08 NES Tech Manual PelleBurn

08 NES Tech Manual PelleBurn
EN
PELLET BURNING BOILER
PelleBurn series
TECHNICAL PASSPORT
INSTALLATION and OPERATION MANUAL FOR
AUTHORIZED INSTALLER / SERVICE SHOP
Version i0.8
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
2
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
TABLE OF CONTENTS
1.
EXPLANATION OF SYMBOLS AND SAFETY INSTRUCTIONS .................................... 4
1.1. Explanation of symbols ......................................................................................... 4
1.2. Requirements to burner installation room ............................................................ 4
1.2.1.Instructions to burner installer.............................................................................. 4
1.2.2.Instructions to installation user ............................................................................. 5
1.2.3.Minimum clearances for installation. Combustibility of construction materials ... 6
2.
PRODUCT DESCRIPTION ......................................................................................... 6
2.1. Design structure of boiler PelleBurn ..................................................................... 6
2.2. Design of pellet burner Pell ................................................................................... 7
2.3. Safety devices of pellet boiler and burner ............................................................ 8
2.4. Design of pellet auger ........................................................................................... 8
2.5. Design of fuel hopper FH 500 ................................................................................ 8
3.FUELS ...................................................................................................................... 9
4.TRANSPORTATION ............................................................................................... 11
5.
DELIVERY PACKAGE .............................................................................................. 13
6.
INSTALLATION OF THE HEATING BOILER .............................................................. 13
7.
SETUP OF THE HEATING BOILER .......................................................................... 14
7.1. Connecting the boiler to a chimney .................................................................... 14
7.2. Pellet boiler connection to the pellet burner, auger and fuel hopper ................ 15
7.3. Connecting the boiler to the mains power supply .............................................. 15
7.4. Connecting the boiler to the heating installation ................................................ 20
7.5. Connecting diagrams ........................................................................................... 22
8.
FILLING THE HEATING INSTALLATION .................................................................. 26
9.
OPERATION OF BOILER ........................................................................................ 26
9.1. Operation of pellet boiler PelleBurn with pellet burner Pell ............................... 26
9.2. Important recommendations for long-lasting and correct operation of the boiler......27
9.3. Cleaning and maintenance by authorized installer / service .............................. 27
10. CONTROLLER UNIT .............................................................................................. 30
10.1. Controller view. Explanation of buttons and indicators ...................................... 30
10.2. User menu ........................................................................................................... 32
10.3. Installer menu ..................................................................................................... 34
11. SETTING OUTPUT MODES OF OPERATION OF THE PELL PELLET BURNER
CONNECTED TO PELLEBURN PELLET BOILER........................................................ 38
11.1. Calibration of auger fuel feed rate ...................................................................... 38
11.2. Burner output adjustment .................................................................................. 38
12. MOUNTING OF FUEL HOPPER FH 500 ................................................................. 40
13. WARRANTY TERMS .............................................................................................. 40
14. TECHNICAL FEATURES ......................................................................................... 42
14.1. Technical features of PelleBurn pellet boiler ....................................................... 42
14.2. Technical parameters of PelleBurn pellet boiler................................................... 45
14.3. Technical features of fuel hoper FH 500 .............................................................. 47
15.RECYCLING ........................................................................................................... 49
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
gas extraction as well as chimney
connection.
•Regulations and norms concerning the
fitting of the heating installation with
safety devices.
•Required installation of a smoke
detector in the boiler room.
1. EXPLANATION OF SYMBOLS AND
SAFETY INSTRUCTIONS
1.1. Explanation of symbols
CAUTION!
Important
recommendation
or
warning
concerning safety conditions during
installation and operation of the pellet
burner
DANGER! - fault or improper use
may cause injury or be hazardous
to life of humans or animals.
FIRE HAZARD! - fault or improper
installation and operation may
cause fire.
INFORMATION
–
Important
information on the proper
operation of the product.
i Use only original BURNiT parts
1.2. Requirements to boiler installation
room
This
manual
contains
important
information for the safe and correct
installation, start-up and trouble-free
operation and maintenance of the boiler.
The Dual-chamber boiler can be used
for heating rooms only in the manner
described in this manual.
The application and any other was the
area of operation is not recommended by
the manufacturer and is not responsible
for the occurrence of defects or failures.
Note the boiler type data on the factory
rating label and the technical data
provided in chapter 14 in order to ensure
proper operation of the product.
1.2.1. Instructions to boiler installer
During installation and operation, the
country-specific
requirements
and
regulations must be observed:
•Local construction regulations on
installation, air supply and exhaust

!

WARNING! Installation and setup
of pellet burner should be done
by an authorized specialist /
service shop and must follow the
safety instructions and rules of
operation.
DANGER
of
intoxication,
suffocation.
Inadequate inflow of fresh air
to the boiler room may result in
dangerous leak of exhaust gases
during boiler operation.
-Make sure the air inlets and
exhaust gas outlets are not
clogged or closed.
-If faults are not remedied
immediately, the boiler must not
be operated.
-The user must be provided with
written instructions on the fault
and the hazard it entails.
DANGER of fire when burning
flammable materials or liquids.
-Flammable
materials/liquids
must not be left in close proximity
of the burner and heating boiler.
-Instruct system user of the
allowed minimum clearances
from surrounding objects.
It is mandatory to assure a
backup power generator of
corresponding rated power! (see table 1)
Customer must undergo boiler
operation/maintenance training
by authorized installer/service
shop.
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
you must regularly inspect the boiler
room.
- Do not use flammable liquids for ignition
or increase of burner output.
- Clean the burner surface using nonflammable agents only.
- Do not place flammable objects onto
the burner housing and heating boiler
cabinet or in their proximity. (see diagram
1 for the minimum clearances)
- Do not store flammable materials in the
boiler room.
- It is mandatory to strictly observe
instructions for connecting the burner
to power network as well as to all
peripherals.
- Structural changes pellet boiler by user
can cause damage to equipment or injury.
- Do not allow contact transmission of
electrical wire or touch any part of the
boiler, where the surface temperature
can exceed 70 °C.
- This manual should be kept throughout
the lifetime of the boiler.
Table 1.
Electricity consumption of the boiler
Maximum electrical input
Electrical input at nominal heat
output
Electrical input at minimum heat
output
780 W
80 W
60 W
1.2.2. Instructions to installation user
DANGER of intoxication or
explosion
Toxic gases may be discharged
when burning waste, plastics,
liquids.
-Use only the fuels indicated in
this manual.
-In case of danger of explosion,
ignition or discharge of exhaust
gases in the room, stop the pellet
burner from operation.
CAUTION! Danger of injury
/ damage of system due to
incompetent operation.
-The boiler must be serviced only
by persons familiar with the
operation manual.
-As user, you are only allowed to
start the boiler up, adjust the
temperature of the boiler, shut
the boiler down and clean it.
-Unattended children must not be
allowed access to premises with
running boiler inside.
It is mandatory to assure a
backup power generator of
corresponding rated power! (see table 1)
Customer must undergo boiler
operation/maintenance training
by authorized installer/service
shop.
$

Safety rules for user operation:
- Operate the pellet burner on
recommended fuel only, and to that end
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL

For general safety considerations, we
recommend that the boiler be placed on
a foundation made of class A material, see
table 2.
CAUTION! Hot surface!
Risk of burns if you touch the
running system. Burner housing,
body and flange are hot surfaces
during burner operation.
It is strictly prohibited to open
boiler inspection doors with the
burner running.
The hopper hatch cover is not
allowed to remain open for
longer periods of time.
Also, exercise caution when
touching the observation port for
monitoring the burning process.
It may be hot.
1.2.3.
Minimum
clearances
for
installation
and
flammability
of
construction materials
The applicable minimum clearances in
your country may differ from the ones
specified below. Please, consult your
installer.
The minimum distance from the burner,
heating boiler or exhaust gas pipe to
objects or walls must be at least 200 mm.
Diagram 1
Recommended clearances between boiler
and walls.
2. PRODUCT DESCRIPTION
Ecological and highly-efficient pellet
boiler PelleBurn is designed for firing
wood pellets. The mantle fully covers
the combustion chamber. Efficiency rate
reaching 91%. Approved in accordance
with EN 303-5, class 5. Set includes pellet
burner, auger and pellet fuel hopper
(option).
Table 2. Flammability of construction
materials
Stone, bricks, ceramic tiles,
Class
А – non- baked clay, solutions, plaster
flammable free of organic additives.
Gypsum board panels,
Class B basalt fiber needled felt,
– hardly fiberglass board, AKUMIN,
flammable Izomin, Rajolit, Lignos, Velox,
Heraklit.
Class С1/С2 Wood beech, oak. Wood
Medium
flammable softwood, layered wood
Asphalt,
cardboard,
Class
cellulose, tar, fiberboard,
C3 – easy
polyurethane,
flammable cork,
polyethylene.
2.1. Design structure of boiler PelleBurn.
Cylindrical body design is made of highquality boiler steel sheets with thickness
of 4 mm for the combustion chamber and
3 mm for the water mantle.
• Ecological. A high-end pellet boiler. The
wood pellets used for fueling the boiler
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
are a renewable fuel with minimum
carbon emissions and ultimate burning
efficiency.
• Automated. All boiler functions are fully
automated – no human intervention is
needed for the normal operation of the
boiler. Owing to an improved algorithm
with optional adjustment of a wide
variety of parameters, the system may
be finely tuned to any particular heating
system to achieve optimum efficiency
and fuel consumption.
Controller functions:
1)fully automated ignition and pellet
feed;
The burner consists of two parts:
combustion
chamber
tube
and
external tube with sheet metal mantle.
Longitudinally, under the housing, there
are blow chamber, fuel ignition heater, fan
and power supply. On the upper part of the
burner there is a feeder chute to which the
pellet auger is attached. The combustion
chamber consists of two tubes:
Ember resistant steel tube inside the
burner with holes for air intake along
its entire length, opening for the hot air
from the fuel ignition heater, opening for
photosensor.
Outer stainless steel tube. Between the
two tubes there is a gap which provides
for free circulation of the air necessary
both for cooling and oxygen supply into
the combustion chamber.
The feeder chute allows 360° rotation
for its best convenient positioning when
connecting the pellet auger to the hopper.
2)fan ensures stable operation of the
boiler;
3)self-cleaning function
4)controls the operation of the
circulation pump of the central
heating;
5)controls the operation of the pump
of the domestic hot water;
6)controls by room thermostat;
7)sensor for flue gas;
• Efficient. To keep from losing heat into
the ambience, the boiler is insulated
on the outside by 100 mm hightemperature wool. With its state-ofthe-art combustion control system and
cylindrical body design construction the
PelleBurn boiler achieves efficiency rate
of as much as 91%
2.2. Design of pellet burner Pell
The burner is made of high-quality stainless
steel able to withstand temperatures of up
to 1150°С. The burner must be installed on
a heating boiler.
Diagram 2. Design of Pellet Burner Pell
Other elements of the burner are
• Internal auger.
• Dry contactless resistance heater
assuring ignition of fuel.
• Pneumatic cleaning system of the
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
2.4. Design of pellet auger
The auger transports pellets from fuel
hopper to burner. Auger elements are:
auger pipe, auger hose, motor, conveyor
belt for moving the pellets.
combustion chamber.
• Feed fan, smooth regulation (0% to 100 %).
• Telescopic pull-out system of burner
Pell for easy maintenance
2.3. Safety devices of pellet boiler-andburner
A complex of safety devices provide for
the safety of the appliance. Air-feed fan,
step –regulated, controls the combustion
according to energy needs and is
maintained in optimal working order.
Independent STB thermostat shut-off the
burner and shut off the fuel feeding in
the combustion chamber in case of rising
boiler temperature.
• Elbow-shape feeder chute. The
geometrical shape of burner feeder
chute prevents backfire entry from
burner into pellet hopper. The flexible
tube is melted at a temperature above
80°C. Thus prevent access to the hopper
of the fire.
• Thermostatic protection (80°С). The
thermostatic protection is fitted on the
feeder chute. When the surface of the
feeder chute reaches 80°С, the control
stops the feeding of pellets into the
burner and signals for fault (BB Alarm).
• Fuse. In case of electrical fault in the
system of the burner (short circuit,
current overload, etc.), the overload is
borne by the electrical fuse fitted on the
main control panel of the burner (10 А).
• Power
interruption.
Innovative
controller. In case of power interruption,
all parameter settings are stored in the
memory of the controller. Upon the
subsequent restart of the burner, the
controller resumes the execution of
the program from the point when the
power interruption occurred.
Diagram 3. Design of pellet auger
8
2.5. Design of fuel hopper FH 500
Pellet hopper, designated to serve biomass
pellet-fired boilers. Pellet hopper design
allowing installation by choice on either
side of boiler. Made of cold-rolled steel
sheets with PVC coating. Comfortable
pellet charging hatch secured with holder
mechanism. Pellets inside hopper are fed
into auger in order of reception. Precision
leveling of hopper possible via screw-in
legs. Elevated foundation with drain holes
and container for separation and removal
of pellet powder.
The hopper capacity is determined using
as calculation base the daily or weekly
fuel consumption rate of burner. The
pellet hopper usable volume of 500 litters
allows charging of 280-300 kg of pellets
with diameter 6 mm, and top-up/refill
once a week (for burner of rated power
up to 40 kW).
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
food products or ethyl alcohol (ethanol).
The raw material is processed under highpressure and temperature and is pressed
to produce small-size cylindrical pellets.
The production process may utilize soft
wood material (such as softwood, pine),
hardwood (oak) as well as recycled waste
wood. Wood pellets are produced in
hammer mills or wood pellet plants.
Advantages of wood pellets:
Convenient storage.
Pellet bags can be stored on a small area
in a dry garage, basement, service room
or shed.
Easy loading.
In most cases the boiler hopper needs
loading only once a week – this depends
on the hopper capacity.
Diagram 4. Design of fuel hopper FH 500
Better control of fuel quantity.
The small size of the pellets allows
for precise fuel feeding. On the other
hand, the supply of air for reaching
optimal combustion efficiency is easier
to adjust since the fuel quantity in the
combustion chamber remains constant
and predictable.
3. FUEL
All pellets are biomass manufactured
from common low-growing plants and
trees. The most common household type
pellets are made of sawdust and milled
wood chippings which are waste material
from wood used in the production of logs,
furniture and other products. Wood is the
richest raw material which does not have
any impact on the production costs of
Fuel efficiency.
High combustion efficiency is also
determined by consistently low moister
content of pellets (consistently under
10% as opposed to 20% to 60% moisture
content of the logs). Low moisture
content, controlled fuel portions and
precise air setting means high combustion
efficiency and very low carbon oxides in
the flue gases.
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
i
The optimal density of the pellets which
guarantees their quality is 605-700 kg per
cubic meter.
Pellet moisture content must not exceed
10%. Make sure you store your fuel in a
dry and well-ventilated place.
The optimal pellet ash content is ≤ 1%.
This also provides for less frequent
cleaning intervals for the burner.
The table below contains the parameters
which we recommend that you take into
consideration when choosing fuel for your
Pell burner.
When purchasing pellets, ask
for conformity declaration and
certificate issued by an accredited
laboratory and make sure the
fuel meets the requirements
indicated in the manual. If
you purchase large amount of
pellets (bulk supply for the entire
heating season for example), ask
your supplier to provide accurate
and true information about the
storage conditions.
We recommend to use pellet with size of
6 - 8 mm. Density 600 - 750 kg/m3 heating
value 4.7-5.5 kWh/kg. Ash content – less
than 1% and moisture content up to 8%.,
EN 14961-2:2011.
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Table 3. European Certification of Wood Pellets for Heating Purposes
Parameters
Units
Diameter
mm
Length
Bulk density
Calorific/heating value
Humidity /moisture
Dust
Mechanical durability
Ash
Melting point of ash
Chlorine content
Sulfur content
Nitrogen content
Copper content
Chromium content
Arsenic content
Cadmium content
Mercury content
Lead content
Nickel content
Zinc content
mm
kg / m2
MJ / kg
Ма .-%
Ма .-%
Ма .-%
Ма .-% 2)
°C
Ма .-% 2)
Ма .-% 2)
Ма .-% 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
mg / kg 2)
ENplus-A1
6 (± 1)
8 (± 1)
15 ≤ L ≤ 40 1)
≥ 600
≥ 16,5-19
≤ 10
≤ 1 3)
≥ 97,5 4)
≤ 0,7
≥ 1200
≤ 0,02
≤ 0,03
≤ 0,3
≤ 10
≤ 10
≤ 1,0
≤ 0,5
≤ 0,1
≤ 10
≤ 10
≤ 100
ENplus-A2
6 (± 1)
8 (± 1)
15 ≤ L ≤ 40 1)
≥ 600
≥ 16,3-19
≤ 10
≤ 1 3)
≥ 97,5 4)
≤ 1,5
≥ 1100
≤ 0,02
≤ 0,03
≤ 0,3
≤ 10
≤ 10
≤ 1,0
≤ 0,5
≤ 0,1
≤ 10
≤ 10
≤ 100
EN-B
6 (± 1)
8 (± 1)
15 ≤ L ≤ 40 1)
≥ 600
≥ 16,0-19
≤ 10
≤ 1 3)
≥ 96,5 4)
≤ 3,5
≤ 0,03
≤ 0,04
≤ 1,0
≤ 10
≤ 10
≤ 1,0
≤ 0,5
≤ 0,1
≤ 10
≤ 10
≤ 100
not more than 1% of the pellets may be longer than 40 mm, max. length 45 mm;
dry weight;
3)
particles <3.15 mm, particulate matter, before handing over the goods;
4)
measurements with Ligno-Tester limit value ≥ 97,7% by weight.
1)
2)
4. TRANSPORTATION OF THE BOILER
We recommend to transport the heating
boiler to the installation site in its
packaging placed on the pallet. During
transport and installation, depending on
the weight, suitable safety devices should
be used in accordance with Directive
2006/42/EC.
11
When transporting items weighing more
than 30 kg, the use of pallet jack, fork
truck or other hoisting devices is a must.
Product must be in original packaging
following the instructions on the label to be protected from adverse weather
conditions (snow, rain and dust) from
the shocks, and other activities likely to
cause damage. In case of malfunction of
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Important: When installing the boiler,
the wooden pallet onto which the
boiler is placed must be removed by
unscrewing the bolted connections using
flat ring wrench S13.
the fan or the motor drive (noise, friction)
or failure of high-tech elements such as
broken LCD screen, contact your nearest
authorized service center for repairs and
maintenance.
The boiler is securely fastened with
fasteners to a wooden pallet.
Table 4.
Overall dimensions of Set Pellet boiler PelleBurn, Pellet burner Pell and Fuel Hopper FH 500
A1, mm
A2, mm
A3, mm
B1, mm
B2, mm
B3, mm
C, mm
D1, mm
D2, mm
D3, mm
Weight, kg
PelleBurn
Pellet boiler, burner and pallet
Auger, box
Fuel Hopper, box
Pellet boiler, burner and pallet
Auger, box
Fuel Hopper, box
Pellet boiler, burner and pallet
Pellet boiler, burner and pallet
Auger, box
Fuel Hopper, box
Pellet boiler, burner and pallet
Auger, box
Fuel Hopper, box
15 kW
710
120
840
1100
260
810
125
1430
1700
1220
185
8
48
Diagram 5
Indications dimensions
12
25 kW
710
120
840
1100
260
810
125
1630
1700
1220
200
8
48
40 kW
810
120
840
1320
260
810
125
1775
1700
1220
325
8
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
5. DELIVERY OF THE BOILER
-All boiler rooms must have correctly
calculated vent depending on the boiler
output. The vent must be protected by
means of a net or grate.
• Inspect the integrity of the packaging
upon delivery.
• Check whether all components
have been delivered to you. Boiler
consignment package includes:
The size of the vent is calculated
according to the formula:
1)Pellet boiler PelleBurn with pellet
burner Pell
2)Auger
3)Fuel hopper FH 500 (option)
4)Safety valve 3 bar.
5)Fire irons
6)Technical passport. Installation and
operation manual
7)Service booklet and Warranty card
А=6,02Q - where:
А – area of the vent in cm2,
Q – boiler output in kW
-Remove the packaging without polluting
the environment
-Observe
building
supervision
instructions, in particular the existing
Ordinance on combustion devices and
storage of combustion materials, on
building requirements applicable to
installation sites and on ventilation;
If any of the above items are missing,
contact your supplier.
-The boiler must be placed on a
foundation whose surface area is larger
than the base of the heating boiler
according to diagram 1;
6. INSTALLATION OF THE HEATING
BOILER
-The boiler must be placed in a position
which allows for the easiest possible
cleaning and servicing;
The assembly, installation and
set-up of the boiler must be
performed by a technician
authorized for such operations.
Installer must indicate to the user
of the installation the minimum
clearances from flammable
materials and liquids.
-Installation must be carried out
according to installation diagram 1
which shows the boiler housing;
-No objects made of flammable materials
or liquids may be placed on/near the
boiler;
Requirements:
-Boiler room must be frost-proof;
-Boiler room must allow for continuous
access of air necessary to maintain
combustion;
-Boilers must not be placed in inhabitable
rooms;
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TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
7. SETUP OF THE HEATING BOILER
7.1. Connecting the boiler to a chimney
Boiler-to-chimney
connection
must
always comply with the existing standards
and rules. The chimney must provide
sufficient draught for evacuation of the
smoke under any conditions.
The proper functioning of the chimney
requires adequate sizing of the chimney
itself since the draught it produces affects
combustion, boiler’s output and life span.
The draught created by the chimney
is in functional relation to its crosssection, height and the roughness of its
interior walls. No other appliance may
be connected to the chimney serving the
boiler. Chimney diameter must not be
smaller than the flue outlet of the boiler.
Flue outlet must be connected to the
chimney opening. In terms of mechanical
properties, the flue outlet must be sturdy
and properly sealed (to avoid gas leak)
and allow for easy access for cleaning
on the inside. The inner section of the
flue outlet must not be greater than the
effective section of the chimney and must
not narrow. Avoid using elbow joints.
The chimney cleaning opening has to be
in its lowest part. The chimney’s wall has
to be three plied where the medium layer
is from mineral wool. The thickness of the
insulation is not less than 30 mm when
the chimney is setting up inside the house
and the thickness is 50 mm, when the
setting up is outside.
Please entrust choosing a chimney and
its installation by a qualified professional.
The required distance between the boiler
and the chimney is 300-600 mm. Draught
regulator (1) must be installed at least 600
mm from the joint (connection).
45o
Boiler size and chimney parameters
Table 5. Recommended minimum sizes and
chimney draft
Boiler
output
15 kW
25 kW
40 kW
i
14
Chimney
diameter, mm
Ø 130
Ø 130
Ø 150
Chimney
draft, Pа
10-20
10-20
10-20
Data in the tables are for indicative
purposes.
Draught depends on the diameter, height, uneven sections along the
chimney surface and differences
in temperature of combustion
products and outside air. We
recommend that you use chimney
fitted with flue terminal. Heating
specialist must calculate the
precise sizing of the chimney.
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
7.2. Pellet boiler connection to the pellet
burner, auger and fuel hopper
-Take the auger hose (from the auger
set). Using a bracket, clamp one end of
the hose onto the motor-end outlet of
the pellet auger.
-Using a bracket, clamp other end onto
the feeding chute of burner
-Remember pellet auger must be installed
at 45° angle to the ground horizontal
surface.
-Fill the hopper with fuel (see table 2 for
parameters of the fuel types used)
-Plug the power cord of the pellet auger
into the indicated Schuko-type boiler
socket on the left side of the boiler
housing.
7.3. Connecting the boiler to the mains
power supply
Such connection must be
performed by a technician /
service shop authorized for such
operations.
Caution!
ELECTRIC
SHOCK
HAZARD!
-Before opening the unit: switch
off the voltage and secure the
unit against accidental restart.
-Observe installation instructions.
Improper cable connections may
damage the regulator!
The device may be damaged if
struck by a lightning. Make sure
it is unplugged during the storms.
To bring into exploitation the boiler and
auger must be connected to the electricity
network 220V/50Hz with power cord.
Create tight connection with the electrical
mains which complies with the local
regulations.
1. Pellet boiler PelleBurn;
2. Pellet burner Pell;
3. Auger hose;
4. Auger;
5. Fuel Hopper FH 500.
Diagram 6. Pellet burner Pell and Fuel Hopper
FH 500 connected to Pellet boiler PelleBurn
15
L
N
Power supply
220V 50Hz
Room
termostat
L
N
CH Pump
220 V
L
N
DHW Pump
220 V
L
N
DHW
Sensor
L
N
Buffer
bottom sensor
L
N
Buffer
top sensor
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Diagram 7. Wiring diagram of connection
16
PE
I02
220V
L
N
003
L
of boiler elements to the controller
17
N
I01
N
L
I03
I04
I05
L
I18
heater
_
+
005
I06
signal
_
+
006
I07
_
L
007
+
I08
016
L
Y
L
008
U
I09
009
_
+
010
I10
017
Y
U
011
I11
012
I12
013
I13
014
I14
015
018
I15
019
I16
I17
L
N
004
N
N
N
002
N
001
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
020
021
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
yellow-green
yellow-green
red Electric motor
white of self-cleaning
blue
system
brown
brown
blue
blue
Capacitor 1,2 µF 450V
N
Lug Ø6,3
RF-M6 yellow-green
blue
Auger for
cleaning
ashes
014
red
white
blue
015
018
blue
020
019
yellow-green
brown
brown
L
021
+
_
007
yellow-green
N
220V
PE
L
N
8
BB
FC
FM
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
y.g.
IGN
SB
1 1
1 1 BB
L=300
2 2
1 1
2 2
1 1 FC
L=300
L=300
2 2
2 2
STB
(KSD)
L=300
3 1
1 3 FM
L=300
4 2
2 4
5 1
1 5 IGN
L=300
L=300
6 2
2 6
L=300
7 1
1 7 SB
L=300
8 2
2 8
L=300
Main
Burner
Fan
red
white
blue
I18
signal
_ +
heater
_
+
004
001
yellow-green
006
005
blue
002
3
4
5
6
brown
blue
N
9
10
Ø4
RF-BM 4
brown
016
008
brown
blue
Ø4
RF-BF 4
blue
Y
U
yellow-green
y.green
brown
009
_
010
+
017
Y
011
U
L
012
013
Capacitor 1,2 µF 450V
NPBC V5M
003
L
7
Cleaning
Fan
Heater of
The Burner
Internal
Auger of
The Burner
yellow-green
brown
blue
Capacitor 1,2 µF 450V
yellow-green
Diagram 8. Wiring diagram of connection of burner
18
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
1
BB
2
3
FC
I17
4
I16
5
FM
1
2
3
4
5
6
7
8
9
10
y.g.
6
I15
7
IGN
I14
8
9
SB
I13
10
I09
I10
I11
I12
yellow-green
1
2
I01
I02
I03
I04
I05
I06
I07
I08
Exhaust gas
temperature
sensor
Boiler
temperature
sensor
yellow-green
brown
blue
elements to the controller and connecting socket
19
1
2
3
4
5
6
7
8
9
10
11
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Legend /Diagrams 7 and 8/
Elements
Room thermostat
Boiler sensor
STB termostat of the burner
Sensor water heater
Sensor exhaust
Temperature sensor at the top of the buffer
Temperature sensor at the bottom of the buffer
Elements
Fan smoke gases
Ignitor
Fan cleaning of the burner
Screw fuel
Screw burner
Pump heating
Pump water heater
Electric motor of self-cleaning system
Electric motor of clean ash
INPUTS
I02
I03
I04
I05
I06
I08
I17
Означение
RT
B
RB
WH
PT
AT
NA1
OUTPUTS
О 01
О 03
О 04
О 05
О 06
О 07
О 08
О 10
О 11
Означение
FSG
IGN
FC
SF
SB
PH
PHW
CS
CA
7.4. Connecting the boiler to the heating
installation.
off fittings may be installed between the
relief valve, expansion vessel and boiler.
Such connection must be
performed by a technician /
service shop authorized for such
operations.
When the boiler is connected to a heating
system, it is mandatory to install a 3 bar
relief valve and expansion vessel. No shut-
It is mandatory to install a threeway valve (Laddomat or similar)
or a four-way mixing valve which
to ensure that the temperature
of the heating medium fed into
the boiler from the heating
installation is at least 65°С.
Table 6. TROUBLE-SHOOTING TABLE
Cause
Solution
Installation damage
1. Due to unsealed connections 1. Install the connecting piping strain-free to the boiler
connections.
2. Due to freezing
2. If the heating installation, including the piping network, has
not been built frost-proof, we recommend that you fill the
heating installation with a liquid which has low freezing point
and corrosion protection and antifreeze agent.
Boiler water too hot, heating bodies too cold
1. Hydraulic resistance is too Make sure the circulation pump has been properly selected
high.
and the heating installation is of the proper dimensions. (You
2. Air in the system
must contact your installer.)
3. Inoperable circulation pump
20
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
The STB safety thermostat has Upon reaching a temperature of 95°С, the thermostatic safety
been triggered.
protection device is triggered and the fan is turned off. To
resume protection, remove the black cap on the front panel of
the boiler and press the button on the STB-thermostat. Contact
your installer to determine the cause of protection triggering.
Low boiler temperature.
Unable to reach normal temperature mode of 65°-85° С
Inadequate
sizing
and/ Immediately consult your installer about the problem.
or combination of heating
appliances
Ejection of unburned pellets into the combustion chamber of the boiler
Poor adjustment of the fuel- Contact your installer. It is necessary to set the burner properly
to-air ratio from the burner using gas analyzer
controller
Utilization of low-quality pellets Use only fuel which meets the requirements specified in the
manual. (see section 3. Fuel)
Formation of clinkers and noncombustible inclusions inside burner body
Utilization of low-quality pellets
(see section 3. Fuel)
Low performance of the
automatic cleaning system
Improper setting of fuel-air
mixture
Use only fuel which meets the requirements specified in the
manual.
Increase turn-on frequency of the automatic cleaning system.
Poor chimney draught or high
internal resistance of the boiler
combustion chamber
Blockage of burner combustion
chamber due to build-up of
noncombustible materials
Improper setting of fuel-air
mixture
Dust on the photosensor
Immediately consult your installer about the problem.
Adjust using gas analyzer
Smoke in the pellet hopper
It is necessary to clean the burner combustion chamber using
brush
Adjust using gas analyzer
It is necessary to clean the photosensor. Refer to the manual
for the cleaning procedure.
Boiler temperature too high. Controller failure.
Grid power fluctuations
Power failure
It is mandatory to assure a backup power generator of
corresponding rated power! (see table 1)
exhaust tubes of boiler water jacket are clogged with
High temperature of exhaust Fume
heat transfer. The boiler should be cleaned.
gases. High temperature soot. Reduced
Please
contact
an authorized specialist / service shop to
alarm is turning on
clean the boiler.
High temperature in boiler
water jacket and low 1. Incorrect ON/OFF temperature settings of pumps.
temperature in the buffer 2. Incorrect sizing of heating system.
tank.
21
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
7.5. Connection diagrams
Such connections must be
performed by a technician /
service shop authorized for such
operations.
RT - room thermostat
CHPUMP
Diagram 9. Connection of boiler PelleBurn to three-way valve
22
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
CHPUMP
TTOP
TBOTTOM
Diagram 10. Connection of boiler PelleBurn to P type buffer tank and three-way valve
23
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
CHPUMP
TBOTTOM
TTOP
Diagram 11. Connection of boiler PelleBurn to combi tank KSC2, flat plate solar collector PK
and three-way valve
24
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
CHPUMP
DHW
sensor
DHWPUMP
TTOP
TBOTTOM
Diagram 12. Connection of boiler PelleBurn to solar tank SON, buffer thank P, flat plate solar
collector PK and three-way valve
25
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
8. FILLING THE HEATING INSTALLATION
Table 7
Problem
Prevention
Possible installation damage due
Fill the heating installation only in cold conditions
to strains in the material caused
(inlet temperature must not exceed 40°C).
by temperature differences
-Do not operate the heating boiler for a long period
Danger of installation damage of time in partial load mode
due to accumulation of deposits -The temperature at the boiler inlet must not be
Condensate formation and tar less than 65°C, boiler water temperature must be
deposits may shorten boiler’s between 80°C and 85°C.
operational life.
-Use the boiler for a short period to heat warm
water in the summer.
burning rate of the fuel. Flame intensity
is monitored by a photosensor which
monitors the burning and feeds data into
the control unit which enables the starting
or stopping of the combustion process,
if necessary. The output of the burner
is determined by the intervals preset on
the control panel taking into account the
heating value, size and density of the
pellets.
9. OPERATION OF BOILER
Failure to observe the installation
and operating requirements
described in the manual and
the service booklet voids the
warranty.
9.1.
Operation of pellet boiler
PelleBurn with pellet burner Pell
Ignition. After the start up of the boiler
from the control panel, the main pellet
auger conveys certain amount of fuel
from the pellet hopper to the burner.
This specific amount of pellets is set
by the installer and depends on the
fuel characteristics. The fed-in quantity
of pellets is conveyed from the auger
conveyor built in the burner to the
combustion chamber where it is being
ignited using hot air.
Burning. The burning process takes
place in the combustion chamber and,
after it has been fed into the combustion
chamber, the fuel is then transported
from the internal auger conveyor to
the combustion chamber in portions.
This allows for constant and optimal
26
Automatic cleaning system. The pellet
boiler is equipped with innovative
automatic cleaning system for combustion
chambers of both devices.
A powerful cleaning motor built in the
burner body, air is being blown in at high
speed and rate thus removing all residues
– ash, noncombustible inclusions, etc.
built up into the combustion chamber of
the boiler.
At the same time the boiler turns
on automatic ash removal which is
transported to the ash container through
screw located in the lower part. These
automatic cleaning cycles last several
seconds and can be additionally adjusted
as well as their repeat rate depending on
the load of the burner.
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
9.2. Important recommendations for
long-lasting and correct operation of the
boiler
-For assembly and installation of the
burner follow the requirements in this
manual.
-Use only recommended in this manual
fuel.
-Disassemble the burner from the boiler
body before clean it. Depending on fuel
and burner settings, clean the pellet
burner once a month.
-User`s training for operation and
maintenance of burner is performed by
an authorized installer or service shop.
Diagram 13
-It is mandatory to clean once a month
the combustion chamber of the burner.
Attention!
Cleaning
and
maintenance of the boiler
should be carried out only by
an authorised installer/service
shop.
Failure to observe the installation
and operating requirements
described in the manual and
the service booklet voids the
warranty.
Before the start of the heating season
it is mandatory to check and clean the
following components of the boiler:
9.3.1 Cleaning and maintenance of
suction fan
9.3. Requirements for the cleaning and
maintenance of PelleBurn pellet boiler
with pellet burner.
Attention! Important instructions
regarding cleaning of boiler

Caution! Hot surfaces.
Before cleaning the boiler, make
sure the fire in it has died out and
the boiler has cooled down.
-It is mandatory to clean the ashes from
the container once a week. Unhook the buckles on both sides of ash container.
Pull ash container out of the boiler and
clean it.
Once you have emptied the container of
ashes, please make sure you close the
container cover tightly, buckle-lock it to
the container buckles, then buckle-lock
the container to the boiler buckles.
Diagram 14
-Remove the two parts of the boiler top
cover by lifting them upwards
2
1
Diagram 15
27
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
-Remove the cover of the inner boiler
body (2) using wrench S13.
-Clean the fan blade (1) and the dust and
soot deposits. Use a brush. If the fan is
not properly cleaned, this will affect the
boiler performance.
of the entire cleaning system. Also check
the drive mechanism, located outside
the combustion chamber.
-Upon detection of worn piece/part, it is
recommended to have it replaced with a
new one.
-Dismantle flue pipes from the cleaning
system of the boiler and clean them
well. For this purpose: remove the upper
ring of the automatic cleaning system
(2). Use wrench S10. Use a brush to
clean the flue pipes thoroughly one by
one. Mount back the flue pipes and the
upper ring of the cleaning system.
-Check silicone gasket mounted on the
edge of the boiler. Replace if cracked or
hardened.
-Mount back the top cover.
-The ashes from the cleaning system
are collected in a drawer container
for ash and soot. Upon completion
of the cleaning procedure, empty the
container.
Diagram 16
-Check the nut holding the fan blade (2)
to be well tightened. Attention: the nut
is left threaded!
-Upon assembling the gasket of the
fan must fit well in place. If necessary,
change the fan gasket.
-Mount back the top cover
9.3.3. Servicing of the burner:
-Remove the burner casing from the
boiler cabinet body – using the handles
(1) lift it up then pull it towards yourself
(Diagram18).
9.3.2. Cleaning and maintenance of the
cleaning system:
-Remove the top cover (9.3.1).
-Cleaning system (1). Clean the ash
deposits using a vacuum cleaner and/or
a brush.
Diagram 18
-Remove connector (2) housing the wire
connections between the burner and
the controller. Unscrew the 2 marked
plastic head bolts (1) to release the slide
rail onto which the burner is mounted.
Diagram 17
-Hold a visual inspection of the condition
28
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
-Clean the inside of the burner chamber
thoroughly from residues. Use a bodkin
to release all clogged orifices along the
combustion chamber.
-Remove the ashes from inside the
burner. Use a vacuum cleaner and a
brush.
-Inspect and clean the motors and
sensors in the boiler.
-When mounting the burner back onto
the boiler, replace the seal between the
burner flange and the boiler.
9.3.4. Feeding auger:
-Completely empty the pellet hopper.
-Dismantle the auger from the pellet
hopper: release the top of the flexible
hose (1) from the auger tube; extract the
auger (2) by pulling it out of the hopper.
Diagram 19
-Carefully slide out the rail with the
burner mounted on.
Diagram 20
-The rail itself is hinge-fixed to the boiler
body, swing it to the right to withdraw
the burner from the boiler body.
Unscrew the marked bolts to dismount
the burner from the flange holding it
fixed to the rail.
Diagram 22
-Clean the Auger from the ashes of the
transport of pellets: Dust off (3) and
clean the ashes from the collected (4)
-Mount the feeding auger back to the
pellet hopper.
Important!
calibrate it.
Diagram 21
-Disassemble the burner combustion
chamber.
29
Fill
Auger
and
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
9.3.5. Pellet hopper:
-Completely empty the pellet hopper
-Clean the pellet ash residues from the
bottom of the hopper. Use the scraper
and a vacuum cleaner.
10. CONTROLLER UNIT
appears in upper part of display. Means
than Central Heating priority is set to
heat up the central heating.
Domestic Hot Water /shower/
priority symbol appears in upper
part of display. Means than DHW
priority is set to heat up the domestic hot
water. When set DHW temperature is
reached, DHW pump stops and CH pump
is activated.
Parallel pumps /shower and
radiator/ symbol appears in upper
part of display. Means that is set
equal priority to both pumps. They work
in parallel and are controlled by
temperature sensors.
Summer mode /shower and sun/
symbol means than is set Summer
heating mode. Only DHW pump is active.
Burner flame symbol appears in
upper right part of display. Means
that burner is activated. Burner goes into
Ignition mode and upcoming boiler fire
up.
Flame 2 symbol means Maximum
output mode of boiler. In this mode
the boiler operates at maximum output.
Flame 1 symbol means Low output
mode of boiler. In this mode the
boiler operates at minimum output.
The notice "Hi" appearance on the
screen
where
the
boiler
temperature is displayed means
that the measured boiler body
temperature is above 120°C. Flashing and
beeping alarm is activated. When the
issue is corrected, notification can be
deleted. Disconnect fuel auger from boiler
plug-in socket. Upon any such occurrence
please contact immediately your installer
10.1. Controller view. Explanation of
buttons and indicators.
When
logging
LCD screen:
The
controller
screen displays the
information for the
operation of the
facility.
Explanation
of
buttons:
into a menu, use
arrow keys UP
and DOWN
to move from one page to another.
Enter button
permits adjustment of
the page.
When adjustment is enabled, use arrow
keys UP
and DOWN
to adjust
the parameter.
Press ENTER
to change the
parameters.
Press F
to exit the menu.
Confirm with Enter button
.
Display symbols explanation:
Auto Clean symbol appears in right
upper part of display. Active auto
cleaning symbol means boiler automatic
cleaning mode.
Crossed-out flame symbol appears
in upper right part of display. Means
that the boiler enters into Extinguish
mode.
CH priority /Radiator /symbol 30
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
for system checkup.
Boiler increased temperature. Those two symbols appearance on
the screen where the boiler
temperature is displayed means that
boiler temperature has increased up to
99°C. In such a case, please contact
immediately to your installer to check the
system.
Error symbol appears in right upper
part of display. Flashing and beeping
error symbol mean error or fault in
boiler operation. Use “Enter“ button to
move to next screen with error notification
in lower left part of display. When the
issue is corrected, error notification can
be deleted. When disconnect the boiler
from electrical supply for few seconds and
then switch on it again, boiler goes back
to normal operation (error notification is
deleted).
S
A
This alarm appears when
TE Alarm gas оtemperature rises above
220 С
Temperature sensor of
TE E1
exhaust gases is missing
Short circuit of temperature
TE E2
sensor of exhaust gases
Temperature sensor of
part of buffer tank
CH btm E1 lower
is missing (when in chosen
scheme with buffer tank)
Short circuit of temperature
of lower part of
CH btm E2 sensor
buffer tank (when in chosen
scheme with buffer tank)
Temperature sensor of
part of buffer tank
CH top E1 upperr
is missing (when in chosen
scheme with buffer tank)
Short circuit of temperature
of upper part of
CH top E2 sensor
buffer tank (when in chosen
scheme with buffer tank)
Cleaning system of exhaust gas
tubes is activated.
When restarting the controller alarm is
deactivated.
Notify the authorized installer/
service to be performed
immediately inspection of the
boiler and heating installation.
"С" symbol means that
the motor of automatic
cleaning system is
activated.
The symbol "T"
indicates that a room
thermostat
is
connected to the controller of the burner
(the boiler). In "CH Priority” mode the
room thermostat controls the burner by
starting and stopping it. In “DHW Priority”
mode the room thermostat controls the
heating installation pump by starting it
when the temperature of the domestic
hot water has reached the maximum
preset temperature. In "Parallel Pumps"
Ash cleaning system is activated.
Factory setting - Alarms
Reverse fire Alarm (when
BB ALARM the thermostat contact RB
input is open)
Boiler Temperature Sensor
SENSOR E1
is missing (input B)
Boiler Temperature Sensor
SENSOR E2
Short circuit ( input B)
IGNITION
Failure ignition
FAIL
Water Heater Temperature
DHW E1
Sensor is missing (input WH)
Water Heater Temperature
DHW E2 Sensor Short circuit (input
WH)
This alarm appears when
Cleanup gas оtemperature rises above
180 C
31
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
mode the room thermostat controls the
heating installation pump regardless of
the temperature of domestic hot water. In
"Summer Mode" the room thermostat is
disabled.
Lights for operating:
- Pump heating system
- Pump Domestic hot water.
selected the menu option for boiler
control according to buffer temperature.
Parameter tE indicates
exhaust
gases
temperature.
Set
maximum
temperature of the
boiler
through
navigation arrows.
Press button F and hold for 3 seconds to
set the follow parameters:
Possibility for forced
turn on of ash and soot
transport screw. Time
setting
of
screw
operation. To set start and operating time
use buttons “Navigation arrow Up” and
“Navigation arrow Down”. After entering
the correct value press button “Enter”.
Use this menu to adjust
switch-on temperature
of
central
heating
pump.
From this menu you can
preset buffer tank
circulation
pump
switch-on and switchoff temperatures provided such heating
installation scheme (with buffer tank
included) is selected, whereas the two
sensors reading these temperatures are
mounted in the upper, respectively lower
part of the buffer tank (cf. boiler
connection schemes).
From this menu you can
adjust the maximum
temperature in the
domestic hot water
storage tank, whereas by navigating from
the arrow keys up and down and using the
Enter button you can change the
10.2. User menu
10.2.1. Initial (start-up screen) „Standby“
The burner is in
standby mode.
The display shows:
Temperature in the
boiler (23 degrees),
time, and by pressing the Enter button
you can browse the quick menu (bottom
left) where the following read-only data
is displayed: Maximum set temperature
t=85oC, temperature of domestic hot
water where such heating circuit is
connected); Light intensity in the burner;
Burner status (detected errors, if any);
Date.
Error message. If there
is an emergency in the
operation of the facility for any reason will
be displayed as an error.
Мaximum set boiler
temperature.
Current date.
Parameter
tDHW
indicates temperature
of domestic hot water inside the water
heater.
Parameter tСН indicates
the
value of instantaneous temperature at upper and
bottom part of the buffer tank.
This screen is active only when has been
32
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
pump for the heating installation (CH
pump). In this mode, the boiler can
be managed via a room thermostat
or be temperature-controlled by the
temperature inside the connected
buffer tank to it (depending on the
connection scheme) (see item 10.3.4,
menu CH Mode).
-Summer Mode – Boiler works for
heating of domestic hot water only.
If you have selected the
(CH + DHW) option,
upon confirmation of
command via the F
button you may navigate to the next
screen.
From this menu you can
set up and adjust DHW
pump activity periods.
Use the arrow keys to
set time (HH:MM). Use “Enter” button to
checkmark desired time period option.
If no option is check-marked, the
controller will maintain DHW temperature
as a priority. Only when its preset value
is reached, the CH circulation pump will
start.
parameters. You can adjust the maximum
domestic hot water temperature inside
the storage tank, as well as the switch-on
hysteresis for the circulation pump after a
drop of DHW temperature inside the
storage tank.
Use UP and DOWN
arrow keys in Set Time
menu to set the unit’s
built-in timer/clock.
Use UP and DOWN
arrow keys in Set Date
menu to set the date.
Use UP and DOWN
arrow keys in Contrast
menu to adjust the LCD
display backlight level.
Confirm settings by shifting to next
submenu through a single pressing of the
functional key F.
Use this menu to choose
the language of the
controller. Choose a
language by pressing
navigation arrows and button “Enter”.
10.2.2. Burner start-up „Switch mode“
Burner start-up. After
pressing the “F” button
and using the navigation
arrows, the “Auto” or
„Standby” menu is selected.
Set the priority mode of
the burner through
“navigation arrows.”
*
Important: The use of “External
room thermostat for the burner”
option (Thermostat) is active only
if option is selected (CH Priority
– priority of central heating
installation pump).
10.2.3. Burner shut-down „Standby“
- CH + DHW – Both pumps /CH-central
heating pump and DHW – domestic hot
water pump /are active.
- CH only – In this mode of operation the
only active pump is the CH circulation
33
Pressing the “F” button
will take you to the main
menu and by using the
navigation arrows you
can select the “Standby” menu and
confirm the selection by pressing “F”. The
burner goes into extinguishing mode. Set
the temperature to start heating pump.
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
10.3. Installer menu (setting the
combustion parameters in the burner
controller)
CAUTION! We recommend that
this menu be used only by an
authorized installer/service shop
in order to ensure efficient and
safe operation of the equipment
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter. Time-setting
for parameter (FAN) determines burner
cleaning , damping and ignition of the
boiler.
Important: With the arrow keys up
and down arrow can switch from
one to the next page or return to
the previous page.
Use Cleaner In this submenu you can
activate or deactivate
 On Start
the automatic cleaning
 On Stop
of the burner in Ignition
(Start) mode and extinguished (Stop)
mode.
The checkmark in the box indicates that
the automatic cleaning system is active.
Setting up the run-time
of the main boiler flue
pipe cleaning motor.
Select the desired
option using the navigation arrows. Use
the „Enter” button to open the next
parameter.
Setting up the runtime
of the ash carrier screw
taking the ashes from
the boiler to the ash and
soot container. The ash carrier screw
runtime is set in seconds. The runtime of
main pellet auger is set in number of
cycles. Once the set number of cycles is
completed, the boiler will launch the selfcleaning procedure after which the main
auger will start automatically.
Select the desired option using the
navigation arrows.
Quiet Mode menu.
Setting the time interval
when
self-cleaning
system of burner is OFF.
To access the settings
adjustment mode,
simultaneously press
the “Enter” and „F”
buttons and hold them
pressed for 4 /four/ seconds.
This will display the controller hardware
and software version on the screen. Press
again button “F” and this will open the
initial page for the burner settings.
To access the service
settings
must
be
entered service code.
Service menu includes
only parameters that
directly affect the boiler combustion
process, and the management of the
installation (depending on the capabilities
of the management of peripheral devices
from the controller to the boiler).

Fuel switching and / or change
the configuration of the heating
installation must be performed
by an authorized installer /
service. Some of these reasons
may affect the safe operation of
the facility.
10.3.1. Cleaning setup and Clean Ashes
The burner performs automatic cleaning
before each ignition and shut-down.
You can use this menu
to adjust the running
time of the main fan
(FAN) and of the
cleaning motor (Cleaner).
34
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
For example: from 22:00 to 06:00. Check
mark in the box activates Quiet Mode.
• Feeding of pellets – Feed;
• Pause time – Pause;
• Number of cycles – Cycles.
From this menu you can also set the
number of cycles and time for feeding
the pellets during ignition mode, while
the temperature of exhaust gases has not
risen. This step is executed in order to
progressively secure a stable combustion.
From this menu you can
make adjustment of the
o
temperature difference
at which the boiler
would
shift
from
maximum to minimum power.
Example:
When
the
maximum
temperature Is set at 85°C the boiler will
shift from maximum to minimum power
once the temperature drops to 80°C.
10.3.2. Ignition First Feed
Ignition First Feed In this submenu you
can set the number of
25 sec
attempts (Retries) to
ignite the burner and
the time of the initial feed portion of
pellets (Feed).
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
05
10.3.3. Cycle setup
From this submenu you
can set:
- Heater – the runtime
for the electric ignition
heater
- Fan B/E – the runtimes and power
levels of the main burner fan (FanB) and
the exhaust gas fan of boiler (FanE) in
the process of kindling the initial dose of
pellets.
Operation principle: After the feed-in of
the initial dose of pellets the heater will
work for 3 min, then for another 2 min
period parallel to the heater will start the
burner fan (FanB) and the exhaust-gas fan
(FanE), respectively at 15 % and 40 % of
their rated power (exact parameters listed
on p. 41).
If after this period of time the exhaust
gas sensor has not reported a rise in the
exhaust gas temperature, the controller
will shift on to the Unfolding Setup menu.
Through the navigation keys you set the
desired value. Using the button "Enter"
you can navigate to the next parameter.
Unfolding Setup Unfolding Menu Setup.
Feed
4 sec Use to set the values
Pause 30 sec for:
Cycles 10
10.3.4. Burn Level
In this submenu you can
adjust the performance
of the main operation
mode –
Maximum
Burner
Output. You can change the pellet feed
quantity (Feed), the peelet feed time
interval (Cycle) and the fan operation
power level in percentages (FAN B/E).
Example: At a set period of 20 seconds.
the auger will feed pellets to the burner
for 7 seconds, and stay idle for 17 seconds.
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
In this submenu you can
adjust the criteria for
minimum boiler power
pellet
feed.
We
recommend the setting to be 35% of the
main mode. You can change the pellet
feed quantity (Feed) in % of the set value
at maximum power, and the power of
35
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
both fans: the burner fan (FanB) and the
exhaust gas fan (FanE).
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
Auto Clean Setup Use this menu to adjust
 12:00  18:00 the automatic cleaning
 00:00  06:00 of burner and boiler
 06:00  21:00 Set the time and the
number of automaticsystem cleaning
(Clean Count). At least one cleaning per
24-hour period is required.
Maximum cleanings - not more than six
times per 24-hour period.
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
This menu is not active
at the moment.
Does not affect the
boiler operation.
Use this submenu to
activate (with check
mark) or deactivate
additional peripherals.
CH PUMP – central heating pump
DHW PUMP – domestic hot water pump
Thermostat .
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
From this screen menu
you can choose the
boiler
operation
management
mode.
This menu is valid only
in the event of "CH only" option selected.
By selecting the checkmark "Buffer" the
boiler will be controlled according to
temperature inside the buffer tank
connected to the boiler. The setting of the
temperature of the buffer tank circulation
pump start and stop temperatures is done
as described above. When selecting the
boiler management via thermostat
option the boiler will be controlled by the
signal input from the thermostat, whereas
the options are: thermostat normally
open or thermostat normally closed. Its
type is introduced at a later step on the
controller menu.
In this menu you can
select the type of the
thermostat used (if that
option is selected)
NO - normally open;
NC - normally closed.
From this menu, the
following parameters
are configured:
The dT parameter sets
the temperature difference of exhaust
gases upon which the controller should
register ignition. The start point of
watching this difference is the moment of
start of the main burner fan in the process
of ignition. From that point on whenever
the temperature of the exhaust gases in
the boiler rises with 6 degrees an ignition
shall be registered and the boiler will go
into normal operating mode.
The next parameter > 060 ° C/30 min.
determines the time after the boiler shift
to normal operating mode during which
the boiler must exceed the specified
temperature of exhaust gases. Upon
fulfillment of this condition the boiler will
register itself in normal working mode.
If the exhaust gases temperature drops
below 55 °C the boiler will shift into
extinguishing mode (Error Burnout).
Use this submenu to
adjust the internal
auger of the burner as a
percentage value of the operation ofthe
36
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
external pellet auger. Example: If the
external pellet auger runs for 10 seconds
and feeds fuel in the burner, the internal
auger will run for 20 seconds, if the setting
is Duty 0-300% (see picture).
The check mark in the box indicates that
the device is active.
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
This menu allows you to
select maximum boiler
temperature. In other
words, the maximum
temperature to heat the boiler on which
the burner has been installed. The
maximum value for this setting is 85°С.
Select the desired option using the
navigation arrows. Use the „Enter” button
to open the next parameter.
Use this menu to
conduct fan operation
test. You can control the
fan in real time, without
confirming anything, using only the
navigation arrows.
Test EFan Speed Use this menu to test
exhaust gases fan. You
can control the fan in
real time, without
confirming anything, using only the
navigation arrows.
Important. This menu is for installers
only and it is active and visible only if the
controller is in „Standby” mode.
Test Outputs This menu allows you to
check the operation of
 A1  VF
the various pellet boiler
 CS  CA
components / outputs.
Using the navigation
arrows, you can turn on
and off the various
components and each
time the respective components is being
activated a check mark will appear in
front of its name. Use the „Enter” button
to select the individual components /
outputs.
Test controller imputs
by using this menu.
Menu includes:
Description of components/outputs:
CS – Clean soot motor;
VF – motor of the vacuum system for
refueling;
CA – clean ash motor;
FF – Fuel Feeder;
BF – Burner Feeder;
CH – Central Heating pump;
DHW – Domestic Hot Water pump;
Ign – Ignition;
CM –Cleaning Motor;
Important. This menu is for installers
only and it is active and visible only if the
controller is in „Standby” mode.
37
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
socket and measure the amount of pellets
collected in the bag over a period of 15
minutes using scales/weighing scale.
(In our example, the amount of pellets
collected in the bag over a 15-minute
period is 7875 grams. (900 sec). We
then divide 7875 by 900 and get 8.75
grams of pellets per 1 second. Repeat
the measurement in order to obtain
conclusive results.
11. SETTING OUTPUT MODES OF
OPERATION OF THE PELL PELLET
BURNER CONNECTED TO PELLEBURN
PELLET BOILER
CAUTION! You must use gas
analyzer when setting the burner.
The Pell pellet burner is equipped with
two-step output adjustment and their
setting depends on the boiler and heat
requirements of the heating installation.
11.2. Burner output adjustment.
In the burner output settings menu you
can adjust the running time of the main
auger (Feed); main running interval
(Cycle) and fan output (Fan). Example for
Pell 25 model: we select mode Cycle =
20 sec. The heating value of your fuel is
4.8 kWh/kg. (manufacturers indicate the
heating value of the fuel on the packing
– take it from there). We then employ the
following formula to calculate the number
of seconds for setting the operation of the
main auger for these 20 seconds.
tFEED = 25 000/(4.8 x 180 x 8.75) hence
tFEED = 3.3 sec., where 25 000 is the desired
output of the burner in Watts (W), 4.8 is
the heating value of the fuel in kWh/kg,
180 is the number of burning cycles per
1 hour, 8.75 is the amount of pellets in
grams fed by the auger per 1 second.
This way the output mode can be
changed and instead the number 25 000
– 25kW, we input the desired kilowatts
(40 kW=40000 W, 70 kW=70000 W etc.).
Take also note of the fuel heating value
which would change the value for the
feed and the burner output.
Using the above procedure, you can
set any of the two output modes of the
burner.
11.1. Calibration of auger fuel feed rate.
The auger fuel feed rate changes
depending on the density and size of the
fuel used. Therefore it is necessary to
calibrate the main auger every time you
change the type of the fuel used.
CAUTION! It is recommended to
use the same fuel throughout
the heating season.
Once you have installed the pellet auger
according to the instructions in the
manual, fill the hopper with fuel (pellets).
Connect the power supply of the pellet
auger directly to the power mains. The
auger is now in operation. Wait about
15-20 minutes for the pellet auger to
fill with pellets. The auger is filled with
pellets when pellets begin to fall from the
T-branch of the auger at the point where
the auger hose is attached.
Filling of the pellet auger is necessary
when the fuel in the hopper has been
depleted or when fuel has been changed.
Once you have ensured that the pellet
auger has been filled, take an empty
plastic bag and fixed it securely on the
pellet auger, at the place of the auger
hose. Reconnect the auger to the power
38
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Important: For each of the
output modes the optimal fan
setting is tweaked by using gas
analyzer to control the oxygen
amount registered by the device
(for Max Power Setup within the
range 8÷10%, and for Min Power
Setup up to 13%). The specific
setting depends also on the
internal resistance of the boiler
combustion chamber on which
the burner has been installed as
well as on the chimney draught.
Therefore it is not possible to
provide here the exact value for
the fan output and it must be
entered by a competent installer
or service technician using gas
analyzer.
Mode
: Max Power Setup - It is
indicated by two flames.
Pellet auger running time (Feed) – 3.3
sec. (25kW)
Main combustion cycle (Cycle) – 20 sec.
(recommended)
Fan output (Fan) - adjust using gas
analyzer
Mode
: Min Power Setup – It is
indicated by one flame. We recommend
setup value of 35% (0.35) of the main
mode.
Pellet auger running time (Feed) – 1.2
sec. (7.5 kW; 3.3 х 35% = 1.2)
Main combustion cycle (Cycle) – 20 sec.
(recommended)
Fan output (Fan) - adjust using gas
analyzer.
CAUTION! You use a burner
whose carbon footprint values
are approximately (СО=100
ppm), which is 2.5 times lower
than the maximum allowed
limits for harmful emissions in
the EU Member States. Thus
you can reduce the amount of
harmful emission and contribute
to environment protection.
39
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Fuel hopper hatch-cover must be closed
during operation. Detailed description for
the assembly of a fuel hopper FH 500 will
find the User manual for assembling the
fuel hopper FH 500.
12. MOUNTING OF FUEL HOPPER FH 500
Fuel hopper FH 500 has a capacity of
500 liters pellets. Its design allowing
installation by choice on either side of
boiler. An important condition is to be
leveled. Before loading the pellets, make
sure that the hopper is clean. Empty the
container for pellet powder and dust.
40
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
Parameter
Sevice code
Cleaning Setup
Use Cleaner
Display
15 kW
25 kW
40 kW
Fan
Cleaner
******12
700sec
20sec
******12
700sec
20sec
******12
700sec
20sec
On Start
x
On Stop
x
x
x
90sec
300 sec
0200 cycles
90sec
300 sec
0150 cycles
CH Pump
DHW Pump
22:00/06:00
25sec
3min
2min/05/70
03sec
30sec
15
5oC
2,6
20
18/52
35%
6/25
v 8:00
□ 00:00
x
x
22:00/06:00
25sec
3min
2min/05/70
03sec
30sec
15
5oC
3,3
20
10/47
35%
5/40
v 14:00
□ 00:00
x
x
22:00/06:00
35sec
3min
2min/08/70
03sec
30sec
15
5oC
8
20
12/60
35%
6/30
v 22:00
□ 00:00
x
x
Thermostat
x
x
x
Thermostat
Buffer
NO
NC
dT
Burn On
Burn Out
Duty
x
x
x
x
x
x
05o
o
>95 /20min
05o
o
>95 /20min
05o
o
>95 /20min
Clean Ashes
Ignition Setup
Cycle Setup
Max/Min Power
Max Power Setup Min Power Setup
Feed
Heater
Fan B/E
Feed
Pause
Cycle
dT
Feed
Cycle
Fan B/E
Feed
Fan B/E
Auto Cleaning Setup
Addons Activation
CH Mode
Room Thermostat
Burn On / Burn Out Setup
Burner Feeder
Set Temperature
x
90sec
300 sec
0300 cycles
Clean Soot
Quiet Mode
Ignition First Feed
x
85o<
300%
85
41
85o<
300%
85
85o<
300%
85
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
13. WARRANTY TERMS
The warranty terms are described in the Service booklet included in the supply.
14. TECHNICAL FEATURES
14.1. Technical features of PelleBurn pellet boiler
14.1.1. Elements of PelleBurn pellet boiler
1.Housing
2. High efficiency thermal insulation
3. Chimney
4. Flue gas extraction fan
5. Fume exhaust tube
6. Automatic cleaning system
7. Water mantle
8. Combustion chamber
9. Ash-and-soot container
10. Burner housing
11. Pellet burner
12. Burner flange
13. Controller unit
14. Ash and soot transport screw with stirring
mechanism
Diagram 23. Elements of PelleBurn pellet boiler
42
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
14.1.2. Technical parameters of PelleBurn pellet boiler
PelleBurn PelleBurn PelleBurn
15
25
40
Heat output
Heating surface
Height H
Width L / Depth D
Mantle volume
Combustion chamber volume
Combustion chamber resistance
Required chimney draught
Boiler
Insulation
Doors
Electric power supply
Recommended fuel
Loading door size
Operating temperature range
Operating pressure
Weight
BURNiT Pell pellet burner
Power
Pellet fuel hopper
Cold water inlet
Hot water outlet
Safety line sleeve
Air vent
Flue
Cleaning opening
Drain
Combustion viewer
kW
5÷15
m2
60÷150
mm
1290
mm
640/1120
l
55
l
43
Pa/mbar 10/0.10
Pa
10÷20
10÷40
120÷380
1700
700/1120
101
73
12/0.12
10÷20
100 mm high-efficiency thermal wool
lined with aluminum foil
20 mm high-efficiency black veil rockwoo
V/Hz/A 230/50/10 230/50/10 230/50/10
wood-pellets, diameter 6÷8 mm
mm
400x220
490x260
490x260
°C
65-85
65-85
65-85
bar
3
3
3
kg
220
240
358
kW
4÷15
L
A, mm
B, mm
К
I
F, ø
mm
J, mm
O, mm
E
V
500
R 1’’/100
R 1’’/980


133
1280
320
140/300


Boiler flue gas extraction fan W1, mm
Burner air-feed fan W2, mm
Automatic cleaning device P, mm
Cleaning device motor
M
Z
Burner flange
Ash and soot transport motor
N, mm
Ash-and-soot container
Т
Control unit
U
43
8÷25
80÷220
1430
640/1120
70
53
11/0.11
10÷20
8÷25
12÷40
500
500
R 1’’/100
R 1’’/100
R 1’’/1120 R 1’’/1417




133
150
1480
1700
320
350
140/300
140/300




1220
510
1385
510
1665
565
950


170


1090


170


1390


170


TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
D
F
W1
M
L
P
U
V
H
B
W2
Z
Т
A
N
O
J
L
K
W
F
P
D
44
B
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
14.2. Technical features of Pell pellet burner
14.2.1. Elements of Pell pellet burner
1. Pellet burner Pell 25;
2. Auger hose;
3. Auger motor;
4. Automatic pellet auger;
5. Feeder chute;
6. Burner (inner) auger;
7. Combustion chamber corps;
8. Combustion chamber;
9. Automatic cleaning system;
Diagram 24. Elements of Pell pellet burner
45
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
14.2.2. Spare parts for Pell pellet burner
Diagram 25. Spare parts for BURNiT Pell pellet burner
№
Part Number
1
1
2
2
3
3
4
5
5
6
7
8
9
10
11
12
13
13
14
82801300000002
82801300000003
82801300000001
82801300000004
89801300000006
89801300000024
89800000000005
89801381000001
89801381000002
78801100000001
32800032000001
89080000000006
89801200000006
89800000000004
32590000000092
89080000000007
32640000000004
32640000000003
32800000000006
Model BURNiT Model BURNiT
PEll 25
PEll 40
х
х
Х
х
х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
Х
x(C130)
x(C130)
46
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
14.3. Technical features of fuel hoper FH 500
14.3.1. Elements of fuel hopper FH 500
1. Pellets loading hatch-cover with holder mechanism
2. Side panels
3. Auger mounting side-panel opening
4. Auger holder
5. Pellet-guide plates
6. Drainage holes
7. Leveling feet
8. Dust container cover
9. Dust container
10. Pellet-collecting bottom
11. Foundation
12. Guide plate seal
Diagram 26. Elements of fuel hopper FH 500
47
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
14.3.2. Technical parameters of fuel hopper FH 500
FH 500
Capacity
l
Max/Min wood pellets load ø, 6÷8 mm
kg
Height H
mm
Width L / Depth D
mm
Foundation
B, mm
Auger mounting opening C, ø mm
Auger holder
E
Pellet-load hatch
F, mm
Hatch support
G
Drainage holes
J
Dust container
X
Inclination of guide plates
P
Pellet-colecting bottom
R, mm
Leveling feet
Z
Guide plate seal
Weight
kg
48
500
280÷300 / 15
1260
772 / 730
53
76
P
400 / 772
P
P
P
45°
300 / 300
P
P
82
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
15. RECYCLING
Obsolete equipment shall be collected
separately from other recyclable waste
containing materials with adverse effect
on health and environment.
15.1.Recycling of boiler packaging
Parts of the packaging made of wood or
paper can be used as combustible for the
burner. Submit the rest of the packaging
material for recycling according to the
local regulations and requirements.
Replaced heating installation components
must be submitted for processing to an
authorized factory which complies with
the environmental protection regulation.
Metal details, as well as non-metal ones
shall be sold to licensed recyclable metal or
non-metal waste collection organizations.
Those should not be treated as domestic
waste.
15.2. Recycling and waste disposal
At the end of life cycle of each product its
components are due to be disposed of in
conformity with regulatory prescriptions.
49
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
50
TECHNICAL PASSPORT. INSTALLATION and OPERATION MANUAL
ISO 9001:2008
BUREAU VERITAS
Certification
BG119996Q
12 Madara Blvd.,
9700 Shumen, Bulgaria
t: +359 54 874 555
f: +359 54 874 556
e-mail: [email protected]
129 Vitosha Blvd.,
1000 Sofia, Bulgaria
t: +359 02 952 24 05
f: +359 02 952 67 20
e-mail: [email protected]
www.sunsystem.bg
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