Gordic Environment AB PELLX Installation Manual

Gordic Environment AB

P.O Box 11, SE 280 22 Vittsjö, Sweden

Installation Manual

PellX 20 kW Pellets Burner

Eng. Edition 1.0 2004, Nov.

1

1 INFORMATION ...................................................................................................................2

1.1 INTRODUCTION ..................................................................................................................2

1.2 TECHNICAL DATA. DIMENSIONS ........................................................................................3

1.3 DELIVERY CHECK ..............................................................................................................4

2 INSTALLATION ..................................................................................................................5

2.1 PRECAUTIONS ....................................................................................................................5

Boiler..................................................................................................................................6

Chimney..............................................................................................................................6

2.2 MOUNTING ........................................................................................................................8

General...............................................................................................................................8

Burner installation..............................................................................................................9

Pellet storage......................................................................................................................9

Feed screw installation.....................................................................................................10

Installation of the control box ..........................................................................................11

Connection of temperature sensor....................................................................................13

Draft regulator .................................................................................................................14

2.3 ELECTRICAL INSTALLATION.............................................................................................15

Mains supply.....................................................................................................................15

Connections inside the burner..........................................................................................16

2.4 SETTINGS.........................................................................................................................17

Control box functions .......................................................................................................17

Description. Control box adjustments..............................................................................18

First start/adjustment during operation...........................................................................20

Modifications/Adaptions...................................................................................................22

Eng. Edition 1.0 2004, Nov.

2

1 Information

1.1 Introduction

This installation manual is a supplement to the Operation and Maintenance
Manual, which is supplied with the PellX burner.

The manual presumes general knowledge regarding installation of pellets
burners and boilers, which are suitable for being fitted with a pellets burner. In
case that you are not acquainted with the burner or if there are any other unclear
questions, please contact the authorized PellX dealer for more detailed
information.

This burner is different from earlier versions. The electronic control system is
completely new and the design is improved in many other respects. To get to
know the function of the burner, we recommend you to study the Operation and
Maintenance Manual carefully.

Used symbols

Warnings and safety regulations

This sign is used to draw your attention to instructions especially important from
the safety point of view. Non-compliance may cause serious damage to the
equipment and be a risk to yourself and the safety of other people.

Eng. Edition 1.0 2004, Nov.

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1.2 Technical data. Dimensions

Heat output, max. ___________________ approx. 20 kW
Heat output, min. ___________________ approx. 13 kW
Output levels ___________________ 65 %, 100 %
Combustion efficiency ___________ approx. 95 %
Combustion air consumption ___________ approx. 30 – 40 m

3

/h
Weight ___________________________ approx. 13 kg
Power supply _________________ 230 V 50 Hz
Power consumption (ignition)__________ 400 W
Power consumption (operation)_________ 40 W
Fuel ___________________________ Wood pellets: ∅ 6 or ∅ 8 mm
max. length 30 mm

Dimensions (outside the boiler):
Depth __________________________ 300 mm
Width _________________________ 225 mm
Total height ______________________ 520 mm

Dimensions, combustion chamber tube in the boiler:
Length _________________________ 205 mm
Diameter _______________________ 155 mm

Recommended exhaust gas values:
CO

2

___________________________ 10 – 13 %

CO ___________________________ < 300 ppm

Recommended exhaust gas temperature _ 180 ±20ºC

(Measured directly after the boiler)

Eng. Edition 1.0 2004, Nov.

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1.3 Delivery check

The standard delivery includes the above shown equipment.

(Sealing cord, 2 pcs. and stop screw, 1 pc. belong to the mounting flange).

The following items are also included in the box:

• Operation and Maintenance Manual

• Short m aintenance instruction (A4 poster)

• Plastic tubing (blue pellets tubing)

• Hose adapter between plastic tubing and flame trap pipe

• Hose clamps, 2 pcs. (for the plastic tubing)

• Suspendor (straps for the feed screw)

• Signal cable, 3 m (15-poles D-Sub cable)

• Mains cable, 2.5 m (for m ains supply to the burner)

• Net cable, 2.5 m (for connection between burner and feed screw)

• Tem perature sensor, 2 or 5 m (temp.sensor start/stop, for connection to the

control box)

If a PellX feed screw is included in the delivery, the motor will be packed in the
box, while the tubing/screw, 1.7 or 2.3 m, is in a separate package.
A flat mounting plate, 350 x 350 mm, is available as option. If ordered, it will be
packed in the box.

Eng. Edition 1.0 2004, Nov.

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2 Installation

2.1 Precautions

Before selling a PellX burner, the dealer has to be sure that all conditions
necessary for creating a functional installation are fulfilled. If extra
modifications have to be carried out, information must be given before selling
the burner.

Always check the local regulations for new/changed installations with the
housing committee in the municipality, where the installation is to be made. A
permit might be required. Also contact the local chimney sweep.

The boiler room, where the pellets burner is to be installed, the chimney and
other auxiliary equipment must comply with the current fire protection
regulations and local standards. The boiler room must be provided with an open
air inlet valve with a free area corresponding to the chimney cross sectional area.
A warm air boiler may not take warm air from the boiler room.

The burner installation shall be carried out by an authorized installation
contractor in accordance with the instructions in the PellX Installation Manual
and according to local regulations. Electrical authorization is required for the
electrical installation. Final inspection, function control and adjustment of the
installation are to be carried out by a person with PellX authorization.

Eng. Edition 1.0 2004, Nov.

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Boiler

Check the condition of the boiler to avoid that unexpected operational troubles
will occur in the future.

Exhaust valves, if any, shall be fully open. All doors and exhaust connections on
the boiler shall be tight.

It is important that the fire place is big enough, so that the flame will not be in
contact with water-cooled walls. The burner’s capacity must conform to the size
of the boiler. The fireplace, where the burner is mounted, must be dimensioned
for the output of the burner. In so called combi-boilers, the fireplaces for oil and
wood can be dimensioned for different maximum output. There must be enough
space for the ash. The exhaust channels must be wide enough not to be easily
plugged with ash.

The distance between the upper edge of the pellets burner’s combustion
chamber tube and the fireplace roof must be at least 50 mm. As general the
distance between the front edge of the burner and the rear fireplace wall should
be 300 mm, which however can often be reduced to 200 mm. The important
thing is that the flames from the combustion chamber tube never reach the boiler
wall. The minimum distance to the bottom of the fireplace depends on the boiler
design. There must be enough space for the quantity of ash that is created during
at least one week use in wintertime.

The directions above are general for most installations. If you are not familiar
with the boiler type in question or not sure about any other detail, please contact
the authorized PellX dealer for more information. In some cases smaller
modifications of e.g. the boiler might be required for a proper function of the
installation.

Chimney

We recommend you to have the local sweep make an inspection and give advice
and instructions about measurements, which might be necessary for the chimney
and the exhaust pipe connections.

The following has to be considered before and after operation start of the plant:

• The burner is adjusted to a chimney draft of 15-20 Pa. If the depression is

too much, a draft regulator has to be fitted. As a draft regulator is an
advantage also in other respects, we recommend it also in cases of normal
depression; see the chapter Draft regulator under 2.2 Mounting.