings, proceed as follows: Fill the storage tank via coupling 1 up to the level of the transverse members(coupling 2 closed!). Fill the tank via coupling 2 up to Maximum (coupling 1 closed!). Fill the tank via coupling 1 up to Maximum (coupling 2 closed!). 6. Disconnect the hose coupler and close the filler coupling. Installation manual FIeXILO storage tank � PE274 USA 2.2 Filling tank Maximum toads of the storage tank Maximum filling volume Maximum filling volume Storage tank type = Maximum admissible Storage tank type = Maximum admissible load load FleXILO tn.sh. d �7 > S110 H 0.5 RT S160 H 2.8 s S190 H 3.5 fi S220 H 4 S260 H 5.1 ` ' � `� " 'r S2216 H 3.4 FIeXILO COMPACT N S2219 H 3.7 KGT1814 N 2.4 S2619 H 4 KGT2614 N 3.6 S2622 H 4.6 KGT2618 N 4.7 KGT2620 N 5.5 KGT2626 N 7.2 Collapsing of the storage tank Never fill the storage tank to more than the maximum load shown. In view of the different pellet qualities it is possible that although the storage tank is full,the maximum weight has not yet been reached. PE274 USA 2.2 Installation manual FIeXILO storage tank Manufacturer: MAINE ENERGY SYSTEMS LLC 8 Airport Road — P.O. Box 547 Bethel Maine 04217 e-mail: info@maineenergysystems.com web: www.maineenergysystems.com @MAINE ENERGY SYSTEMS LLC Subject to modifications