MODEL: PROPEL

BE SURE TO READ THIS MANUAL AND KEEP IT NEAR THE HEATING SYSTEM
FOR EASY REFERENCE

Green Energy Engineering Ltd, 198 Lurgan Road, Dromore, Craigavon, Co.Down, Northern Ireland. BT25 1HL
Tel: +44 (0) 28 38 820 043 Fax: +44 (0) 28 38 820 987 Email: [email protected]

TABLE OF CONTENTS
Section
Introduction
Safety instructions
How to biomass system Works

Page
3
4
6

Specifications
Installation
Operating the Heating system
Maintenance Overview
Troubleshooting

8
11
14
15
18

Installation Scheme

20

Electrical Scheme

22

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INTRODUCTION
Congratulations on your purchase of a biomassfired heating system from KOZLUSAN HEATING
SYSTEMS.
With proper installation and maintenance, your heating system will provide years of non-polluting,
low cost heat for your home.
To insure correct installation and safe operation of your Kozlusan biomass heating system, you
should:

Hire a licensed heating contractor to install the biomass heating system and integrate it with
your heating system. This contractor should have experience with installation and operation of gas, oil,
and solid fuel heating appliances and be familiar with local building codes, fire codes and other
regulations.
Read this manual and learn how to safely operate and maintain your Kolzusan biomass heating
system.
The assembling and start up (setting) of Kozlusan biomass boiler has to be carried out by
our own customer service or by authorized qualified technicians.
Do not use any other fuels than specified below:

-Norm M 7135
DIN-PLUS Norm
SWISSPELLET
Diameter: 6 mm Length: 5-30 mm (20% - 45 mm)
DD: CEN / TS 14961 : 2005

Only this way low-emission, economical and reliable operation can be guaranteed. Any disregard of
these requisites leads to immediate expiry of warranty.

The pellets must be stored in dry conditions to enable them to be transported without problems
and to achieve trouble-free operation with optimum combustion combined with the greatest possible
efficiency.
We do not assume any liability for unauthorized technical modifications, and resulting damages
are not covered by warranty.
Operational procedures or alterations of any sort, carried out by unauthorized persons, as well as
disregarding the general guidelines and the indicated safety instructions as specified here, result in
immediate termination of all warranty claims.

Please read the safety instructions below before operating the system. Disregarding the safety
instructions may lead to injuries, perilous situations or damage the pellet boiler.

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SAFETY INSTRUCTIONS
The pellet heater system may only be operated be in faultless technical condition. Malfunctions
and damage which affect or could affect safety must be corrected immediately by our trained
personnel.
The assembly may only be conducted by our customer service, or by a certified specialist. The
system is equipped with rotating parts, which move with a relatively large turning movement
(crushing hazard).
Under the casing and in the terminal box there are voltaged components. Do not remove the casing
or terminal box.
Never open the inspection openings of the boiler while in continuous operation, hot exhaust gas
and dust may escape.
The system should be turned off before the implementation of maintenance work. Wait until the
pellet boiler has cooled down (check the temperature on the display).
The boiler needs to be switched off before carrying out the cleaning of the chimney. Wait until the
pellets have burned down completely (approx. 20 minutes danger of explosion through back up of
exhaust gas.
Never pour flammable liquids into the burner.
Never perform independent repair work on our system, call trained personnel!
Put a signboard into the heating room that forbids to smoke or to use open light or fire.
A certified fire extinguisher must be installed in the boiler room.
Ensure enough air supply in the heating room.
Secure the boiler room against unauthorized access, especially by children.
Once a month, test the boiler doors and the water connections for leaks and damage.
Once a year, test the safety temperature limiter.
Safety and monitoring devices may not be removed, bypassed or taken out of service in any other
way.

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Always wear a dust mask when cleaning the system and when removing ashes to avoid damages to
your health.
When setting the domestic water temperature above 60 C, you have to ensure that the hot water is
mixed with cold water to avoid scald.
The pellet heater system may only be set up and operated in heating and plant rooms which
comply with legal requirements.
Provide an appropriate air relief valve on top of the boiler.
Annual control of safety devices by a specialist.
Regular control of expansion tank by a specialist.
Regular control of pellet feeding devices, automatic ignition devices and feeding features.
Please note that even when the system is turned off, different functions are in operation. (For
example the anti-freeze protective device; pumps and mixers are moved periodically during the night
avoid an accumulation of the storings). To ensure that no electricity runs through the system, take
off the system from electricity.
Make sure that the return temperature does not drop below 50 C. Disregarding leads to expiry of
warranty!

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How the biomass heating system works

The Kozlusan biomass heating system produces few emissions and achieves a high level of heating
efficiency because of its unique design. The fully automated fuel delivery is poured from top into
an air fed burn pot where the fuel is self ignited before the full modulation control system controls
the burn for minimum emissions with maximum heat output.

To understand how the Kozlusan heating system works, have a to look at the flow of air, fuel
and gases through the heating system and the transfer of heat from the superheated gases to
the thermal transfer fluid. We also need to understand some of the terminology used to
describe the systems operation;

Air Flow through the Biomass heating system

1. Fuel is fed from the fuel store via an auger. The fuel is poured from the top into the cylindrical burn
pot to maintain a physical separation between the fuel store and the fuel feed. There is sucktion fan
availabe for the combustion. Various sensors measure temperature in the boiler (a thermostat that
works in water) a flue gas temperature sensor (probe in the chimney), outside temperature sensor (the
weather or room temperature) and a safety cut off temperature sensor to protect against overheating
(high limit stat).
2. As air flows through the firebox, its temperature rises to nearly 1000 C.
3. This superheated air rises upwards and then through a series of heat tubes where the heat is
transferred into the thermal fluid.

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4. By the time the exhaust air reaches the flue, most of its thermal energy has been absorbed. The final
temperature of the escaping flue gas is less than 175 C.

Fluid Flow through the Heating system

1. Kozlusan heating systems recommends a mixture of water and propylene glycol as a heat transfer
fluid. Glycol is a non-toxic solution that works like the antifreeze in your car to prevent corrosion and
freezing.
2. A pump pushes fluid around the heat transfer jacket which absorbs heat from the combustion gases.
The fluid exits the internal manifold at about 80-85 C.
3. The fluid flows past an aquastat (water thermostat) that regulates the burn rate of the heating system
in conjunction with the flue gas temperature sensor that measure the temperature in the flue. This
information is used to determine the amount of air and fuel being used to ensure efficient heat transfer
and to ensure the fan does not simply blow the heat up the flue. The heated fluid is used to transfers
the heated fluid to your home system where it provides warmth to your home, garage, basement and
other structures; preheats your domestic hot water; heats your pool; and/or melts snow on your
driveway.
4. Having transferred the heat to the home system, the fluid exits the external heat exchanger and
repeats its path through the internal manifold.

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SPECIFICATIONS

Propel-25

Propel 40

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AIR ELIMINATOR VALVE &

BLOW OFF

FOR PROPEL 25

AIR ELIMINATOR VALVE &

BLOW OFF

FOR PROPEL 40

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TECHNICAL DATA

PROPEL 25

PROPEL 40

Max. Heat Performance(kW)

25

40

Min. Heat Performance (kW)

Max. Boiler Temperature(C)

90

90

Max. Utility Water Temperature(C)

80

80

Max. Operating Pressure (bar)

Test Pressure

4,3

4,3

Max. Suction Flow Rate Of Flue(m/h)

60

100

Exhaust Fan sucktion pressure at full

-7

-10

Total Weight(kg)

420

480

Water Content (lt)

65

127

Bunker Capacity(kg)

220

240

Ash Box-Useable(lt)

20

20

load(pascal)

Dimensions

Water & Chimney Connections

Hot Water Outlet

Cold Water Inlet

Safety Outlet

Boiler Emptying (Mains Water Inlet)

Chimney Diameter(mm)

128

128

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INSTALLATION

Your Kozlusan heating system must be installed by a qualified heating contractor who is thoroughly
familiar with gas, oil, and solid fuel heating appliances. Also, you must be sure to comply with local
building codes, fire codes and other regulations when installing the heating system.
Safety Practices
Hire a licensed contractor with experience in design and installation automated heating systems.
Comply with local building codes, fire codes and other regulations when installing this heating
system.
Minimum clearances to combustible surfaces. 1000mm circumference.
Make sure to identify sources of make-up air in the room where the heating system is located. The
Kozlusan Heating System, exhaust fans and other appliances all draw air from the room. Be certain
there is an adequate source of fresh air (ventilation) to offset these demands or you may create
negative pressure in the room and prevent the heating system of combustion and create draft problems
in your flue.
Connect the heating system to a properly installed and operating chimney and vent it to the
outside.
Be sure your chimney is safely constructed and in good repair. Before installation, have the
chimney inspected by a qualified inspector.
Be sure to provide thermal spike protection for the heating system
(see Wiring and Controls pg. 30).
DO NOT connect the heating system to an aluminum Type B gas vent.
DO NOT vent the heating system to another room or inside a building.
DO NOT share a chimney flue with another appliance.
DO NOT install the heating system in a mobile home or trailer. Instead, install the heating system
outside in a covered enclosure and pipe the hot water into the mobile home.

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Chimney Installation
A chimney performs two functions: it removes smoke and flue gases from the heating system, and it
provides draft for the fire. Draft is the term used to describe the suction that occurs when hot air
rises and creates a vacuum in the firebox. That vacuum draws fresh air into the firebox and feeds
combustion of the wood. No heating system can operate properly without adequate draft.
Proper installation of the chimney flue is critical to the performance of your Kozlusan Heating System.
The majority of problems encountered after installation are attributable to a flue that is improperly
sized or otherwise provides inadequate draft to the heating system.
You may connect the Kozlusan Heating System to an existing flue or chimney subject to the following
conditions.
1. A qualified professional has inspected, repaired (if necessary), thoroughly cleaned the chimney and
determined it is suitable for use with a residential heating appliance that burns solid fuel.
2. The chimney or flue should be at least 3-4 m tall and sized correctly for the Kozlusan Heating
System model installed.
3. Do not share a flue with another heating system, appliance or fireplace. Do not use a flue that
already provides make-up air to the cellar or basement.
4. Tightly close the cleanout opening in the base of the chimney.
Frost & Overheat Protection
The heating system is leak-tested at the factory during final assembly, and the heat transfer fluid
drained for shipment. The recommended solution is a mix of 30% propylene glycol to 70% water
unless you are located in a very cold climate, or you plan to leave the heating system unused for a long
period of time. A 30% solution of propylene glycol is adequate to lower the freezing point to -13 C
and raise the boiling point to 102 C.
CAUTION: DO NOT use ethylene glycol-based (automotive antifreeze) coolant in your Kozlusan
Heating system or in your homes heating system. Always use propylene glycol-based coolants.

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OPERATING THE HEATING SYSTEM

Safety Practices
1. Keep fuel dry.
2. DO NOT use chemicals, gasoline, lantern fuel, kerosene, charcoal lighter fluid or other flammable
liquids to start or freshen up the fire, always let the automatic ignition start the fire.
3. DO NOT open the access doors unless the system is off.
4. DO NOT BURN anything other than pellets in this heating system.
WARNING EXPLOSIVE GASES
Gasses formed during solid-fuel combustion may cause a small explosion when the
heating system is refueled.
Always clean burner and remove access pellets before refueling.

5. Use the tools provided if it is necessary to rake ashes or unburnt fuel from the burnpot
6. DO NOT open the access door during operation try to add.
7. DO NOT throw fuel into the burnpot via the access door
8. Keep the access door closed tight except when tending the burnpot.
9. Keep the heating system area clear of combustible materials, gasoline, and other flammable vapors
or liquids.
10. DO NOT forget to regularly empty the ash collection box.
11. DO NOT store fuel or combustables within the appliance installation clearances or within the
space required for fueling, ash removal, and other routine maintenance operations.
12. DO NOT allow anyone who is under the influence of drugs or alcohol or is unfamiliar with the
correct operation of the heating system to add fuel or otherwise use this heating system.
13. DO NOT let children play around the heating system when in operation. Alert all persons to the
hazards of hot heating system surfaces.
14. For adjustments of digital control panel, please read the TCNet Boiler Controller Manual
that is provided together with the boiler you bought.

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MAINTENANCE OVERVIEW
Safety Practices
1. Check your fuel supply regularly and allow suitable time for deliveies try not to run out of fuel
2. Check the ash box and empty regularly.
3. Inspect chimney, flue pipes, flue pipe joints, and flue pipe seals regularly to ensure that smoke and
flue gases are not drawn into, and circulated by, your homes air circulation system. If you observe
rust or any smoke leakage, replace the pipe immediately.
4. Exercise the safety relief valve at least once a year.
5. Check the water pressure is between 1 and 2 bar if too low top up system with more water.
6. DO NOT clean heating system surfaces when the unit is hot. Wait until the unit cools and then
clean with soap and water.
ATTENTION
This work may only be performed by certified specialists or by Kozlusan customer
service personel. The boiler requires a minimum of 1 anual service by certified personel
to maintain warranty guarantee!
Periodical Maintenance
Brushing Burnpot

Take out front door cover

Unloose the star handles

Remove burnpot door

Brush inside the burnpot and remove the flue ashes in the combustion chamber with vacuum cleaner

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Cleaning the residual ashes below exhaust fan

Unloose the wing nuts to take out door

Via the help of a vacuum cleaner, remove the residual ashes

ATTENTION
We recommend to let the boiler cool down for at least 6-8 hours later switching off the
system before proceeding with these works.
Yearly Maintenance

Cleaning Heat exchanger and baffles

Remove outer body cover and internal cover insulation

Unscrew all bolts and remove cover to access baffle tubes and cleaning springs
Remove baffles and springs, clean components and vacuum all chambers

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Cleaning of secondary air channels in burnpot and the base of burnpot

Disconnect hopper from boiler and unscrew internal pellet feed auger from cumbustion chamber

Unscrew burnpot from cumbustion chamber and remove for cleaning

In Addition
Inspection of the grate cleaning lever
Inspection of gaskets on the combustion chamber door and ash box
Operational test of the heat exchanger cleaning
Cleaning of the exhaust sensor
Test the ignitor tube for residue
Test upper and lower parts of the burner for damage and leaks
Test the intervals of the sensors (grate motor, separator)
Lubrication of the heat exchanger cleaning drive and grate bar
Exhaust gas measurement
Maintenance every 3 years
Maintenance volume from the yearly maintenance and the following additional work
Visual check and cleaning of the hoist basket lever for the heat exchanger cleaning:
In addition, remove the boiler cover, vacuum out the existing ashes and check the function of the hoist
basket lever. According to function control, using caulking strip newly caulk the boiler cover and
reassemble.
Cleaning of secondary air channels in burnpot and the base of burnpot.
Detach the hopper tank from the boiler firstly. Then remove the burnpot carefully.
Test run of all electrical equipment

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TROUBLESHOOTING
FAILURE
Dark Screen

Error:Out of Pellets

Error :Ignitions failed

Error:Overtemperature detected

Error:Back burning to auger

Error:Memory allocation error

Error:FLASH checksum error

Error:FILESYSTEM error

CAUSE

REMEDY

Emergency switch turned OFF

Turn it ON

Safety Temperature Limiter has relased

Let the boiler coll down to 80C

No more pellets in fuel hooper

Reset the safety temperature limiter and

search for cause (e.g. defect pump)
Refill

Defective pellet level sensor

>Inform customer service

Too cold ambient temperature

Low quality pellets

The ambient temperature should be 0-45C

for proper working
Change pellets

Ignition device malfunction

>Inform customer service

Exhaust fan malfunction

>Inform customer service

Boiler temperature exceed 95C

Let the boiler cool down

Circulation pump malfunction

>Inform customer service

Defective controlled board

>Inform customer service

Defective temperature sensor

>Inform customer service

The temperature of the augerexceeded

the limit thermostats value
Back burning to auger
Defective back burning detection
thermostat
Lost connectivity between the controller
and back burning detection thermostat
Problem occured in the control panel

>Inform customer service

f the problem persists after reset

>Inform customer service

Problem occured in the control panel

Reset controller

f the problem persists after reset

>Inform customer service

Problem occured in the control panel

Reset controller

f the problem persists after reset

>Inform customer service

T3:boiler-defective sensor

>Inform customer service

T2:weather- defective sensor

>Inform customer service

T1:buffer tank- defective sensor

>Inform customer service

Tc1:exhaust- defective sensor

>Inform customer service

>Inform customer service

Reset controller

Error:Sensor malfunction(sensor no)

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TROUBLESHOOTING
FAILURE

CAUSE

REMEDY
Burner is new (wait)

Burner creaks
Poor insulation

Insulate the chimney well

Low exhaust temperature

Increase the minimum power/ the boiler

temp.. , it may be necessary to restore the
chimney
Check return flow increase at external
control

The boiler is on utility water operation mode

Change operating mode

Hydraulic problem

Contact installer

Altered heating curve

Adjust

Heating circuit pump is defect

>Inform customer service

Air in the system

Bleed air from system

Pumps run on wrong ration speed

>Inform customer service

No water in boiler

Fill the system with sufficient water

Circulation pump is not working

Active/Inform customer service

Air in the system /boiler

Remove /emliminate/Inform customer

service

Defective boiler temperature sensor

>Inform customer service

Chimney is sweating

Pellet boiler is sweating

Heating circuits do not work/

Heating system is slow to heat up

High temperature value on screen

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