kunzel PK 20 Installation guide

Brand: kunzel

Model: PK 20

Category: Water heaters & boilers

Type: Installation guide

This manual is also suitable for

PK 10

Installation manual

pellet boiler

PK 10, PK 15 and PK 20

May 4, 2009

Important!

This operating manual contains important information for the operator. The

boiler must be professionally installed and operated in order to avoid potential

accidents.

Familiarize yourself with the contents of this manual before installing and

operating the boiler.

Be sure to also comply with the regional regulatory provisions; they may differ

in full or in part from the requirements named in this manual. In this case, the

regulator requirements always have precedence! The master chimney sweep

responsible for your region can always provide information.

The company KÜNZEL would like to thank you for your trust!

Contents

1 Installation manual pellet boiler 4

1.1 Usage in compliance with statutory regulations ...................... 4

1.2 The key controls and components ............................. 4

1.3 Installation ......................................... 5

1.3.1 The boiler room ................................... 5

1.3.2 Transportation of boiler .............................. 6

1.4 Installation of the burner .................................. 6

1.5 Installation of the burner hood ............................... 7

1.6 Operate cleaning lever (only PK 10 and PK 20) ...................... 8

1.7 Chimney connection .................................... 9

1.8 Heating connection ..................................... 9

1.8.1 General ....................................... 9

1.9 Electrical supply connection ................................ 10

1.9.1 General ....................................... 10

1.9.2 Boiler and burner ................................. 11

1.9.3 Boiler sensors .................................... 11

2 Installation instructions for external pellet ﬁlling system 12

2.1 External conveyor screw .................................. 12

2.1.1 Rigid conveyor screw from the silo built by the building contractor ........ 12

2.1.2 Flexible conveyor screw from pellet storage room ................. 15

2.1.3 Flexible conveyor screw from bag silo ....................... 16

2.1.4 Storage tank with rigid conveyor screw ...................... 17

3 System proposals for the pellet boiler 18

3.1 PK2 system package - pellet boiler with domestic water heater and buffer tank . . . . . 18

3.2 PK3 system package - pellet boiler with combi-buffer tank ................ 20

3.3 PK4 system package - pellet boiler with solar-suppl. heating and domestic hot water . . . 22

3.4 PK5 system package - pellet boiler with solar-supplemented heating ........... 23

3.5 Legend for the system packages .............................. 24

4 Technical data 25

4.1 Wiring diagrams ...................................... 27

Cover image: Rigid conveyor screw from the silo built by the building contractor

1 Installation manual pellet boiler

1.1 Usage in compliance with statutory regulations

This pellet boiler is approved for the operation of an open or closed circuit hot water heating system with

a permissible operating pressure of up to 3 bar and a maximum ﬂow line temperature of 95◦C.

It is not permitted to operate the pellet boiler without a return ﬂow booster. The operation of the return

ﬂow booster is to be monitored. A 4-way mixing valve is sufﬁcient as a return ﬂow booster on systems

with a buffer tank.

The boilers supplied by KÜNZEL are stationary units that comply with the WEEE Directive. The elec-

trical and electronic components contained in the boilers do not fall within the remit of this directive and

will therefore not be taken back by KÜNZEL. Please take these components to the recycling depot.

We do not assume any liability for any malfunctions resulting from the use of non-genuine KÜNZEL

components. This particularly applies to control units, external materials handling equipment and fuel

pipes from other manufacturers. We also do not assume any liability for operational difﬁculties resulting

from inadequate hydraulic and/or exhaust gas systems.

We reserve the right to make technical changes.

1.2 The key controls and components

Figure 1: The key controls and components

1 Boiler thermometer 11 plugged connectors for boiler sensors, serial interface

2 boiler thermostats 12 Igniter safety device

3 Temperature safety limiter 13 Burner quick release lock

4 Mains power switch 14 Burner door

5 Fullness sensor 15 Flame deﬂector

6 Filling spout 16 Ash pan

7 Burner control unit 17 Burner door catch

8 Main burner fuse 18 Door contact switch

9 Connection cable for conveyor screw 19 Type identiﬁcation plate

10 Connection cable burner

1.3 Installation

•Before installing the pellet boiler approval must be obtained from the responsible master chimney

sweep.

•A ﬂue gas system must be available that is approved for the operation of the pellet boiler.

•Please check whether planning permission is required.

•The boiler may only be installed by an approved heating specialist.

•When installing the boiler, ensure that all combustible or temperature-sensitive materials (cables,

insulation) are kept at least 40 cm away from the exhaust gas duct and 20 cm away from the boiler

shell.

•No combustible materials are permitted to be directly beside, above or in front of the boiler or the

ﬁlling hose. They must always be kept a minimum of 40 cm away.

•The boiler installation (heating system, electrical supply, safety equipment) must be state of the

art.

•If the heating system is operated with a ﬂow line temperature of more than 100◦C , the boiler

plant must be reported to the responsible trade supervisory centre in accordance with the German

Ordinance on Steam Boilers.

•The relevant standards and building authority regulations must be complied with. Among other

regulations, the following apply: the German Fire Code (FeuVo), the Federal Immission Control

Ordinance (BImSchV.), the VDE guidelines, EN 303-5 and to the heating system DIN 4751.

1.3.1 The boiler room

The pellet boiler may only be installed and the pellets stored in a dry, frost-proof room that isapproved for

the installation of boilers and the storage of fuels. The building contractor is to ensure that the installation

space is sufﬁciently ventilated.

A level, sufﬁciently strong ﬂoor manufactured from non-combustible material is adequate for the

installation of the pellet boiler. Should a foundation pedestal be used, this is to be made at least as

large as the dimensions of the boiler. The installation must also comply with the local regulations and

guidelines applicable to boiler room installations.

The boiler installation should already take account of the subsequent position of the materials handling

system!

Figure 2: Minimum offset dimensions for installation (view from above)

1.3.2 Transportation of boiler

As a result of its compact design, it is possible to bring the pellet boiler through a 750 mm door opening

into the installation space. In order to make the boiler casing easier to carry, carry bushings have been

ﬁtted to the boiler, into which 1 inch pipe ends can be screwed.

•On the PK 15, these are located to the right and left below the covering caps.

•On the PK 10 and PK 20, the carry bushings are located at the front below the slanted cover panel

and beneath covering caps.

Once the installation has been completed, it should be ensured that the turbo gratings are correctly seated.

Illustrations on this subject can be found in the operating manual for the pellet boiler in the section

entitled "Maintenance and care" / "ﬂue gas ducts".

1.4 Installation of the burner

Figure 3: Lock open Figure 4: Lock closed

The burner is secured in position using quick-release locks ﬁtted to the burner door. When installing the

burner, proceed as follows:

•Remove the ﬂame deﬂector from the burner shell. Important: The burner may only be installed or

removed without the deﬂector, otherwise the door insulation may be damaged.

•Now slide the burner into the burner hole in the burner door.

•Now set the two locks so that the burner is seated ﬁrmly in front of the burner door and the burner

contact switch is actuated. The burner is only permitted to have a very modest amount of play.

•As the burner seal beds in it is necessary to check the locks once again after about 4 weeks and

adjust them if required.

•Now re-install the ﬂame deﬂector in the burner.

Only PK15:

At last the red hood has to be slid onto the burner ﬁtting the rear metal sheet of the hood between washer

and clip (see pic. below).

Figure 5: Sliding on the hood

1.5 Installation of the burner hood

The pellet burner is supplied with the hood mounted. For maintenance or cleaning purposes, it can be

necessary to remove the hood. Before starting to do this, disconnect the burner completely from the

mains power supply. When removing the hood, proceed as follows:

•Remove the discharge chute cover. This requires the use of a T10 torx bit.

•Release the fastening screw holding the control module and lift it carefully upwards out of its

seating.

•Release the screwed fastenings holding the hood.

•Withdraw the hood rearwards

Use this procedure in reverse to install the hood. Only the torx screws provided may be used for the

installation of the hood. Please note: The burner may not be operated without a properly installed

hood. There is otherwise a risk of injury and the danger of electrical shocks !

Figure 6: The burner hood

1.6 Operate cleaning lever (only PK 10 and PK 20)

As standard, the lever for the manual register cleaning mechanism is located on the right hand side of

the boiler (in the case of PK 15 on left hand side). Yet, sometimes it can be more sensible to move the

cleaning lever to the left hand side of the boiler, although it is only possible to do this on PK 10 and PK

20 boilers.

Figure 7: The cleaning lever

•Remove the red panel cover from the boiler and open the register cover located below it with an

Allen key.

•Release the screws marked with an arrow in the illustration and withdraw the shaft and handle

from the boiler in a rightward direction.

•Remove the black collar from the housing.

•Open the pre-cut hole on the left hand side of the boiler and re-insert the collar in this hole.

•Now slide the shaft from the left into the boiler; ensure it is positioned correctly (underneath the

follower lever, see ﬁgure!)

•Bolt the shaft and the follower lever back together.

1.7 Chimney connection

The KÜNZEL pellet boiler is ﬁtted with a forced draft fan. In order to ensure safe operation of the pellet

boiler, it is necessary to ensure that the ﬂue gas branch of the pellet boiler has a negative pressure of at

least 10 Pa under all operating conditions. However, this negative pressure may not exceed 18 Pa under

any operating conditions. KÜNZEL recommends the use of a draft regulating device. When putting the

unit into service for the ﬁrst time, the draft is to be measured and recorded when the unit is cold and

when it is operating at its maximum output setting.

The exhaust gas duct to the chimney should be as short as possible, without any bends and installed at

a slight incline. The connection to the chimney should have an aerodynamic design that curves upward.

The connector joining the furnace and the chimney must comply with EN 1856-2:2004 and have the

required identiﬁcation marking (CE). In accordance with EN 1856-2:2004, non-insulated connectors

must be kept at least 40cm cm away from combustible components. We recommend the use of insulated

connectors.

The ﬁgures required for the chimney design calculations can be found in the technical data listed in

section 4on page 25. Calculated chimney diameters that are smaller than the ﬂue gas branch of the boiler

are not permissible.

Important: Please note that the low exhaust temperatures occurring during prolonged operation may

mean that it is necessary to ﬁt a moisture-resistant chimney (thermal conductivity factor - resistance

group I in accordance with DIN 18160/T1).

Before connecting the pellet boiler to an existing chimney, subject it to a chimney calculation or obtain

a chimney report. Before commencing with the installation it is essential to obtain the approval of your

local master chimney sweep.

It is essential to ensure that the ﬂue gas duct is airtight. Exhaust gases could otherwise leak into the boiler

room under some circumstances. This applies in particular to the cleaning hatches on the duct elbows.

1.8 Heating connection

1.8.1 General

The PK type pellet boiler are designed for use with open or closed-circuit heating systems with a maxi-

mum operating pressure of 3 bar and a maximum ﬂow line temperature of 95◦C.

The following safety equipment is to be installed by the building contractor:

•A pressurised expansion tank (please take account of any buffer tanks ﬁtted to the system)

•A safety valve with a maximum actuation pressure of 3 bar at the highest point of the heat generator

•A thermometer and a manometer

Figure 8: The chimney connection

Please note: Only products whose components have been tested may be employed

We recommend designing the heating system in line with the example system detailed in section 3 on

page 25. KÜNZEL absolutely recommends the use of a buffer tank with a capacity of at least 500 l.

. Using a buffer tank ensures that the boiler can operate with extended burner operation times even

when the heat consumption of the heating system is either low or ﬂuctuating markedly. This leads to

a signiﬁcant reduction in emissions, as well as wear and tear and soiling of the burner and igniter element.

In order to prevent the pellet boiler from corroding, the boiler is operated with an elevated minimum

temperature. This is 50◦C for systems without a buffer tank, and 60◦C for systems with a buffer tank.

For this reason, a separate return ﬂow temperature booster has to be ﬁtted, e.g., the Thermomix valve

(Part. No. 150218) from KÜNZEL.

Due to the elevated minimum temperatures, the heating system must always be equipped with an au-

tomatic mixing valve. 3-way mixing valves are to be ﬁtted to systems with buffer tanks. 4 way mixing

valves are to be ﬁtted to systems without a buffer tank.

1.9 Electrical supply connection

1.9.1 General

•The electrical supply must be connected by an approved electrician.

•A residual current circuit breaker is to be ﬁtted.

•The electrical supply connection for the boiler is to be protected by a max. 10 A fuse.

1.9.2 Boiler and burner

The mains power supply for the boiler, burner and conveyor screw is routed via the mains power cable

to the rear panel of the boiler (white plugged connector) and can be disconnected using the mains power

switch on the boiler control panel.

Figure 9: Plugged connectors on the rear panel of the boiler

The burner thermostat control circuit (green plugged connector) serves to connect the differential tem-

perature control unit (Thermomat) or another control system.

A circuit diagram can be found in the appendix.

1.9.3 Boiler sensors

The sensors for the boiler thermostat and the temperature safety limiter are already installed beneath the

cover panelling.

The boiler sensor for the differential temperature control unit must be inserted into a vacant immersion

sleeve beneath the cover (see ﬁg.). On the PK 15, the immersion sleeves are below the panelling with

the control panel. These must be removed previously. The screws can be accessed from the rear.

The sensor should be positioned in the immersion sleeve so that it can be easily pressed against the wall

of the sleeve. Sensors that are loose in immersion sleeve have poor heat transfer characteristics and could

lead to switching errors. In order to improve the switching accuracy, we recommend ﬁlling the immersion

sleeve with heat conductive paste

Figure 10: Position of the immersion sleeve below the cover

2 Installation instructions for external pellet ﬁlling system

We offer various silo and materials handling systems for installation in pellet storage rooms or bag silos

set up by the building contractor.

You can ﬁnd information about the design of the pellet storage room in our pellet design folder or relevant

literature. An impact mat is to be ﬁtted. Chipped off parts of the wall or plaster can fall into the pellet

feed chute and cause damage to the burner that is not covered by the guarantee! In addition, the intake of

dust is detrimental to the combustion process and can lead to increased slagging in the burner.

2.1 External conveyor screw

2.1.1 Rigid conveyor screw from the silo built by the building contractor

This 3 metre long conveyor screw is supplied with a 240 V motor and is part of the product contents for

the PK pellet boiler. The conveyor screw is controlled directly by the pellet burner.

In order for the pellet feed system to function perfectly, it is very important that certain angles, shown in

the following ﬁgures, are observed.

The external conveyor screw is suspended from the ceiling of the installation space using the supplied

tensioning hook. Ensure the ceiling is sufﬁciently strong to bear the load before starting the installation

procedure. The equipment must be fastened using suitable means.

Figure 11: The suspension arrangement

If the ceiling is not sufﬁciently strong, a suspension frame (part no.: 100053) is available as an optional

accessory.

Fasten the downpipe hose to the output of the external conveyor screw and the input of the burner using

hose clamps; apply some washing-up liquid to the internal surface of the hose if necessary to simplify

the installation procedure. Stretch the hose so that it is not possible for any pellets to become trapped

within it. Otherwise the hose could become blocked and necessitate repair work. However, please note

that the hose must be long enough to allow the burner door to swing open.

In order to ensure that the external pellet silo is emptied as well as possible, position the input to the

external conveyor screw in the centre and/or at the lowest point of the external silo. Please note that a

storage room can never be emptied entirely because the pellets generally have an angle of repose of

about 45◦(in the case of ﬂour it can be as much as 80◦). The amount of remaining material depends on

the design of the storage room and can only be used if it is moved so that the pellets can be captured

by the conveyor screw once again. Providing the walls with inclined smooth surfaces improves the

emptying of the silo.

Figure 12: Correct installation of the conveyor screw

The rigid 3 metre long conveyor screw can be shortened to any length required, as long as its inclination

is kept to between 30◦and 50◦(see ﬁg.). The pipe end must then be cut to 30◦again. The conveyor screw

may not protrude from the pipe.

Figure 13: Outlet angle of the rigid conveyor screw

The size of the hole in the wall depends on the wall thickness and the suspension angle. For example,

a suspension angle of 50◦and a wall thickness of 10 cm would require a hole height of 26 cm (wall

thickness [cm] * tan50◦+ 14 cm), the width remains unchanged at roughly 10 cm.

Please note: Do not touch the conveyor screw when the drive motor is connected. There is a risk of

injury!

2.1.2 Flexible conveyor screw from pellet storage room

The conveyor screw is controlled by the burner control unit. The building contractor is to provide a

3-phase 400 Volt 3 x 16 ampere electrical supply connection that is in turn controlled via the motor

connection set relay (part no.: 100052).

Figure 14: Flexible conveyor screw from the storage room

The length of the conveyor screw is not permitted to exceed 25 metres. Two conveyor screws with a

transfer device are to be used if a greater distance has to be bridged. The minimum installation radius

for the conveyor screw is 1.5 metres. All of the curves followed by a conveyor screw must together have

an angle of not more than 135◦. The maximum angle than can be achieved in one bend is 90◦. After

this only one bend with an angle of not more than maximal 45◦is permissible, but this must be in the

opposite direction to the ﬁrst bend.

Figure 15: External conveyor screw

The number of inlet funnels required varies according to the dimensions of the pellet storage room.

Please note that a storage room can never be emptied entirely because the pellets generally have an angle

of repose of about 45◦(in the case of ﬂour it can be as much as 80◦). The amount of remaining material

depends on the design of the storage room, and can only be used if it is moved so that the pellets can be

caught by the inlet funnels once again.

The ﬁrst inlet funnel must be located at least 600 mm away from the wall. The other funnels are then

positioned at a distance of not less than 600 mm and not more than 1000 mm.

The following set-up is suitable for a pellet storage room with a length of 2.5 m.

1. 1 Stk. conveyor screw 5.5m

2. 1 Stk. pipe bend 45◦

3. 1 Stk. pipe 2.5m

4. 1 Stk. pipe 1.8m

5. 3 Stk. inlet funnels

6. 1 Stk. motor (0,37kW; 400 volt, 3x16 ampere) with ﬂange and motor mounting

7. 1 Stk. connection hose

8. 1 Stk. motor connection set (electrical contactor and motor circuit breaker)

9. 1 Stk. various minor components

Further accessories for the storage room:

1. Filling connection kit (part no.: 100065) consisting of 2 x Storz connections type ALU, 2 x blind

cover incl. ﬁttings.

2. Filling and air bleeding connections 50 mm (part no.: 100060), 200 mm (part no.: 100061), 500

mm (part no.: 100062), 500 mm with earthing clamp (part no.: 100067), 1000 mm with earthing

clamp (part no.: 100063)

3. Bend for ﬁlling and air bleeding line 5◦(part no.: 100070), 15◦(part no.: 100071), 30◦(part no.:

100072), 45◦(part no.: 100073), 60◦(part no.: 100074), 90◦(part no.: 100075)

4. Z-bend for storage room(part no.: 100018) consisting of 2 x Z-bend each 2 m in length

5. Impact mat (part no.: 100017) consisting of plastic impact mat - 1.50 m x 1.50m.

2.1.3 Flexible conveyor screw from bag silo

The conveyor screw is controlled by the boiler control system. The building contractor is to provide a

3-phase 400 Volt 3 x 16 ampere electrical supply connection that is in turn controlled via the motor

connection set relay (part no.: 100052).

Figure 16: Flexible conveyor screw from bag silo

Further design of the conveyor screw is not required. The unit is installed directly onto the outlet of the

bag silo using the installation instructions provided with the silo system.

2.1.4 Storage tank with rigid conveyor screw

Figure 17: Storage tank with rigid conveyor screw

3 System proposals for the pellet boiler

3.1 PK2 system package - pellet boiler with domestic water heater and buffer tank

The system proposal in accordance with the PK2 system package permits the construction of a straight-

forward, economical and space-saving pellet heating system with a regulated domestic hot water tank

and buffer tank. A 4-way mixing valve is not sufﬁcient to serve as a return ﬂow booster for this system.

For this reason the Thermomix valve must be ﬁtted.

Ensure that the boiler circulation pump (15) and the heating pump (18) are correctly matched to one

another.

We recommend installing the Thermomix valve and the buffer tank so that they can be completely iso-

lated in order to simplify maintenance work.

Please read the operating and installation manuals for all of the units before installing the system. The

electrical installation for the system may only performed by a qualiﬁed electrician. The use of PVC-

insulated cables is not permitted in the boiler.

Hydraulic diagram

Figure 18: PK2 system package

Figure 19: PK2 system package with hydraulic quick assembly - wiring diagrams

Wiring diagram

Figure 20: Wiring diagram for PK2 system package with hydraulic quick assembly

Figure 21: Wiring diagram for PK2 system package

3.2 PK3 system package - pellet boiler with combi-buffer tank

The system proposal in accordance with the PK3 system package permits the construction of a straight-

forward, economical and space-saving pellet heating system with a combi-buffer tank and an unregulated

domestic water heater. A 4-way mixing valve is not sufﬁcient to serve as a return ﬂow booster for this

system. For this reason the Thermomix valve must be ﬁtted. In particular, this system design is also suit-

able for the construction of a solar heating system that is intended to supplement a conventional heating

system.

Ensure that the boiler circulation pump (15) and the heating pump (18) are correctly matched to one

another.

We recommend installing the Thermomix valve and the buffer tank so that they can be completely iso-

lated in order to simplify maintenance work.

Please read the operating and installation manuals for all of the units before installing the system. The

electrical installation for the system may only performed by a qualiﬁed electrician. The use of PVC-

insulated cables is not permitted in the boiler.

When installing the combi-buffer tank, remember to check the state of the protective anode in the storage

heater; a defective anode can unnecessarily reduce the service lifetime of the boiler. We recommend

checking the anode at least once a year.

Hydraulic diagram

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kunzel PK 20 Installation guide

Brand: kunzel

Model: PK 20

Category: Water heaters & boilers

Type: Installation guide

This manual is also suitable for

PK 10

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kunzel PK 20 Installation guide

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kunzel PK 20 Installation guide

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