Erato Pony PS9 User Manual

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USER MANUAL

of hot air automated pellet stove

ERATO Pony PS9

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Thank You for buying hot air automated pellet stove „ERATO Pony PS9”. This manual will help You to use and maintain the unit properly.

ATTENTION!

IN INTEREST OF YOUR PERSONAL SECURITY IT IS OBLIGATORY TO READ THOROUGHLY AND CAREFULLY THIS INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY ACTIONS WITH THE BOILER – MOUNTING, CONNECTING, ETC. IN CASE THAT REQUIREMENTS, DEPICTED IN THIS MANUAL ARE NOT SATISFIED, FAILURES OF THE UNIT COULD BE EXPECTED, OR EVEN FATAL CONSEQUENCES, FOR WHICH ERATO COMPANY DOES NOT TAKE RESPONSIBILITY.

Producer

ZMM-Haskovo Ltd

Address

Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd.

Phone

+359 38 603060; +359 38 603062

Fax

+359 38 603070

e-mail

zmm@erato.bg

home page

http://www.erato.bg/zmm

Hot air automated pellet stove “ERATO Pony PS9” user manual; (document version: 13.03.2011 11:53)

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CONTENTS

Page

1. Description and advantages of hot air automated pellet stove “ERATO Pony PS9” 5

The unit could utilize following types of fuel:.................................................................... 5

The unit is equipped with:...................................................................................................5

The unit is supplied with: ....................................................................................................6

2. Technical data of hot air automated pellet stove, “ERATO Pony PS9”................. 7

3. Description of the construction of hot air automated pellet stove “ERATO Pony PS9” 11

4. Installation process..................................................................................................... 15

5. Entering the appliance in service.............................................................................. 23

5.1. Basic fuel requirements. ........................................................................................ 23

5.2. Starting hot air pellet stove “ERATO Pony PS9” procedure. ...........................24

5.2.1. Interface control board of hot air pellet stove“ERATO Pony PS9” ...................25

5.2.2. Description of the function of the buttons of the interface panel. .......................27

5.2.3. Power supply of the stove........................................................................................ 29

5.2.4. Turning on the appliance. ....................................................................................... 29

5.2.5. Set up of the stoves parameters .............................................................................. 30

5.2.6. Set up of the stove according to the thermal power needed................................. 34

5.2.8. Nominal operation mode of the stove..................................................................... 35

5.3. Adjustment of the thermal capacity of the stove................................................. 36

5.3.1. Decreasing the thermal capacity of the stove ........................................................36

5.3.2. Decreasing the thermal capacity of the stove...................................................... 36

5.4. Stopping the operation of the stove. ..................................................................... 37

5.5. Cleaning the stove................................................................................................... 37

5.6. Turning OFF the stove........................................................................................... 41

5.7. Showing and teaching the end user about the maintenance and adjustment

procedures........................................................................................................................... 42

5.8. Safety and unexpected risks.................................................................................. 42

5.9. Operation faults and their repairing from the end user.....................................44

5.10. Alarm messages, shown on the display of the stove............................................ 46

5.11. Operation faults and their repairing from the service personal........................ 47

5.12. Hot air pellet stove „ERATO Pony PS9” warranty form completion. ............... 50

5.13. Actions, after the unit is not in exploitation anymore......................................... 50

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6. Electrical scheme of the apliance.............................................................................. 51

QUALITY CERTIFICATE .................................................................................................. 52

WARRANTY CONDITIONS............................................................................................... 53

WARRANTY SERVICE PROCEDURES LIST ................................................................ 54

Declaration of Conformity..................................................................................................... 55

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1. Description and advantages of hot air automated pellet stove

“ERATO Pony PS9”.

“ERATO Pony PS9” is steel-plate hot air pellet stove, which uses solid

biomass fuel in shape of pellets. The stove is designed for local heating of domestic and office spaces. The boiler uses wood pellets, as well as other type/shape of biomass; the resulting heat energy from thermo-chemical conversion (i.e. combustion process) is transmitted from the heat-exchanging surfaces to the surrounding air.

The unit is equipped with:

• Hot air automated pellet stove– 1 ct;

• Battery – Toshiba 23A, 12v, V23GA – 1 ct;

• Remote control - 1 ct;

• Plastic heels M10 X 43 - 4 ct;

• Handel - 1 ct;

• Supply cable PC AC 220V - 1 ct;

• Users guide for “ERATO Pony PS9” – 1 ct;

The unit could utilize following types of fuel:

• Wood pellets, having diameter 6 mm, categorized in the range of: A, AB, B, (according to the methodology, developed for pellets properties estimation in ERATO company);

• Other solid biomass based pellets, but confirmation for these fuels utilization need testing and approval by ERATO company laboratory;

The unit is equipped with:

• Steel plates welded heat exchanger for heating-up the surrounding air;

• Flue gas fan;

• Fan for forced convection of the hot air

• Burner’s ash removal mechanism – removes the ash residuum out of

the burner’s grate;

• Daily fuel hopper with capacity of about 19 kg;

• Programmable operating module, which controls the functions of the

unit and is adjustable to the specific need of the client.

• Ash container with capacity of 0.5 kg;

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The unit is supplied with:

• Automatic fuel ignition system;

• Automatic fuel feeding auger system;

• Remote control;

Unit’s advantages:

• The hot air stove gives you an incredible feel of warmth and comfort due

to a controlled and highly efficient combustion process.

• The hot air stove is designed to utilize solid biomass fuel, making it

environmentally friendly, CO2 neutral and does not contribute to the

global warming process – result of fossil fuel utilization;

• The specific price of the heat energy, delivered by solid biomass

utilization is less dependent on the world fuel market trends and

practically the heat energy price is competitive to the conventional energy

sources;

• The stove is automatic and the thermal comfort achieved is close to that,

originating from exploitation of fully automatic heaters, (for example

liquid or gas fuel, as well as electric heaters). The stove is equipped with

integrated programmable room thermostat (daily, weekly and weekend

programs);

• The unit is equipped with automatic fuel ignition system and another one

for burner’s ash cleaning;

• High efficiency;

• Low pollutant contents in the flue gases;

• Automatic fuel feeding system, transported from the built-in “daily”

hopper to the burner;

• Simplified maintenance and service procedures;

• Minimized running costs;

• The unit utilizes solid biomass fuel, in shape of pellets (wood pellets),

defined in following norms: ENplus (EN 14961-2:2010), ONORM

M7135, DIN 51731 и DINPlus;

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2. Technical data of hot air automated pellet stove, “ERATO

Pony PS9”

• Thermal and technical data for hot air stove “ERATO Pony PS9”,

utilizing wood pellets are given in Table 2.1;

• Dimensions and technical data for hot air stove “ERATO Pony PS9”,

are given in Table 2.2;

• Recommended solid fuel properties – wood pellets, are given in Table

2.3;

•

Pellets classification, considering their physical properties (based on fuel proximate analysis) are shown in Table 2.4;

Parameter Dimension Value

Nominal thermal capacity kW 9 Thermal capacity operation range kW 3.5 – 9 Utilized solid fuel Wood pellets diameter d+6mm Utilized pellets, complying ERATO classification methodology

A, AB, B

Wood pellets fuel consumption rate at nominal thermal capacity

kg/h 2.1 kg/h 16 - 18

Fresh air flow rate, required for effective combustion process and boiler operation

m3/h 14 - 16

Averaged wood pellets consumption rate kg/h 1.2 Average refueling cycle h Up to 20 Thermal efficiency at nominal capacity ℅ Up to 90 Air excess ratio

1.6 – 1.9 Flue gases temperature at nominal thermal capacity

ºC 160 – 200

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 for hot air stove “ERATO Pony PS9”, utilizing wood pellets.

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Parameter Dimension Value

Weight kg 91

dm³ 29 Fuel hopper capacity

19 kg wood pellets

d=6mm Overall dimension of the unit (WxDxH) mm 470x612x1083 Class

(according to EN 303-5)

- 3 Recommended air temperature in the heated space

ºC 20

Minimum air temperature in the heated space

ºC 14

Draught Pa 4-10

Fresh air channel

Connections

Flue gases duct

mm 80

Electrical supply - 50Hz; 230V Electrical power

<100

< 350 (at ignition

process)

- IP20

Table 2.2 Dimensions and technical data for hot air stove “ERATO Pony PS9”, utilizing wood pellets.

The recommended fuel for hot air stove “ERATO Pony PS9”, utilizing pellets is: wood pellets with specific size – diameter 6 mm. Main characteristics of the fuel are given in the next table.

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Parameter Dimension Value

Pellet’s characteristic size mm 6 Pellet’s characteristic length mm Max 30

MJ/kg >17.2 Recommended fuel net calorific value (low

heating 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 fuel properties – wood pellets

Pellet’s category Ad DU

%6.0≤

%0.97

≥

%6.0≤

%0.97

%0.16.0 ≤<dA

%0.97

≥

%0.16.0 ≤<dA

%0.97

%0.2%0.1 ≤<dA

%0.97

≥

%0.2%0.1 ≤<dA

%0.97

%0.3%0.2 ≤<dA

%0.97

≥

%0.3%0.2 ≤<dA

%0.97

%0.3>

%0.97

≥

%0.3>

%0.97

Table 2.4 Pellets classification, considering their physical properties (based on fuel proximate analysis) – according to fuel evaluation methods, developed and applied in ERATO company;

where: Ad – ash contents, dry basis, [%];

DU – mechanical durability, [%];

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The European wood pellets standard EN 14961-2:2010 defines wood pellets certificate ENplus for pellets, utilized in boilers and appliances for domestic heating systems. The certificate EN-B is applied for pellets, utilized in industrial boilers. In principal the ENplus standard defines two quality

classes: А1 и А2. The class А1 is highly restricted, considering the ash content. The class А2 the limit of the ash content of the wood pellets is higher – up to 1.5%. For industrial boilers the certificate EN-B is applicable, which defines fewer restrictions on the pellets quality.

Parameter Dimension ENplus-A1 ENplus-A2 Diameter mm 6 (± 1) 6 (± 1) Length mm 3,15 ≤ L ≤ 40

3,15 ≤ L ≤ 40 1) Bulk density kg/m³ ≥ 600 ≥ 600 Low calorific value MJ/kg ≥ 16.5 ≥ 16.5 Moisture content % ≤ 10 ≤ 10 Dust % ≤ 13) ≤ 1

Mechanical durability % ≥ 97.5

≥ 97.5

Ash content % 2) ≤ 0,7 ≤ 1.5 Ash melting point temperature °C ≥ 1200 ≥ 1100 Cl %

≤ 0.02 ≤ 0.03

S %

≤ 0.05 ≤ 0.05

N %

≤ 0.3 ≤ 0.5

Cu mg/kg

≤ 10 ≤ 10

Cr mg/kg

≤ 10 ≤ 10

As mg/kg

≤ 1 ≤ 1

Cd mg/kg

≤ 0.5 ≤ 0.5

Hg mg/kg

≤ 0.1 ≤ 0.1

Pb mg/kg

≤ 10 ≤ 10

Ni mg/kg

≤ 10 ≤ 10

Zn mg/kg

≤ 100 ≤ 100

1) not more that 1% of the wood pellets should be with length of 40 mm, the maximal pellet length is 45 mm ;

2) determined on dry mass;

3) the particles are <3.15 mm, fine particles, before fuel delivery;

4) in case the test measurements are performed with Lignotester, than the limit value is ≥

97.7% m.w.;

Table 2.5 ENplus - European standard for wood pellets;

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3. Description of the construction of hot air automated pellet

stove “ERATO Pony PS9”

The heat exchanger of the stove complies with the acting requirements for

such kind of units, defined in operating norm: EN 303-5/2000 – „Heating

boilers for solid fuels, hand and automatically fired nominal heat output up to 300 kW. Terminology, requirements, testing and marking”.

The unit consists of:

• Main part of the unit is heat exchanger. In the combustion chamber of

this exchanger is mounted specialized grate burner, designed for horizontal fuel feeding;

• The heat exchanger is welded construction of carbon steel plates. The

lower part of the exchanger is designed as combustion chamber. The burner is mounted in this chamber and under is the ash container.

• Combustion chamber: It is designed to provide conditions for optimal

burning process and helps for complete burning of the fuel. The chamber is closed by a door with heat-prove glass, giving the possibility to see the burning process ant also provides direct heat radiation to the surrounding objects.

• Stainless steel burner, mounted in the combustion chamber of the heat

exchanger;

• Ash container, positioned in the lower part of the combustion chamber,

below the burner;

• Fuel hopper is mounted right behind of the stoves’s burning chamber. In

the hopper (in the center and on angle) is mounted a fuel-auger separator.

• Fresh air for burning is provided by a pipe. The air for burning needs to

be with room temperature. Do not connect the pipe directly to the outside of the building.

• Flue gases exit duct is positioned in the lower rear side of the heat

exchanger (after the flue gases fan, concerning the flue gases track), utilized for forced flue gases extraction;

• Control unit it is placed in a cool zone of the stove and provides save

function of the appliance. The control is equipped with a lithium battery, which has a live time of 5 years – it is used for memorizing the settings of the control in cases of interrupted main power supply. In order to maintain save function the stove is supplied with a pressure gadget for monitoring the functionality of the chimney. In cases of malfunction of the chimney, that pressure gadget stops the stove immediately, preventing damages to

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the appliance and emergency situations. Also the stove is monitoring the temperature of the smoke gases. In cases of increased temperatures, above the save a limit, the stove goes in minimum power, or in critical values shuts down itself.

• Interface panel is used for set up of the control unit. And to monitor the

work parameters and massages.

• The heat exchanger, fuel hopper and other modules of the stove are

covered with decorative covers painted in different colors.

Figure 3.1. External view and description of the main modules of hot air stove “ERATO Pony PS9”;

Interface panel of the control

module of the stove

Fuel hopper cover

Decorative guiding screen for the hot air

Door with fire-prove glass

Handel

Cover for the ash container

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Main dimensions of hot air stove “ERATO Pony PS9” are given in figure 3.2.,

3.3 and 3.4.

Figure 3.2. Front and back view of hot air stove “ERATO Pony PS9”;

Figure 3.3.Top and left-hand side view of hot air stove “ERATO Pony PS9”

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Main modules/elements of hot air stove “ERATO Pony PS9” are given in figure

3.4.

Figure 3.4. Cross section view and description of the main modules/elements of hot air stove “ERATO Pony PS9”

Fuel hopper

Fuel-auger

Interface panel of the control

module of the stove

Fuel-auger motor

Pipe for fresh air

Hot air fan

Stainless-steel burner

Flue-gas channel

Flue-gas fan

Ash container

Door of the burning chanber

Guiding plate – back of the burning chamber

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Installation process.

Norms and recommendations.

In order to meet the safety requirements is necessary to meet the following:

• At least two people are needed to unpack, move and install the stove. Be

careful not to damage the covers of the stove or the stove itself.

• During transportation you need to take in count the information provided

on the package.

• The moving and placing of the stove needs to be done with proper

equipment, following the safety requirements.

• If lifting equipment is used (cranes, forklifts), do not life the stove close

to them.

• In case of using ropes during transportation, take in count their strength

and condition.

• During transportation keep the stove as straight as possible; do not tilt it

too much.

• During unpacking of the stove be careful not to damage the side covers of

the stove or the stove itself.

• After unpacking take out, of the burning chamber, all the accessories (if

there are any). Also take out all elements used for safe transportation of the stove (pasteboard, cardboard, plastic)

ATTENTION: Keep all packing materials out of reach of children. Throw them away in the designated for that purpose places.

Requirements during installation of hot air stove “ERATO Pony PS9”

• The room, dedicated to mount the stove, should be supplied with fresh air

supply duct, necessary for optimal combustion process as well as room ventilation. Place the stove where it will be easily checked, maintained or repaired.

PROHIBITED is installing the stove in bedrooms, bathrooms and rooms in which is installed other heat source without a vent (open fire place for instance)

• Installation and service procedures should be performed by authorized

qualified and certified personal ONLY;

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• The Stove needs to be installed on a floor with required strength and fire-

resistance. In case of not meeting these requirements you need to chose other place for installing the stove or to take the necessary actions in order to improve the place for installation in order to meet the requirements. Most often the stove is installed on fire-proved floors with size larger than the stove itself so safety operation is ensured and possibility of fire is taken to the minimum and also provides easy access for cleaning and maintenance. The minimum size of the fire-proved floor needs to be 150mm from the sides of the stove and at least 300mm in front of the stove. In case of using a metal sheet for meeting above mentioned safety requirements it needs to be at least 2mm thick.

• It is strongly recommended burning objects (wood beams, furniture,

curtains and flammable liquids) to be placed on distance at least 1meter from the zone of intensive heat radiation. In cases that such objects are near to the stove, you need to protect them with a lair of fire-prove insulating material. If the floor is made of flammable material (wood) it is necessary in front of the stove to be placed protective sheet with size 300mm minimum.

• Before entering the stove in service you need to check the draught of the

chimney and to ensure that the stove is properly connected to the chimney.

• Maintenance procedures of the boiler should be performed by trained

adult persons, which have read the user manual of the unit;

Installation procedure of the stove requires engineering project for the heating system, prepared according to the acting local norms and recommendations as follows:

• To the heating system - EN 303-5/2000 - „Heating boilers. Part 5 :

Heating boilers for solid fuels, hand and automatically fired, nominal heat output of up to 300 kW. Terminology, requirements, testing and marking”;

• To the chimney;

• Fire prevention requirements;

• To the power circuit - EN 60335-1/1997- “Household and similar

electrical appliances – safety, Part 1 – General requirements”;

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Erato Pony PS9 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual