Erato GP20+ Instruction Manual
Instruction manual for installation and operation of automatic pellet burner “ERATO GP20+”
(Version : 02.02.2010 10:36) p. 1/50
Instruction manual
for installation and operation of
Automatic pellet burner
ERATO GP20+
http://www.erato.bg
Instruction manual for installation and operation of automatic pellet burner “ERATO GP20+”
(Version : 02.02.2010 10:36) p. 2/50
Thank You for buying our product – automatic pellet burner „ERATO GP20+”.
This manual will help You to use and maintain the unit properly.
ATTENTION!
IN INTEREST OF YOUR PERSONAL SECURITY IT IS
NECESSARY TO READ THOROUGHLY AND CAREFULLY THIS
INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY
ACTIONS WITH THE BURNER – INSTALLATING, CONNECTING,
OPERATING, ETC. IN CASE THAT REQUIREMENTS, DEPICTED IN
THIS MANUAL ARE NOT SATISFIED, FAILURE OF THE UNIT
COULD BE EXPECTED, OR EVEN FATAL CONSEQUENCES, FOR
WHICH ERATO COMPANY DOES NOT TAKE RESPONSIBILITY.
Instruction manual for installation and operation of automatic pellet burner “ERATO GP20+”
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Table of contents
Page
1. Automatic pellet burner “ERATO GP20+” – description and
advantages............................................................................................................5
The burner could utilize following types of fuel ...........................................5
The unit is equipped with................................................................................5
The burner is equipped with ........................................................................... 6
Advantages of the burner................................................................................6
2. Automatic pellet burner “ERATO GP 20+” technical data ....................8
Table 2.1 Thermal and technical data of automatic pellet burner “ERATO
GP20+”, utilizing wood pellets..........................................................................8
Table 2.2 Dimensions and technical data of automatic pellet burner “ERATO
GP20+” ..............................................................................................................9
Table 2.3 Recommended solid biomass fuel properties – wood pellets...........9
Table 2.4. Pellets classification, considering their physical properties..........10
3. Description of the construction of automatic pellet burner “ERATO
GP20+”...............................................................................................................11
3.1. Main properties....................................................................................11
3.2. Specific design measures in order to increase the safety operation of
the burner.......................................................................................................14
4. Installation of automatic pellet burner.....................................................15
4.1. Some basic requirements for correct installation of automatic pellet
burner “ERATO GP20+” are.......................................................................15
4.2. Installation of the burner....................................................................15
4.3. Overall and attachment dimensions of the burner’s main unit......16
4.4. Arrangement and installation of the pellet burner’s modules........18
5. Initial steps and starting of pellet burner “ERATO GP20+”................20
5.1. Basic fuel requirements.......................................................................20
5.2. Staring automatic pellet burner “ERATO GP 20+”........................20
5.2.1. Interface control board of automatic pellet burner “ERATO
GP20+” ........................................................................................................21
5.2.2. Automatic pellet burner power supply.......................................21
5.2.3. Switching on the burner...............................................................22
5.2.4. Burner’s operating algorithm .....................................................24
5.2.5. Operating control parameters of the burner.............................26
• Description of LED indication (positioned on the control board of
the unit):......................................................................................................26
Table 5.1. Description of the operating parameters of the burner’s control
board.................................................................................................................28
5.2.6. Adjustment process of the burner, according to the heat
demand of a consumer...............................................................................30
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5.2.7. Nominal thermal load of the burner...........................................31
5.3. Adjustment of the thermal capacity of the burner...........................32
5.3.1. Decreasing thermal capacity of the burner................................32
5.3.2. Increasing thermal capacity of the burner.................................32
5.4. Stopping the pellet burner..................................................................33
5.5. Turning the burner OFF.....................................................................33
• Emergency burner stop .......................................................................34
5.6. Showing and teaching the end user about the maintenance and
adjustment procedures of the burner..........................................................35
5.7. Safety and unexpected risks ...............................................................35
5.8. Operation faults and repairing procedures ......................................36
Table 5.3. Automatic pellet burner faults and repair procedures....................42
Table 5.4. Detailed description of control board’s alarm mode indications...43
5.9. Automatic pellet burner “ERATO GP20+” warranty form
completion.......................................................................................................44
5.10. Actions, after the burner is not in exploitation anymore.............44
6. Electrical scheme of automatic pellet burner “ERATO GP20+”..........44
QUALITY CERTIFICATE .............................................................................46
WARRANTY FORM........................................................................................47
WARRANTY CONDITIONS..........................................................................48
WARRANTY SERVICE PROCEDURES LIST...........................................49
Instruction manual for installation and operation of automatic pellet burner “ERATO GP20+”
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1. Automatic pellet burner “ERATO GP20+” – description and advantages
“ERATO GP20+” is automatic pellet burner, which utilizes wood pellets.
The burner is designed to be installed on already operating heating boilers or
other equipment, thus allowing fuel switch procedure to a renewable energy
sources - biomass. The installed burner operates on wood pellets and the
thermal energy, resulting from the intensive combustion process is directed
to the heat exchange surfaces of a boiler or another thermal consumer.
The burner could utilize following types of fuel
• Wood pellets, having diameter 6 and 8 mm, categorized in the range
of: A, AB, B (according to the methodology, developed for pellets
properties estimation in ERATO company);
• Pre-dried pits (from cherries for example);
• Fuel mixture – pellets and pits (for example mixture ratio could be
50% - 50%);
• Other solid biomass based pellets, but these fuels need testing and
approval in ERATO company laboratory;
The unit is equipped with
• adjustable operating module, which controls the functions of the unit
and is adjustable to the specific needs of a heating system;
• auger, which transports fuel from a bunker to the main unit;
• fresh air supplying fan, equipped with a Hall sensor, which returns
information to the control unit;
• electric heater, which ignites the fuel;
• combustion chamber, which gives environment for efficient
combustion process;
• removable grate of the combustion chamber, allowing easy access and
ash cleaning;
• photosensor, which gives information for the status of the combustion
process to the control unit and allows dynamic operation of the burner;
• interface panel, equipped with light indicators;
• the control board is equipped with led indicator for indicating the
status of adjustable parameters index value;
• a variable potentiometer, which allows easy thermal capacity
adjustment;
• a position switch, which confirms that the burner is installed properly
and could work safely;
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The burner is equipped with
• automatic fuel ignition system;
• automatic fuel transport system – from bunker to the combustion chamber
of the main unit;
• safety system, which blocks its operation if the main unit is not installed
properly;
• safety system, which blocks its operation in case that at any circumstances
the fuel delivery pipe is preheated above certain temperature safety level;
• photosensor, which allows dynamic monitoring of the combustion process
status;
• transition system, which modulated the air supply fan operation at ignition
process;
Advantages of the burner
• the burner automatically utilizes renewable energy source – biomass,
which makes it environmental friendly and does not contribute to the
global warming and pollution;
• the burner is installed in order to apply the so called fuel switch process
for appliances, utilizing fossil fuels – diesel, natural gas, LPG, coal;
• the burner’s design allows easy installation on manual fed boilers – such
as those, designed for coal, wood logs. The heating system and the
boiler/equipment however need minor redesign and reconstruction in
order to allow such fuel switch process;
• the resulting heat energy, based on organized combustion process of
renewable energy source - biomass, is less influenced by the global trend
of the energy sources and as result the price is competitive, compared to
price of the popular energy sources;
• the burner operates automatically and achieves operation comfort,
delivered by operating of fossil fuel burners – working with liquid and
gaseous fuel, which permits remote control by programmable room
thermostat;
• the burner’s control unit is equipped with automatic fuel ignition
procedure;
• automatic operation of the burner allows variable thermal load adjustment
and economic operation of the heating system, which guarantees optimal
thermal comfort and reduced fuel consumption;
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• simplified installation procedure and initial adjustment, which guarantees
faster assembly and unified approach;
• opportunity to utilize biomass, pellet shaped as well as other dried nuts,
according the appropriate fuel table;
• high efficiency;
• low pollutant emissions;
• automatic fuel transport from a bunker, built according to the local units
arrangement and need of the client (the bunker is not part of the burner
equipment delivery);
• simplified maintenance and service;
• minimal operating costs;
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2. Automatic pellet burner “ERATO GP 20+” technical data
2.1. Thermal and technical data of automatic pellet burner “ERATO
GP20+”, utilizing wood pellets are given in Table 2.1;
2.2. Dimensions and technical data of automatic pellet burner “ERATO
GP20+” are given in Table 2.2;
2.3. Recommended solid biomass fuel properties – wood pellets, are
given in Table 2.3;
2.4. Pellets classification, considering their physical properties (based
on fuel proximate analysis) are shown in Table 2.4;
Parameter Dimension Value
Nominal thermal capacity kW 32
Thermal capacity operation range kW 5 – 32
Utilized solid fuel
• Wood pellets;
• Pre-dried cherry nuts;
• Other dried nuts;
Utilized pellets, complying ERATO
classification methodology
A,AB,B
Wood pellets fuel consumption rate at
nominal thermal capacity
kg/h 6.8
kg/h
55 – 65
Fresh air flow rate, required for effective
combustion process and boiler operation
m
3
/h
50 - 60
Averaged wood pellets consumption rate
(the unit is operating in a popular heating
system)
kg/h 5.0
Air excess ratio λ 1.6 – 1.8
Solid fuel residue ash The quantity
depends on the ash
contents in the raw
fuel, as well as
operating
conditions
Table 2.1 Thermal and technical data of automatic pellet burner “ERATO
GP20+”, utilizing wood pellets
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Parameter Dimension Value
main module kg 18
Weight
fuel transport auger kg 14
main module mm 250 х 570 х 530 Overall dimension of
the unit (WxDxH)
fuel transport auger mm 220x1890x110
Power supply -
1PEN ; 50Hz;
230V;
at nominal load 0.2 A Power consumption
rate
at ignition 4.5 A
Electrical capacity
VA <100 + 1100 (at
ignition process)
Electric protection - IP20
Table 2.2 Dimensions and technical data of automatic pellet burner “ERATO
GP20+”
Parameter Dimension Value
Pellet’s characteristic size mm 6 – 8
MJ/kg >17.2 Recommended fuel net calorific value
kWh/kg >4.7
Wood pellets category
A, AB, B
Ash content % See Table 2.4.
Moisture content % Max. 8 – 10%
Table 2.3 Recommended solid biomass fuel properties – wood pellets
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Classification of wood pellets, considering their physical properties (based on
fuel proximate analysis) – according to fuel evaluation method, developed and
applied in ERATO company is show on the following table.
Pellet’s category A
d
DU
A %6.0≤
d
A %0.97≥DU
AB
%6.0≤
d
A
%0.97
<
DU
B %0.16.0 ≤<
d
A %0.97≥DU
BC %0.16.0 ≤<
d
A %0.97
<
DU
C %0.2%0.1 ≤<
d
A
%0.97≥DU
CD %0.2%0.1 ≤<
d
A %0.97
<
DU
D %0.3%0.2 ≤<
d
A %0.97≥DU
DE %0.3%0.2 ≤<
d
A
%0.97
<
DU
E %0.3>
d
A %0.97≥DU
EF %0.3>
d
A %0.97
<
DU
Table 2.4. Pellets classification, considering their physical properties
where :
A
d
– ash contents, dry basis, [%];
DU – mechanical durability, [%];
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3. Description of the construction of automatic pellet burner “ERATO
GP20+”
3.1. Main properties
The burner consists 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;
• On-position switch (safety sensor), which stops and blocks the
burner operation if it is detached from the appliance- heat energy
consumer;
• 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;
• Transparent window, though which the operation of the control
board could be checked without removing the cover and any
interventions;
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• 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 o f 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;
The main modules of the pellet burner and their arrangement are shown of the
following figure.
Figure 3.1 Arrangement of the modules of the pellet burner (top view);
Elements and modules of the main unit are shown on figure 3.2 and figure 3.3.
Main unit
Fuel transport
auger (from the
bunker to the main
unit)
Flexible
pipe
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Figure 3.2 Section view of the elements of the main unit of the burner;
Figure 3.3 Side view of the main unit of the burner;
Combustion chamber
Photosensor
Power supply cable
Auger power supply
plug
Control board of the
burner
Interface panel
Flap and air supply fan
“Back fire” safety alarm
thermo-
p
robe
Fuel delivery pipe and
“back fire” safety
thermo-probe
Grate of the combustion
chamber
“L” shaped element and
on-position safety
Installation flange for
attaching the main
module to a consumer
unit
Control board monitoring transparent window
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3.2. Specific design measures in order to increase the safety operation of
the burner
• The ignition and the combustion process is monitored by microprocessor
control board;
• The ignition process is monitored and in case that the fuel is not ignited
for some reason, after certain number of ignition trials, the operation of
the burner is stopped and alarm mode is indicated;
• In case that fuel is consumed from the hopper, than after the defined
number of ignition trials the burner will go out in stop mode and alarm is
indicated as well;
• The flexible hose, which connects the fuel transport auger with the main
unit, is transparent and is made of specific heat resistant material;
• Information stickers are applied, indicating certain precautions measures
and correct operation of the unit;
• The burner is equipped with safety elements, which are involved in back
fire protection system:
o Free falling duct, which practically interrupts the fuel flow between
the transport auger and the main module. This duct is
approximately 250mm long. Beside that, the fuel auger is
connected to the main unit by a flexible hose, which does not
contain fuel. The grate of the burner is however charged with
controlled amount of fuel, which is utilized at controlled
combustion process and possibility of back fire is strongly reduced;
o Sensor of “back fire” alarm thermo-probe, which is positioned on
the fuel delivery pipe of the main unit, activates at surface
temperature levels above 90 – 95
o
C. In case of alarm thermo-probe
activation, the main unit and the fuel transport auger are stopped
and switched to alarm mode. This mode is indicated by appropriate
signals of the LEDs on the control board of the main unit. The
alarm mode is not automatically deactivated and needs manual
restarting. The cause of the alarm situation should be clarified and
precaution measures should be taken before restarting the burner
(performed by switching OFF and back ON the main power
supply).
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