hot water pellet boiler of series “PELLETHERM V4”

hot water pellet boiler of series “PELLETHERM V4”
User manual
of hot water pellet boiler of series
„Pelletherm 18v4”,
„Pelletherm 25v4”,
„Pelletherm 30v4”
and
automatic pellet burner of series
“GP25” and “GP32”
http://www.erato.bg
Producer
Address
Telephone
Fax
e-mail
home page
ERATO Product Ltd
Bulgaria, Haskovo 6300, blv.“Saedinenie” 67
+359 38 603050 , +359 38 603052
+359 38 603054
produc[email protected]
http://www.erato.bg/product/
Thank You for buying the system, consisting of : hot water pellet boiler of
series „Pelletherm v4” and a pellet burner of series “GP”. This manual will help
You to use and maintain the units properly.
This document is intended to be used as additional information for the
service team, which will install and adjust the system, as well as maintenance
information, which will help the end user.
The producer requires the service staff, which will perform the above
mentioned procedures, to get training course at the producer’s training center
and get certified as well.
EXPLANATION : in this manual is used the following description of the hot
water boilers : „Pelletherm v4”, which covers the following models „Pelletherm
18v4”, „Pelletherm 25v4” и „Pelletherm 30v4”, as well as the pellet burners of
series “GP25” and “GP32”.
The trade names of the hot water boilers of series “Pelletherm v4” are :
MARIO, DakonERA, Practika, GreenECOtherm.
ATTENTION!
• In interest of your personal security it is obligatory to read thoroughly
and carefully this instruction manual before proceeding with any actions
with the system – mounting, connecting, etc. its elements. In case that
requirements, depicted in this manual are not satisfied, failures of any
element of the system could be expected, or even fatal consequences, for
which the system’s producer does not take responsibility;
• In interest of your personal security it is obligatory to read thoroughly
and carefully instruction manual of the pellet burner of series “GP”
before proceeding with any actions with the burner – mounting,
connecting, etc.. In case that requirements, depicted in its manual are not
satisfied, failures of the pellet burner could be expected, or even fatal
consequences, for which the burner’s producer does not take
responsibility;
USER MANUAL of hot water pellet boiler of series „Pelletherm v4” and automatic pellet burner
of series “GP” (Document version: 14.07.2011 10:02)
p. 2/60
CONTENTS
p.
1.
Main properties and advantages of the system, consisting of: hot
water pellet boiler of series “PELLETHERM V4” and pellet burner of
series “GP”........................................................................................................... 6
2.
Description of the system: hot water pellet boiler of series
“PELLETHERM V4” and automatic pellet burner of series “GP”. ............. 8
2.1. Description of the heat exchanger of hot water pellet boiler of series
“PELLETHERM V4” ..................................................................................... 8
2.2.
Description of the pellet burner of series “GP”................................ 10
3.
Technical data for the system, consisting of: hot water pellet boiler of
series “PELLETHERM V4” and a pellet burner of series “GP”................. 15
4.
Installation process of the system .......................................................... 23
4.1. Special features and requirements for assembly and installation of
automatic pellet burner of series “GP” and hot water pellet boiler of
series “PELLETHERM V4”......................................................................... 23
4.2. Requirements for installation of system : hot water pellet boiler of
series “PELLETHERM V4” and pellet burner of series “GP”:............... 23
4.3. Installation and attachment of the modules of the system : hot
water pellet boiler of series “PELLETHERM V4” and automatic pellet
burner of series “GP” .................................................................................... 24
4.3.1.
Basic requirements for installation of hot water pellet boiler
of series “PELLETHERM V4” : ..................................................................... 24
4.3.2.
Installation of the system .......................................................... 25
4.3.3.
Installation of the hot water pellet boiler of series
“PELLETHERM V4”, considering it’s easy maintenance and servicing : . 25
4.3.4.
Boiler’s positioning according to the requirements for
attachment to the electric power supply circuit ............................................. 26
4.4. Procedure for installation of the modules of the system ................... 26
4.4.1.
Connecting to the chimney ....................................................... 26
4.4.2.
Connecting to the heating system ............................................ 27
4.4.3.
Installation of the automatic pellet burner of series “GP” ... 27
4.4.4.
of the boiler
Installation of the two ceramic plates in the combustion chamber
..................................................................................................... 28
p. 3/60
4.4.5.
Install the secondary ash lid at the bottom of the convective part
of the boiler; ..................................................................................................... 29
Installation of the flue gases duct lid .......................................... 29
4.4.6.
4.4.7.
Installation/verification of the horizontal combustion lids and the
combustion chamber cover.................................................................................. 31
4.4.8.
Install the heat exchanger’s convective duct lid ......................... 31
4.4.9.
Install the boiler’s heat exchanger combustion chamber lid....... 32
4.4.10.
Connect the pellet burner of series “GP” to the hot water boiler of
series “PELLETHERM V4” ............................................................................... 33
4.4.11.
Installation of the pellet transport auger ..................................... 34
4.4.12.
Pellet transport auger fuel charging. ........................................... 34
4.4.13.
Connect the control box of the boiler to the power supply;........ 34
4.4.14.
Final view of the system ............................................................. 35
4.4.15.
Recommended principal hydraulic scheme for the hot water
pellet boiler ..................................................................................................... 36
System starting procedures.................................................................... 38
5.
5.1.
Basic fuel requirements....................................................................... 38
5.2. Starting up the system (consisting of hot water pellet boiler of series
“PELLETHERM V4” and automatic pellet burner of series „GP”). ...... 39
5.2.1.
Interface control board of hot water pellet boiler of series
“PELLETHERM V4”....................................................................................... 40
5.2.2.
supply.
Hot water boiler of series “PELLETHERM V4” power
..................................................................................................... 42
5.2.3.
System very first start ............................................................... 42
5.2.4.
Operating parameters of the boiler. ........................................ 43
5.2.5.
Operating parameters for adjustment of the pellet burner of
series “GP” ..................................................................................................... 43
5.2.6.
5.3.
Nominal operating mode of the system. .................................. 45
Control of the thermal capacity of the system. ................................. 46
5.3.1.
Decreasing the thermal capacity of the system: ..................... 46
5.3.2.
Increasing the thermal capacity of the system: ...................... 46
5.4.
Adjustment of the combustion process.............................................. 47
5.5.
Stopping the operation of the system................................................. 47
5.6.
Turning OFF the system. .................................................................... 47
p. 4/60
•
Emergency stop of the system. ............................................................. 48
5.7. Showing and teaching the end user about the maintenance and
adjustment procedures. ................................................................................. 48
5.8.
Safety and unexpected risks ............................................................... 50
5.9.
Operation faults and their repairing ................................................. 52
5.10.Pellet system warranty form completion. ........................................... 55
5.11. Actions, after the modules of the system are not in exploitation
anymore........................................................................................................... 56
6.
Electrical scheme of hot water pellet boiler of series “PELLETHERM
V4”. ................................................................................................................... 57
QUALITY CERTIFICATE ............................................................................. 58
WARRANTY SERVICE PROCEDURES LIST ........................................... 60
p. 5/60
1. Main properties and advantages of the system, consisting of:
hot water pellet boiler of series “PELLETHERM V4” and
pellet burner of series “GP”.
The hot water pellet boiler of series “PELLETHERM V4” is steel-plate hot
water pellet boiler, which uses solid biomass fuel in shape of pellets. The
boiler is designed to be connected to local hot-water heating systems, as well
as heating up domestic hot water. The boiler uses wood pellets, as well as
other type/shape of biomass, described in the user manual of the pellet burner
of series “GP”, the resulting heat energy from thermo-chemical conversion
(i.e. combustion process) is transmitted to the circulation water in its water
jacket and the heat energy is transported to the heating system/consumer.
The system of the hot water pellet boiler of series “PELLETHERM
V4” includes:
• hot water boiler – 1 sp.;
• automatic pellet burner of series “GP” – 1 sp.;
• ash tray – 1 sp.;
• bottom cap (for the cleaning section between the secondary and
tertiary flue gases duct) – 1 sp.;
• ceramic elements – 2 sp.;
• flap – 1 sp.;
• door holder – 1 sp.;
• cleaning set (rake – 1 sp., hook – 1 sp.);
• electrical connectors – for room thermostat – 1 sp., for flue gas fan
– 1 sp. ;
• power supply cable – 1 sp.;
• nut and washer M10 – 2 sp.;
• instruction manual – 1 sp.;
The automatic pellet burner of series “GP”, which is an element of the
system, could utilize following types of fuel:
•
Wood pellets, having diameter 6 - 8 mm, categorized in the range of:
A, AB, B (according to the methodology, developed for pellets properties
estimation in ERATO company) or class ENplus-A1, according to EN
14961-2:2010;
•
Pre-dried nuts (cherries for example);
•
Fuel mixture – pellets and nuts (for example mixture ratio could be
50% - 50%);
p. 6/60
•
Other solid biomass based pellets, but confirmation for these fuels
utilization need testing and approval by ERATO company laboratory;
The system consists of :
• Hot water pellet boiler of series “PELLETHERM V4” – a steel plate
heat exchanger, equipped with control board;
• Automatic pellet burner of series “GP”;
System advantages
• The system is designed to utilize solid biomass fuel, making it
environmentally friendly, CO2 neutral and does not contribute to the
global warming process – result of fossil fuel utilization;
• The specific price of the heat energy, delivered by solid biomass
utilization is less dependent on the world fuel market trends and
practically the heat energy price is competitive to the conventional energy
sources;
• The system, consisting of : pellet boiler of series “PELLETHERM V4”
and a pellet burner of series “GP” is automatic and the thermal comfort
achieved is close to that, originating from exploitation of fully automatic
boilers, (for example liquid or gas fuel, as well as electric boiler), which
makes it applicable in heating systems, equipped with programmable
room thermostat;
• Automatic operation of the system, easy adjustment of the thermal
capacity of the burner (utilizing the burner’s potentiometer), the operation
of the system could be controlled by programmable room thermostat, thus
achieving high levels of thermal comfort and fuel consumption economy;
• The burner utilizes solid biomass fuel, in shape of pellets (wood pellets),
dried nuts (cherry nuts for example) – for additional information see the
burner’s user manual;
• High efficiency;
• Low pollutant contents in the flue gases;
• Compact design, allowing simplified installation procedure and easy
maintenance (at servicing as well as ash deposits cleaning);
• The system could be utilized to heat-up domestic hot water;
• Simplified maintenance and service procedures;
• Minimized running costs;
p. 7/60
2.
Description of the system: hot water pellet boiler of
series “PELLETHERM V4” and automatic pellet
burner of series “GP”.
The system consists of :
• Hot water pellet boiler of series “PELLETHERM V4”;
• Automatic pellet burner of series “GP”;
2.1. Description of the heat exchanger of hot water pellet boiler of series
“PELLETHERM V4”
The hot water pellet boiler is steel plate welded construction, which is
applied as heating unit for domestic heating systems which could be realized as
driven by natural convection of the circulating water or systems, equipped with
circulating pump. The hot water boiler is a module of the automatic heating
system, designed for automatic wood pellets utilization and domestic hot water
heating. The ash deposits cleaning is performed by special tool – grating the ash
off the heat exchanging surfaces, collecting the mineral mass and other residues
in the ahs container and waste depositing it into specially designed ash
container. The combustion process, realized by the pellet burner, along with the
combustion chamber of the hot water boiler, is optimized and sustains the high
efficiency of the system. However, the overall performance of the system: hot
water pellet boiler of series “PELLETHERM V4” and the pellet burner of series
“GP” depends on the chimney’s draught. In principal, the draught of the
chimney depends on its condition , i.e. its height, as well its temperature and ash
deposition, (other factors, which influence the draught).
The heat exchanger of the hot water pellet boiler of series
“PELLETHERM V4” complies with the acting requirements for such kind of
units, defined in operating norm : EN 303-5/2000 – „Heating boilers for solid
fuels, hand and automatically fired, nominal heat output up to 300 kW.
Terminology, requirements, testing and marking”.
p. 8/60
Figure 2.1. Front view of the hot water pellet burner of series “Pelletherm
25v4”, “Pelletherm 30v4” – left picture, “Pelletherm 18v4” – right picture.
The hot water boiler consists of the following elements/modules:
• The main part of the hot water boiler is the heat exchanger, which has
side orifice for pellet burner installation. The heat exchanger is
produced in two versions – “left sided” – the pellet burner will be
installed on its left side (looking in front of the boiler) and “right
sided” – the burner will be installed in the orifice of the heat
exchanger, made in its right side (again looking in front of the boiler);
• The heat exchanger is steel plate welded construction. In the front
section of the heat exchanger is formed a combustion chamber and
underneath is positioned the ash container. The heat exchanger is
relatively compact construction and is designed as so called “three way
heat exchanger” – the flue gasses duct is realized as three passes one.
This design allows intensive heat exchange ratio and relatively small
overall dimensions of the system;
• Ceramic elements, installed in the combustion chamber, which
provide optimal conditions for the combustion process and efficient
fuel utilization;
p. 9/60
• Ash tray is positioned on the bottom of the combustion chamber. It
collects the ash residue and allows easy de-ashing of the boiler’s heat
exchanging surfaces;
• Inlet and outlet orifices of the inflow and outflow circulating water,
positioned on the back side of the boiler and are connections with
female (internal) thread of size G1½”, though which the boiler is
connected with the heating system;
• Drainage orifice is an connection with female (internal) thread of size
G½”, which should be equipped with drainage valve;
• Flue gas orifice is positioned in the upper part of the back side of the
boiler, the chimney should be connected to that flue pipe;
• Steel plate heat exchanger, its lid and doors are insulated with
mineral wood, which ensures low heat loses rates to the surroundings;
• Control board, equipped with operating thermostat, controlling the
operating mode of the pellet burner, alarm thermostat, which protects
the boiler of overheating, thermo-manometer gauge, central
“POWER” switch and a “START “ switch;
• External decorative plates, produced from carbon steel, color
painted;
2.2. Description of the pellet burner of series “GP”
The automatic pellet burner of series “GP” is mounted horizontally on
either on the boilers of series “PELLETHERM V4” left or right side, the burner
is a separate and independent module of the system.
The pellet burner of series “GP” is separate module, which could be
installed on already existing hot boilers and thus to perform fuel switch, i.e. to
change the energy source from fossil fuel (like coal, wood logs, LPG, etc) to
biomass based densified fuel – wood pellets, making the boiler’s operation
automatic.
The wood pellets allow easy automation of the combustion process as
well as high efficiency at energy utilization. The wood pellets are solid biomass
fuel and as they are utilized, solid residue – mineral ash will remain in the
combustion chamber as well as on any other flue gas duct surfaces. However,
the quantity of the ash residue is less that the ash of any solid fuel, due to the
low ash content of the fuel. The specific price of the heat energy, produced at
wood pellets utilization is concurrent, compared to the price of the energy,
achieved from any other fuels and energy sources. The process performance of
p. 10/60
the automatic pellet burner of series “GP” corresponds to the process control,
performed by any automatic burner, utilizing fossil fuel (for example: gas, oil,
heavy oil, etc). The operation process includes: automatic start-up and ignition,
nominal operation and control of the high efficient combustion process are
controlled by the control board of the burner. These properties of the burner
allow achieving high levels of thermal comfort, which is known from the
popular fossil fuel based burners, but the fuel is biomass based product, with its
advantages – attractive price and ecologically oriented.
• Description of the construction of automatic pellet burner of series
“GP”
The automatic pellet burner of series “GP” is compact, module based
construction, consisting of the following elements/modules:
•
The basis part of the pellet burner is the main unit, which consists of:
• Combustion chamber, which forms combustion domain and
optimal environment for solid biomass combustion, is designed of
high quality stainless steel;
• Grate of the combustion chamber, which could be easily
detached and reveals access for ash removal;
• Air duct, which uniformly distributes the airflow and ensures safe
cooling of the elements of the burner;
• Electric heater, which heats and ignites the fuel. The heater is
positioned beneath the inclined plate of the grate in the combustion
chamber;
• Air supply fan, equipped with Hall sensor for rotation speed
monitoring;
• Photosensor, which monitors the intensity/presence of the
combustion process, installed aside of the combustion chamber for
easy access and cleaning;
• Alarm thermo-probe, which stops and blocks burner operation in
case of “back fire” process in the fuel delivery pipe;
• Control board, which monitors and controls the operation of the
burner and indicates its status;
• Transport auger connector, which realizes power supply to the
electric motor of the auger;
• Interface panel, which is equipped with light indicators and
thermal capacity control gauge;
p. 11/60
• Transparent window, though which the operation of the control
board could be checked without removing the cover and any
interventions;
• Electrically driven (external for the main unit) fuel transport auger,
which extracts the solid fuel from the bunker and delivers pellets to the
main unit, according to the operating mode of the burner. The transport
auger consists of electric gear-motor, a transport pipe with one end in the
fuel hopper and the other end is side opened and delivers fuel to the main
unit though a aperture;
• Flexible hose, which is made of specific semitransparent thermal resistant
material (in case of combustion process it does not emit toxic substances
and does not sustain combustion process), which connects the transport
auger and the main module;
COMMENTS: Actual and detailed information for the technical information of
the automatic pellet burner of series “GP” is described in its user manual;
Figure 2.2. External isometric view of automatic pellet burner of series „GP”.
The main modules of the pellet burner and their arrangement are shown of the
following figure.
p. 12/60
Fuel transport
auger (from the
bunker to the main
unit)
Flexible
pipe
Main unit
Figure 2.3. Arrangement of the modules of the pellet burner (side view);
• Preliminary information for the fuel hopper
The fuel hopper is the “reservoir” for the fuel of the pellet package, which
ensures conditions for compact fuel storage of the required fuel, needed
for nominal operation of the system for appropriate period of time and
optimal operating conditions of the pellet transport auger, as well as the
main unit of the burner. In case that the pellet hopper is designed onsite,
then it’s construction must allow easy and unobstructed fuel gravity
driven transport of the wood pellets to the fuel extraction orifice of the
hopper. The design of the hopper should consider easy fuel charging, easy
access for wood fine particles cleaning and mainly appropriate capacity
for prolonged and reliable pellet system operation.
ERATO company is a producer of an prefabricated pellet hopper, which is
designed to be assembled onsite. The hopper is produced from zinc coated
steel plates. The capacity of the main module of the pellet hopper is
250kg, one or two (no more than two) additional sections could be
attached and the overall fuel capacity will be 450kg and 650kg
respectively;
p. 13/60
Figure 2.4. Main module of the prefabricated metal pellet hopper (the
figure shows the main module with wood pellets capacity of 250kg);
p. 14/60
3.
Technical data for the system, consisting of: hot water
pellet boiler of series “PELLETHERM V4” and a
pellet burner of series “GP”.
• Thermal and technical data for the system: hot water pellet boiler of series
“PELLETHERM V4” and pellet burner of series “GP”, utilizing wood
pellets are given in Table 3.1;
• Dimensions and technical data for the system: hot water pellet boiler of
series “PELLETHERM V4” and pellet burner of series “GP”, utilizing
wood pellets are given in Table 3.2;
• Properties of the recommended fuel, which could be utilized on the pellet
system, are described in the user manual of the automatic pellet burner
of series “GP”;
• Classification of the wood pellets, according to their proximate analysis is
shown are described in the user manual of the automatic pellet burner
of series “GP”;
EXPLANATION : the hot water pellet boiler of series “PELLETHERM V4” is
produced in two versions – “left side flanged” for the attachment of the pellet
burner and “right side flanged” (looking in front of the boiler).
p. 15/60
Parameter
Hot water pellet boiler
model
Pellet burner model
Nominal thermal capacity
Thermal capacity
operation range
Utilized fuel
Dimension
kW
kW
•
•
•
Value
Pelletherm
Pelletherm
18v4
25v4
GP 25
15
25
7.5 - 15
is operating in a popular heating
system)
Thermal efficiency at
nominal capacity
Air excess ratio
Flue gasses temperature
at nominal thermal
capacity
Solid fuel residue
9 - 30
Wood pellets;
Pre-dried cherry nuts;
Other dried nuts;
Classification of the pellets
according to ENplus
Classification of the pellets
according to ERATO
methodology
Wood pellets fuel
consumption rate at
nominal thermal capacity
Fresh air flow rate,
required for effective
combustion process and
boiler operation
Flue gases mass flow rate
Averaged wood pellets
consumption rate (the boiler
7.5 – 25
Pelletherm
30v4
GP 32
30
ENplus-A1
A, AB, B
kg/h
3.65
6.05
7.15
kg/h
27 – 30
45 – 50
57 - 64
m3/h
24 – 27
39 – 44
50 - 56
g/s
9.4
15.6
19.8
kg/h
2.5
4.1
4.9
℅
89
89
89
λ
1.5 – 1.7
ºC
180 – 200
ash
The quantity depends on the ash contents in the
raw fuel, as well as operating conditions
Table 3.1 Thermal and technical data for the system: hot water pellet
boiler of series “PELLETHERM V4” and pellet burner of series
“GP”, utilizing wood pellets.
p. 16/60
Parameter
Hot water pellet boiler model
Dimension
Pellet burner model
Weight of the boiler
Weight of the system
Boiler’s water jacket capacity
Overall
W-width
dimension of
D-depth
the system:
H-height
(WxDxH)
Class of the boiler
kg
kg
dm³
(according to EN 303-5)
Operating overpressure of the
circulating water
Heating system expansion
vessel type
Factory tested overpressure
Recommended circulating
water temperature in the boiler
Minimal recommended return
water temperature in the boiler
Draught
Supply/return
flow
Connections Drainage
Flue gases duct
Hydraulic losses of the
circulating water at nominal
thermal capacity
Power supply
Electrical capacity
Electric protection
-
mm
Value
Pelletherm Pelletherm
18v4
25v4
GP 25
160
180
192.2
212.2
44
50
Pelletherm
30v4
GP 32
190
222.2
60
631
1030
1030
770
770
770
883
964
1045
-
3
MPa
0.25
-
Opened or closed (upto 0.25MPa)
MPa
0.4
ºC
80
ºC
60
hPa
0.1 - 0.2
G
1½”
G
½”
mm
149
hPa
VA
-
1.86
2.38
3.24
L1, N, PE, 50Hz; 230V;
<100 + 1100 (at ignition)
IP20
Table 3.2. Dimensions and technical data for the system: hot water pellet
boiler of series “PELLETHERM V4” and pellet burner of series “GP”, utilizing
wood pellets.
p. 17/60
The next figures show the dimensions and the design of the modules of the
system.
H
Figure 3.1. Front side view of the
hot water pellet boiler of series
“Pelletherm v4” (the overall as well
as the attachment dimensions are
shown) – front side view;
D
H
Figure 3.2. Side view of the boiler
of series “Pelletherm v4” (the
overall as well as the attachment
dimensions are shown) – burner
flange side view;
p. 18/60
Figure 3.3. Front view of
the system (the overall
dimensions are shown) – hot
water pellet boiler of series
“Pelletherm v4” and a pellet
burner of series “GP” (left
side burner attachment is
shown);
H
W
D
Figure 3.4 Top view of the
system (the overall as well as
the attachment dimensions
are shown) – hot water pellet
boiler of series “Pelletherm
v4” and a pellet burner of
series “GP” (left side burner
attachment is shown);
W
p. 19/60
H
W
Figure 3.5. Back side view of the system (the overall as well as the attachment
dimensions are shown) – hot water pellet boiler of series “PELLETHERM V4”
and a pellet burner of series “GP” (right side burner attachment is shown);
p. 20/60
Top cover of the boiler
Convective duct lid
Front top lid of the
combustion chamber
Combustion chamber’s
door cover
Flange for pellet burner
attachment
Figure 3.6. Isometric view of the system – hot water pellet boiler of series
“PELLETHERM V4” and a pellet burner of series “GP” (right side burner
attachment is shown);
p. 21/60
Top cover of the boiler
Flue gases exit duct
„Tertiary pass” of the flue gases in the
boiler
„Secondary pass” of the flue gases in the
boiler
„First pass” of the flue gases in the boiler
Convective duct ash removal lid
Combustion chamber of the boiler
Combustion chamber door
Ash container
Figure 3.7. Cross section of hot water pellet boiler of series “PELLETHERM
V4” (the flue gasses pathway is schematically shown, the main elements of the
heat exchanger are pointed, right side burner attachment is shown);
p. 22/60
4.
Installation process of the system
4.1. Special features and requirements for assembly and installation of
automatic pellet burner of series “GP” and hot water pellet boiler of
series “PELLETHERM V4”
The automatic pellet burner of series „GP” is attached and mounted on the heat
exchanger of hot water pellet boiler of series “PELLETHERM V4”. The design
of the heat exchanger of hot water boiler of series “PELLETHERM V4” allow
only either “left” or “right” side installation of the burner (through an attachment
flange), so the choice of the position of the pellet burner should be performed at
the heating system project development. The installation of the burner should
achieve reliable insulation between the burner and the boiler, so to prevent flue
gases extraction out of the boiler’s combustion chamber out to the ambient
environment, either ambient air penetration to the combustion chamber. The
burner’s attachment and installation procedures should follow the requirements,
depicted below:
• easy access for ash cleaning procedure of the burner’s grate;
• reliable and safe operation of the burner and system’s modules;
• possibility for adjustment and service procedures of the systems “ hot
water boiler of series “PELLETHERM V4” and the pellet burner of series
“GP”– for burner’s operation adjustment, for fuel transport auger service
procedures and maintenance, for loading the fuel hoper and maintenance,
etc.;
4.2. Requirements for installation of system : hot water pellet boiler of
series “PELLETHERM V4” and pellet burner of series “GP”:
Preliminary notes : the achieved thermal capacity of the system : hot water
pellet boiler of series “PELLETHERM V4” and automatic pellet burner of
series “GP” depends on:
• The thermal capacity of the pellet burner (i.e. its thermal capacity
adjustment);
• The ash deposition on the heat exchanging surfaces of the boiler;
• The condition of the gasket between the burner and the heat exchanger, as
well as the combustion chamber’s door gasket rope;
• Chimney’s draught;
The efficiency of the system : hot water pellet boiler of series “PELLETHERM
V4” and automatic pellet burner of series “GP” at nominal thermal capacity and
nominal operating conditions will be in the range of 89% (depending the
p. 23/60
individual variation of each system) – this is achieved through combustion
process adjustment by utilizing gas-analyzer measurement (performed by
trained technician);
4.3. Installation and attachment of the modules of the system : hot water
pellet boiler of series “PELLETHERM V4” and automatic pellet
burner of series “GP”
Install the hot water pellet boiler, following the requirements and
instructions, described below:
4.3.1. Basic requirements for installation of hot water pellet boiler of
series “PELLETHERM V4” :
p. 24/60
•
The room, dedicated to mount the system, should be supplied
with fresh air supply duct, necessary for optimal combustion
process as well as room ventilation;
•
Installation of the system in inhabitable premises, including
dwelling corridors, is not allowed;
•
The hot water boiler should be connected to the heating
system by authorized technicians only;
•
Installation and service procedures of solid fuel hot water
boiler as well as the pellet burner should be performed by
authorized qualified and certified technician ONLY;
•
The hot water pellet boiler of series “ PELLETHERM V4”
should be connected to heating system, supplied with
OPENED or CLOSED expansion vessel. In case of closed
expansion vessel, the heating system must be supplied with
alarm pressure valve, which opens at pressure above the
operating pressure of the boilers (0.25MPa) and should have
certificate according to PED 97/23;
•
Both the entire heating system and the hot water boiler
should be totally filled with circulating fluid (water) and airfree before operating the boiler;
•
Maintenance procedures of the modules of the system should
be performed by trained adult persons, which have read the
user manual of the unit;
4.3.2. Installation of the system
Installation procedure of the system: hot water boiler of series
“PELLETHERM V4” and the pellet burner of series “GP” requires
development of engineering project for the heating system, prepared
according to the acting local norms and recommendations as follows:
•
To the heating system - EN 303-5/2000 - „Heating boilers. Part 5 :
Heating boilers for solid fuels, hand and automatically fired, nominal
heat output of up to 300 kW. Terminology, requirements, testing and
marking”;
•
Local requirements for attachment to the chimney;
•
Local requirements for fire prevention requirements;
•
To the power circuit - EN 60335-1/1997- “Household and similar
electrical appliances – safety, Part 1 – General requirements”;
4.3.3. Installation of the hot water pellet boiler of series
“PELLETHERM V4”, considering it’s easy maintenance and
servicing :
o The minimal space in front of the boiler for cleaning, maintenance
etc, should be 1000 mm;
o The minimal distance allowed between the back side of the boiler
and a wall should be 400 mm;
o The minimal distance from the boiler’s side, where the pellet
burner of series “GP” will be attached and a wall should be 500
mm, in order to allow easy maintenance and servicing procedures
of the burner as well as the pellet hopper;
COMMENTS: the requirements for the installation of the fuel
transport auger are given in the user manual of the automatic
pellet burner of series “GP”;
o The minimal distance between the opposite side (on the pellet
burner’s one) of the boiler and a wall should be 500 mm in order
to ensure easy access to the heat exchanger and to allow easy
cleaning of the deposited ash;
o The minimal distance between the top side of the boiler and a wall
(ceiling) should be 600 mm, in order to ensure easy access for the
cleaning and maintenance procedures of the heat exchanger (for
example for ash cleaning);
o The minimal distance between the hot water boiler of series
“PELLETHERM V4” and the pellet hopper should be 1000mm in
p. 25/60
order to ensure fire safe operating conditions and prevent and
alarm modes;
4.3.4. Boiler’s positioning according to the requirements for
attachment to the electric power supply circuit
The system should be positioned and should allow easy access to the
power supply plug box (230V/50Hz);
4.4. Procedure for installation of the modules of the system
After the hot water boiler of series “PELLETHERM V4” has been positioned, it
should be connected to the heating system as well as to the chimney, considering
the appropriate requirements. In order to ensure safe and reliable operation of
the boiler, it should be horizontally leveled, which will allow easy air relieving
of the circulating water.
4.4.1.
Connecting to the chimney
After the boiler has been positioned and leveled, it should be connected to the
chimney, following the requirements for efficient and reliable operation of the
system.
Circulating water outflow
connection
Flue gases exit duct pipe
Drainage outlet
Circulating water inflow connection
Figure 4.1. Backside view of the boiler of series “PELLETHERM V4”;
p. 26/60
4.4.2.
Connecting to the heating system
The boiler of series “PELLETHERM V4” should connected to the heating
system by appropriate fittings and other control elements – it should be
performed following the prepared project.
4.4.3.
Installation of the automatic pellet burner of series “GP”
EXPLANATION – at the installation of the automatic pellet burner of series
“GP” it is necessary to follow strictly the requirements, depicted in the burner’s
user manual. Use the applied mineral wool insulation gasket, applied to the
pellet burner. Please take care to prevent any gasket damages as the burner is
attached to the flange of the boiler – this gasket both reduces the ambient air
penetration into the combustion chamber as well as plays role of thermal
insulation and thus reduces the heat flow rate back to the burner’s main module.
Orifice for the pellet
burner
Screws to attach the
pellet burner of series
“GP” to the boiler
Figure 4.2. Side view of the orifice and the flange for attaching the pellet
burner to the hot water boiler;
After the pellet burner has been mounted in the orifice of the boiler, the next
step is to tighten the attachment nuts in order to ensure air tight assembly
between the heat exchanger and the burner’s attachment flange.
p. 27/60
Figure 4.3. ИSide view of the pellet burner of series “GP”, installed on
the boiler’s heat exchanger;
4.4.4. Installation of the two ceramic plates in the combustion chamber of
the boiler
Install of the two ceramic plates in the combustion chamber of the boiler – they
will direct and flue gases and will allow efficient combustion process (these
plates are packed and positioned in the at ash tray at the transport of the
boiler);
Figure 4.4. The ceramic elements are installed in the combustion chamber of the
hot water boiler of series “PELLETHERM V4” (they are positioned on specially
welded supporting plates);
p. 28/60
4.4.5. Install the secondary ash lid at the bottom of the convective part of
the boiler;
Ash lid
Figure 4.5. The ash lid (which covers the orifice for ash cleaning between
the secondary and tertiary flue gases duct of the heat exchanger) is
positioned;
EXPLANATION: the correct installation of the ash lid is strongly
required, as its correct position allows proper and efficient operation of
the boiler. That’ why after the boiler has been positioned and leveled, the
position of the ash lid should be checked and verified, as well as each ash
cleaning of the internal surfaces of the heat exchanger;;
4.4.6. Installation of the flue gases duct lid
The flue gases duct lid should be positioned by supporting it’s side to the
specially welded supporting elements on the heat exchanger and
supporting the other lid’s side on the heat exchanger vertical wall.
EXPLANATION : this lid directs the flue gases from the secondary flue
gases duct to the tertiary one, in case of alarm modes (for example at high
pressure in the combustion chamber, due to fuel explosions) this lid open
(due to pressure difference) and thus allow damage prevention and
pressure pulse reduction
ATTENTION : this lid is thermally loaded, that’s why it is symmetric. It
is recommended to turn over this lid periodically (for example to turn it
upside down on a period of two to three week operation of the boiler).
p. 29/60
The directing lid is put aside,
on the upper surface of the
heat exchanger, before being
installed
Figure 4.6. The flue gases lid is put aside and the flue gases exit duct of
the boiler is seen;
Flue gases lid is correctly
positioned
Flue gases lid hanger (for easy
handling)
Flue gases lid lower support
(welded on the heat exchanger)
Figure 4.7. The directing lid correct position is shown;
p. 30/60
4.4.7. Installation/verification of the horizontal combustion lids and the
combustion chamber cover
Figure 4.8. Positioning the cover
elements of the hot water boiler of
series “Pelletherm v4”
4.4.8. Install the heat exchanger’s convective duct lid
EXPLANATION : this lid has thermal insulation protection plate,
produced from stainless steel.
Figure 4.9. The convective part lid is put at the place of its position;
p. 31/60
4.4.9. Install the boiler’s heat exchanger combustion chamber lid
EXPLANATION: this lid has thermal insulation protection plate,
intended to operate at high temperature levels of the flue gases in the
combustion chamber of the boiler.
Figure 4.10. The combustion chamber lid is put at its position;
Figure 4.11. Both flue gases directing lids are positioned on their place of
the hot water boiler’s heat exchanger;
ATTENTION : these flue gases directing lids are not one and the same, do not
change their position.
p. 32/60
4.4.10.
Connect the pellet burner of series “GP” to the hot water
boiler of series “PELLETHERM V4”
Connect the automatic pellet burner to the boiler by plugging burner’s connector
to the boiler female connector.
On the back side of the hot water boiler are installed electrical connectors –
these connectors are for the power supply of the boiler, for connecting the pellet
burner, for connecting a room thermostat, for connecting a flue gas fan (this fan
is an option, i.e. it is not a module of the system).
ATTENTION : these electrical connectors are equipped with an element, which
prevents involuntarily detachment of the connectors – do not force them, use
appropriate tool in order to unplug;
Flue gases fan connector ;
EXPANATION - the flue gas
fan is an option, it’s not part of
the system;
Room thermostat connector
Pellet burner connector
Power supply connector
Figure 4.12. Back side view of the boiler – the electrical connectors are
labeled;
p. 33/60
4.4.11.
Installation of the pellet transport auger
The process of pellet transport auger is described in the pellet burner’s
user manual.
At the installation of the pellet transport auger the requirements, which are
described in details in the automatic pellet burner of series “GP” user
manual should be followed;
EXPLANATION : The angle (between the axis of the auger and
horizontal plane ) of inclination of the transport auger influences on its
productivity, i.e. on the fuel flow rate, achieved at the local conditions on
the systems installation. That’s why at variation of the auger’s inclination
the burner could require adjustment of its operation mode. The burner’s
adjustment is done by trained authorized technician only;
4.4.12.
Pellet transport auger fuel charging.
The transport auger of the pellet burner of series “GP” is initially empty
(no fuel inside it’s pipe). The power supply plug should be connected to power
supply, thus the motor of the auger will operate constantly. Charge the pellet
hopper and wait until the pellets start to drop out of the exit orifice of the auger,
then unplug the power supply of the auger and connect it to the female plug of
the pellet burner (positioned on burner’s right side), then switch on the power
supply of the pellet boiler of series “PELLETHERM V4”.
ERATO company reserves the right to make any changes of the design and
factory setting of the burner as well as the hot water boiler, without obligation
to inform about that the end users.
4.4.13.
Connect the control box of the boiler to the power supply;
Use the applied connectors, connect the power supply cable to the boiler,
then connect it to the main power supply chain. The connection should be
performed by authorized technician only.
EXPLANATIONS :
• The producer reserves the right to make changes of the design of the
modules of the system, without noticing the end user;
• At initial start-up of the pellet burner as well as when the contents of the
pellet hoper is consumed, the auger must be filled-up with fuel. This fuel
charging process is described in the automatic pellet burner’s user
p. 34/60
manual. This operation should be explained and demonstrated on the end
user by trained service technician;
4.4.14.
Final view of the system
Figure 4.13. Final view of the system: hot water pellet boiler of series
“PELLETHERM V4” and a pellet burner of series “GP”;
p. 35/60
4.4.15.
Recommended principal hydraulic scheme for the hot
water pellet boiler
Recommended principal hydraulic scheme for connecting the hot water pellet
boiler of series “PELLETHERM V4” to a heating system, equipped with
OPENED expansion vessel is shown on the following figure.
Tap water
OPENED
expansion
vessel
To the heating
system
Domestic hot
water
From the
heating system
Tap water
Drain
age
Figure 4.14. Recommended principal hydraulic scheme for connecting the
hot water pellet boiler of series “PELLETHERM V4” to a heating system,
equipped with mixing valve and a heat accumulator.
Index
1
2
3
4
5
6
7
8
9
10
11
Designation
Hot water boiler
“PELLETHERM V4”
Safety valve
Hot water boiler
Return valve
Circulating pump 1
Control valve
Expansion vessel
Control valve
Three way mixing valve
Circulating pump 2
Control valve
Index
12
13
14
15
16
17
18
22
23
24
Designation
Water filter
Thermovalve TV
Return valve
Contact thermostat
Heat accumulator
Automatic circulating water
charger
Drainage valve
Automatic air separator
Safety valve
Return valve
Table 4.1. Description of the elements, indexed on figure 4.14
p. 36/60
EXPLANATION : According to EN 303-5 the heat accumulator tank is
obligatory module of a local heating system, operating with solid fuel hot water
boiler. The heat accumulator capacity calculation is made according to the
above mentioned norm, as well as heat accumulator methodology, developed by
ERATO.
ATTENTION: The finalization of the system installation and performing the
commissioning tests should be filled in the appropriate documents of the
boiler as well as the pellet burner, where the required data fields should be
filled in (this is obligatory).
p. 37/60
5.
System starting procedures.
ATTENTION: the system, consisting of “ hot water pellet boiler of series
“PELLETHERM V4” and an automatic pellet burner of series “GP” should be
installed and commissioned by trained, authorized and certified company only.
5.1.
Basic fuel requirements.
• The fuel, pellet shaped, should be dry. The unit producer recommends that
the fuel should be stored in dry and well ventilated rooms;
• It is strongly forbidden to store the fuel in close region of the system (both
the boiler and the burner), the minimal safety distance between the fuel
and the appliance is 400 mm;
• The system producer recommends an optimal distance between the boiler
and the fuel container to be at least 1000mm. It is recommended to store
the fuel in room, next to that, where the boiler is installed;
• At the installation procedure of the system, as well as the fuel storage one,
fire prevention recommendation should be considered. It is also
recommended to install a fire-extinguisher in a safe and easy accessible
place;
In principle heating systems, which are hydraulically opened to the
atmosphere allow direct contact between the circulating fluid (in most cases it is
water) and the air. During the heating season the water content in the expansion
vessel absorbs oxygen from the atmosphere though the free surface. The
increased oxygen content in the water threatens the metal of the unit, as well the
pipes. Through the free surface of the expansion vessel water evaporation is
observed as well. Considering these, appropriate water should be added through
the expansion vessel – it must cover the requirements of norm BDS 15207-81.
During the heating season regular checking of circulating water level in
the expansion vessel should be performed by the end user. The water content in
the circulating system should be kept constant. If additional water is required,
then precautions should be taken, not to add air in the heating system as well.
The water, utilized for filling purposes of the heating system should be
decontaminated and air-free, and is not dedicated for any other purposes, but as
a circulating fluid only. Any heating system drainage is inadmissible, except
when repairing modules/sections of the system. Practical experience shows that
water level checkup should be performed regularly in a period of 14 days in
order to sustain quasi-constant water content.
p. 38/60
In case that additional water is required, the filling process should be
performed carefully, when the hot water boiler is cooled to the ambient
temperature. This precautions are induced due to prevent rising of thermal stress
of the steel boiler’s body and its damage (leakage).
In case that the boiler as well as the heating installation will not be in
exploitation for a long period, then in order to prevent local water freezing and
damages, it is advisable to perform total drainage of the circulating water. Please
take into account that the presence of liquid in the heating system, as well in the
boiler will prevent oxidation process of the metal surfaces, corrosion and system
failures.
5.2.
Starting up the system (consisting of hot water pellet boiler of series
“PELLETHERM V4” and automatic pellet burner of series „GP”).
Basic requirements:
•
Any maintenance procedures should be performed in accordance with the
described in this manual;
•
Any intervention in the working process of the system, which could lead to
unit’s failure and/or dangerous and health threatening situations, are strongly
prohibited;
•
The system should be checked by the maintenance staff or any trained
personal regularly;
•
The end-user should not perform any interventions, repairs, etc. of the
system. In case that warning and failures arise, check the failures table
(applied at the end of this manual) and call the service support if the case is
not described there;
•
Any adjustments of thermal capacity higher than the nominal thermal load of
the modules are not allowed;
•
The ash, deposited in the combustion chamber of the boiler, should be
collected in fireproof containers and cooled down to ambient temperature.
The cooled ash should be disposed in appropriate waste containers. Please
take into account that the mineral ash, result of wood biomass pellets could
be considered as soil fertilizer and dispersed for agricultural purposes for
example;
p. 39/60
5.2.1. Interface control board of hot water pellet boiler of series
“PELLETHERM V4”
Alarm thermostat
START indicator
Alarm signal
(boiler’s overheating)
“POWER” switch
START switch
Operating thermostat
Thermo-manometer
Fuse
Figure 5.1. Interface control board, equipped with control and operating devices
of hot water pellet boiler of series “PELLETHERM V4”.
START
indicator
Alarm signal
(boiler’s overheating)
Thermometer
Manomenter
START switch
Operating thermostat
Figure 5.2. Interface control board, equipped with control and operating devices
of hot water pellet boiler of series “PELLETHERM 18 V4”.
p. 40/60
Interface control board devices
description:
Figure 5.3. View of the control
elements, installed on the back
panel of “Pelletherm 18 v4”.
• Main “POWER” switch –
switches ON and OFF the
main power supply of the
hot water pellet boiler of
series
“PELLETHERM
V4” and the pellet burner
of series “GP”;
• Operating thermostat –
assigns the set-point of
circulating
water
temperature in the boiler.
The pellet burner of series
“GP” (i.e. the system) will
run until this set-point is
reached and will supply
heat energy to the heating
system;
• Emergency thermostat –
protects the hot water
boiler
of
series
“PELLETHERM V4” from
exceeding
emergency
temperature levels and
overheating.
This
thermostat is factory preset
to switch off the power
supply of the pellet burner
of series “GP” at water
temperature in the boiler
above 95oC (factory set);
• “START” switch – sends “START/STOP” signal to the process
control module of the pellet burner of series “GP”, which controls
its operation;
• Thermo-manometer – indicates the operating temperature of the
circulating water in the heat exchanger jacket of the boiler, well as
water overpressure;
• Alarm indicator – emergency boiler overheating – indicates
emergency overheating state of the boiler, due to activation of the
emergency thermostat of the boiler. In case of activation, cool down
p. 41/60
the unit and check and repair the reason for the emergency
situation, finally reset the emergency thermostat;
• “START” indicator – indicator lamp, light up at presence of
operating signal for the pellet burner of series “GP”;
• Fuse – main electrical power fuse of the boiler;
5.2.2.
Hot water boiler of series “PELLETHERM V4” power supply.
• The unit should be connected to the main power supply, according to the
safety rules and appropriate norms. The system includes a power supply
cable – use this to connect the boiler;
5.2.3.
System very first start
The pellet hopper (which is not an element of the system: pellet boiler of
series “PELLETHERM V4” and pellet burner of series “GP”) should be
filled with pellets, in order transport material by the pellet feeding auger to
the burner.
Read the user manual of the pellet burner of series “GP” first.
The system is switched on by the main “POWER” supply switch, placed on
the control board of the pellet boiler. The system gets activation signal by
switching ON the “START” and goes into automatic operating mode – it
goes through ignition mode if needed. If the “START” switch is OFF then
the burner goes (or stays) into stand-by mode and waits until new command
arise. In case of power supply break-down the burner will go into the same
state of the unit before the interruption. The “START” signal for the pellet
burner is given by the operating thermostat of the boiler (in case that room
thermostat is installed, then this thermostat should set “START” mode as
well).
ATTENTION:
• It is possible to observe flue gases emission out of the boiler at starting up
the system, especially in case that the chimney does not have appropriate
draught (for example lack of chimney’s height or the chimney’s flue duct
is clogged. The above mentioned gases could be released through the
door gasket or the upper section of the boiler, where the flue gases lids
are positioned – check and verify their position. It is recommended to
check the condition of the chimney as well. The same process could be
observed during the transition periods (during spring and autumn), when
p. 42/60
the natural draught of the chimney is not covering the loses in the flue
duct of the system, due to the high levels of the ambient temperature;
• It is possible due to incorrect adjustment of the initial doze of the fuel to
observe smoke extraction out of the boiler, due to uptightness of the
gaskets of the hot water boiler. In case of this situation it is necessary to
make adjustment of the operating parameters of the burner – this
procedure is performed by authorized, trained and certified technician
only;
EXPLANATIONS:
• In ignition mode, the electric heater is activated (i.e. switched on) – this
heater is mounted under the inclined plate in the combustion chamber of
the burner. This electric element heat up the fuel until the pellets are
ignited and combustion process is stabilized. The photo-sensor of the
burner senses the presence of light from the flame. Additional information
about the ignition process is described in the pellet burner’s user manual;
• The automatic pellet burner of series “GP” operates by predefined
algorithm, which is implemented through specialized control board of the
burner. The adjustment of the operating parameters of the control board of
the burner is performed by authorized, trained and certified technician
only;
5.2.4.
Operating parameters of the boiler.
The operating mode of the hot water boiler of series “PELLETHERM
V4” is defined directly by setting its operating thermostat set-point. However,
one should consider that the inflow circulating water temperature influences the
operating mode of the system, reflecting on its reliability and efficiency.
ATTENTION: The producer guaranties effective and reliable operation of the
system : hot water pellet boiler of series “PELLETHERM V4” and a pellet
burner of series “GP” only when the operating mode is in the range of the
parameters, described in Table 3.2 of this user manual.
5.2.5.
Operating parameters for adjustment of the pellet burner of
series “GP”
In the user manual of the pellet burner “GP” are given the adjustable parameters
of the burner, which determine the operating mode of the burner, as well as the
burner’s thermal capacity. The user accessible parameters (the P2 parameter, the
fuel, etc.) should be explained to the end user by the installer, thus giving
opportunity to control the burner according to the client’s heat demands and
comfort requirements.
p. 43/60
EXPLANATION: It is recommended to make any changes of the operating
parameters of the burner ONLY when the influence of this parameters on the
overall performance of the burner’s operation are know in advance. It is
recommended to make any changes of the operating parameters by trained
technician.
ATTENTION : In case the model of the hot water boiler is “Pelletherm 18v4”,
then the thermal capacity of the pellet burner of series “GP25” should be
adjusted not to exceed the nominal thermal capacity of the boiler. This
requirement is covered by adjusting the operating parameter of the burner P2=4
(not more), defined by the potentiometer, positioned on the control board of the
burner. In case the boiler is “Pelletherm v4” the pellet burner should be
adjusted in the range of P2=1….4.
COMMENTS:
•
In the user manual of the automatic pellet burner of series “GP” are shown
the operating parameters, which define the thermal capacity of the boiler, as
well as the adjustment procedure;
•
The user manual of the pellet burner contains information about the default
values, the adjustment and the influence of the operating parameters of the
unit – their variation and adjustment should be performed by trained
authorized technician only;
•
The producer reserves the right to make any changes of the factory settings
of the burner, without any obligations to inform the end users;
•
The adjustment of the thermal capacity of the system: hot water pellet boiler
if series “PELLETHERM V4” and pellet burner of series “GP” could be
realized by determination of the fuel flow rate (i.e. to measure the mass of
the pellets, transported for defined period of time), considering the calorific
value of the fuel and the thermal efficiency of the system. Detailed
description of such procedure could be found in the user manual of the pellet
burner;
•
During the nominal operation mode of the burner, alarm or abnormal
situations could rise – i.e. unsuccessful fuel ignition, to run out of pellets,
etc. The pellet burner will go into alarm mode and will indicate its status
through appropriate indication of its LEDs. In case of such situation, the
burner should be restarted – this is performed by swithching off the power
supply and then back on, only after the alarm mode issue has been clarified
and removed;
NOTES :
p. 44/60
• In principal the fuel’s ash content does not change its low calorific value.
However, the combustion process is greatly influenced by the presence of
mineral mass, i.e. ash, but requires specially designed burner in order to
achieve efficient and reliable operation. The above mentioned requires
appropriate testing and verification of the fuel’s applicability as energy
source for the pellet burner of series “GP” before making nominal
exploitation of the unit. Consult the requirement for fuel of the burner or
the appliance producer’s assistance;
5.2.6. Nominal operating mode of the system.
After the initial start-up of the automatic pellet burner of series “GP” (i.e.
the fuel is successfully ignited) and the boiler has reached its nominal
thermal conditions, the circulating water and the entire heating system are
in steady state thermal conditions (i.e. they are tempered, which takes
time), it could be considered that the system is in nominal operation mode.
The adjustment of the operating (both the boiler’s as well as the pellet
burner’s) parameters should be performed. Detailed description of the
pellet burner adjustment is given in its user manual.
At nominal operation of the system the commissioning of the burner’s and
boiler’s operation should be performed, following the governing local
requirements.
NOTES:
• The temperature of the return flow of the circulating water of a heating
system is recommended to be above 60oC, because of possibility to
achieve condensation of the water vapor on the internal surfaces of the
boiler;
• It is recommended to operate the boiler’s thermal capacity in the range,
described in Table 3.1. In case that lower thermal capacity are needed,
this modes are much less efficient and heat accumulator is
recommended to be attached to the system (see 4.4.15), in order to
ensure reliable and efficient operation of the system;
• At the initial start-up of the pellet boiler of series “PELLETHERM V4”
intensive water vapor condensation could be observed. This is a single
process and does not influence the performance of the system, neither
causing any operating issues;
p. 45/60
5.3.
Control of the thermal capacity of the system.
The control of the thermal capacity of the system is performed by adjustment of
the thermal capacity of the pellet burner of series “GP”. For detailed
information about this process, please refer to the user manual of the pellet
burner.
ATTENTION : In case of change of the fuel type (for example changing the
pellets category, supplier, size, etc.) it should be followed by adjustment of the
thermal capacity parameters and the operating mode of the burner.
ATTENTION : in case the hot water boiler model is “Pelletherm 18v4”, the
pellet burner of series “GP25” should operate in the thermal capacity range,
not exceeding the nominal thermal capacity of the boiler, i.e. the operating
parameter of the burner should vary in the range P2=1….4.
5.3.1. Decreasing the thermal capacity of the system:
It is realized by turning the thermal capacity potentiometer (on the control
board of the pellet burner) anticlockwise. For more information – refer to
the pellet burner user manual;
ATTENTION: do NOT decrease the thermal capacity of the burner
below the minimal one for the system, as such operating modes strongly
decrease the thermal efficiency of system and lead to its low reliability;
5.3.2. Increasing the thermal capacity of the system:
It is realized by turning the thermal capacity potentiometer (on the control
board of the pellet burner) clockwise. For more information – refer to the
pellet burner user manual;
ATTENTION: do NOT increase the thermal capacity of the burner
above the nominal one for the system, as such operating modes strongly
increase the thermal loads of some of the components of the system, which
could lead to alarm situations and eventually thermal deformations of
parts of the combustion chamber of the pellet burner, the reliability of the
system is decreased as well;
ATTENTION : in case model of the hot water boiler is “Pelletherm
18v4”, the maximal allowed value of the operating parameters P2 is 4.
p. 46/60
5.4.
Adjustment of the combustion process.
The adjustment of the combustion process of the pellet burner is described
in details in the pellet burner’s user manual. The combustion process adjustment
should cover the requirements for the flue gases parameters of norm EN 303-5,
as well as the requirements for nominal, safe and reliable operation of the
system.
5.5.
Stopping the operation of the system.
Stopping the operation of the system should be performed by turning OFF the
“START” switch, mounted on the interface panel of the hot water boiler of
series “PELLETHERM V4”. Respectively, the starting process will be invoked
by turning “START” switch in ON position. In case that the system will not
operate for a relatively short period of time, than it is recommended to clean the
ash deposited on the easy accessed heating surfaces of the heat exchanger, as
well as the combustion chamber’s walls of the pellet burner.
EXPLANATION: the stopping operation mode of the pellet burner of series
“GP” is described in details in the burner’s user manual;
ATTENTION : In case that the system will not operate for a long period of
time, then the hot water boiler’s heat exchanger should be thoroughly cleaned
from the deposited ash. The deposited on the metal surfaces ash acts corrosively
on the carbon steel surfaces, which will lead to a decrease of the lifetime of the
systems main modules – heat exchanger of the boiler as well as the burner. It is
obligatory to perform service procedures and preventive observations of the
systems by trained service personal only as well as thorough cleaning at the end
of each heating season. Completing these requirements will ensure long
exploitation duration of the system and its high efficiency and reliability.
5.6.
Turning OFF the system.
The system (i.e. pellet boiler of series “PELLETHERM V4” and pellet burner
of series “GP”) is turned off by changing the “START” switch of the boiler into
OFF position - this is the recommended method for turning the system off.
During the working process in OFF state, the control board of the pellet burner
performs so called “controlled turning off procedure” in which the operating fan
is working and certain operating system parameters are controlled. After the
boiler has cooled down to ambient temperature, the system should be switched
off by turning off the boiler’s main “POWER” switch. It is recommended to
clean the deposited ash thoroughly of the heat exchanging surfaces of the boiler.
p. 47/60
• Emergency stop of the system.
In operating process of the system emergency situations could arise and the
component (i.e. the boiler and the pellet burner) will go into alarm/failure
mode. Some situations are detected by the safety units and the process
control board and the systems will go into automatic preventive regimes in
order to protect the boiler and the heating system. These regimes are
operated by appropriate automatic preventive measures as well as the
control board indicates alarm mode, through its LEDs. Please refer to the
pellet burner user manual, as well as this document before taking any
actions. After the cause of the alarm situation is clarified, take adequate
actions for bringing back the system into normal operating conditions and
restart the burner by switching OFF and back into ON state by turning the
main “POWER” switch of the pellet boiler of series “PELLETHERM V4”.
ATTENTION :
• in case of emergency situation – boiler overheating, the emergency
thermostat is activated and the alarm indicator lamp is lit. In this
case the boiler should be cooled down and the reason for such
excessive process should be investigated and preventive measures
should be performed. The emergency thermostat should be manually
reset by unscrewing its preventive cap and its stem should be pressed
until the thermostat switches back on (a “click” sound is heard in
this process), screw the cap back. After the boiler is checked and the
cause for overheating is determined and repaired, restart the pellet
burner by turning off the boiler’s the main “POWER” switch and
then back on in order to operate the system in normal state;
• in case that the pellet burner of series “GP” has reached alarm
mode, it will stop and go into alarm mode, which is indicated with
the LEDs on its control board. Please refer the pellet burner’s user
manual for description of the alarm mode and take preventive
actions;
• in case that the alarm mode is neither described in this documemnt
or the pellet burner’s user manual, then it is strongly recommenced
to contact the system’s servicing company in order to resolve the
issue and start the nominal operation of the system;
5.7. Showing and teaching the end user about the maintenance and
adjustment procedures.
It is necessary to read thoroughly this user manual as well as the user
manual of the pellet burner of series “GP”, as well as the basic properties of the
modules of the system. It is necessary to know the operation process of the
p. 48/60
boiler as well as the burner – i.e. starting, running, switching off, cleaning the
ash, etc.
It is necessary to show and teach the end user the maintenance procedures
for operating the boiler efficiently and keep its reliability in high degree order.
Also the installer should demonstrate and teach the end user how to change the
operative parameters of the control module of the boiler in order to operate the
unit in different modes and heat capacities, according to the local heat
consumption:
• Fuel hopper charging – the fuel is poured out in the hopper of the
system. The pellet auger takes out the fuel from the hoper and transport
the fuel to the main module of the pellet burner;
• Ash cleaning procedure – it is recommended periodically (at least
once per every 72 hours of system’s operation) to stop the pellet burner
by switching off the “START” switch of the control board of the boiler,
wait until the system cools down (at least 30 minutes) and clean the ash
residue of the heat exchanger of the hot water pellet boiler of series
“PELLETHERM V4” by manually scrapping and brushing the ash.
Take away the ash residue, collected in the ash tray of the boiler if
necessary. Covering this requirement will ensure effective heat
exchanging process and will sustain optimal operating conditions of the
boiler. Switch the boiler ON by turning on the “START” switch and the
systems will start (if there is signal for operation);
ATTENTION : regular cleaning of the ash residue, deposited on the
heat exchanging surfaces of the boiler will ensure long-life reliable
exploitation period, economic and efficient performance of the unit;
• pellet burner grate ash cleaning procedure – after the system has
been switched off and the burner is cooled down to ambient
temperature level, it is necessary to open the door of the boiler’s
combustion chamber, take away the grate of the burner, clean the ash
residue, put the burner’s grate back, then close the door and switch on
the “START” and start the system;
EXPLANATION : the door of the pellet boiler’s combustion chamber
is closed by a handle. It is recommended not to apply high force at the
closing process in order to protect the door’s gasket heat resistant rope
and to ensure combustion chamber’s tightness. The opening of the door
is performed by turning the handle clockwise (the handle’s lever should
be lifted upwards);
p. 49/60
Figure 5.4. Scrapping the ash residue off the walls of the pellet boiler of
series “PELLETHERM V4” heat exchanger;
Figure 5.5. Taking the ash tray out of the combustion chamber and
cleaning the ash;
Open the combustion chamber’s door and take out the ash tray, positioned on
the bottom of the boiler, the ash residue is collected there. Pour the ash residue
in heat resistant container (or any appropriate container), put the ash tray back
on its position, close the door, check the position and tightness of the upper lid
on the heat exchanger as well;
ATTENTION : regular cleaning of the ash residue, deposited on the heat
exchanging surfaces of the boiler will ensure long-life reliable exploitation
period, economic and efficient performance of the unit;
5.8.
Safety and unexpected risks
Risks could arise at the exploitation of the system:
The modules of the system– hot water pellet boiler of series “PELLETHERM
V4” and automatic pellet burner of series “GP” are designed and produced
according to the safety requirements of the operating European standards and
p. 50/60
norms. However safety and unexpected risks could arise in situations like
following:
• Hot water pellet boiler of series “PELLETHERM V4” is operating
incorrectly;
• Automatic pellet burner of series “GP” is operating incorrectly;
• The system is installed by unauthorized/unqualified personal;
• The safety instructions, described in this manual are not followed and
fulfilled;
• The safety instructions, described in the user manual of the pellet
burner of series “GP” are not followed and fulfilled;
Unexpected risks :
The modules of the system (pellet boiler of series “PELLETHERM V4” and
pellet burner of series “GP”) are designed and produced according to the
requirements of the operating EU safety norms. However, in spite of that
possible risks are considered as a result of the operating process of the modules,
it is possible to arise risks as follows :
• Cauterization risks, caused by high temperatures, as a result of the
combustion process in the combustion chamber and/or direct access to the
front door of the combustion chamber, at manual cleaning processes of the
surfaces of the burner and/or combustion chamber, or ash residue
cleaning, accumulated in the ash tray or any unburned fuel material,
smoldering in the ash tray;
• Electrical shock risks at indirect contact. The pellet boiler and the pellet
burner are connected to the power circuit and their operating modules are
separated in specialized electric control box, equipped with required
protective and short-circuit preventive devices. It is obligatory to perform
boiler ground connection by authorized personal/technician;
• Fingers injuring risks at opening/closing the doors/caps of the boiler at
maintenance and cleaning process of the unit. It is recommended to use
appropriate individual resources for self-protection;
• Suffocation risks due to flue gas uncontrolled emissions in the boiler’s
room, in case when the chimney draught is insufficient, in case that the
convective part of the boiler is clogged, or in case that the flue gas duct is
not fully tightened and gas leaks are possible;
p. 51/60
5.9.
Operation faults and their repairing
In case of system failure, it is necessary to clarify the issues and find
appropriate solution. Some of the operating faults are described in the pellet
burner’s “GP” user manual and appropriate solution is proposed. This document
contains additional information, which will be helpful both for the end user as
well as the technicians.
No
Operation fault
Cause
1.
Low temperatures Insufficient
in
the
heat capacity
supplied rooms
2.
High temperatures
in
the
heat
supplied rooms
3.
The
boiler
active, but
combustion
process
4.
Difficult
ignition
p. 52/60
is
no
fuel
Method for repairing
thermal Adjustment of operating
parameters of the burner is
required – check the
burner’s user manual;
Low set-point temperature It is necessary to increase
of the boiler’s operating the set-point of the boiler’s
thermostat
operating thermostat (up to
90oC)
Low set-point temperature It is necessary to increase
of the remote room the set-point of the room
thermostat (if connected)
thermostat
High set-point temperature It is necessary to decrease
of the boiler’s operating the set-point of the boiler’s
thermostat
operating thermostat (it is
recommended to keep it
above 60oC)
High set-point temperature It is necessary to decrease
of the remote room the set-point of the room
thermostat (if connected)
thermostat
“START” signal is not It is necessary to check the
present
status of the operation
signal of the pellet burner check
the
room
thermostat,
“START”
switch, boiler’s operating
thermostat.
Low quality fuel
It is necessary to replace
the fuel, most probably
due to its high moisture
content, which could be
above the required value
for nominal operation of
the burner.
5.
Boiler’s
emergency
overheating
6.
No fuel ignition
It is necessary to check the
correct operation process
of the heating installation
and eventually appropriate
adjustment
of
the
operating parameters of
the pellet burner and/or
control valves of the
installation – this should
be
performed
by
authorized
technician.
After the boiler is cooled
down
to
ambient
temperature and the reason
for boiler overheating is
serviced out, the protective
cap of the emergency
overheating
thermostat
should be unscrewed, its
rod should be pressed until
the thermostat is reset and
it’s cap should be screwed
back. The main “POWER”
switch is turned OFF and
back ON afterwards and
the
system
is
thus
restarted.
Absence of fuel in the The fuel hopper should be
hopper
charged
Absence
of
heat
consumption or incorrect
adjustment
of
the
parameters of the boiler or
poor operation of the
heating installation
Absence of fuel in the It is possible to manually
burner
restart
the
operation
process of the burner.
Check if the ignition
process needs to be
elongated - the adjustment
should be performed by
authorized
technician
only;
Fuel is present in the In case that the electrical
burner, but it’s not ignited heater is out of order or
or it is fully incinerated not operating, then it
and
the
combustion should be renewed. In case
p. 53/60
process has extinguished;
Abnormal operation or
malfunctioning of the
burner’s photocell
•The flame looks Low quality pellets
“opaque”
and
smoke is observed
at the exit of the
chimney
Inappropriate
operating
parameters adjustment of
the pellet burner
7.
Presence
of Ineffective
unburned fuel in combustion process
the ash tray of the
boiler
8.
High temperature
of the flue gases (if
flue
gas
thermometer
is
mounted)
9.
fuel
The
heat
exchanging
surfaces of the boiler are
deposited
with
ash,
presenting heat resistive
layer, thus decreasing the
heat exchanging intensity
Water
vapor Low temperature of the
condensates on the inlet water flow
surfaces of the
heat exchanger
p. 54/60
that the heater is working,
then it is necessary to
increase the time for
ignition of the initial mass
of the fuel - the adjustment
should be performed by
authorized
technician
only;
The burner’s photocell
should be checked or
replaced – see the pellet
burner’s user manual;
Fuel
replacement
is
recommended,
most
probably the moisture
content is higher than
required;
It is necessary to perform
adjustment
of
the
operating parameters of
the pellet burner and
achieve
efficient
combustion process - the
adjustment should be
performed by authorized
technician;
It is necessary to perform
adjustment
of
the
operating parameters of
the
burner
–
the
adjustment should be
performed by authorized
technician;
It is necessary to clean
thoroughly
the
heat
exchanger surfaces of the
hot water pellet boiler of
series
“PELLETHERM
V4”;
Check the adjustment of
the heating system. It is
necessary to perform
adjustment of set-point
10. Flue gases are
emitted out in the
boiler’s room after
certain period of
exploitation
The gaskets of the lids, the
combustion
chamber
gasket, eventually the
gasket between the pellet
burner and the boiler are
out of order and need
replacement
11. Pellet
burner Overheating of the pellet
combustion
burner
chamber’s thermal
deformation
12. Other failures, not
described above
temperature,
which
controls the circulating
pump of the heating
system. It is recommended
to adjust the thermostat
set-point to minimum of
65oC;
It is necessary to check
and tget tightened the
gaskets,
or
their
replacement
–
this
procedure
should
be
performed by authorized
technician;
It is necessary to change
the operating parameters
of the pellet burner or
eventually replace it;
It is necessary to consult
authorized technician and
eventually
service
maintenance should be
performed
Table 5.1. Description of operation faults of the system (consisting of hot water
pellet boiler of series “PELLETHERM V4” and automatic pellet burner of series
“GP”), causes and methods for repairing
5.10. Pellet system warranty form completion.
The applied WARRANTY FORM should be completed, by filling the
required information in the appropriate fields. The assigned field for
signatures and stamp should be completed as well in order to VALIDATE
the WARRANY FORMS of the hot water pellet boiler of series
“PELLETHERM V4” and the one for the pellet burner of series “GP”.
COMMENT : the automatic pellet burner of series “GP” has its own
warranty form, which should be fulfilled as well;
p. 55/60
5.11. Actions, after the modules of the system are not in exploitation
anymore.
After the lifetime period of the modules of the system have been
completed, then they should be treated properly in order to preserve
environment contamination. The units should be dismounted and disassembled
by environmentally safe methods. This requirement is most commonly
completed by appropriate components recycling, considering separate waste
disposal and utilization methods.
p. 56/60
6.
Electrical scheme of hot water pellet boiler of series
“PELLETHERM V4”.
Figure 6.1. shows the principal electrical scheme of the control board of the
pellet boiler of series „PELLETHERM V4”.
BOILER
Boiler’s operating
thermostat
Connector
Connector
FS1
10A
Brown
L 220 V
Phase
T0
Alarm
boiler
C
Room thermostat
C
Brown
START
1
2
1
1
2
Cable of
the pellet
burner
Black
0
T Alarm boiler
Gray or
blue
N 220 V
START
PE
Yellow-green
PE Yellow
- green
N
Gray or
blue
OPTION
ATTENTION: the room
thermostat connector should
be plugged in. It has factory
set
electrical
bridge.
Remove the bridge and
connect the room thermostat
to this connector.
Flue gas fan
L
N
blue
Yellowgreen
~1
brown
М1
С
black
Connector
The colors of the wiring is valid
for flue gas fan, produced by
ЕВМ PAPST
Figure 6.1. Principal electrical scheme of the control board of the pellet boiler
of series „PELLETHERM V4”;
EXPLANATION: the principal electrical scheme of the automatic pellet
burner of series “GP” is shown in its user manual.
p. 57/60
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