ASTRA MACHINERY PLANT AB • ANNO 1929

PELLET BOILERS
Astra P-16
Astra P-25
Astra P-35

INSTALLATION AND OPERATION MANUAL

CONTACT INFORMATION OF THE FACTORY:
MACHINERY PLANT “ASTRA” AB
ULONŲ G. 33, LT-62161 ALYTUS, LITHUANIA
TEL.: +370 315 75449
FAX: +370 315 52265
E-MAIL: [email protected]
WWW.ASTRA-GAS.LT
CONTENT
1. SAFETY REQUIREMENTS............................................................................................................4
2. INTENDED USE........................................................................................................................5
3. TECHNICAL DESCRIPTION..........................................................................................................5
3.1 Technical specifications.......................................................................................................................................................8
3.2 Boiler safety system;...........................................................................................................................................................8
4. TRANSPORTATION, STORAGE, UNPACKING..................................................................................9
5. INSTALLATION....................................................................................................................... 11
5.1 Installation of the Boiler Room.......................................................................................................................................... 11
5.2 Boiler protection against corrosion................................................................................................................................... 11
5.3 Requirements for the Chimney......................................................................................................................................... 12
5.4 Pellet boiler elements....................................................................................................................................................... 12
5.5 Burner installation in the boiler........................................................................................................................................ 13
5.6 Connection of the lording auger and pellet supply pipe.................................................................................................... 13
• Installation of fuel supply branch pipe.............................................................................................................................. 13
• Connection of the burner electrical part with the boiler.................................................................................................... 13
• Connection of the loading auger....................................................................................................................................... 13
• Connection of the electrical part of the charging auger to the boiler................................................................................. 15
5.7 Electric wiring................................................................................................................................................................... 15
• Connection of the Circulation Pump.................................................................................................................................. 15
• Electrical wiring diagram.................................................................................................................................................. 16
5.8 Connection of the wireless Wi-Fi communication module................................................................................................ 16
• WiRCu module mounting.................................................................................................................................................. 16
• Connection of the WiRCu module to the Wi-Fi network.................................................................................................... 16
6. FUEL.................................................................................................................................... 17
7. CONTROLLER MENU................................................................................................................ 17
7.1 Display.............................................................................................................................................................................. 17
7.2 Navigating the menu........................................................................................................................................................ 18
7.2 Navigating the menu........................................................................................................................................................ 19
7.3 Menu structure.................................................................................................................................................................20
7.5 Setting the weekly timer programs...................................................................................................................................20

7.6 Setting the water temperature .............................................................................................................................22

7.7 Thermal power setting ..........................................................................................................................................23

7.8 Setting the fuel options ........................................................................................................................... 23

7.9 Modifying the setup options .................................................................................................................................23

8. OPERATION...........................................................................................................................25
• Screw feeder operation.....................................................................................................................................................25
• Combustion fan operation................................................................................................................................................25
• Phases of operation..........................................................................................................................................................25
 INSTALLATION AND OPERATION MANUAL

8.1 Fire up phase....................................................................................................................................................................25

8.2 Burning phase..................................................................................................................................................................26
8.3 Cleaning phase.................................................................................................................................................................26
8.4 Fire down phase...............................................................................................................................................................26
8.5 Off phase..........................................................................................................................................................................27
9. ADJUSTMENT........................................................................................................................ 27
• Values of the combustion parameters...............................................................................................................................27
9.1 Filling the screw feeder with pellets..................................................................................................................................27
9.2 Indicators of correct combustion.......................................................................................................................................28
• Flue gas temperature........................................................................................................................................................28
• The flue.............................................................................................................................................................................28
• Contraflow hatch..............................................................................................................................................................28
• Agitators...........................................................................................................................................................................28
• Smoke from the flue.........................................................................................................................................................29
• Smoke emission................................................................................................................................................................29
• The flame..........................................................................................................................................................................29
9.3 Power adjustment of the burner.......................................................................................................................................29
• High power output adjustment.........................................................................................................................................29
• Low power output adjustment.........................................................................................................................................30
9.4 Cleaning operation adjustment.........................................................................................................................................30
• Blow-cleaning period........................................................................................................................................................ 31
• Blow-cleaning duration.................................................................................................................................................... 31
• Combustion fan speed during the blow-cleaning.............................................................................................................. 31
• Mechanical cleaning frequency......................................................................................................................................... 31
10. Cleaning............................................................................................................................ 31
• Burning chamber cleaning................................................................................................................................................ 31
• Flame sensor cleaning.......................................................................................................................................................32
• Boiler cleaning..................................................................................................................................................................32
11. Maintenance...................................................................................................................... 33
11.1 Changing the heating element........................................................................................................................................33
11.2 Changing the actuator....................................................................................................................................................33
11.3 Replacing the controller battery......................................................................................................................................35
12. Troubleshooting................................................................................................................. 35
14. ACCEPTANCE CERTIFICATE......................................................................................................38
SELLING CARD.........................................................................................................................................................................38
BURNER INSTALLATION PROTOCOL..........................................................................................................................................38
WARRANTY AND POST-WARRANTY REPAIR CARD....................................................................................................................39
DECLARATION OF CONFORMITY...................................................................................................40

3
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

1. SAFETY REQUIREMENTS
The pellet boiler must be installed and tested by qualified personnel instructed and authorized by Astra. Please carefully read this use and
maintenance manual before installing and putting the pellet boiler into operation. For further information, please contact your local Astra dealer.
The use of the pellet boiler must comply with national and European regulations. During the operation of the pellet boiler, strictly observe the
following safety requirements:
• The pellet burner is designed to be fuelled exclusively with high-quality wood pellets with a diameter from 6 to 8 mm as described in chapter
4 of this user’s guide;
• Do not attempt to operate the burner using traditional wood!
• To avoid potential fire hazards, the burner should not be used for incineration of household garbage under any circumstances!
• Before installation of the pellet burner, check with local building codes to assure that the installation will comply with applicable technical
and legal norms;
• Installation of the pellet burner and the electrical connections, initial function checks and adjustments must be performed by qualified and
authorized personnel. Correct installation, adjustment and regular servicing will ensure the burner's long term efficiency and lifetime. Optimum
adjustment can only be achieved using flue gas analysis instruments – as a minimum, a soot pump and draught meter;
• Improper installation or poor maintenance (not compliant with instructions of this user manual) may endanger surrounding property and/or
human health. In the case of the aforementioned product misuse, Astra is exempted of civil and criminal responsibility;
• When linking the burner to a boiler, all boiler ducting works must be completed prior to connecting to the electrical supply;
• To avoid boiling of water in a boiler, the burner must be connected to the electrical supply from the boiler. The latter must have a temperature
limiter thermostat which would cut off the electrical supply to the burner if water approaches boiling temperature;
• There must be sufficient air circulation in the room where the burner is installed;
• To avoid a potential fire hazard, never open the boiler door while burning is going on!
• To assure maximum safety while using your burner be sure to follow all use and maintenance operations as described in this manual;
• This pellet burner should not be operated by people with physically or mentally challenging conditions, or who have no experience using such
devices, unless they are under the direct guidance of a qualified and responsible person;
• The pellet burner must not be operated or played with by children;
• To avoid a potential fire hazard, never operate the pellet burner with boiler door open, or if the door is not properly sealed;
• While the burner is in operation, its surfaces may become very hot. Use extreme caution and be sure to use heat-resistant personal protective
equipment when touching these components;
• Kindle the burner only after the daily inspection described in this manual has been performed;
• To avoid a potential fire hazard, do not dry laundry on or near the burner. Keep clothes and other flammable objects at a sufficient distance
from the burner. Keep the burner room free of dust;
• Do not turn off the burner by unplugging it from the electrical supply;
• Do not clean the burner until its body, boiler and ashes have cooled down completely;
• Do not remove and disconnect the thermostat cable from the fuel intake pipe of the burner;
• To avoid the risk of electric shock, do not touch the burner while barefoot or wet;
• The burner must be connected to the electrical supply of the boiler with an easily accessible plug;
• Do not modify the design of the burner;
• To repair the burner, use only original replacement parts supplied by the manufacturer;
• Do not wait for components of the burner to become totally worn before replacing them. Replace a worn component before it is completely
disabled to prevent possible accidents caused by the sudden breakdown of the components. Perform periodic maintenance checks as described
in chapter 8 of this manual;
• In the case of a chimney fire: 1) call fire department immediately, 2) disconnect the burner from the electrical supply, 3) block an air supply
to the burner if possible;
• This pellet burner has been designed to function in all climatic conditions. In the circumstances of particularly adverse weather (high wind,

4
 INSTALLATION AND OPERATION MANUAL

freezing), safety systems may automatically engage and switch off the burner. If this occurs, please contact technical assistance for directions. In
any case, do not disable the safety systems;
• The unauthorized modification or rebuilding of the burner is forbidden.

2. INTENDED USE
Astra P series pellet boilers are steel boilers with an auger conveyor, fired with 6-8 mm wood pellets. They are designed
for heating individual houses and small commercial and industrial premises. P series pellet boiler, S series pellet burner and
PA series auger pellet conveyor consists of a set controlled by an electronic controller and ensuring the long-term controlled
burning of the boiler.
Astra P series boilers meet the European standards EN 303-5, EN 12809, Lithuanian laws and the existing EU directives
relating to product safety.
3 4

1 2
Fig. 1. Boiler components
1 – P series pellet boiler; 2 – S series pellet burner; 3 – PA series auger pellet conveyor; 4 – pellet hopper.
3. TECHNICAL DESCRIPTION
Wood pellets from the bunker (Fig. 1 pos. 4) rise in the auger pellet conveyor (Fig. 1 pos. 3) and in a flexible hose descend
to the burner (Fig. 1. pos. 2), where they are burnt.
Granules flow in the fuel loading branch pipe (Fig. 2 pos. 1) directly into the combustion chamber (Fig. 2 pos. 17). During

5
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

the ignition phase wood pellets are automatically lit with the heating element (Fig. 2 pos. 16). The air supply fan (Fig. 2 pos.
6) supplies adequate amount of combustion air. The flame shape and direction are formed by the deflector (Fig. 2 pos. 5). The
actuator (Fig. 2 pos. 15) is designed for automated mechanical cleaning of the combustion chamber, pushing the chamber
drawer forward/backward during each claim extinction. The flame sensor (resistive photo sensor) (Fig. 2 pos. 4) monitors
the flame and determines whether the combustion takes place in the combustion chamber. The bimetallic thermostat (Fig.
2 pos. 2), when the fuel supply branch pipe heats to dangerous temperature (95 °C), automatically stops the loading auger.
The K-Type thermocouple (Fig. 2 pos. 11) measures the temperature of smoke exiting the boiler (additional option) and the
NTC sensor (Fig. 2 pos. 13) measures the boiler outlet water temperature. The controller (Fig. 2 pos. 9) automatically adjusts
all processes and phases required for pellet burning. The relay block (Fig. 2 pos. 8) acts as the actuator power source, and has
integrated various other relays and fuses for control and operation of other burner elements. All electric elements fitted in the
burner are grounded through the grounding block (Fig. 2 pos. 10). The user can track and control the combustion process by
using the control panel (Fig. 2 pos. 7). Power cable (Fig. 2 pos. 12) transmits electricity to the burner and must be connected
to the boiler outlet (Fig. 3 pos. 1). Interim purpose of the burner (Fig. 2 pos. 3) is to seal the connection between the burner
and the boiler.
Astra P boiler model K h B d M N G
P-16 916 580 150 G1 ½“ 76 990 185
P-25 1017 680 150 G1 ½“ 76 1092 185
P-35 1131 794 150 G1 ½“ 76 1206 185
1 2

6 3

4 5
7

9 15 16 17

14

10 11 12 13
Fig. 2. Burner components
1 – Fuel supply branch pipe; 2 – Overheating thermostat; 3 – Burner gasket; 4 – Flame sensor; 5 – Deflector; 6 – Air supply fan; 7 – Control panel;
8 – Relay block; 9 – Controller; 10 – Grounding block; 11 – Thermocouple; 12 – Power cable; 13 – Water temperature sensor; 14 – Inlet of the
auger pellet conveyor; 15 – Actuator; 16 – Heating element; 17 – Combustion chamber.
6
 INSTALLATION AND OPERATION MANUAL

A B
G L
d

8
9

H
N

K
G

h
1 M d

7
W
10
C
D
3
B

4 2

5
D

Fig. 3. Overall boiler view

A – rear view; B – front view; C – cross-section; D – top view
1. Rear control panel; 2. Front control panel; 3. Fireclay plate; 4. Turbulence insert; 5. Cap; 6. Ashtray; 7. Water draining branch pipe; 8. Water
supply branch pipe; 9. Stack branch pipe; 10. Return water branch pipe

Flame occurring in the burner rises and heats the fireclay panels (Fig. 3 pos. 3). Hot fireclay bricks improve the combustion
of flammable products. Next, hot air flow moves along the channel down and is slowed down by a turbulent liner (Fig. 3
pos. 4). There, heat is intensely transferred through the walls to the fluid circulating inside the boiler. In the next channel the
cooling air flow rises up the chimney of winning. Ash resulting during combustion and cleaning is delivered to the ashtray
(Fig. 3 pos. 6). The ashtrays size determines the autonomous boiler operation time. The bigger the ashtray, the longer are the
intervals between its cleaning. Cap (Fig. 3 pos. 5) is used to cover the hole for removal of deposits cleaned from the boiler
walls. The supplied “hot” water pipe of the heating system (Fig. 3 pos. 8) is connected to the branch pipe. Return “cold” water
pipe of the heating system (Fig. 3 pos. 10) is connected to the branch pipe. Boiler control elements are mounted on the rear
control panel (Fig. 3 pos. 1).

7
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

3.1 TECHNICAL SPECIFICATIONS

Boiler model Astra P-16 Astra P-25 Astra P-35
Burner model Astra S
Pellet loading conveyor model Astra PA-12
Nominal boiler power, kW 16 25 35
Thermal power adjustment range, kW 5-16 5-25 5-35
Boiler class according to EN 303-5 3
Volume of water in the boiler, l 70 75 82
Boiler weight, kg 265 275 285
Height, H 1108 1206 1323
Dimensions, mm Width (with burner) W (L) 575 (984)
Depth D 734
Water pressure in the system, not exceeding, bar 2
Boiler test pressure, bar 3
Recommended water temperature in the boiler, °C 70-90
Minimum return water temperature in the boiler, °C 60
Recommended chimney In reduced power 12
draft, Pa In nominal power 20
Internal thread of return/supply water
G1½
branch pipe, G
Connection dimensions
Filling branch pipe inner thread, G G1½
Boiler flue outlet diameter, mm 150
Electrical characteristics L1; N; PE; 50 Hz; 230 V
System electric power, W 50 (in the initiation stage 1150)
Boiler electrical safety category IP30
Heated area (If a thermal resistance factor of the building is 2.5), m2 100-180 140-250 240-400
Fuel used Wood pellets 6-8 mm
Pellet class according to EN 14961-2: 2010 ENplus-A1, ENplus-A2 ir ENplus-B
Pellet category according to the manufacturer's classification A, AB, B, BC, C, CD, E, EF
Hourly fuel consumption at rated power, kg/h 4 6 8.5
Efficiency at rated power, % 88-92 88-92 88-92
Smoke temperature at rated power, °C 130 160 185
3.2 BOILER SAFETY SYSTEM;
Security system elements include:
1. The boiler has a manually reset thermostat that measures the boiler water temperature and does not allow the water to
boil. At dangerous water temperature of 95 °C the thermostat terminates the power supply to the boiler.. The thermostat can
be reset to the working position only manually when the water in the boiler has cooled down to a safe temperature.
8
 INSTALLATION AND OPERATION MANUAL

2. The flame sensor (resistive photo resistor), which enables the burner controller to capture existence of the flame in the
combustion chamber.
3. The safety thermostat is mounted on the fuel supply branch pipe of the pellet burner. When the pipe heats up to dangerous
90 ± 3 °C temperature, the thermostat terminates the power supply to the auger pellet conveyor. As the temperature drops
to safe level (73 ± 6 °C), the thermostat automatically connects the loading auger power circuit, allowing to continue pellet
supply to the burner.
4. Astra PA series granular loading conveyor has a flexible hose and a meltable hose connecting the loading auger and the
burner fuel supply pipe to each other. In case of emergency and upon ignition of pellets in the burner fuel supply pipe, the
hose would melt from heat of the flame, thus preventing the spread of fire and reaching the fuel stock in the loading auger
and the bunker.
Our product is produced in accordance with the following directives:
2006/95/EC – Low voltage directive;
2006/42/EEC – Machinery directive;
2004/108/EEC – Electromagnetic compatibility directive;
89/106/EEC – Construction products directive.
The following standards were applied in the manufacturer of Astra S-series pellet burners and P-series pellet boilers:
EN303-5 – Heating boilers.
EN 15270 – Pellet burners for small heating boilers.
EN 60335-1 – Safety of household and similar electrical appliances;
EN 60335-2-102 – Safety particular requirements for fuel burning appliances having electrical connections;
EN 55014-1; EN 55014-2; EN 61000-3-2; EN 61000-3-3 – Electromagnetic compatibility.
4. TRANSPORTATION, STORAGE, UNPACKING
Assembling elements of Astra pellet boiler may be transported only in the original packaging. Boilers can be transported
and stored in vertical position.
Storage should take place in a closed room, which is protected against precipitation at a temperature from -40 °C to + 60
°C. Air humidity in the storage room must not exceed 80%.
If the burner has been transported or stored at freezing temperatures, then, before it is used, it must be kept at room
temperature for at least two hours.
After unpacking, check that all the components are in the packages. Standard equipment consists of the following
components:
Boiler: boiler – 1 pcs.; fireclay bricks – 2 pcs.; rake – 1 pcs.; hook – 1 pcs.; cast-iron ash grate – 1 pcs.; steel grille adapter –
1 pcs.; adjustable feet – 1 pcs.; IEC 60320 C-13 C-14 connection cable – 1 pcs.; installation user manual 1 pcs.
Burner: burner – 1 pcs.; fuel supply branch pipe – 1 pcs.; burner gasket 1 pcs.
Pellet loading conveyor: auger – 1 pcs.; flexible hose – 1 pcs.; clamp 2 pcs.
Check whether the painted surfaces have not been damaged during transportation, the housing was not deformed, and
the control devices are not broken and are in designated locations. If you notice any discrepancies or defects, make claims to
the burner reselling company.

9
 Heat production Heat consumption

Water Heating Domestic Water

accumulation.
Air Outlet Preparation
Programmable Heating
Thermostatic Mixing System Processor
Valve
T TM Hot Water

From Water Supply

T
Domestic Water
Flow Control Recirculation
Valve Air Outlet
TM
M TM

3-Way
Servo Drive

10
Pump Mixing Valve

Fig. 4 Principle scheme of the house heating system including heat

Control Heating System Supply
Heating Boiler Thermostatic
Flow Control Switch
Valve Accumulation Tank
Return
Membrane Overflow
Expansion Vessel
PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

Valve

Automatic Water Heating System Return

Addition Valve
T
T

Laddomat 21
Pump Control Thermostatic Mixing Valve Other Notations:
Min 65°C !
Water Supply T Thermometer TM Thermometer - Manometer Filter Automatic Air
Manometer With Valve Outlet

Pressure Relief Pump Valve Return Valve

Valve
 INSTALLATION AND OPERATION MANUAL

5. INSTALLATION
5.1 INSTALLATION OF THE BOILER ROOM
The installation must be carried out according to regulations valid at place. It is the responsibility of an installer to be
aware of the local applicable laws.
The boiler room should be ventilated. The required air inflow necessary for combustion should be also ensured. For this
purpose, boiler room doors should have ventilation grating or there should be a sufficient gap between the doors and the
floor. If there is no possibility to supply air in from another rooms or the house is very tight, it will be necessary to install an
opening in the exterior wall. The cross-section area of the opening should be at least 0.001 m2/kW.
Place the boiler as close to the flue as possible on a hard concrete levelled basement. Leave at least 600 mm gap between
the backside casing of the boiler and the room wall for boiler servicing and cleaning. The smallest distance between a lateral
casing of the boiler and a building structure is 200 mm. If the building structure is made of flammable materials, this distance
should be doubled. A freely approachable space of at least 800 mm should be then left from the opposite side of the boiler
to ensure access to the backside of the boiler, for its servicing and cleaning. The floor under the boiler, within the distance
of 50 cm in front of it and within the distance of 30 cm around the boiler should be made of inflammable materials. Screw
supporting legs onto the base of the boiler and level the boiler with screw nuts using a level; then connect the heating system
circulation pump to the boiler.
The smoke exhaust pipe of the boiler should be connected to the chimney through a metal duct. The internal diameter of
the metal connecting duct should be at least the same as the external diameter of the smoke exhaust pipe of the boiler. To
improve the draught, the connecting duct between the boiler and the chimney should be installed at an inclination towards
the boiler. All junctions should be carefully tightened using a heat-resistant material and insulated using thermal insulation.
If an additional damper is installed between the boiler and the chimney for the draught control purpose, the damper
should not close more than 2/3 of the cross-section area of the opening in its fully closed position.

5.2 BOILER PROTECTION AGAINST CORROSION

Fig. 4 shows the principal scheme of the boiler house. In order to protect the boiler from corrosion, it is necessary to use a
thermoregulatory valve which helps to make the small and the big heat circles and ensures the return water temperature to
the boiler no lower than 65 °C. The higher the return water temperature to the boiler, the lower the possibility of condensation,
resins and acids, are harmful to the body of the boiler. Outgoing water temperature should not exceed 90 °C. Smoke temperature
must not fall below 110 °C, when the boiler is in
working mode. Condensation, resin and acids
occur at low gas temperature, even if the boiler
operating temperature (not exceeding 90 °C)
and the return water temperature (65 °C) are
maintained. For example, improperly adjusted
pellet burner (operating at reduced capacity).
We recommend using the Laddomat 21 unit.
It consists of a cast iron body, thermoregulatory
valve, pump, non-return valve, ball valve and
thermometer. When the water temperature in
the boiler is above the condensation temperature
(min. 65 °C), the thermoregulatory valve will
open the water supply from the big circle. Fig. 5 Positioning of a chimney in respect to vicinity objects
11
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

5.3 REQUIREMENTS FOR THE CHIMNEY

It is recommended to insert acid-resistant stainless steel liner, if the chimney is made from masonry. It improves draught
of the chimney and protects the masonry from destruction due to the impact of condensate. Internal diameter of the liner
should be no less than the external diameter of the smoke exhaust pipe of the boiler. The chimney liner can be round or
oval. It is not recommended to use rectangular-shaped liner as, due to the temperature fluctuations, its walls deform, gaps
appear at the element junction points, through which the condensate falls on the walls of the bricks chimney. Additional air
is sucked in, which reduces draught of the chimney. Draught for each boiler model should correspond to the referred value of
draught in the table “Technical data”. The liner should be factory made. Minimum permissible height of the chimney should
be at least 6 m. The top of the chimney should be above the ridge at least by 0.5 m. If the chimney is further from the ridge
than 1m, the angle horizon- the ridge- the cap of the chimney should consist 10° or less degree. Draught of the chimney
can also be negatively affected by various obstructions near the building: trees, hills, other buildings. Fig. 5 presents the
recommended minimal angles between the chimney, nearby objects and the horizon. Angles larger than those indicated will
cause reduction of draught of the chimney.
The connection of other devices to the chimney to which the boiler is connected is prohibited. The chimney should be
cleaned at least once a year!

5.4 PELLET BOILER ELEMENTS

2 15 16 17

5
6

8 9 10 11 12 13 14
Fig. 6. Pellet boiler elements
1 – Upper casing; 2 – Smoke channel cover; 3 – Hood of combustion chamber; 4 – Combustion chamber door; 5 – Ash chamber door; 6 –
Ashtray; 7 – Door casing; 8 – Door handle; 9 – Gasket; 10 – Decorative plate; 11 – Burner gasket; 12 – Burner; 13 – Flexible hose; 14 – Clamp;
15 – Flue hood; 16 – Pellet loading conveyor; 17 – Pellet hopper.
12
 INSTALLATION AND OPERATION MANUAL

Fig. 7. Preparation of the burner for assembly. Fig. 8. Burner installation in the boiler.
5.5 BURNER INSTALLATION IN THE BOILER
Use the key with hexagon H3 tip to unscrew the two screws (one on the left side of the burner, and the other on the right),
which support the burner enclosure (Fig. 7). Open the enclosure by tilting it back – the remaining two screws in front of the
burner are used as the pivot axes.
Put the following an the boiler flange in sequence: gasket (Fig. 6 pos. 9),
decorative cap (Fig. 6 pos. 10), burner gasket (Fig. 6, pos. 11) and the burner
(Fig. 6 pos. 12). Tighten the four M10 nuts on the boiler flange studs (Fig. 8).
Astra P series pellet boilers are equipped with water temperature sensors
(NTC). The sensor cable end is routed through the hole in rear control panel and
tied with a zip strap (Fig. 12. NTC). Connect the cable ends to the terminals of
the burner controller (22 and 23).
Close the burner cover and tighten the two bolts of the cover you have opened Fig. 9. Pellet supply pipe attachment to the
earlier. frame and connection of the thermostat cable
5.6 CONNECTION OF THE LORDING AUGER AND PELLET SUPPLY PIPE
• Installation of fuel supply branch pipe
Place the pellet feed branch pipe on top of the burner frame – the dark green painted surface with one large and three
small holes. Based on the selected place for future installation of the pellet hopper, turn the pellet supply pipe in a direction
so that the end of the pipe directed upwards is facing directly the pellet hopper. Secure the pellet supply pipe in this position
by tightening the three screws through the pipe flange to the burner frame, to the three small holes specially prepared for the
screws. Use a screwdriver, with PH2 type dip, for tightening the screws. Connect
the cable to the thermostat terminals (Fig. 9).
• Connection of the burner electrical part with the boiler
Use the IEC 60320 C-13 and C14 cable in the set to connect the boiler electrical
socket S1 (Figure 11). with the burner Power socket (Fig. 10).
• Connection of the loading auger
Insert Astra pellet loading conveyor PA-12 in the pellet hopper (Fig. 6 pos.
17) through the special branch pipe. The lower end of the pipe must lie on the Fig. 10. Boiler power cable connection to the
bottom of the pellet hopper. For convenience of installation and maintenance, burner Power socket.
the pellet loading container can be tied to the boiler room ceiling using the loop
on the unit. One end of the flexible hose place onto (Fig. 6 pos. 13) the branch pipe of the pellet loading conveyor, and the
other – on the burner fuel supply pipe. Tighten the two clips (Fig. 6 pos. 14). The use of flexible hose use is mandatory – it
is a safety element. If the pellets ignite in the pellet supply pipe, the hose will melt and break the connection between the
source of fire and the pellet container. The flexible hose must be mounted straight (there must be no visible hose play – dust
and fine granular particles can accumulate in the hose grooves because of the play).

13
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

Fig. 11. Electric mounting scheme of the pellet burner

B1 – Heating element; M1 – Actuator; M2 – Air fan; M2 SC – Air fan hall sensor; FT1 – Flame sensor (resistive photosensor); LCD – User
interface; S1 – Burner power cable; S2 – Boiler connection jack; T1 – water temperature sensor NTC); T2 – Smoke temperature sensor
(thermocouple); T3 – Overheating thermostat of the pellet supply pipe.

14
 INSTALLATION AND OPERATION MANUAL

S2

6
S2:PE

SK1

4
SK:PE

NTC

4
3
J1

FU

5
1

6
S1

FU:3

FU:2
1

S1:PE
5

Fig.12. Electrical mounting scheme of Astra P series pellet boiler

S1 – Burner connection jack; S2 – Power socket of the pellet loading auger; SK1 – STB safety thermostat; NTC – water sensor connection cable;
J1 – switch; FU – fuse.

• Connection of the electrical part of the charging auger to the boiler

The power cable the pellet loading auger is plugged into the power outlet S2 in the boiler (Fig. 12).
The pellet loading auger is operated with the pellet burner controller. It is prohibited to connect he tloading auger
directly to the mains.

5.7 ELECTRIC WIRING

The burner may have a lot of additional options such as wireless communication module, fuel level sensor, external room
thermostat, additional loading auger, additional fan, smoke temperature sensor. When you install a new component, you may
need to change the burner controller settings. The setup-up operations may be carried out only by an authorized technician
• Connection of the Circulation Pump
In order to insure a continuous flow of water, a circulation pump is to be installed in the system, on the return water pipe
behind the mixing valve. The electronic controller of the boiler controls the pump. The circulation pump is connected to the
terminals of the burner controller (O05 and GND).

15
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

• Electrical wiring diagram

Fig. 11 presents the electric mounting scheme of the Astra S series pellet burner. Figure 12. presents the Astra series P pellet
boiler rear control unit and the electrical mounting scheme.
5.8 CONNECTION OF THE WIRELESS WI-FI COMMUNICATION MODULE
Wi-Fi module Fumis WiRCu (Fig. 14) – is an additional module extending the
burner control functions which is connected to the pellet burner controller that
allows users to control the Astra pellet burner remotely from anywhere in the
world. This Wi-Fi module, using your home Wi-Fi network, enables to connect to
your burner using a smart phone or tablet with Android or iOS operating system.
• WiRCu module mounting
Attach the WiRCu (Fig. 14) in a convenient location, within the distance of the
supplied data cable from the pellet burner. Next to it, install and electric outlet
for connection of the WiRCu power block. Connect one end of the cable into the Fig. 13. Rubber gasket at the bottom of the
data jack (Fig. 14 pos. 1), and the second – in the socket of the burner controller. burner for WiRCu signal cable installation to the
inside of the burner.
Use the key with hexagon H3 tip to unscrew the two screws (one on the left
side of the burner, and the other on the right), which support the burner enclosure (Fig. 7). Open the enclosure by tilting it
back – the remaining two screws in front of the burner are used as the pivot axes. If the pellet loading tube prevents the
enclosure from opening, release its screws and turn in the right direction.
Lead the DATA cable into the inside of the burner through the rubber seal (Fig. 13). WiRCu module includes the power cord
with a USB converter. Connect the USB connector plug into the USB port located on the left side of the WiRCu module.
For further instructions and steps, please carefully read and follow the WiRCu module user's manual, which is available
with the WiRCu module
Do not attach and do not connect cables on the actuator – the body may move slightly during operation, and this
movement may terminate the cables. 1 2 3 4 5

• Connection of the WiRCu module to the Wi-Fi network

1. Download Fumis App to your mobile device from
Google's app store (Android) or the Mac App Store (iOS) and
install it.
2. Connect the power supply for the WiRCu.

3. Start the Fumis application on your mobile device.

4. Confirm the license agreement.
5. After the approval of the program will ask whether your
WiRCu device is connected to the Wi-Fi network ("Have you
6 7
already connected the heating device to your WiFi?).
6. Select “No”. 14 Pav. Fumis WiRCu modulis: 1 – data socket; 2- “Conti” light; 3
7. The program asks you to enter your Wi-Fi network - “Status” light; 4 - Wi-Fi indicator; 5 - “Setup WiFi reset” button; 6 -
password ("Enter your wifi password"). Enter the password. module MAC address; 7 - module PIN code
8. In the WiRCu module, press the “SETUP WIFI reset” button. A lamp in the WiFi module (Fig. 14 pos. 3) will start blinking
faster.
16
 INSTALLATION AND OPERATION MANUAL

9. While the WiFi light is flashing, on your mobile device, press the button “Start the WiFi setup”. The WiRCu module will
connect to your WiFi network, when the light WiFi is on without flashing (Fig. 14 pos. 3), and the lamp Status (Fig. 14 pos. 2)
will start flashing.
10. In the mobile device, press the button “Stop WiFi setup”, press the button “Back”.
11. The program asks you to enter the MAC address of the WiRCu module (Fig. 14 pos. 5) and the PIN code (Fig. 14 pos. 6).
12. Now click the button Connect and the program will connect to WiRCu module.
6. FUEL
Use 6-8 mm diameter high quality pellets to fuel the burner. When purchasing pellets, make sure that they comply with
one of standards listed below and that their packing is marked correspondingly:
• EN 14961-2, class A1;
• ENplus-A1;
• DinPlus;
Wood pellets of lower quality could also be used as fuel but the burner’s operation in that case could become unstable
because of the fuel quality. Do not use non-wood pellets for fuelling the burner.
The pellets must be transported and stored in a dry place. They swell up after contact with moisture and become unsuitable
for firing. The pellets must always be protected against humidity both during transportation and storage.
Parameters of pellets according to the EN14961 standard, class A1
Length More than 3, max 15-40 mm
D06 6 +/-1 mm
Diameter
D08 8 +/-1 mm
Weight BD600 > 600 kg/m3
Calorific value Q4.6 > 4.6 kWh/kg
Residual humidity M10 < 10 %
Ashes content A0.7 < 0.7 %
Fines content F1.0 <1%

7. CONTROLLER MENU
7.1 DISPLAY
The Astra burner controller consists of two parts: a display and a control board mounted on a frame of the burner. The
display operates by principle of capacitive touchscreen. Pushing buttons on it requires good contact with the fingertip rather
than force. Therefore, the display will not react if gloves are worn while attempting to use the controller.
Button Description
This button is used to start and stop the combustion process in the burner. The process is launched or
stopped by pressing the button and holding it for 1 second.
Menu buttons are intended to navigate horizontally the controller menu (look at the menu structure tree
presented below). The chosen section of the menu is indicated in the upper line of indicators on the display.

17
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

Edit buttons are used for two purposes: vertical navigation (look at the menu tree) and increasing/
decreasing parameter values in the edit mode, when the selected value blinks.
Enter button is used for entering the edit mode, confirming the set parameter values or entering the
lower menu levels.
Cancellation button is used for discarding the made changes and returning up one level in the menu. If
you press and hold this button for more than 3 seconds, the last error or alert code will be displayed.
3 4 5 6 7 8 9 10 11 12 13
Fig. 15 Display and the remote control unit.
1.Start/stop
1 button and its indicator; 2. Cancel/return button; 3. No fuel indicator; 4.
2
Cleaning required indicator; 5. Servicing required indicator; 6. IR sensor; 7. Weekly
14 timer indicator; 8. Burning power menu indicator; 9. Room ventilator speed menu
18
indicator; 10. Temperature menu19 indicator; 11. Fuel quality menu indicator; 12.
15 Time menu indicator; 13. Setup menu indicator; 14. Edit buttons; 15. Enter button;

16. Menu buttons; 17. Screen; 18. Burning power +/- buttons; 19. Temperature
+/- buttons.
1 17 16

The infrared remote control is intended for day-to-day use when the combustion system is fully configured and operational.
It is used for changing the burning power and temperature settings, turning the combustion in the burner on and off.
In the upper part of the display, there is a line of indicators signalling various modes and alerts of the controller. The IR
sensor in that line is used for communication with the remote control unit.
The screen displays the set or current values for the currently selected menu option. Buttons help to navigate through the
menu and control different functions of the burner controller. The intended use of the buttons is described in the table above.
The display has an integrated beeper. The beeper generates feedback signals, when the display buttons are being pressed.
The following sound signals are available:
• Short high tone: sounds when navigating the menu and editing the settings.
• Long low tone: sounds in case of an invalid operation (wrong button pressed).
• Long high tone: in case of an alert, this tone sounds with the user-defined volume; in case of an error, this tone sounds at 100% volume; for
description of alerts and errors, refer to the chapter “Troubleshooting”.
7.2 NAVIGATING THE MENU
In order to navigate the menu horizontally, in the same level, use the menu buttons . When choosing a menu
option, an icon in the indicator line of the display lights up. At the same time, the screen indicates either the value of the
chosen menu parameter, or, in the case the chosen menu section has a sublevel (for example, Time menu), the value of the
first subsection parameter.
In order to navigate the menu vertically, use the menu buttons . When navigating the lower sublevel of the menu,
a number of a particular menu subsection briefly lights up. For example, the Time menu section has a lower level menu
consisting of four subsections. Each time you skip to the next subsection the number from 1 to 4 lights in the screen.
To modify a setting in the menu, press button to enter the edit mode for the selected setting. The screen value starts
blinking. Use buttons to change the value. To move through the steps in the edit mode, use . buttons. When
finished, press button to save the setting and exit the edit mode. The display returns to the menu entry you have just
edited.
The screen of the display shows the set value or the actual measured value, depending on the setting. For example, when
you edit the temperature, you enter the desired room temperature. After you exit the edit mode, the screen indicates the
actual measured temperature which may differ from the set temperature. When you edit, for example, the burning power
18
 INSTALLATION AND OPERATION MANUAL

setting, the screen indicates the set value.

7.2 NAVIGATING THE MENU
In order to navigate the menu horizontally, in the same level, use the menu buttons . When choosing a menu
option, an icon in the indicator line of the display lights up. At the same time, the screen indicates either the value of the
chosen menu parameter, or, in the case the chosen menu section has a sublevel (for example, Time menu), the value of the
first subsection parameter.
In order to navigate the menu vertically, use the menu buttons . When navigating the lower sublevel of the menu,
a number of a particular menu subsection briefly lights up. For example, the Time menu section has a lower level menu
consisting of four subsections. Each time you skip to the next subsection the number from 1 to 4 lights in the screen.
To modify a setting in the menu, press button to enter the edit mode for the selected setting. The screen value starts
blinking. Use buttons to change the value. To move through the steps in the edit mode, use . buttons. When
finished, press button to save the setting and exit the edit mode. The display returns to the menu entry you have just
edited.
The screen of the display shows the set value or the actual measured value, depending on the setting. For example, when
you edit the temperature, you enter the desired room temperature. After you exit the edit mode, the screen indicates the
actual measured temperature which may differ from the set temperature. When you edit, for example, the burning power
setting, the screen indicates the set value.
To exit the edit mode without saving the changes, press button. This button is also used for returning up one level
in the menu. For example, if you are editing the Program 3 in the Weekly Timer Periods menu subsection, press the Cancel
button to discard the changes and return to Program 3. Pressing the Cancel button further moves you to Weekly Timer
Periods, then - to the Clock menu section.
Power Temperature Fuel Time Setup

Burning power Water Fuel quality Clock Key lock

temperature °C pellets Time/Date

Idle display
Burning power Anti freeze brightness
in (kW) mode Weekly timer
days

Idle display
Weekly timer mode
ON/OFF

Monday

Beeper volume
Weekly timer
Tuesday periods

Wednesday
Temperature unit

Thursday
Program 1
Celsius
Friday FW version
Program 2
Fahrenheit
Saturday

Program 3 Manual feed

Sunday

Program 4
3. Program 2. Program 1. Program Service menu

Start time End time Temperature

Fig. 16 Menu structure

19
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

7.3 MENU STRUCTURE

The menu structure tree (Fig. 16) exhibits all consisting menu entries. The values of parameters are chosen for purpose of
illustration only. The buttons used to reach a particular menu entry are depicted near it.

7.4 SETTING THE CLOCK

The controller enables you to set the current time, date and weekly timer programs. These settings do not disappear even after
power supply failure because the controller has a long-lasting battery. To look up at the current time, press button to enter
the Time menu section. The current time is indicated on the screen . To turn to the other Time menu subsections, use
buttons. The numerical value from 1 to 4 will shortly light up in the screen, when passing each subsection.

Clock and date setting mode. Press button and change the desired values.

With buttons set the desired hour.

With buttons set the minutes value. Press .
Press .
With buttons set the desired day.
With buttons set the month value. Press .
Press .

With buttons set the year value. Press .

7.5 SETTING THE WEEKLY TIMER PROGRAMS

Weekly timer activation. Press button and enter the edit mode. With buttons choose the desired value.

Weekly timer is switched off.

Weekly timer is switched on. The icon in the indicator line lights permanently.
The first step in weekly timer programming is to describe the time intervals- programs. The description consists of specifying
the interval start time, the end time and the desired temperature. Then, the desired programs are assigned to each day of a
week. The controller permits you to create up to 6 different timer programs and to assign a maximum of 3 of them to each
day of the week. The programs with start time in one day and end time in the next day are also allowed. When the weekly
timer is active, the icon in the indicator line lights permanently.
Creating and editing the weekly timer programs. Press button and enter the first program edit mode. Use buttons
to skip to another programs for editing.
First program. Press button and enter the desired values.

With buttons set the start time value. Press .

With buttons set the end time value. Press .

With buttons set the desired temperature of the program. Press for confirmation.

Second program. Press button and enter the desired values.

With buttons set the start time value. Press .

With buttons set the end time value. Press .

20
 INSTALLATION AND OPERATION MANUAL

With buttons set the desired temperature of the program. Press for confirmation.

(the third, fourth, fifth programs are skipped for the purpose of illustration)

Sixth program. Press button and enter the desired values.

With buttons set the start time value. Press .

With buttons set the end time value. Press .

With buttons set the desired temperature of the program. Press for confirmation.

Assigning programs to week days. This is performed after the programs have been created (see above). Press button and
enter the Monday edit mode. With buttons skip to another week days for editing.
Monday. 3 different programs can be assigned to each day of a week. Press button and enter
the desired values. If only 2 programs are planned for a particular day, choose option OFF for one
of the entries.
With buttons set the desired program number. Press .

With buttons set the desired program number. Press .

With buttons set the desired program number. Press for confirmation.

Tuesday. 3 different programs can be assigned to each day of a week. Press button and enter
the desired values. If only 2 programs are planned for a particular day, choose option OFF for one
of the entries.
With buttons set the desired program number. Press .

With buttons set the desired program number. Press .

With buttons set the desired program number. Press for confirmation.
(Wednesday, Thursday, Friday, Saturday are skipped for the purpose of illustration)
Sunday. 3 different programs can be assigned to each day of a week. Press button and enter
the desired values. If only 2 programs are planned for a particular day, choose option OFF for one
of the entries.
With buttons set the desired program number. Press .

With buttons set the desired program number. Press .

With buttons set the desired program number. Press for confirmation.
If two programs with overlapping operation time are assigned to the same day of the week, the controller, during
the overlap period, performs the program with higher title number. For example, program P6 will have priority
against P3.
An example of created programs is presented in the table below:

21
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

P1 Program P2 Program P3 Program P4 Program P5 Program P6 Program

On Off On Off On Off On Off On Off On Off
23:00 4:30 4:30 7:30 17:00 23:00 00:00 7:30 7:30 24:00 7:30 23:00
70°C 65°C 60°C 65°C 70°C 60°C
The above mentioned programs are displayed in the time intervals diagram:
Day/Time 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
(d1) Monday [P1] 70°C [P2] 65°C [P3] 60°C
(d2) Tuesday [P1] 70°C [P2] 65°C [P3] 60°C
(d3) Wednesday [P1] 70°C [P2] 65°C [P3] 60°C
(d4)Thursday [P1] 70°C [P2] 65°C [P3] 60°C
(d5) Friday [P1] 70°C [P2] 65°C [P3] 60°C
(d6) Saturday [P4] 65°C [P5]70°C
(d7) Sunday [P4] 65°C [P6] 60°C

7.6 SETTING THE WATER TEMPERATURE

The burner is capable of sustaining the desired boiler water temperature. It has a NTC temperature sensor for that purpose.
The sensor must be placed in a special immersion pocket of your boiler, or fixed on an outside surface of the flow water
pipe if the pocket doesn’t exist. The burner reacts to indications of the sensor and increases the heating power after the
water temperature has decreased below the set temperature level. When the water temperature nears or overshoots the
temperature which is set as preferred in the controller, the burner decreases the heating power or even stops.
There are two ways to set the desired water temperature:
• use weekly timer programs;
• set the water temperature manually.
When using weekly timer, you describe time intervals for each day of a week and assign the desired water temperatures to
them. For more information about time programing, see the previous chapter “Setting the Weekly Timer Programs”.
It is also possible to set the desired water temperature manually. If a weekly timer program is active at the same time, the
manually set water temperature temporary gains priority. This priority disappears when the current weekly timer program
ends. When the next time program starts, the water temperature again is controlled by the weekly timer.
To view a current water temperature, press button to enter the Temperature menu section. The actual measured
water temperature value is indicated on the screen.
To set the desired room temperature, press . button. The screen indicates the target temperature in the blinking mode.
Increase or decrease this value with buttons.
When finished, press button for confirmation. The actual measured room temperature is indicated on the screen again.
Actual measured water temperature.

Anti-freeze mode. Lets you to select a minimal necessary water temperature that has to be maintained. Burner will
automatically start the burning process to keep the water temperature above the selected necessary temperature. Antifreeze
mode is functional only when the weekly timer is set to ON. It is possible to set minimal necessary water temperature in
range of 3 – 50 ºC
OFF means that Anti-freeze mode funcionality is OFF. Burner will not preserve the water from freezing.
Minimal necessary water temperature is 3ºC
... ...
Minimal necessary water temperature is 50ºC

22
 INSTALLATION AND OPERATION MANUAL

7.7 THERMAL POWER SETTING

To view the current heating power, keep pressing the Menu button until you reach the Power section menu.
There are six manual power setting levels. When changing the transport auger and the exhauster fan speed, the controller
changes the air quantity required for pellets and combustion. If the target room temperature is set, the burner automatically
chooses the optimal power level. You can intervene in this process and set, for example, higher power, if you want the room
temperature to be reached quicker. To save fuel, you can reduce the power level. In any case, when the room temperature
reaches the set temperature, the burner will reduce the thermal power to save fuel. Press the button and change the
necessary data. Select the desired value using the buttons .
First level.
Second level.
Third level.
Fourth level
If the target room temperature is set, the burner automatically chooses the optimum power level. The text “auto” is lit on
the display.
If you need to quickly warm the cold room, set the highest power level

You can see the current status of the burner in the status display window:

The burner is off

The burner is in the initiation stage (rising column)
The burner is in the extinction stage (descending column)
The burner is in the combustion stage. Shows instantaneous
power, kW

7.8 SETTING THE FUEL OPTIONS

The Fuel menu section enables you to select the fuel quality. The quality of pellets are expressed in the following values:
. These values stand for the moisture content in pellets. By selecting one of these three fuel
options, you can adjust combustion air amount. Fuel option is the default and most strongly recommended to use.
– factory combustion air rate;
– 5% less air for combustion;
.– 5% more air for combustion.

7.9 MODIFYING THE SETUP OPTIONS

The Setup menu section enables you to set the options for Key lock, Idle display brightness, Idle display mode, Beeper
volume and view service information.
The Key lock option enables you to lock the keyboard on the display in order to prevent accidental changes of the settings.
With the key lock enabled, you can navigate the menu to display current values, but you cannot edit any of the settings,
except the Key lock itself. Note that this option does not disable the remote control. The Key lock setting offers the following
options:

23
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

The Key lock is disabled, all buttons are operational.

The edit mode is disabled. The Enter button is locked.
The edit and the power on/off modes are disabled. The Enter button and the Power button are locked.
We recommend using the Key lock option, when cleaning the display.

The display brightness in the idle mode can be set from 1 to 5 or set to turn off after 30 seconds.

The display switches off after 30 seconds. The lighting is restored after pressing any button.
Brightness of the display is 1.
... ...
Brightness of the display is 5.

The Idle display mode has the following options:

The display stays in the last selected menu section. In case the menu has been in the edit mode, the changes are discarded
and the edit mode is exited.
The display exits the last selected menu section and cycles between a current water temperature and a clock.
<->
The display exits the last selected menu section and moves to the Temperature menu. The actual measured room temperature
is displayed on the screen.
The display exits the last selected menu section and moves to the Time menu. The current time is indicated on the screen.

Beeper volume setting enables the user to change the volume of the display signals from 1 to 5 or switch the beeper off.

The beeper is off.

The sound level is 1.
The sound level is 2.
... ...
The sound level is 5.

Temperature measurement units.

Celsius.
Fahrenheit.

The controller information menu subsection. Used for service purposes.

After pressing the button you can see firmware version of the display or the controller main board.
Screw feeder control menu. The screw feeder ON/OFF function is used to fill the feeder with pellets when the pellet hopper
becomes empty after some time of the burner operation. It is also used during the first run or after maintenance if the feeder
is completely empty. When the screw feeder is turned ON, the empty tube of the feeder gets stuffed with pellets.

24
 INSTALLATION AND OPERATION MANUAL

Press the button and hold it while the screw feeder motor operates and fills the feeder tube with pellets. Release the
button to stop the feeder’s gear motor. When the gear motor is turned ON, running lines are indicated on the screen.

The service menu subsection. Access for the authorized service personnel only.

The key symbol is indicated on the screen.

To modify the setup options, press button to enter the Setup menu section. The set idle display brightness value
is displayed. To move between the setup options, press buttons to display the settings. To change a setting, press
button and use buttons to increase/decrease the selected values. When finished, press button to confirm the set
value.
8. OPERATION
The Astra pellet burner uses the Fumis ALPHA controller which takes care of all the burning control processes. The ALPHA
controller features a battery powered internal clock, serial communication with PC and Fumis ALPHA keyboard and 16-bit
microcontroller. All sensors and other accessible connectors are doubly insulated. The Fumis ALPHA controller complies with
high safety standards.
• Screw feeder operation
The Astra burner controller can support up to two feeders. The primary screw feeder is used for loading the wood pellet
type fuel into the burning chamber of the burner. The screw feeder operates in an ON/OFF mode. The ratio between the ON
and the OFF times defines the amount of pellets supplied to the burning chamber. The operation of the feeder is defined with
the pertaining parameters and is configured specifically for each burning phase or sequence.
In addition to the primary screw feeder, the second screw feeder unit can be connected. When the pellet level sensor is
used, the second feeder serves as a supplement fuel feeder for filling up an operation pellet hopper from the main pellet
storage.
• Combustion fan operation
The Astra burner combustion system regulates the combustion fan speed based on the motor’s Hall sensor feedback.
The burner controller compensates for all variations in voltage and tolerances of the motor but cannot compensate for the
chimney quality and air pressure. Speed of the motor can vary in a range of 0-2900 rpm.
• Phases of operation
The Astra burner controller defines the following main operation phases of the combustion system:
• Fire Up phase
• Burning phase
• Cleaning phase
• Fire Down phase
• OFF
Each phase is divided further into sequences which can vary depending on configuration.
8.1 FIRE UP PHASE
In this phase, the burner combustion system is turned on. It starts operating and ignites the fuel in the burning chamber.
To start the burner, press and hold the power button for 3 seconds – the green LED indicator near the power button will start
blinking, meaning that the burner is turned on and starting.
25
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

FIRE UP phase is divided into the following sequences:

TEST FIRE. In this sequence, the controller performs a test using a flame sensor to determine if a flame is present in the
burning chamber of the burner. If the flame is detected, the controller goes straight to the next BURNING phase. If there is no
flame in the burning chamber, the controller goes on to the next part of the queue - the HEAT UP sequence.
HEAT UP. In this sequence, a heating element (igniter) warms up and fuel is intensively loaded into the burning chamber. A
fan works at low speed. Duration of the sequence is 120 seconds.
FUEL IGNITION. In this sequence, the heating element heats the fuel which starts glowing and emitting gases; the flame
develops after a while. The sequence is not defined by a specific period - it will continue until the flame sensor reports that
the flame has appeared. Then, the IGNITION TEST sequence starts. However, there is a maximum time limit of 20 minutes set
to pass the sequence. If the designated time has elapsed and the flame has not appeared, the burner stops and the alarm
“Burning chamber or chimney dirty” is shown – the LED indicator with the broom symbol starts blinking.
IGNITION TEST. This sequence is executed when the flame sensor reports the presence of the flame. In this sequence, the
controller starts the combustion fan with a set speed. At the end of the phase, it checks if the flue gases temperature has risen
by more than 3°C per minute or if the flame sensor still reports the flame signal. If so, the BURNING phase starts, if not, the
ignition test is repeated until time-out. The set time-out limit for this phase is 5 minutes. If the limit is reached, the controller
reports the ALARM FIRE error.
8.2 BURNING PHASE
After successful FIRE UP, the BURNING phase starts. Burning power level can be set manually by choosing between levels
from 1to 5 (setting 5 is AUTO) and Hi. When the AUTO mode is chosen, the burner operates at maximum power till it reaches
the set desired water temperature. Then, power of burning is further regulated automatically and modulates to maintain the
selected water temperature. Modulation of the burner is very smooth – there are 1024 steps between the 1 and the Hi power
levels.
8.3 CLEANING PHASE
During the BURNING phase, the controller interferes into it to make a planned cleaning. Cleaning is done after every 25
minutes of screw feeder total OFF time (the controller calculates the durations of screw feeder pauses and sums them up,
until the sum is equal to 25 minutes).
The first five cleanings are blow-type. The screw feeder stops feeding pellets and the combustion fan starts working at
a high speed for 30 seconds. A strong stream of air blows away the ashes incremented in the combustion chamber of the
burner. Having performed the cleaning stage, the burner returns to a usual burning operation.
After succession of five blow-type cleanings, the sixth cleaning done is a mechanical one. The screw feeder stops feeding
pellets and the combustion fan blows air at a high speed. When the flame sensor reports that the fire is gone, the controller
turns on an actuator. A shaft of the actuator moves the drawer of the burning chamber forwards, and then backwards, thus
dumping all the burned content from the chamber. After the mechanical cleaning phase, the burner restarts, ignites pellets
and continues burning process as it has been before. Calculation of the cleaning cycles also restarts from 0.
8.4 FIRE DOWN PHASE
In this phase, the burner combustion system is turned off and the burning chamber starts cooling down. The burner can
be turned off manually (at the control panel by pressing the power button for 3 seconds) or by an external power signal:
by a weekly timer, by a thermostat or by an Android gadget using the WiRCu unit. The feeder stops loading the fuel into
the burning chamber and the combustion fan cools down the burning chamber. There are two sequences in the FIRE DOWN
phase:

26
 INSTALLATION AND OPERATION MANUAL

Stop Fire. Active until the flame sensor gives the No Flame signal. After the Stop Fire has been executed, the combustion fan
accelerates to full speed for a set period of time in order to clean the burning chamber.
Cool Fluid. When the temperature of water at the minimum burning power rises above the set upper threshold (factory set
default value = set water temperature + 5ºC), the combustion system turns off. It restarts automatically when the air/water
temperature falls below the set threshold.
8.5 OFF PHASE
The burner combustion system has cooled down and the fan is turned off. The combustion system is in the standby mode
and can be turned on manually, by a weekly timer, by a thermostat, or by an Android device using the WiRCu unit.
9. ADJUSTMENT
Before the first start of the burner, please make sure that:
• installation has been carried out properly;
• the angle of the screw feeder is 45° from the horizontal plane;
• all control units have been properly adjusted;
• the boiler is in proper functioning order;
• there exists a sufficient air supply for combustion in a boiler room;
• the screw feeder is not empty and wood pellets are being fed to the burner properly;
• the flue has a draught limiter, is fully intact and of right dimensions.
• Values of the combustion parameters
Factory settings of the burner are not instant operational settings. They should be adjusted by using a flue gas analysis
instrument in every single instance. Correct adjustments are important in order to ensure fuel burning efficiency, a high level
of energy efficiency, low emission of substances that may harm an environment, and also for the longevity of the burner
parts which come into direct contact with the flame. Optimal adjustments can only be achieved by using flue gas analysis
instruments.
The values presented below are recommended for optimal combustion of the burner. Note that these values vary during
the combustion stages:
• Flue gas temperature: 130–160 °C
• Efficiency level: >80 %
• CO content: <300 ppm
• Set boiler water temperature: 75–80 °C
• CO2 content, substance: 12.5 % (depending on the type of flue, it can vary by ±2.5%)
9.1 FILLING THE SCREW FEEDER WITH PELLETS
For successful start-up, the screw feeder must be filled with pellets. There are two possible ways to do it:
a. Use the special controller option called “Screw feeder control menu”. The instructions on how to use this option can be
found in this user manual’s section 7.9 “Modifying the setup options”.
b. Connect the screw feeder directly to the power supply. Just connect the screw feeder power supply cable to the same
socket that is used for the Astra pellet burner power supply and is located on your boiler. Keep in mind that the boiler power
supply must be turned ON.
Using any of these two options, fill the screw feeder until the first pellets begin to drop into the burning chamber of the
burner.

27
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

Do not place your hands or objects inside the screw feeder because of risk of injury!

9.2 INDICATORS OF CORRECT COMBUSTION

• Flue gas temperature
While operating at rated output, the temperature in the flue gas pipe of the boiler should be 160-200 °C. Higher temperatures
can be resulted by soot blockage in the boiler, or by excessive combustion air supply. Too high flue gas temperatures cause
poor efficiency levels and unnecessary high pellet consumption.
An older boiler often has higher flue gas temperatures than a modern type boiler in the same conditions.
A low flue gas temperature may be due to poor combustion because of a lack of combustion air, or that the burner is used
in over-sized boiler, especially when running at low power output settings. In this case there is a risk of condensation in the
flue with frost damage as a result.
• The flue
In order to avoid damage to the flue, flue gas temperatures must be checked on every occasion. During combustion process,
water builds up in the form of water droplets. These droplets follow the flue-gases out of the flue, and depending on the drop
in temperature, the droplets can condense into water, which can then cause damage to the flue.
Condensation damage can be avoided if flue gas temperatures are no lower than 70 °C at one metre from the top of the
flue. Even though low flue gas temperatures give a higher efficiency level, this merit has to be weighed against the high risk
of condensation.
The measures to take for raising the flue gas temperatures are these:
• remove any agitators or baffle plates in the boiler;
• mount a contraflow hatch;
• isolate the flue in a cold environment;
• increase the burner's power output level;
• mount an insert pipe.
• Contraflow hatch
All pellet burning equipment should have a contraflow hatch. For flues higher than 5 meters, or with a very high and/or
variable draught, this hatch is a statutory requirement. Draught is affected by temperature, weather and wind. Given the fact
that combustion results are affected by draught, stable draught conditions are very much preferred.
The simplest way to stabilise draught conditions is to mount a contraflow hatch on the waste gas flue. In this case, the air
from the burner combustion chamber slips into the waste gas flue via the hatch. The advantages of having the contraflow
hatch are:
• more stable draught and flue gas temperature;
• reduced losses when in the OFF mode;
• ventilation of the waste gas flue;
• drier flue-gases, which reduces the risk of condensation.
• Agitators
Certain boiler types have, or can be equipped with, flue gas agitators. Their job is to agitate the flue-gases in order to obtain
more heat and thereby raise efficiency levels. With a low burner heating output, the flue gas temperature is low and there
is a risk of condensation build up in the flue. Try to shorten the agitations somewhat until a suitable flue gas temperature is
obtained.
28
 INSTALLATION AND OPERATION MANUAL

• Smoke from the flue

The colour of the smoke reveals how well combustion is proceeding:
• Grey brown: there is a lack of air.
• Invisible: heat shimmer, in temperatures above freezing, or just below, the smoke should be invisible.
• White: with lower outside temperatures, only a weak white trail of steam should be seen.
Where a boiler has previously burned timber, the smoke can be dark and have a strong smell because the tar in the boiler
and flue walls is being burned off. This can last for up to a week.
• Smoke emission
If the unit’s hatches and damper are not sealed correctly, there is a risk of smoke emission, particularly if overpressure
builds up in the boiler. A smoke alarm can be a great help in showing that flue-gases are leaking from the burner room. Boiler
hatches must always be closed when the burner is in operation.
• The flame
The amount of air must be adjusted so that the flame is light yellow. A few minutes after start-up, the flame should have a
yellow-white appearance. It is perfectly normal for the colour to vary between yellow and white.
The colour of the flame is an indicator of how well the combustion process is going:
• Light yellow: good combustion, invisible smoke at normal temperatures;
• Reddish: not enough air or too much fuel, low efficiency level, the boiler heat absorbing surfaces are blocked by soot.
A short flame is due to surplus of air or a lack of fuel. This leads to a low efficiency level and a high
flue gas temperature.
9.3 POWER ADJUSTMENT OF THE BURNER
Due to the screw feeder’s uneven feed ratio during the first day of use, the adjustments should be checked after
approximately one week’s cycle. Adjustments must be carried out using a flue gas analysis instrument.
Adjustments are made by changing the values of the factory parameters through the secured service menu of the
controller. It is strictly forbidden to change any other parameter value than those mentioned in this section. Changing
other parameters may lead to serious failures in the burner’s operation processes.

• High power output adjustment

Perform the next steps:
1. Start the burner and allow it to run at highest power output for approximately 10 minutes.
2. Carry out a CO2 measurement. If the CO2 value (see section 9.Adjustment) is too low, you will need to increase the
Parameter No 18 (P018) value. If the CO2 value (see section 9.Adjustment) is too high, you will need to reduce the Parameter
18 (P018) value.
Parameter 18 defines duration of the fuel dosing interval for the highest power. Increase of its value raises the fuel dosing
rate. The screw feeder delivers doses of pellets in ON/OFF intervals. One ON interval + one OFF interval = 1 period. The period
duration is 10 seconds. By changing the parameter 18 value, you are changing the ON interval duration. For example, if the
Parameter 18 value is 62, this means that the ON interval duration is 6.2 seconds (10 units are equal to 1 second). Accordingly,
the OFF interval duration will be 10 – 6.2 = 3.8 seconds. So, at the high power output, the feeder will be repeatedly working
in 10 second periods, when pellets are dosed for 6.2 seconds, and for 3.8 seconds, pellets are not dosed.
3. Use the secured service menu to change Parameter 18 (Power 5 feeder 1 ON time) regarding the measured CO2 value:
3.1. Press the buttons until the Setup menu is accessed.

29
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

3.2. When the Setup menu icon lights, use the Edit buttons and choose the Setup menu level (Service
menu).
3.3. Press the Enter button . The Key sign appears on the display. This means that the Service menu is locked.
Press the enter button again. A random number from 0000 to 9999 will appear on the display. Sum up each digit of this
number shown on the display, and add 1 to the sum. The number you calculated will be your unlock code (For example, if the
random number shown on the screen is , sum up each digit: 9 + 1 + 6 + 3 = 19. Now add 1 to the sum you got: 19
+ 1 = 20. So, your unlock code is 20).
3.4. Press the Enter button . The display shows . Use the Edit buttons , and change the number 0 to
the number you have calculated as your unlock code (in the example above, it was 20) and then press the Enter button .
3.5. You have successfully unlocked the service menu. Again go to the Setup menu . When the Setup menu icon is lit,
use the Edit buttons and choose the Setup menu level = (Parameters). Press Enter button .
3.6. appears on the screen. Use the Edit buttons , and select the parameter No 18 which you
need to change. Press the Enter button . The current parameter value appears on the screen. Use the Edit buttons
and adjust this value with respect to the measured CO2 value. Press the Enter button and overwrite the default value with
the one you entered (with the Cancel button you can go back by one menu level by every press).
• Low power output adjustment
Perform the next steps:
1. Start the burner and allow it to run at its lowest power output for approximately 10 minutes.
2. Carry out a CO2 measurement. If the CO2 value (see section 9.Adjustment) is too low, you will need to reduce the
Parameter No 24 (P024) value. If the CO2 value (see section 9.Adjustment) is too high, you will need to increase the Parameter
No. 24 (P024) value.
Parameter 24 is the combustion fan speed at the lowest power level. The higher the value, the higher the fan speed, and
accordingly, more air is provided for combustion. To calculate the exact fan speed in rpm, you need to multiply the parameter
24 value by the multiplier *11.4. This means that when the Parameter 24 value is, for example, 100, the fan speed then is 100
* 11.4 = 1140 rpm.
3. Use the secured service menu to change Parameter 24 (Power 1, Fan 1 speed) regarding the measured CO₂ value. Perform
steps from 3.1 to 3.6 described above in “High power output adjustment”. The procedure is analogical.
9.4 CLEANING OPERATION ADJUSTMENT
The Astra pellet burner has some automatic cleaning operations which are done during combustion process. These cleaning
operations are:
• Blow-cleaning. Pellets stop being dosed temporarily, and the combustion fan starts blowing at a higher speed to clean
the combustion area with a stream of air. Possible adjustments of this operation are: the blow-cleaning duration, the fan
speed during the cleaning, and the frequency of cleaning.
• Mechanical cleaning. It is done after a set amount of blow-cleanings. During mechanical cleaning, pellets stop being
dosed, and as soon as the fire is gone in the burning chamber, the actuator extends and then retracts back the burning
chamber drawer, removing all the burned contents: ashes, soot, slag. After the mechanical cleaning, the burner restarts and
burning process continues further. Possible adjustment of this operation is changing frequency of the mechanical cleaning.
The factory settings for the cleaning operation are pretty much optimal for using high quality A1 class wood pellets.
However, using other types of pellets (worse quality), may lead to a different pollution level in the burning chamber. If slag
builds up intensively in the burning chamber, and the blow-cleaning is not able to reduce it effectively, or if after mechanical

30
 INSTALLATION AND OPERATION MANUAL

cleaning, big pieces of slag are still left in the burning chamber, intensification of the cleaning operations may be a solution.
However, if the burning is going perfectly, and there are no signs of excess slag building up, consider reducing the cleaning
intensity and mechanical cleaning frequency. This will lead to longer burning periods with less restarts.
• Blow-cleaning period
The blow-cleaning period describes the time lapse between two blow-cleanings.
To adjust the blow-cleaning period, change the Parameter No 60 value (P060; Fan 1 blow-cleaning period). Parameter No
60 units are minutes. Keep in mind that the blow-cleaning period is not related to the screw feeder ON time, but instead, in
regards to OFF time (the amount of time for pauses when dosing pellets). The Parameter 60 factory value is 25. This means,
that by default, each blow-cleaning will be done after 25 minutes of the screw feeder OFF time. One example is when the
burner is working at such a power output, that the pellets are dosed for 6 seconds, and the pause duration (OFF time) is 4
seconds. The burner controller calculates these OFF times, and when the sum reaches 25 minutes, blow-cleaning will be
done. The higher the power output is, the shorter the OFF time durations happen. This means, that the cleaning is done less
frequently when the burner runs at high power output, and more frequently when it operates at low power output.
• Blow-cleaning duration
The blow-cleaning duration is the time amount in seconds, which describes the time lapse when blow-cleaning is
happening. During it, pellets are stopped feeding. To adjust the blow-cleaning duration, change the Parameter No 61 (P061;
Fan 1 blow-cleaning duration) value. Parameter 61 value units are seconds. This parameter’s factory value is 30, which means
that by default, the blow-cleaning duration is 30 seconds.
• Combustion fan speed during the blow-cleaning
During each blow-cleaning, the combustion fan starts blowing at a higher speed in order to puff out as much as possible
ashes and soot from the burning chamber. To adjust the combustion fan speed during blow-cleaning, change the Parameter
No 62 (P062; Fan 1 blow-cleaning speed) value. Parameter 62 defines the fan speed using the multiplier *11.4. The factory
value for parameter No 62 is 230. This means that by default, the combustion fan speed during blow-cleaning will be 230 *
11.4 = 2622 rpm. The maximum allowed fan speed is 2900 rpm (parameter value 255).
• Mechanical cleaning frequency
The mechanical cleaning is performed after a certain number of blow-cleanings done in a row. To adjust the mechanical
cleaning frequency, change the Parameter No. 64 (P064; Chamber cleaning duration/rot.) value. Parameter No. 64 units are
the number of times that the blow-cleaning is done in a row, less 1 blow-cleaning. The factory value of parameter No. 64 is
6. This means that by default, mechanical cleaning will be done instead of the 6th blow-cleaning – there will be five blow-
cleanings in a row, and then, at the 6th time, a mechanical cleaning will be started, instead of a blow-cleaning. After the
mechanical cleaning, the burner restarts, and the blow-cleaning counter also resets.
10. CLEANING
The Astra S-series burner is equipped with an actuator. The actuator enables the burner to work for much longer periods
without any cleaning efforts required by a user. On the opposite, conventional burners which are not equipped with an
actuator require daily care and a burning chamber cleaning. However, after some time, cleaning operations should periodically
be done in the Astra S-series burners as well.
• Burning chamber cleaning
The actuator extends and retracts the drawer of the burning chamber, thus removing ashes, soot and slag from inside. This
mechanical dumping does not completely prevent the chamber from getting dirty. Combustion residues start to increment

31
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

the walls of the burning chamber; as a result, the combustion air supply holes get clogged. To remove these unwanted
increments, the burning chamber should be cleaned.
Before cleaning the chamber, make sure that the burner is switched off, there must
be no fire inside the boiler, the boiler and the burner have totally cooled down. Open
the upper door of the boiler. Using a brush or any small scraper, scrape off the inner
walls of the burning chamber. Remove the waste with an ash vacuum cleaner.
• Flame sensor cleaning
After longer periods of the burner operation, the flame sensor’s sensing part may
cover up with a layer of soot. The layer hampers the sensor’s ability to effectively
detect the flame. This may lead up to problems during the ignition process: theFig 17. Taking out the flame sensor.
ignition may take longer because the sensor will detect the flame appearance harder and later. The dirty flame sensor may
lead to fake alarms which may stop the burner as well.
Disconnect the burner from the power supply before cleaning. If the burner is already mounted in the boiler, be sure
that the burner is switched off, that there is no fire burning in the fire chamber, and that the boiler and burner have
fully cooled down.
Unscrew two bolts which fasten the casing of the burner (Fig. 7). To open the casing, you may need to straighten the fuel
downpipe (its end should be directed towards the Astra logo on the front of the burner). In some cases, you may also need to
loosen the adjustable brace of the screw feeder flexible hose and disengage the screw feeder from the fuel downpipe. Open
the casing by raising the unscrewed side of it.
The flame sensor is located at the right side of the box which holds the fuel downpipe. Take a wire and pull the sensor out of
its plastic insert (Fig. 17). The tip of the flame sensor has a sensing part with a little peephole. Take a slightly wet fabric patch
and wipe out all dust from the flame sensor, especially from the transparent area. Insert the cleaned flame sensor back into
its place. Reassemble the burner casing.
• Boiler cleaning
The ash is removed from the boiler every 3-7 days. Before carrying out
the boiler cleaning operations, take care of personal protective equipment: 1
appropriate clothing, gloves. 2
Make sure the burner is switched off from the mains there is no
flame in the combustion chamber and the burner is completely cold.
One or two times a month clean the boiler cavities of soot and resin
deposits. For this purpose, lift the top cover (Fig. 6 pos. 1), remove the covers
of the combustion chamber and the smoke channel (Fig. 6 pos. 2 and 3).
Remove the turbulent insert (Fig. 3 pos. 4), fireclay plates (Fig. 3 pos. 3), flue
top (Fig. 18 pos. 1) and lower caps (Fig. 3 pos. 5)).
Clean soot and deposits from the combustion chamber and the flue walls
with a rake or a wire brush. Deposits dropped from the combustion chamber
3
wall fall directly into the ashtray. There is an opening to clean the deposits
dropping on the bottom of the flue channel to which the soot and deposits
fall into the ashtray. Pull out the ashtray and remove the ash. Collect fallen
deposits and ash with a vacuum cleaner. Fig. 18 Boiler cleaning.
After cleaning, MOUNT the boiler components in reverse order. 1 – Upper chimney cover; 2 – Poker; 3 – Ashes drawer.

32
 INSTALLATION AND OPERATION MANUAL

11. MAINTENANCE
11.1 CHANGING THE HEATING ELEMENT
Disconnect the burner from the power supply. The burner is powered by
the ~230V, AC electrical current, and any direct user contact with it may
be life threatening. If the burner is already mounted in the boiler, make sure
that the burner is not working, that there is no fire burning in the fire chamber,
and that the boiler and the burner have cooled down completely.
Disconnect the flexible hose of the screw feeder from the fuel downpipe.
Then, using the same instructions as in section 5.3, part “Mounting the burner
onto the boiler”, only in reverse order, open the lid of the burner, and unmount
the burner from the boiler by unscrewing the two nuts, which hold the burner Fig. 19 Dismounting the deflector from the burning
chamber.
to the boiler.
To reach a heating element and change it, the next steps should be performed:
1. Unscrew the bolt on the top of the burning chamber. Dismount the deflector
plate (Fig. 19);
2. Unscrew two bolts on the burning chamber lateral walls. Then, remove the
guiding plates from inside the burning chamber (Fig. 20);
3. When the guiding plates have been removed, you can disconnect the
heating element wires – the two wires are connected to the relay board contacts
designated “IGNITER”, the third, grounding wire is connected to the grounding
terminal (Fig. 1, position 10); Fig. 20 Removing the guiding plates from the
4. Now you are can take out the heating element plate: unscrew further four chamber.
bolts on the burning chamber lateral walls. Take out the heating element
unit together with a plate (Fig. 21);
5. Unscrew the nut which holds together the heating element and the
thermal screen plate. Remove the thermal screen, dismount the heating
element (Fig. 22).
6. Change the heating element and assemble the chamber in the reverse
order. To route the wires of heating element, pull them through the rubber
bushing on the rear wall of the chamber (Fig. 23).
When positioning the new heating element onto the heating
element plate, make sure that the heating element touches
Fig. 21 Taking out the heating element unit together
the two metal fingers of the plate (Fig. 22). Then slots of the plate find
with a plate.
themselves in between winding of the heating element and air can move
through unobstructed.

11.2 CHANGING THE ACTUATOR

Disconnect the burner from the power supply. The burner is
powered by the ~230V, AC electrical current, and any direct user
contact with it may be life threatening. If the burner is already mounted
in the boiler, make sure that the burner is not working, that there is no
fire burning in the fire chamber, and that the boiler and the burner have Fig. 22 Disassembling the heating element unit.
cooled down completely.

33
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

There exists a low probability that the actuator may malfunction, and
will need to be replaced by another one in the distant future. For the
actuator replacement, first, disconnect the flexible hose of the screw
feeder from the fuel downpipe. Then, using the same instructions as
in section 5.3, part “Connection to a Boiler”, only in a reverse order,
disconnect the burner from the boiler.
To exchange the actuator, perform the next actions:
1. Make the same steps No. 1 – 4 described in section “11.1 Changing
the heating element”; Fig. 23 The rubber bushing used to route the wires of the
heating element.
2. Return the burner power supply cable back to the boiler or connect
it directly to the electrical network. Press and hold the ON key on
the controller panel of the burner for three seconds, then release it, and
after a while, press it again for three seconds. Thus, you imitate a start
of the burner, and then instantly- a turn off. The actuator will start to
extend. Wait until it fully extends and stops (Fig. 24). Be prepared for this
moment, and when the actuator has stopped in the extended position,
disconnect the burner power supply cable from the boiler or electrical
network.
3. Inside the casing of the burner: unscrew the nut which holds the
supporting leg of the actuator to a frame of the burner (Fig. 25);
4. Back in the burning chamber: unbend the thin split pin and pull it Fig. 24 Actuator and a drawer extended, exposing a joint
out from the thick pin. The latter serves as a coupling connecting the of the drawer and the actuator.
drawer and the actuator. Remove the thick pin and pull the drawer out (Fig. 26);
5. In the front of the burner, unscrew the two bolts that are holding the lid of the casing – one on left side, another one on
the right. Disconnect the controller data cable from the control panel in the lid, and remove the lid off the burner (Fig. 27);
6. Now, because the lid of the burner does not obstruct the actuator anymore, you can take the actuator out through the
existing opening in the electrical components bracket (Fig. 28). Before pulling it out, do not forget to disconnect its wires
from the relay unit;
7. Disconnect the support leg from the actuator – unbend the split pin, and pull it off from the thick pin which serves as a

Fig. 25 Unscrewing the nut fastening the Fig. 26 Disconnecting the actuator from the Fig. 27 Taking out the lid of the burner casing.
actuator to the frame of the burner. drawer.

34
 INSTALLATION AND OPERATION MANUAL

coupling connecting the support leg and the actuator (Fig. 29).
8. Now, take the new replacement actuator, and in reverse order, assemble
everything back. Check the electrical circuit diagram (Fig. 12) for correct wire
connection.
After the reassembly and replacement, the controller will remember
that it have extracted the actuator earlier, and in a few seconds it will
start retracting it. The replaced actuator and the drawer are already retracted,
so this discrepancy may trigger an alarm appearing on the control panel (the
orange coloured LED indicator with a broom symbol lighting up). Clear this
Fig. 28 Removing the actuator with its
alarm by pressing the power button on the panel for three seconds. After
supporting leg from the burner.
you release the button, the alarm indicator should disappear.

11.3 REPLACING THE CONTROLLER BATTERY

The controller of the burner switches to its on-board battery during power
failure, or when it is disconnected from the electrical power supply. The battery
powers the internal clock and maintains the internal microprocessor memory.
When the battery is empty, the controller operates normally while connected
to the electrical power supply. During a power supply failure, the internal clock
stops and the operational phase is not stored in its memory. After the power
supply returns, the clock is reset, and the controller stays in the OFF phase.
Fig. 29 Disconnecting the actuator from its
To replace the battery: support leg.
1. Disconnect the electrical power supply;
2. Locate the battery on the controller board;
3. Remove the old battery from the holder with INSULATED tweezers or a similar tool. Take care not to bend the battery
holder contacts;
4. Check the polarity orientation and insert the new battery;
5. Reconnect the electrical power supply.
12. TROUBLESHOOTING
The display of the burner provides warnings for alerts and errors which can occur during the operation of the controller. The
alarm icons in the indicator line of the display signal a problem. An alert notification is indicated by blinking icons, and errors
are indicated with continuously lit icons. In case of an alert, the combustion system remains operational. In case of an error,
the combustion system has malfunctioned seriously and becomes disabled. To solve the problem, a service technician should
be contacted. Each alert and error has a code which can be used to identify the problem. To display the code, press and hold
the Cancel button for 3 seconds. If there is no information on the alert/error code, the screen shows .

35
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

• ALERTS
No fuel
Indication: Code: ---- Cause: When the fuel in the hopper runs out, the Solution: Refill the pellets hopper. Delete the alert
Icon No fuel is notification is triggered. The combustion system turns by pressing and holding the Start/stop button on
blinking off and cannot be restarted. the display.
Combustion chamber or chimney is dirty
Indication: Code: A003 Cause: The combustion chamber or the chimney are Solution: Inspect and empty the combustion
Icon Cleaning is dirty and require cleaning. There is too much ash or chamber or contact service personnel to sweep
blinking unburned pellets in the combustion chamber; and/or the chimney.
Indication: Code: ---- the chimney is congested with soot.
Icon Cleaning is
blinking
Low battery
Indication: Code: A004 Cause: The controller battery gets discharged. The Solution: Contact service personnel to change the controller
Icon Service is combustion system is still operational. battery. Do not attempt to change the battery on your own.
blinking
Fan 1 – the exhaust fan- speed sensor failure
Indication: Code: A005 Cause: The speed sensor of the exhaust fan is Solution: Contact service personnel.
Icon Service is malfunctioning. The combustion system is still
blinking operational.
Regular maintenance required
Indication: Code: A002 Cause: The time to the next service has run out. If set up by Solution: Contact service personnel.
Icons Service service personnel, the Time to service counter counts time
and Cleaning is in hours in the reverse direction. When this counter reaches
blinking zero, the Service icon starts blinking. This value is read-only
and can be modified by authorized personnel only.
Remote control battery empty
Indication: Cause: The battery of the remote control is empty. The Solution: Replace the battery. Refer for the
Remote control is remote control uses the CR2025 or CR2032 battery. instructions to the back side of the remote
not responsive control unit.

36
 INSTALLATION AND OPERATION MANUAL

• ERRORS
Service required
Indication: Code Cause: The combustion system Solution: note the error code and
Icon Service lights E001: Keyboard error has malfunctioned and not contact service personnel.
constantly E002: IR communication error operational.
E003: RF communication error
E004: MB communication error
E101: Fire error
E105: NTC2 error
E106: NTC3 error
E107: TC2 error
E108/109: Security switch or Pressure switch error
E110: NTC1 error
E111: TC1 error
E112: Pellets hopper overheating error
E115: General error
Unspecific errors on the display
Indication: Unknown error is displayed on the screen Cause: Certain information stored Solution: disconnect and then
Icon Service lights in the controller is updated to the reconnect the display to reset it.
constantly display at startup moment, for If the problem persists, contact
example, configuration data. An service personnel for support.
unexpected error appears on the
screen when making changes to
the controller settings.

• POWER SUPPLY FAILURE

During power supply failure, the Duration of power Operation before the Operation after the power supply failure
controller remains active due to internal supply failure power supply failure
battery. Its internal status remains as it Fire up phase The controller continues normally.
was before the power failure. Internal The controller checks the flue gases temperature and
Less than 1 minute Burning phase continues in the Burning phase or restarts in the Fire
electronics runs in power saving mode Up phase.
consuming very little amount of energy. OFF phase Remains OFF.
In case of the power supply failure, the Fire Up phase The controller continues normally.
controller operates as follows:
The controller checks the flue gases
temperature. If the flue gases temperature
More than 1 dropped below some setting (PAR56), the
minute Burning phase combustion system restarts in the Fire Up
phase, otherwise it continues in the Burning
phase.
OFF phase Remains OFF.

37
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

13. WARRANTY TERMS AND CONDITIONS

The manufacturer provides a warranty for the burners, the main conditions of which are the following:
• the installation of the burner as well as the initial kindling, adjustment and repairs are carried out by an authorised company;
• the burner is installed and operated following the requirements of this operation manual;
• the client presents this operation manual with the validated selling card form in it;
• the duration of the warranty period for the burner is 24 months with the exceptions of the below presented components;
• the warranty does not apply for the following components of the burner:
• gaskets;
• an ignition element;
• the warranty repairs are performed when the fault has occurred due to the manufacturer’s fault;
• damages originated from transportation, careless storage and handling will not be covered by the warranty. The claims for such kind of damages
should be presented to the vendor company;
• the warranty term is not extended after removing the faults which have occurred during the warranty period;
• cleaning of the burner and installation works are not covered by the warranty;
• the damage caused to the premises and the property in the premises, human health due to the burner fault will not be compensated;
• the warranty repair works and replacement of parts during the warranty period are free;
• the warranty period starts from the burner purchase date;
• all the warranty obligations of the manufacturer are listed in this chapter; the manufacturer cannot be held responsible for additional obligations
undertaken by third parties.

14. ACCEPTANCE CERTIFICATE

The pellet boiler Astra P-....., serial No. ................................., the pellet burner Astra S-....., serial No. ................................., the auger pellet
conveyor Astra PA ....., serial No. ................................., the pellet hopper Astra PK-....., serial No. ................................., conforms to the technical
documentation, requirements of the standard EN 14785 and is approved as fit for operation.

Manufacturing date 201 ................................................................

L. S.
Head of Quality Service ..................................................................

SELLING CARD
Pellet burner sold by:
Company: .................................................................................................................................................................................................................
Address: ...................................................................................................................................................................................................................
Telephone: ...............................................................................................................................................................................................................
Date of sale: .............................................................................................................................................................................................................
Signature: ................................................................................................................................................................................................................
BURNER INSTALLATION PROTOCOL
Pellet burner installed by:
Company (Technician): .............................................................................................................................................................................................
Address: ...................................................................................................................................................................................................................
Telephone: ...............................................................................................................................................................................................................
Installation date: ......................................................................................................................................................................................................
Installation data:
Boiler model, type, thermal capacity: .......................................................................................................................................................................
Screw feeder model, type: ........................................................................................................................................................................................

38
 INSTALLATION AND OPERATION MANUAL

Height of the chimney: .............................................................................................................................................................................................

Diameter of the flue: ................................................................................................................................................................................................
Draught of the chimney: ..........................................................................................................................................................................................
Other information concerning installation: ..............................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................

The pellet burner was tested on site, adjusted, the control and safety elements were checked and found to be operating properly

Person responsible for installation and testing: ........................................................................................................................................................

(Name, surname, signature of the employee)

I accept the installation works: .................................................................................................................................................................................

(Name, surname, signature of the employee)

WARRANTY AND POST-WARRANTY REPAIR CARD

Pellet burner repaired by:
Company (technician): .............................................................................................................................................................................................
Address: ...................................................................................................................................................................................................................
Telephone: ...............................................................................................................................................................................................................
Repair date: ..............................................................................................................................................................................................................
Information on fault, works performed: ...................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
Signature of the technician: .....................................................................................................................................................................................
Pellet burner repaired by:
Company (technician): .............................................................................................................................................................................................
Address: ...................................................................................................................................................................................................................
Telephone: ...............................................................................................................................................................................................................
Repair date: ..............................................................................................................................................................................................................
Information on fault, works performed: ...................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
Signature of the technician: .....................................................................................................................................................................................
Pellet burner repaired by:
Company (technician): .............................................................................................................................................................................................
Address: ...................................................................................................................................................................................................................
Telephone: ...............................................................................................................................................................................................................
Repair date: ..............................................................................................................................................................................................................
Information on fault, works performed: ...................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
.................................................................................................................................................................................................................................
Signature of the technician: .....................................................................................................................................................................................

39
 PELLET BOILERS: Astra P-16, Astra P-25, Astra P-35

DECLARATION OF CONFORMITY
Manufacturer: Machinery plant “Astra” AB.
Address: Ulonu g. 33, 62161 Alytus, Lithuania.
LT
Product designation: pellet burner Astra S-25
Our product is manufactured in accordance with the following directives:
Our product is manufactured in accordance with the following directives:
2006/95/EC – Low voltage directive;
2006/42/EEC – Machinery directive;
2004/108/EEC – Electromagnetic compatibility directive;
89/106/EEC – Construction products directive.

The following standards were applied for the Astra S-25 pellet burner:
EN 15270 – Pellet burners for small heating boilers;
EN 60335-1 – Safety of household and similar electrical appliances;
EN 60335-2-102 – Safety particular requirements for fuel burning appliances having electrical connections;
EN 55014-1; EN 55014-2; EN 61000-3-2; EN 61000-3-3 – Electromagnetic compatibility.

Viktoras Bondarevas
Head of Heating Products Division
AB machinery plant Astra

40