Ferroli BOIPELLET PRO Pellet Boiler

Safety Instructions and Precautions

Observing the prescriptions of this manual is in the user's favour and is one of the warranty conditions. Compliance with this instruction is in the interest of the consumer and one of the warranty terms.

Instructions for Security:

• This appliance is not intended for use by people (including children) with limited physical, sensory or mental abilities or lack of experience and knowledge. The installation must be performed by a qualified expert in the field of heating installations or authorized by “FERROLI” service. The place and way of connecting the boiler should be selected carefully in accord with the safety instructions. Install away from flammable objects!
• Before starting any operation, the user must read and fully understand the contents of this instruction manual. Incorrect setup may cause hazardous conditions and / or incorrect function of the boiler.
• Do not wash the boiler with water. Water can get inside the fireplace and damage the electronics and cause an electric shock.
• Do not put clothes to dry on the boiler. Any clothes hangers and other objects must be located within a reasonable distance from the fireplace. Fire hazard.
• The user is fully responsible for the proper use of the product, which exempts the company from liability for any user errors or misbehaviour or omissions.
• Any intervention or replacement made by unauthorized people or using non-original spare parts for the product can be risky for the user and release the company from all liability.
• Most surfaces of the boiler are extremely hot (the door handle, glass, flue pipe, etc.). Avoid contact with these parts before assuring yourself that you use temperature-resistant gloves as well as suitable temperature-resistant instruments.
• Under no circumstances should the fire be ignited with the door open or broken glass.
• The product must be electrically connected to a system equipped with an effective earth conductor (must be grounded).
• Turn off the boiler in case of failure or malfunction.
• All unburned pellets in the burner after each unsuccessful ignition attempt must be removed before a new ignition.
• When installing the product, all fire safety requirements must be respected.
• If there is a fire in the flue pipe, extinguish the boiler, disconnect the power cord, and never open the door. Call competent authorized service technicians.
• Do not light the boiler with flammable materials if the ignition system failed.
• Periodically check and clean the smoke outlet ducts of the boiler (connection to the flue pipe).
• Pellet boiler is not a cooker.
• Always keep the cover closed.

Safe Distances:

When installing the product, a safe distance of at least 600 mm must be respected. This distance applies to the product located near materials of B or C flammability level. The safe distance is doubled if the product is close to materials of C3 combustion level.

1. Purpose

The boiler is purposed to heat domestic and public premises by the means of pellets. The boiler is equipped with a steel water jacket designed for heating systems with water temperature up to 90° C at a maximum super pressure up to 0.15 Mpa. Tests are run at pressure of 0.3 Mpa.

The boiler is designed and manufactured to work with A-class pellets only (DIN plus 51731) with the following characteristics:

• Material: 100% pure conifer or broad-leaf wood;
• Diameter: Φ6/8 mm;
• Length: 20-30mm;
• Calorie capacity: 5.2 kW/kg;
• Ash content: < 8%;

The use of pellets with characteristics different from the recommended may result in power decrease, unstable and inconsistent work of the boiler.

What are the pellets:

The pellets are produced by compressed wooden waste left from the production of various furniture, sawmills, and others. This type of fuel is environmentally friendly because in the production process no agglutinate agents (glues, resins, and others) are added. Actually, the integrity of the pellets is guaranteed by the lignin – a natural ingredient contained in the wood itself. While the wood has a calorie capacity of 4.4 kW/kg (15% humidity at 18 months drying), the pellets have 5.2 kW/kg.

Info: To ensure the proper work of the boiler, the pellets must be stored in a dry place!

Recharging of pellets can be done during work, with the following sequence:

1. Open the bunker (located at the top rear of the product);
2. Fill the hopper, using a non-combustible container;
3. Close the lid of the bunker.

Attention!!! Use gloves! Beware of hot surfaces!

Diagram: Internal Components

A diagram shows a cross-section of the boiler, illustrating its internal components:

• Display: The control panel interface.
• Cleaning mechanism: Part of the system for ash removal.
• Pellet Bunker: Storage for the fuel pellets.
• Combustion Chamber: Where the pellets are burned.
• Auger: Transports pellets to the combustion chamber.
• Exhaust gas fan: Removes combustion gases.
• Igniter: Starts the combustion process.

2. Technical Data

The following table details the technical specifications for different models of the Boilers BioPellet PRO:

3. Assembly

3.1 General conditions:

For ensuring the proper and safe work of the boiler, the observation of the following prescriptions is required:

• The assembly of the boiler and the related equipment must be performed by authorized personnel only.
• The foundation upon which the boiler is going to be placed must be even and horizontal, made out of non-flammable materials with a dimension of at least 40 cm. in front of the boiler and not less than 20 cm from both sides and the rear side.
• If flammable materials or constructions are present, the distance between them and the boiler must be at least 80 cm.
• When assembling the boiler, make sure that the joints between the separate pipes and the chimney socket are well insulated.
• A smell on first start-up of the boiler is due to the burning of the paint. The boiler is painted with thermal resistant paint which reaches its final resistance after a couple of start-ups and warm-ups. THAT IS WHY THE OUTER SURFACES MUST NOT BE TOUCHED in order to avoid damage to the casing.
• The periodic cleaning of the ash tray must be done only when the boiler is cold.

3.2 Basic rules and prescriptions:

The boiler with water jacket operates on the water heating boiler principle. The advantage of this type of heating system is the maximum utilization of the heat that is produced during the combustion process. With this method, the heat from the combustion chamber is taken to remote and hard-to-reach premises for normal heat exchange in order to maintain an even temperature and warmth comfort.

• Ensure that every branch and element of the installation is airtight at every single moment of its exploitation.
• All elements of the installation must be protected from freezing, especially if the enlarging pot or other parts are situated in non-heated premises.
• The circulation pump can be chosen by the capacity required using the following formula: G=0.043 ⋅ P₁ (m³/h), in which P₁ (kW) is the heat output of the water jacket. The circulation pump can be turned on and off by the means of a thermostat in combination with an electric switch.
• The first service cleaning of the pump's filter must be done immediately after testing the installation.
• If an old installation is going to be used, it must be washed several times to ensure the removal of any accumulated dirt on the surfaces of the water jacket.
• Do not drain the circulating water of the installation during the non-heated season.
• Chemical treatment of the circulating water is not recommended.

Chart 1 is a basic combined chart for heating with a solid fuel boiler, electrical boiler equipped with a water serpentine, and a solar panel. For economy and efficiency of the system and a constant availability of cheap hot water, a qualified assembly of the automatic shifter controlling the thermal flows to and out of the solar panel and the boiler is required.

Chart 2 shows a one-storey heating with a compulsory circulation. The advantage of this chart is that the water-conducting elements can be hidden.

The enlarging pot must have a direct atmosphere connection, which means that it must be placed on the highest spot in the system. Its capacity can be determined as 0.1 part of the total capacity of the system. The filling or unloading of the system is done via a hose through a faucet mounted in the lowest area. Mounting a membrane enlarging pot is permitted when constructing a closed-type system.

During the initial 3-4 start-ups, condensation on the surfaces of the water jacket may occur, which, depending on the fuel's humidity and the temperature of the incoming water, may reach 0.3 liters on a single start-up. The accumulating char reduces the temperature difference and the condensation.

• “FERROLI” provides a warranty and out-of-warranty service and replacement of the water jackets.
• The warranty is not valid in case of a boiler with a swollen water jacket which is a result of pressure increase in the system and improper connecting.
• The water jackets are tested under pressure of 400 kPa (4 bar).

It is recommended that the assembly is performed by an authorized specialist.

3.3 Assembly of the duct components:

Duct components and pipes

For the assembly of the duct pipes, the use of non-flammable materials, resistant to flammable products and condensation, is obligatory. The assembly must be performed in such a manner so it guarantees airtight sealing and prevents condensation. If possible, avoid adding horizontal sections. Direction shifts are done by using knee joints with a maximum angle of 45°.

For heating devices equipped with a smoke ventilator, i.e., all of the “Ferroli” boilers, the following instructions must be observed:

• Horizontal sections must have a minimum incline of 3° upwards.
• The length of the horizontal sections must be as short as possible, but without exceeding 3 m.
• More than four direction shifts are forbidden, including cases where a T-shaped element is used.
• The duct components must be airtight and insulated if extending outside the premises in which the fireplace is installed.
• The duct components must allow soot cleaning.
• The duct components must have a constant section. A section change is allowed only in the chimney joint.

Chimney

The chimney or the duct component must conform with the following requirements: to be airtight, waterproof, and properly insulated; to be constructed with materials resistant to normal mechanical wear and to the heat coming from the combustion products and condensation. It must be kept away from flammable materials.

The recommended chimney draft at work is from 12-20 Pa.

Attention!!! In case of a fire hazard, turn off the product from the display. This will stop the oxygen flow to the product.

3.4 Air intake

A diagram illustrates the air intake system:

• The suction pipe or air intake is placed in the back and has a circular section with a diameter of 48-60 mm.
• The combustion air can be aspirated:
• From the room, as long as it is near an air intake communicating with the outside wall having a minimum area of 100 cm², properly positioned and protected by a grid.
• Or by connecting directly outside with a suitable tubing having an inner diameter of 48-60 mm and a maximum length of 1.5 m².

3. Hydraulic Diagram

Two hydraulic diagrams are provided, illustrating system connections. These diagrams show the boiler connected to a heating system and domestic hot water (DHW) circuits. Key components include the boiler itself, DHW tank (ECOUNIT HP), expansion vessel, pumps (DHW pump, boiler pump), sensors (DHW, room thermostat), and various valves (three-way valve, one-way valve). The diagrams indicate that the boiler includes a pump and that an additional expansion vessel may be necessary. Some labels in the diagrams are in Romanian, such as "Boiler cu acumulare ECOUNIT HP" (Boiler with DHW tank ECOUNIT HP), "Senzor a.c.m." (DHW Sensor), "Vas de expansiune" (Expansion vessel), "Pomp inclus în cazan" (Boiler included pump), "Circuit înclzire" (Heating circuit), "Ventil termic de amestec" (Mixing thermostatic valve), and "Van deviatoare cu 3 căi" (Three-way valve). The diagrams also state that they do not replace a project and installation must follow technical manual instructions.

4. Cleaning

Cleaning the fireplace should be done only when cold. The cleaning of the combustion chamber must be carried out daily. For this purpose, make sure the fireplace has ceased operation and is completely cold. Pull up the combustion pot and remove it from the boiler, then clean it from soot. When the fuel pot is removed, a hole designed for accumulated ash opens at the bottom of the combustion chamber. Collect ashes in the ashtray and return the fuel pot to its place, then close the door. The fireplace is ready for operation.

Cleaning of flues and chimneys is conducted once every 1.5 tons of fuel used.

Diagrams: Cleaning Access

Images show access points for cleaning:

• One image shows the boiler with the combustion chamber door open, highlighting the removable Combustion pot.
• Another image shows a service door open, indicating the Mechanical Cleaning mechanism.
• A diagram with numbered points identifies key components: 1. Mechanical cleaning mechanism, 2. Combustion Pot, 3. Ashtray, 4. Inferior cleaning door. It explains that using the manual cleaning mechanism will drop ash into the ashtray and the service chamber beneath.

Images also show the Right Service Door and Left Service Door, which allow easy access to all components of the boiler. The Back Service Door provides access for cleaning the pellet bunker. Connection points at the rear are labeled: 1. DHW PUMP; 2. PUMP COLD WATER; 3. SAFETY VALVE; 4. HOT WATER; 5. EXHAUST FAN; 6. POWER SUPPLY; 7. AIR INTAKE.

5. Maintenance Program

The following maintenance program is recommended:

6. Safety and Unexpected Risks

Terms of danger may arise in the following cases:

• Automated pellet boiler is used incorrectly.
• The unit is installed by unqualified personnel.
• The safety instructions described in this manual are not met.

Unforeseen risks:

The Pellet fireplace “FERROLI” has been designed and manufactured in accordance with safety requirements on national, regional, and European levels. Although considered possible risks arising from improper use, you may experience the following:

• Risks of spreading combustion outside fireplace: Opening the door of the fireplace chamber may cause hot/burning particles (hot ash and small particles of burning coal) to fall out, which could lead to a fire in the heated room. It is therefore necessary that the product always works with a tightly closed door. It can only be opened when the product has completely cooled down.
• Risks of burns: High temperatures resulting from the combustion process in the combustion chamber and/or access to the door of this chamber when the product is not completely cool can cause burns.

In case of fire hazard, the product should be stopped by the controller and power supply until the cause of the problem is determined.

7. Control Panel: Use and Functions

The control panel provides access to various functions and settings. The main frame displays time, date, chrono activation, combustion power and recipe, functioning state, error code, main temperature, main thermostat, and summer/winter mode.

Buttons:

• P1: Exit Menu/Submenu.
• P2: Ignition and extinguishing (push for 3 seconds), Reset errors (push for 3 seconds), Enable/disable chrono.
• P3: Enter in User Menu 1/submenu, Enter in User Menu 2 (push for 3 seconds), Save data.
• P4: Enter in Visualizations Menu, Increase.
• P5: Activation chrono time band.
• P6: Enter in Visualizations Menu, Decrease.

LED Indicators:

• D1: Igniter ON.
• D2: R: Igniter ON.
• D3: A: Pump ON.
• D5: V2: Pump DHW ON.
• D9: External Chrono reached.
• D10: Lack of pellet.
• D11: Local Room Thermostat reached.
• D12: Sanitary water demand.

Alarms:

The system provides various error codes (ErXX) and messages to indicate operational status or faults:

• Er01: Security Error input H 1. May intervene with the system off. High temperature boiler.
• Er02: Security Error input H 2. Intervenes only if the Combustion fan is active. High temperature auger.
• Er03: Extinguishing for low exhaust temperature or missing light in the brazier.
• Er04: Extinguishing for water over temperature.
• Er05: Extinguishing due to high exhaust temperature.
• Er06: Pellet Thermostat open (flame return from the brazier).
• Er07: Encoder Error (lack of signal from Encoder).
• Er08: Encoder Error (problems of adjustment of the number of revolutions).
• Er09: Water pressure low.
• Er10: Water pressure high.
• Er11: Clock Error (problems with the internal clock).
• Er12: Extinguishing for ignition failure.
• Er15: Extinguishing due to power failure for more than 50 minutes.
• Er16: RS485 communication error (Display).
• Er17: Adjusting the Air Flow Failed.
• Er18: No more Pellet in the bunker.
• Er23: Boiler probe or Back boiler probe or probe Buffer open.
• Er25: Engine cleaning brazier broken.
• Er26: Engine cleaning broken.
• Er27: Engine cleaning 2 broken.
• Er34: Depression below the minimum threshold.
• Er35: Depression above the maximum threshold.
• Er39: Sensor Flowmeter broken.
• Er41: Minimum air flow in Check Up is not reached.
• Er42: Maximum air flow exceeded.
• Er44: Open door error.
• Er47: Error Encoder Auger: missing signal Encoder.
• Er48: Error Encoder Auger: Auger regulation speed not achieved.
• Er52: Error Module I/O I2C.
• Er57: Test 'Forced Draught High' in Check Up fail.
• Service: Service error, indicating planned hours of functioning reached; requires service call.

Messages:

Visualizations:

• Exhaust T. [°C]: Exhaust temperature.
• Room T. [°C]: Local room temperature (visible only if ambient probe is selected).
• Buffer T. [°C]: Buffer Temperature.
• Pressure [mbar]: Water pressure.
• Air Flux: Air flow.
• Fan Speed [rpm]: Exhaust fan speed.
• Auger [s]: Auger work time.
• Recipe [nr]: Combustion recipe set.
• Product Code: S10 - Product code.

User Menu 1:

Combustion Management:

• Power: Modify combustion power (automatic or manual). In automatic mode, the system chooses power; in manual, the user selects it. Displays combustion modality (A=automatic, M=manual) and working power.
• Recipe: Select the combustion recipe.
• Auger Calibration: Modify Auger's speed or On times (range -7 to +7, default 0).
• Fan Calibration: Modify Combustion Fan's speed (range -7 to +7, default 0).

Heating Management:

• Boiler thermostat: Change the boiler thermostat value.
• Buffer thermostat: Change the Buffer Thermostat value.
• Room Thermostat: Modify the Local Room Thermostat's value (visible only if ambient probe is selected).
• Summer-Winter: Select Summer-Winter mode.

Manual Load:

Activates pellet manual loading via the Auger engine. Loading stops automatically after 600 seconds. The system must be OFF for this function to be activated.

Cleaning Reset:

Resets the 'System Maintenance 2' function.

8. Chrono and User Menu 2

Chrono:

Allows selecting programming modalities and Ignition/Extinguishing time slots.

• Modality: Select desired modality or disable all programming. Enter modification mode (P3), select modality (Daily, Weekly, Week-End), enable/disable chrono (P2), save settings (P3).

Programming:

The system supports three programming types: Daily, Weekly, Week-end.

• Daily Programming Example: Set times for Monday: ON 09:30, OFF 11:15. Other days can be programmed similarly. The system turns on at 20:30 on Tuesday and turns off at 6:30 on Wednesday.
• Weekly Programming: Programs are the same for all days of the week.
• Week-end Programming: Choose between 'Monday-Friday' and 'Saturday-Sunday' to set switching on and off times.

User Menu 2:

Accessed by pressing P3 for 3 seconds.

Keyboard Settings:

• Time and Date: Set the day, month, year, and current time.
• Language: Modify the language of the LCD board.

Keyboard Menu:

• Set Contrast: Regulate display contrast.
• Set Minimum Light: Regulate display lighting when commands are not used.
• Keyboard Address: Change the RS485 node address (16 for local, 17 for remote).
• Node List: Displays board communication address, typology, firmware code, and version.
• Acoustic Alarm: Enable or disable the acoustic alarm.

9. Electrical Diagram

The electrical diagram illustrates the wiring connections for the boiler. It shows connections for various sensors, including Water Sensor, Pressure Sensor, Air Flow Sensor, Fan Encoder, Boiler Sensor, DHW Sensor, Room Thermostat, and Smoke Sensor. The diagram details connections to the control panel interface (RS232, RS485, CN1 connector) and power supply (230V). Key components wired include the Fan, Combustion system, DHW Pump, Igniter, Boiler Pump, Overheat Thermostats, Protection, and Auger. Specific parameters for DHW pump activation (P44=15, P75=9) are noted.

Disclaimer

FERROLI disclaims any responsibility for possible inaccuracies contained in this manual if they are due to printing or transcription errors. FERROLI reserves the right to make any change that appears to be necessary or useful without harming the essential characteristics.