GreenEcoTherm GP XX SC Series, GP 20 sc, GP 32 sc, GP 25 sc, GP 18 sc Installation, Operation And Maintenance Manual

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MANUAL

FOR INSTALLATION, OPERATION AND MAINTENANCE OF

AN AUTOMATED PELLET BURNER FROM SERIES

“GP xx sc”

http://www.greenecotherm.eu

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Manufacturer

ZMM Haskovo PLC

Address

Phone number

Fax

e-mail

home page

67 Saedinenie blvd., 6300 Haskovo, Bulgaria +359 800 15 145 +359 38 603 070

[email protected] www.greenecotherm.eu

The manufacture company thanks you for your choice. The manufacture company submits this manual to help the team that will install, adjust and

service the pellet burner, as well as to the customer that will operate it. The manufacturing company requires that the technicians, performing the above mentioned

procedures, had successfully passed the product’s technical training.

Manual for installation, operation and maintenance of an automated pellet burner from series

“GP xx sc”

(Edition: 13.11.2013 г. 14:48)

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CONTENT

page.

1. USERS SAFETY INFORMATION. ................................................................................................. 4

2. DESCRIPTION AND ADVANTAGES OF THE AUTOMATED PELLET BURNER “GP xx sc”. ..... 5

3. TECHNICAL DATA OF THE AUTOMATED PELLET BURNER FROM SERIES “GP xx sc”. ....... 7

4. CONSTRUCTION DESCRIPTION OF THE AUTOMATED PELLET BURNER “GP xx sc”. ....... 10

4.1. GENERAL CONDITIONS. ................................................................................................... 10

5. MOUNTING AND INSTALLATION OF THE PELLET BURNER. ................................................. 11

5.1. MAIN REQUIREMENTS FOR INSTALLATION OF A PELLET BURNER ”GP xx sc”. ........ 11

5.2. INSTALLATION OF THE PELLET BURNER. ...................................................................... 11

5.3. OVERALL DIMENSIONS OF THE BURNER’S MAIN MODULE. ....................................... 11

5.4. POSITIONING AND MOUNTING OF THE BURNER’S MODULES. ................................... 12

5.5. INFORMATION ABOUT INSTALLATION AVAILABILITIES OF AN AUTOMATED PELLET

BURNER “GP xx sc” AND ITS CO-OPERATION WITH HOT WATER BOILERS. .......................... 13

6. INITIATION TO OPERATION OF THE AUTOMATED PELLET BURNER “GP xx sc”. ............... 14

6.1. MAIN REQUIREMENTS ABOUT THE USED FUEL TYPES. ............................................. 14

6.2. INITIATION TO OPERATION OF A PELLET BURNER FROM SERIES “GP xx sc”. ......... 14

6.2.1. INTERFACE PANEL OF AN AUTOMATED PELLET BURNER “GP xx sc”. ................... 15

6.2.2. CONNECTING AND POWER SUPPLYING OF THE BURNER. ..................................... 15

6.2.3. SWITCHING ON THE PELLET BURNER FROM SERIES “GP xx sc”. ........................... 16

6.2.4. ALGORITHM OF OPERATION OF A PELLET BURNER “GP xx sc” .............................. 16

6.2.5. OPERATIONAL PARAMETERS FOR ADJUSTMENT OF A BURNER “GP xx sc” ......... 18

6.2.6. DESCRIPTION OF THE PRIMARY MENU, THE METHODS OF STARTING AND

OPERATIONAL PARAMETERS ADJUSTMENT OF A PELLET BURNER “GP xx sc” .................... 19

6.2.7. BURNER ADJUSTMENTS ACCORDING TO THE CONSUMED HEATING OUTPUT ... 22

6.2.8. NOMINAL OPERATION MODE OF THE BURNER. ........................................................ 22

6.2.9. OPERATION MODES OF A PELLET BURNER FROM SERIES “GP xx sc”................... 22

6.2.10. USER MENUS IN THE CONTROL MODULE OF A PELLET BURNER “GP xx sc”. ....... 24

6.2.11. MENU “EFFECT LEVEL”. ................................................................................................. 24

6.3. ADJUSTMENT OF THE BURNER’S HEATING OUTPUT. ................................................. 26

6.3.1. DECREASING THE BURNER’S HEATING OUTPUT. ............................................... 26

6.3.2. INCREASING THE BURNER’S HEATING OUTPUT. ................................................ 26

6.4. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP xx sc”. ....... 26

6.4.1 STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP xx sc”

THROUGH THE SWITCH “START”. ................................................................................................ 26

6.4.2. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP xx sc”

THROUGH A MENU FROM ITS COTROLLER KEYBOARD. ......................................................... 26

6.5. SWITCHING OFF A PELLET BURNER FROM SERIES “GP xx sc” THROUGH EXTERNAL

MODULE, MANAGING ITS OPERATION. ....................................................................................... 28

6.5.1. EMERGENCY SHUT DOWN OF A PELLET BURNER FROM SERIES “GP xx sc”. . 28

6.6. MENU DISPLAYING A LIST WITH THE LAST FAILURES, OCCURRED DURING

OPERATION OF A PELLET BURNER FROM SERIES “GP xx sc”. ................................................ 29

6.7. RESTART OF THE PELLET BURNER OPERATION. ........................................................ 29

6.8. DESCRIPTION OF THE TEMPERATURE STICKERS FUNCTION FOR MONITORING OF

THE SYSTEM’S CONDITION. .......................................................................................................... 29

6.9. CLEANING AND MAINTENANCE OF A PELLET BURNER FROM SERIES “GP xx sc”. .. 31

6.10. USER INTRODUCTION WITH THE MAINTENANCE AND ADJUSTMENTS

PROCEDURES OF A PELLET BURNER FROM SERIES “GP xx sc” ............................................. 32

6.11. SAFETY AND UNPREDICTED RISKS. .......................................................................... 32

6.12. COMPLETION OF THE BURNER’S WARRANTY CARD. ............................................. 33

6.13. ACTIONS AFTER EXPIRY OF THE LIFE CYCLE OF A PELLET BURNER FROM

SERIES “GP xx sc”. .......................................................................................................................... 33

7. FAILURES AND TROUBLESHOOTING. ................................................................................. 34

8. WIRING DIAGRAM OF AN AUTOMATED PELLET BURNER FROM SERIES “GP xx sc”. ....... 38

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USERS SAFETY INFORMATION.

The manual for installation, operation and maintenance of the automated pellet burner from series “GP xx sc” is designated for end users and authorized servicing specialists.

The users must know that:

 All activities regarding installation of the pellet burner should be performed only by an

authorized installers, which have acquired legal rights by the legal authorities;

 All activities regarding the electrical installation must be performed only by electrical-

technicians;

 The primary technical initialization to operation, including visual check of the entire

heating installation, adjustments and start of the pellet burner must be performed by a person that is authorized by the manufacturer.

Please observe the following conditions during installation, start, adjustment and initialization to operation of the automated pellet burner from series “GP xx sc”:

 All legal provisions regarding safety;  All legal provisions regarding environment protection;  Provisions regarding installation, start and adjustment;  All harmonized provisions of the European Union, applicable for your country;

Please strictly observe the presented safety instructions, in order to avoid any risks or harms to people, properties and environmental polluting.

Please pay attention to the following symbols in the present manual book: Danger

This symbol warns the users about possible health risks.

Warning This symbol warns the users about possible risks and harms to properties and environment.

Information This symbol presents texts with additional information for the users.

The current manual book uses notation “GP xx sc”, which includes the pellet

burner models "GP 20_18 sc” with heating output of 18kW, “GP 25 sc” with heating output 25kW and pellet burner “GP 32 sc” with installed heating output of 32kW.

For your personal safety and before taking any actions regarding the

appliance installation and operation, it is highly recommended to read carefully this manual book. Non-compliance to the instructions presented below might lead to fatal consequences, for which the manufacture company will not be responsible.

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2. DESCRIPTION AND ADVANTAGES OF THE AUTOMATED PELLET BURNER FROM SERIES “GP xx sc”.

The automated modulating pellet burner from series “GP xx sc” utilizing wood pellets is designated for mounting to hot water boilers and other appliances. The burner utilizes wood pellets and other types of biomass, which are described below, as the generated heat energy is adopted by the boiler body’s heat exchanging surfaces, to which it is mounted or by other heat energy consuming appliances.

The pellet burner from series “GP xx sc” delivery kit consists of:

 Main module – 1pc;  Fuel transport auger – 1pc;  Flexible pipe – 1pc, with locking brackets – 2 pcs;  A pair of working gloves – 1pc;  Manual for operation – 1pc;  Main module package – 1pc;  Fuel transport auger package – 1pc;  Manual for installation, operation and maintenance of a pellet burner from series

“GP xx sc” – 1pc.

The automated pellet burner from series “GP xx sc” can utilize the following fuel types:

 Wood pellets with diameter Ø 6-8mm, from categories ENplus-A1, ENplus-A2 and

ENplus-B according to standard EN 14961-2:2010, or categories A, AB, B, BC, C, CD, E, EF according to the manufacture company’s classification;

 Dried nuts (from cherries, from morello);  Mixture of pellets and nuts (for example in 50% - 50% ratio);  Other biomass with pellet shape, but after approval test in the burner manufacture

company’s laboratory.

The pellet burner from series “GP xx sc” is equipped with:

 Microprocessor controller managing the burner’s modules;  Display panel with keyboard, used to manage the burner’s modules;  Fan for fresh firing air supply equipped with Holl sensor, which controls the rotation

frequency;

 Electrical heating element used for ignition of the fuel;  Auger for automatic fuel transportation from a hopper to the burner;  Combustion chamber, in which an optimal burning process is realized;  Photic sensor for dynamic control of the burning process;  Reversible temperature sticker for indication of the system’s operation mode and of

the necessity for cleaning of the appliance/chimney, to which it is fixed;

 Irreversible temperature sticker for indication of registered overheating of the burner,

used also as precondition to deny a warranty claim.

The pellet burner is equipped with:

 System for automatic fuel ignition;  System for automatic feeding of the fuel to the burner’s combustion chamber;  System for automatic cleaning of the combustion chamber  Security system, which blocks the burner in case the fuel feeding inlet pipe has been

overheated, as a result from emergency situations;

 Photic sensor for dynamic control of the burning process;  System for modulation of the firing air flow rate during the process of initial fuel

ignition;

 System for modulation of its operation mode, providing optimal operation modes and

low fuel consumption;

 Availability to perform final combustion followed by blowing, through a defined period

of time, for cleaning purposes and for new automatic restart.

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Advantages of the pellet burner:

 The burner is designated for biomass utilization, which makes it ecologically clean

and does not contribute to environment polluting and to planet’s global warming;

 It is used to replace the fuel type in boilers for utilization of wood and coal;  Modern and multifunctional microprocessor control module, made in Sweden,

providing precise operation of the burner’s process components, through parameters adjustment;

 Automatic testing of the system’s functions;  Five levels for modulation of the heating output through quick access, as they can be

easily changed by the users;

 Automatic modulation – adjustment of the needed fresh air quantity, according to the

heating output chosen by the user;

 Automatic self-adjustment of the system, according to the transport auger’s feeding

rate / productivity, to specific climate conditions and to the fuel’s caloricity;

 Indication of the heat carrier (or water) temperature in the boiler;  Availability to save the current adjustments and to restore the factory settings;  Passwords for limiting the access to certain levels, to parameters for the users and

for the servicing staff;

 Availability for operation with temperature sensor, boiler and room thermostats;  Special measures to increase the reliability and the safety of the product;  Independence from the quality of the burned wood pellets with diameter Ø 6-8mm;  Availability to choose from 4 types of adjustments, depending on the quality of the

burned pellets, at stable efficiency;

 Innovative and unique automatic cleaning of the combustion chamber, through

mechanical scraping of the combustion chamber’s fire-grate;

 Availability to control a circulations pump;  Availability to control a flue extraction fan;  Easier servicing through the control module’s function – “History errors”;  The burner is equipped with system for automatic fuel ignition;  Simplified installation and adjustment of the burner, which accelerates the installer’s

work;

 High efficiency;  Low harmful emission;  Automatic fuel feeding from a hopper, which can be build according to the local

conditions (it is not included in the burner’s standard delivery kit);

 Simplified maintenance;  Minimum operation costs.

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+1100

3. TECHNICAL DATA OF THE AUTOMATED PELLET BURNER FROM SERIES “GP XX SC”.

The technical data of the automated pellet burner from series “GP xx sc”, operating with wood pellets, is presented in Table 3.1.

Table 3.1. Technical parameters of the automated pellet burner from series “GP xx sc”,

operating with wood pellets.

PARAMETER DIMENSION VALUE

Burner model - GP 20_18 sc GP 25 sc

GP 32 sc Nominal heating output kW 18 25 32 Heating output adjustment range kW 7-18 7-25 10-32

Used fuel - Wood pellets Wood pellets category according to

- ENplus-A1, ENplus-A2 и Enplus-B standard EN 14961-2:2010 Used pellets categories (according to

- A, AB, B, BC, C, CD, E, EF the manufacture company’s classification) Wood pellets consumption at nominal

kg/h 4.2 5.3 6.8

heating output

The quantity depends on the pellets ash

Wastes after complete fuel burning Ash

content and on the burner’s operation

mode

The automated pellet burner from series “GP xx sc” is designated for utilization of

wood pellets complying with the classification of standard EN14961-2:2010, categories ENplus-A1, ENplus-A2 and Enplus-B, and also with the developed classification by the manufacture company.

The dimensions and technical parameters of the automated pellet burner from series “GP xx sc” are presented in Table 3.2.

Table 3.2. Dimensions and technical parameters of an automated pellet burner from series

“GP xx sc”.

PARAMETER DIMENSION VALUE

Model - GP 20_18 sc GP 25 sc GP 32 sc Weight

Main module kg 19.6 19.6 Fuel feeding

kg 8.5 8.5 8.5

19.6

auger Overall dimensions (WхLхH)

Main module mm 250х705х 488

Fuel feeding

auger

mm 184x1520x107

Power supply voltage - L1, N, PE, 50Hz; 230V; Electrical

consumption

In nominal mode

In ignition mode A 4.5 4.5 4.5 Electrical power W

A 0.2 0.2 0.2

<100

(with ignition)

Electrical protection - IP20

Table 3.3 Recommended fuel parameters.

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≥

PARAMETER DIMENSION VALUE Pellets diameter mm 6 - 8 Recommended fuel caloricity (low temperature of combustion) Wood pellets category according to standard EN 14961-2:2010 Wood pellets category A, AB, B, BC, C, CD, E, EF Ash content % See tables 3.4 and 3.5 Water content % Max. 8 – 10%

Wood pellets classification, developed and applied by the manufacture company, depending on their physical properties is presented in table 3.4.

Table 3.4. Wood pellets classification, developed and applied by the manufacture company,

depending on their physical properties.

PELLETS CATEGORY AD DU

In which: Ad – ash content as dry mass, %; DU – mechanical durability, %.

With the adoption of the new EU standard for wood pellets (EN 14961-2) in 2010, a new certificate ENplus for wood pellets used in domestic hot water boilers has been introduced, as well as EN-B for industrial pellets used in industrial hot water boilers (Table 3.5). The ENplus standard defines two quality categories: A1 and A2. The strictest limits for content of ash in the pellets are introduced in class A1. The ash content in class A2 is up to 1.5%. The certificate EN-B is applied for industrial pellets with reduced quality requirements.

MJ/kg >17.2

kWh/kg >4.7

ENplus-A1, ENplus-A2 and Enplus-B

%6.0≤

%0.16.0 ≤<dA %0.16.0 ≤<dA

%0.2%0.1 ≤<dA %0.2%0.1 ≤<dA %0.3%0.2 ≤<dA

%0.3%0.2 ≤<dA %0.3> %0.3>

DU DU DU DU DU DU DU DU DU DU

%0.97 %0.97 %0.97 %0.97 %0.97 %0.97 %0.97 %0.97 %0.97 %0.97

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Table 3.5 Wood pellets standard EN 14961-2:2010

PARAMETER DIMENSION ENplus-A1 ENplus-A2 EN-B

6 (± 1) 6 (± 1) 6 (± 1)

Diameter mm

8 (± 1) 8 (± 1) 8 (± 1) Length mm 3,15 ≤ L ≤ 40 1) 3,15 ≤ L ≤ 40 1) 3,15 ≤ L ≤ 40 Bulk density kg / m2 ≥ 600 ≥ 600 ≥ 600 Caloricity MJ / kg ≥ 16,5-19 ≥ 16,3-19 ≥ 16,0-19 Water content Ма .-% ≤ 10 ≤ 10 ≤ 10 Dust Ма .-% ≤ 1 3) ≤ 1 3) ≤ 1 3) Mechanical durability Ма .-% ≥ 97,5 4) ≥ 97,5 4) ≥ 96,5 4)

Ash Ма .-% 2) ≤ 0,7 ≤ 1,5 ≤ 3,5 Ash melting point °C ≥ 1200 ≥ 1100 -

Chlorine content Ма .-% 2) ≤ 0,02 ≤ 0,02 ≤ 0,03 Sulfur content Ма .-% 2) ≤ 0,03 ≤ 0,03 ≤ 0,04 Nitrogen content Ма .-% 2) ≤ 0,3 ≤ 0,3 ≤ 1,0 Cuprum content mg / kg 2) ≤ 10 ≤ 10 ≤ 10 Chromium content mg / kg 2) ≤ 10 ≤ 10 ≤ 10 Arsenic content mg / kg 2) ≤ 1,0 ≤ 1,0 ≤ 1,0 Cadmium content mg / kg 2) ≤ 0,5 ≤ 0,5 ≤ 0,5 Mercury content mg / kg 2) ≤ 0,1 ≤ 0,1 ≤ 0,1 Plumbum content mg / kg 2) ≤ 10 ≤ 10 ≤ 10 Nickel content mg / kg 2) ≤ 10 ≤ 10 ≤ 10 Zink content mg / kg 2) ≤ 100 ≤ 100 ≤ 100

1) No more than 1% of the pellets can be longer than 40mm, as the maximum length is 45mm;

2) Defined from dry mass;

3) Particles <3.15mm, fine dust particles, before delivery of the goods;

4) For measurements through “Lignotester” maximum allowed value is ≥ 97.7 mass %.

Logo of ENplus-A1 Logo of ENplus-A2 Logo of EN-В

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4. CONSTRUCTION DESCRIPTION OF THE AUTOMATED PELLET BURNER FROM SERIES “GP XX SC”.

4.1. GENERAL CONDITIONS.

The main part from the construction of a pellet burner from series “GP xx sc” is the main module, which consists of:

 Combustion chamber, which forms conditions for optimal burning process and is

made of high quality stainless steel;

 Combustion chamber’s fire-grate;  System for automatic cleaning of the combustion chamber;  Air distribution tract, which provides equal firing air feeding and also cooling of the

burner’s components;

 Heating element, which ignites the fuel, positioned under the tilted part of the

combustion chamber’s fire-grate;

 Firing air feeding fan, equipped with sensor for controlling of the rotation frequency

and also for adjustments;

 Photic sensor, which monitors the burning process, mounted on the burner’s side and

with availability for easy cleaning;

 Emergency temperature sensor for protection from the so called “back fire” in the

main module’s pellets feeding pipe;

 Control module, which monitors and manages the burner’s operation;  Display panel with keyboard, which visualizes the burner’s operation mode and is

used to perform the necessary adjustments;

 Connector for the fuel transport auger, used to supply the auger with electrical power;  Flexible pipe, made of special transparent high temperature resistant material (in

case of fire it does not separate toxic substances), used to connect the auger and the main module of the burner.

Figure 4.1. View of the main module of a pellet burner from series “GP xx sc”.

Interface panel (display + keyboard)

Pellets feeding inlet pipe to combustion chamber

Photic sensor

Socket for power supply and control of the transport auger

Main module housing Combustion

chamber’s fire-grate

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Emergency sensor for “back fire” protection

Flange for mounting of the main module to an appliance

Combustion chamber

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5. MOUNTING AND INSTALLATION OF THE PELLET BURNER.

5.1. MAIN REQUIREMENTS FOR INSTALLATION OF A PELLET BURNER FROM

SERIES ”GP XX SC”.

The following requirements must be observed during installation of a pellet burner from series “GP xx sc”:

 The burner must be positioned in a way providing enough free space for its cleaning

and maintenance;

 The burner must be mounted to appliance (hot water boiler, or other heat energy

consumer) in a way providing availability for easy maintenance and cleaning of the appliance;

 It is not allowed to mount the burner to appliance, which has been installed in living

premises, including corridors;

 The installation and mounting of the burner to appliance must be performed only by a

qualified technician;

 The installation and maintenance of the automated pellet burner must be performed

by specialized companies which have acquired legal rights for such activities;

 The automated pellet burner from series “GP xx sc” must be connected to the

electrical supply installation only by an authorized electrical technician;

 Before initiation of the burner to operation, the heat energy consuming appliance’s

operational condition must be checked;

 The burner attendance must be performed only by adult persons, which are well

familiar with the appliance’s manual for operation.

The mounting of the burner to a boiler (consumer-appliance) can be performed

through bolts (or studs) and nuts. The tightening of the burner has to be performed by a tool (for example wrench). It is not allowed to fix it through handles or others. The fixing and dismounting operations of the burner must be performed by a qualified person equipped with proper tools.

5.2. INSTALLATION OF THE PELLET BURNER.

The installation of the pellet burner from series “GP xx sc” to appliance requires preliminary prepared technical project, complying with the acting provisions and regulations:

 In case the consuming appliance is a hot water boiler, then the requirements

presented in standard BNS EN 303-5/2000 – “Hot water boilers for central heating part 5 – Hot water solid fuel boilers with nominal heating output up to 300 kW – terminology, tests and notifications”, must be observed;

 In case the heat energy consuming appliance is not a hot water boiler, then the

requirements presented in the relevant standards for such type of appliances must be observed;

 Fire safety provisions;  About the electrical supply network – BNS EN 60335-1/1997 – “Securing of electrical

domestic appliances”.

When installing a pellet burner to a hot water boiler, please observe the relevant

chimney draught requirements, presented in the boiler’s technical data sheet.

5.3. OVERALL DIMENSIONS OF THE BURNER’S MAIN MODULE.

Figure 5.1 and 5.2 present the overall dimensions of the burner’s main module, which have to be taken in mind during the mounting and installation of the appliance.

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Figure 5.1. Main module’s overall dimensions of a pellet burner from series “GP xx sc”.

Figure 5.2. Overall dimensions of the burner’s main module.

5.4. POSITIONING AND MOUNTING OF THE BURNER’S MODULES.

The main module of a pellet burner from series “GP xx sc” has to be mounted horizontally to the appliance, which will consume the heat energy generated by the fuel burning. Depending on the appliance type a technical evaluation has to be performed in advance, regarding the burner’s main module position, in order to achieve reliable operation, easy cleaning, maintenance and servicing. The burner’s main module has to be mounted to the heat energy consuming appliance by using the attached sealing. The fuel transport auger has to be positioned near to the burner, in order to ensure the connection between it and the main module through the flexible tube, through which the fuel transits. It is also recommended that the tilting angle between the transport auger and the horizontal plane is fixed to 45o, which will provide optimal operation of the auger’s electric motor and of the burning process.

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In order to ensure optimal operational conditions of the fuel transport auger it is recommended to use a pellet hopper “BP” – produced by the burner’s manufacture company. This hopper is not included in the standard delivery kit of the pellet burners from series “GP xx sc”.

Change of the auger’s tilting angle leads to changes in the fuel consumption and

respectively to the burner’s heating output:

- Decreasing the auger’s tilting angle leads to increased fuel consumption,

respectively to increased heating output;

- Increasing the auger’s tilting angle leads to decreased fuel consumption,

respectively to decreased heating output.

Figure 5.3 presents a scheme for installation and positioning of the fuel transport auger.

Figure 5.3. Scheme for installation and positioning of the fuel feeding auger.

Fuel Hopper”

“BP”

45о

The auger on the scheme is equipped with metal support bar, which is optional equipment to the burner’s delivery kit. The auger’s axis has to be positioned at 45o angle relative to the horizontal plane.

5.5. INFORMATION ABOUT INSTALLATION AVAILABILITIES OF AN AUTOMATED

PELLET BURNER FROM SERIES “GP XX SC” AND ITS CO-OPERATION WITH HOT WATER BOILERS.

The automated pellet burner from series “GP xx sc” is a standalone module (requires power supply and signal – assignment for operation), which can be mounted to a heat energy consuming appliance. The practice shows that the heat energy consuming appliance is most frequently a hot water boiler, used in local heating installation. The manufacture company has accomplished continues tests for compatibility, reliability and efficiency of the burner in co-operation with series of popular hot water boilers. Depending on the hot water boiler model additional transition modules and components might be used, in order to improve the system’s performance that is consisting of a pellet burner and a hot water boiler, and to increase its efficiency and reliability.

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6. INITIATION TO OPERATION OF THE AUTOMATED PELLET BURNER FROM SERIES “GP XX SC”.

The automated modulating pellet burner from series “GP xx sc” has to be initiated to operation only by a specialized company, authorized for such activities.

6.1. MAIN REQUIREMENTS ABOUT THE USED FUEL TYPES.

During initiation to operation of a pellet burner from series “GP xx sc” the following main requirements about the used fuel types must be observed:

 To achieve complete fuel burning it is necessary to use only dry fuels. It is

recommended to store the fuel in dry and ventilated premises;

 It is forbidden to store the fuel next to the appliance to which the burner is mounted or

at distance less than 400 mm from it;

 The optimal recommended distance between the appliance (to which the pellet

burner is mounted) and the fuel is at least 1000 mm. It is preferable to store the fuel in a neighbor room;

 When installing the pellet burner from series “GP xx sc” to the desired appliance and

when storing the fuel, all fire safety requirements must be observed. It is recommended to position a fire-extinguisher at an easy access and safe place near the boiler.

6.2. INITIATION TO OPERATION OF A PELLET BURNER FROM SERIES “GP XX SC”.

When initiating to operation a pellet burner from series “GP xx sc”, the following main requirements must be observed:

 Maintenance and attendance of the burner must be performed in accordance to the

manual for maintenance and operation;

 The operation mode of the system: a pellet burner from series “GP xx sc” and a heat

energy consumer, must provide minimum under-pressure (pressure lower than the atmosphere’s) in the appliance’s combustion chamber, within range 5 – 20Pa;

Non-compliance with the above requirement might lead to emergency modes or to ineffective operation of the burner. The value of the under-pressure in the heat energy consuming appliance’s combustion chamber depends on the chimney draught and on other modules (for example a flue gas extraction fan). Operation modes, non-complying with this requirement might be ascertained through the temperature value indicated by the reversible temperature sticker.

 Any interference to the operation of the appliance that might lead to risks for the

health of the servicing/attending personal or to other indirectly linked people is strictly forbidden;

 During operation the burner has to be periodically checked by the user/attending

staff;

 The user must not perform any repairs over the system’s modules. If a failure or a

problem occurs during operation then the users must ask for technical assistance by a servicing company;

 It is forbidden to increase the burner’s heating output above the nominal output;  The ash residues from the burning process must be gathered in proper fire-proof

container and after cooling to ambient temperature it has to be dumped to proper for the purpose places.

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6.2.1. INTERFACE PANEL OF AN AUTOMATED PELLET BURNER FROM SERIES “GP

menu)

XX SC”.

Figure 6.1 presents a view of an interface control panel equipped with display and keyboard, used to manage the automated pellet burner from series “GP xx sc”.

Figure 6.1. Interface panel of a pellet burner from series “GP xx sc”.

Components of the interface control panel and their functions:

 Button “ S ” – is used to choose a submenu and to confirm the performed

adjustments;

 Button “ - ” – is used to decrease a currently changing parameter value from the

controller’s menu;

 Button “ + ” - is used to increase a currently changing parameter value from the

controller’s menu;

 Button “ESC” – is used to cancel a change of chosen parameter from the controller’s

menu and to exit a chosen operational menu.

The above presented buttons of the burner’s interface control panel might have another function, which will be described on the display panel. .

6.2.2. CONNECTING AND POWER SUPPLYING OF THE BURNER.

All activities over the burner’s electrical installation, adjustments requiring dismounting of cover panels or other components, which protect from direct contact with electrical parts, must be performed only by qualified staff.

The burner must be connected to the electrical installation of the appliance to which it is mounted, by observing all technical safety rules. Use the power supply cable and the attached wiring diagram for connecting to power supply voltage and to the burner’s operation control module. The fuel feeding auger is mounted to the hopper and is positioned in a way providing the required fuel feed rate, as it is also filled with fuel. The sensitive component of the circulations water temperature sensor has to be mounted in a sleeve for measuring of the outlet water temperature of the hot water boiler or has to be screwed in a threaded orifice (depending on the sensor type).

Button “-” (its function

depends on the chosen

Button “+” (its function

depends on the chosen

Button “Escape”

Button “Enter”

Pellet burner GP xx sc 15

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6.2.3. SWITCHING ON THE PELLET BURNER FROM SERIES “GP XX SC”.

The burner switching ON has to be performed through the power supply of the appliance, to which it is mounted. If the burner has been in operational mode (or in “hot reserve”) but the power supply has been interrupted, then when the power supply restores the burner will continue its operation automatically.

In case the appliance to which the burner is mounted is not properly sealed and the burner is operating, smoking of flue gasses through the unsealed sections is possible to occur, as well as through the fuel feeding flexible pipe. It is recommended to seal these sections and to adjust the burner’s heating output in order to avoid such smoking. The same effect might be monitored during the transition seasons – autumn and spring, when the natural chimney draught is decreased due to higher ambient temperatures.

During the burner’s ignition mode the heating elements activate, which are positioned under the combustion chamber’s fire-grate. This zone is heated to high temperatures and could be dangerous in case it is touched – manipulations in the burner’s combustion chamber zone should not be performed. If necessary to stir (spread) or remove the fuel then proper tools and personal protection equipment must be used.

When initiating the burner to operation for the first time the auger (fuel feeding) device must be filled with pellets – this is continues process requiring time. Therefore the auger must be connected to external power supply, through its standard plug and to wait until the fuel starts to drop from its top orifice. After that it must be connected to the power supply socket of the burner’s main module.

The burner’s main module constantly checks if the feeding auger is connected to its socket and if this condition is not fulfilled the system will transit to emergency mode, until the auger’s power supply cable is connected properly. After that it is necessary to restart the burner’s main module in order to transit to normal operational mode.

If the power supply cable of the transport auger has been disconnected from the burner’s main module socket (this situation is treated by the controller as an emergency mode – i.e. there is no motor connected to the socket) and the burner has been operating at that time, then an emergency mode activates and the burner operation stops. To reset the alarm it is necessary to connect the auger’s plug back to the burner’s main module and to switch the burner’s power supply button to position OFF and then back to ON (restart).

The burner operates through a preliminary set algorithm, which is installed in its control module. The optimal operation parameters are adjusted in the manufacture company’s factory and their change is generally not required.

6.2.4. ALGORITHM OF OPERATION OF A PELLET BURNER FROM SERIES “GP XX

SC”.

The pellet burner starts operation when the following conditions are observed:

 The burner’s main module is mounted to the appliance to which it will operate;  Presence of electrical power supply;  Activated start through the display panel;  Installed circulations water temperature sensor – in case such method is used to

regulate the burner’s operational mode;

Pellet burner GP xx sc 16

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 Lack of emergency signals;  The fuel hopper and the transport auger are filled with fuel.

When the above conditions are fulfilled the control module executes the following algorithm:

 Submits power and the external transport auger, the heating element and the firing air

feeding fan switch ON;

 After expiry of the preliminary set (by the manufacturer) time, which provides loading

of the combustion chamber with the so called “ignition” fuel doze, the auger’s power supply cuts off and it stops;

 After the photic sensor in the burner registers presence of burning process the

heating elements power supply cuts off. For a defined period of time the burner reaches the assigned heating output. If the photic sensor does not register a flame within a set period of time, the controller performs new attempt for ignition through the above presented algorithm. The ignition attempts are limited to two;

 In case of successful fuel ignition the system transits to nominal operation mode of

the burner, which is realized through periodical fuel feeding and pauses for burning. The times for fuel feeding and pauses are adjusted in the control module’s software. The burner heating output can be changed by selecting one of its output levels;

The maximum heating output level - 5

-th

of the burner is not recommended. This level should be chosen only in cases when the used fuel type is with lower caloricity value or when higher heating output is temporarily needed. The recommended output levels are from 1 to 4, as normally level 4 reaches the nominal heating output.

 A NTC sensor is used as control device for determining of the circulations water

operational temperature:

- When the assignment is nearly reached the burner’s control module decreases its heating output (so called modulation of the operation mode);

- If the circulations water temperature decreases the burner restores its heating output.

 If the operation signal drops out during operation (for example by room thermostat),

then the burner will switch off through the above presented algorithm;

 If during rest the operation assignment changes and it receives signal for operation,

then it will start operation through the above presented algorithm. The same condition is valid in case the circulations water temperature is lower than the adjusted in the burner’s control module;

 If the fuel does not ignite within the first attempt a new attempt is automatically

performed, as the ignition attempts are maximum two (defined by the manufacturer). In case of second unsuccessful ignition there is possibility of presence of unburned fuel over the main module’s fire-grate. It is necessary to find and remove the reason for unsuccessful ignition and also to clean the combustion chamber’s fire-grate from the fuel residues;

If the gathered fuel over the burner’s fire-grate has not been removed, after successful ignition (for example after restarting the burner) it might lead to difficult firing of relatively larger amount of fuel, to separation of inflamed gasses and respectively to their explosive ignition. Such explosive ignitions might lead to mechanical damages of the appliance, to which the burner’s main module is mounted.

 If the photic sensor does not register a burning process during operation, then the

fuel ignition algorithm starts again;

 If two unsuccessful attempts for ignition have been performed, for example in case

the fuel has been depleted, then the burner stops the main algorithm and transits to emergency mode, which is shown on the display panel and should be considered as

Pellet burner GP xx sc 17

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a necessity for intervention by the user, as the failure reason requires removal. After the failure has been removed the new start has to be performed through consecutive switching OFF and then back ON (restarting) of the appliance’s common power supply, to which the burner is also connected.

Before starting the burner’s fire-grate has to be checked for presence of unburned fuel and ash. If so, the fuel and the ash residues have to be removed.

 If the power supply has been interrupted the burner will start automatically when the

supply restores.

During operation the burner might transit to final combustion and blowing, if the relevant option for cleaning during operation is switched ON – parameter “Max.comb.time”. This parameter is in “Advance menu”, as the access to it is password protected.

6.2.5. OPERATIONAL PARAMETERS FOR ADJUSTMENT OF A PELLET BURNER FROM SERIES “GP XX SC”.

The operational parameters are preliminary set in the burner’s control module by the manufacturer, as the user and/or other attending staff are not required to perform changes. In order to achieve optimal and economic operational conditions of the burner it is necessary to assign such heating output that will provide optimal operation and low fuel consumption. The practice shows that the constant operation of the burner provides optimal fuel consumption.

The controller’s display panel and the keyboard are used to show information about the burner’s operation mode. The operational parameters adjustments have to be performed by trained specialist.

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



6.2.6. DESCRIPTION OF THE PRIMARY MENU, THE METHODS OF STARTING AND OPERATIONAL PARAMETERS ADJUSTMENT OF A PELLET BURNER FROM SERIES “GP XX SC”.

Figure 6.2. Starting display, shown when starting an automated pellet burner from series

“GP xx sc”.

After the software has been loaded (after a few seconds) the display panel shows a question: whether to start the burner? (Activate?):

Figure 6.3. Menu for starting a pellet burner from series “GP xx sc”, through inviting question.

To start the burner’s operation press the button “S”, as presented on the figure. After starting the burner’s operation a message is shown on the display panel, as presented

on the next figure.

GREEN ecoTHERM

V2.3 2E

Activate?

ENTER

ESC

Version of the software for management of the burner

ESC

Pellet burner GP xx sc 19

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Figure 6.4. The display shows information about the operation mode of the burner’s



controller – in this case it checks the operation of the firing air feeding fan.

TEST – BLOWING: – shows the operation mode – a starting blowing of the burner’s fire-grate through the fan is processed (shows the current phase from the burner’s ignition).

”32о” – shows (at the lower left corner of the display panel, over the button “S”) the water temperature in the hot water boiler (degrees Celsius). The temperature value is displayed if a water temperature sensor is installed and the option is activated from the controller menu.

”FC: 0% ” – shows the light intensity of the photic sensor, in percent – it is shown at the lower right corner of the display panel, over the button “ESC”.

Figure 6.5. The display panel shows information about the burner’s operation mode – in this

TEST - BLOWING

case ignition of the primary fuel doze.

IGNITION 1 150

32o FC: 0%

FC: 0%

ESC

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After the starting blowing by the fan, the burner feeds primary fuel doze and starts the process of ignition. The display panel shows ”IGNITION 1” – first attempt for ignition, which has to be completed within a period of time, defined in the controller’s software.

The burner’s controller is factory programmed with the optimal operation mode adjustments. Discrete number of heating output levels are set, through which the burner operates. The last, maximum level of the heating output is adjusted in a way that provides higher heating output than the burner’s nominal output – this mode is designated for situations when the used fuel caloricity is lower than the normal or when the heat energy consumption exceeds the burner’s nominal output.

Only short time for operation (totally 10 hours for entire heating season) of the burner in modes exceeding its nominal heating output are recommended, because such modes lead to increased heat-loading of the burner’s construction and to decreased life resource.

The practice shows that the factory adjusted parameters of the burner do not need additional corrections, even if different fuel types are used.

The manufacture company reserves its rights to change the settings of the appliance, without obligation to inform the end users.

The values of the parameters, which define the heating output of the pellet burner from series “GP xx sc”, are determined under the following conditions:

 The utilized wood pellets are with diameter Ø 6-8mm, quality category ENplus-A1,

ENplus-A2 and ENplus-B, according to standard EN 14961-2:2010 or category: A, AB, B, BC, C, CD, E, EF (see Tables 3.4 and 3.5);

 The tilting angle between the longitudinal axis of the transport auger and the

horizontal plane is 45o;

 The ash content (mineral, inflammable mass) does not change significantly the fuel’s

calorific value, but requires special construction of the burner in order to achieve efficient and economic burning process. Therefore the applicability and efficiency of a certain fuel have to be tested and after positive results such fuel should be utilized by the burner;

 The manufacture company reserves its right to change the default parameters, which

manage the burner’s operation, without obligation to inform its customers;

 Table 6.1 presents the factory settings of the heating output levels, through which the

burner achieves optimal operation performance;

 The presented heating output levels define the heating output and the operation

modes of the burner;

 The primary adjustment of the burner at the customer’s site is performed by trained

servicing technician, after that the user is not required to perform more changes;

 The next texts below describe how to define the fuel consumption and to calculate the

burner’s heating output:

 Switch the burner ON;  Dismount the flexible pipe, that connects the auger and the main module, from the

burner and direct the free end to a container (for example plastic bag or other), so the dropped pellets by the auger gather inside;

 Then an authorized technician chooses the menu ”Advance menu” and activates

the parameter ”Stoker adj”;

The access to this menu is protected by password!

Pellet burner GP xx sc 21

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 Leave the auger operating for 6 minutes. The pellets quantity gathered in the

container have to be measured and registered in the controller through the relevant buttons, as directing information is shown on the display panel. After that activate the burner operation. The pellets caloricity value can be also entered in the controller, but only in case that it is necessary and the available information is correct. The factory adjusted wood pellets caloricity is 4.8kWh/kg. After the data has been entered it must be saved through the relevant button from the menu – the information on the screen provides directions about the required steps for completion of the procedure for primary adjustments. After completing this primary adjustment the burner heating output is guaranteed.

6.2.7. BURNER ADJUSTMENTS ACCORDING TO THE CONSUMED HEATING OUTPUT.

For optimal, reliable and efficient operation of the pellet burner from series “GP xx sc” and of the heat energy consuming appliance, to which it is mounted, is recommended to adjust the burner according to the needed heat consumption. This can be performed by changing the burner’s heating output level, as presented in Table 6.1.

When changing the burner’s heating output level it is not necessary to adjust the firing air fan flow rate. It is performed automatically through the program installed in the burner’s control module.

6.2.8. NOMINAL OPERATION MODE OF THE BURNER.

After completion of the burner’s starting process (the fuel in the burner’s combustion chamber is successfully ignited) and the consuming appliance, to which the burner is mounted and which utilizes the generated heat energy, has been tempered it can be accepted that the system is in nominal operation mode. Adjustments and checks of the burner have to be performed in nominal operation mode (as well as of the consumingappliance depending on its operation mode). For the burner it is necessary to assign the operational heating output, which has to comply with the consumed heating output of the appliance in nominal operation mode.

In nominal heating output mode the so called “hot test” of the system has to be performed, according to the acting legal provisions.

The firing air flow rate is significant for the operation mode and the efficiency of the system – burner and appliance. When the air quantity is less than the optimal, it might lead to incomplete fuel burning. Also when the air consumption is higher than the optimal, it leads to cooling of the burning zone and again to incomplete fuel burning. Therefore it is important to provide free access to air (to the burner as well as to the room where the system is installed), which to be fed from the fan to the burning zone, in order to ensure optimal work parameters and economic operation.

6.2.9. OPERATION MODES OF A PELLET BURNER FROM SERIES “GP XX SC”.

After successful fuel ignition the burner transits through a mode for stabilization of the burning process, as the display panel shows the following information (Figure 6.6):

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

Figure 6.6. The display panel shows information about the burner’s operation mode –

transition mode – transition from ignition to stabilization of the burning process in minimum

heating output mode.

TRANS. : 10kW

32o FC: 65%

”TRANS.:10kW” – indicates that the burner is in transitional phase for

stabilization of the burning process, with heating output of 10kW.

After completing the transition mode the burner transits directly to normal operation mode, as presented on Figure 6.7.

Figure 6.7. The display shows information about the burner’s heating output level, as in this

case it is the maximum heating output mode.

“COMBUST 5 – 35kW” – indicates the burner’s heating output level (in this case 5th level providing heating output of 35 kW);

“72о”- indicates the current water temperature, oC; “FC: 98%” – indicates the light intensity by the photic - sensor, %.

COMBUST 5 35kW

72o FC: 98%

ESC

Pellet burner GP xx sc 23

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

6.2.10. USER MENUS IN THE CONTROL MODULE OF A PELLET BURNER FROM SERIES “GP XX SC”.

To enter the burner’s menu press and hold the button “S”. To exit already entered submenu press the button “ESC”.

Figure 6.8. To choose a submenu from the burner’s controller press the button “S”.

6.2.11. MENU “EFFECT LEVEL”.

Figure 6.9. Menu ”EFFECT LEVEL” – choice of a heating output level of a burner from

This menu is used to choose the heating output level for operation of the burner. The heating output levels values achieved by the burner are presented in Table 6.1

COMBUST 5 35kW

75o FC: 98%

EFFECT LEVEL

ENTER  EXIT

series “GP xx sc”.

ESC

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

Table 6.1. Heating output of a pellet burner from series “GP xx sc”, depending on the heating

output level.

PARAMETER DIMENSION VALUE Model - GP 20_18 sc GP 25 sc Heating output level kW

1 kW 2 kW 3 kW 4 kW 5 kW

It is recommended to operate the burner up to 4th level - including, as the 5th level should be used exceptionally, but only for short periods of time.

To enter the menu ”EFFECT LEVEL” press the button under ENTER – “S”. To switch to another menu press the button “+” under the arrow on the display. The button “ESC” is used to exit the menu and to return to the main menu. When entering the menu ”EFFECT LEVEL” the user can choose one of the 5 levels of heating output for operation of the burner.

Figure 6.10. Choice of heating output level of a pellet burner from series “GP xx sc”.

Through the buttons “+” and “–” choose the desired heating output level of the burner. After that press the button “S” to confirm the changes. To exit the menu press the button “ESC”.

Effect level [n]

O:5 N:5

- -

7.0 7.0 10.0

10.0 15.0 20.0

15.0 20.0 25.0

18.0 25.0 32.0

20.0 28.0 35.0

ESC

GP 32 sc

Pellet burner GP xx sc 25

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6.3. ADJUSTMENT OF THE BURNER’S HEATING OUTPUT.

The burner’s heating output adjustment can be performed through adjustment of its heating output level. Information about the burner’s heating output within all different levels is presented in Table 6.1.

In case the used fuel type has been changed (for example change in the wood pellets quality category) it might be necessary to re-adjust the burner’s heating output level.

6.3.1. DECREASING THE BURNER’S HEATING OUTPUT.

It can be performed through decrease of the burner’s heating output level, as the heating output assignment decreases and respectively the fuel consumption decreases too.

6.3.2. INCREASING THE BURNER’S HEATING OUTPUT.

It can be performed through increase of the burner’s heating output level, as the heating output assignment increases and respectively the fuel consumption increases too.

When changing the heating output, respectively the fuel consumption, the controller’s algorithm automatically changes the firing air flow rate supplied by the fan, which feature ensures optimal operation modes within wide heating output range.

6.4. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP XX

SC”.

Stopping the burner operation can be performed through the control module, which submits command for operation of the burner. Restoring of the burner’s operation can be performed through changing the control module’s adjustment.

6.4.1 STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP XX

SC” THROUGH THE SWITCH “START”.

Through the button “START” (which has to be installed by the servicing technician during the burner mounting and in accordance with the attached wiring diagram) the burner can be started to operational mode and respectively can be switched OFF. When switching the burner OFF its display panel shows a message “FINAL COMBUSTION”.

The burner switching OFF must be performed only through the switch “START” and not through stopping the appliance’s power supply. The reason is because through the switch “START” the burner performs controlled stopping, which includes cooling of the appliance and complete fuel combustion, as this process preserves the appliance’s reliability.

6.4.2. STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES “GP XX

SC” THROUGH A MENU FROM ITS COTROLLER KEYBOARD.

The following actions have to be performed in order to stop the burner’s operation:

 Press and hold the button “ESC” (for more than 5 seconds);  Choose the answer “YES” when the display shows - ”Make final combustion?“.

When the choice for stopping is confirmed a message ”Final combustion” is shown on the display panel and the burner performs stopping procedure.

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There is also another method for stopping the burner’s operation: through the menu ”MAKE



FINAL COMB.” from the burner’s controller.

This option is used to stop the pellet burner’s operation by performing final combustion of the fuel, located on the burner’s fire-grate.

Figure 6.11. Choice of the menu ”MAKE FINAL COMB.”, which is used to stop the

operation of a pellet burner from series “GP xx sc”.

To enter the menu ”MAKE FINAL COMB.” press the button “S” and to exit (cancel) press the button “ESC”. The buttons “+” and “-“ are used to scroll through the other menus.

Figure 6.12. The controller’s display panel shows a message, asking to start the stopping

To perform fuel final combustion press the button “S”, positioned under the message [YES]. To cancel the process of final combustion or to return to previous menu press the button “ESC”, positioned under the message [NO].

MAKE FINAL COMB.

ENTER   EXIT

process of a pellet burner from series “GP xx sc”.

Make final comb.?

[YES] [NO]

ESC

Pellet burner GP xx sc 27

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When the control module receives signal to stop the operation of a pellet burner from series “GP xx sc” the fuel supply stops, but the firing air feeding fan continues to operate. Therefore after confirmation of the stopping procedure the burner continues to operate and to generate heat energy, which makes it inert, respectively the system in which it operates is also inert. This specific feature has to be taken in mind especially if the heating radiators are equipped with thermostatic valves (or other control components), which close the circulations water flow. As a result of this process it is possible that the generated heat energy, from the fuel final combustion, can’t be adopted by the heating system (can’t be unloaded) and to lead to overheating of the appliance. Therefore in case the pellet burner from series “GP xx sc” is operated in heating systems with radiator regulation valves, it is necessary not to completely close the radiator valves, but to adjust them to minimum value. Also one of the radiators should not be equipped with regulation valve, in order to ensure adoption of the heat energy generated during the process of final combustion.

6.5. SWITCHING OFF A PELLET BURNER FROM SERIES “GP XX SC” THROUGH

EXTERNAL MODULE, MANAGING ITS OPERATION.

The burner stopping could be performed through an external module or through the procedure described in the chapter above. When the burner transits from burning mode to standby mode or to switched OFF mode, then its managing control module performs the so called “controlled stopping”, during which the firing air feeding fan continues to operate and the control module monitors for emergency signals. After cooling of the burner it has to be switched OFF through its power supply. It is also recommended to clean the system - burner and consuming appliance, from the ash deposits.

6.5.1. EMERGENCY SHUT DOWN OF A PELLET BURNER FROM SERIES “GP XX SC”.

During operation of the burner emergency situations might occur, as the burner will transit to emergency mode. Such types of situations are indicated by the burner’s control module, which automatically performs prevention procedures. The burner’s control module transits to emergency mode, which is indicated with a relevant failure code message on the burner’s display panel. Descriptions of the failure codes and other messages are presented in Table

7.2. Description of the possible failures, shown on the control module’s display panel, of a pellet burner from series “GP xx sc”, is also presented in Table 7.3. If emergency situation occurs the failure code, indicated on the control module’s display panel, has to be checked and the relevant corrective measures should be performed. After that the burner has to be restarted through switching OFF and then back ON its power supply.

If the consuming appliance, to which the burner is mounted, has been overheated (emergency situation) its emergency thermostat activates. This thermostat is a MANDATORY equipment and is not included in the burner’s standard delivery kit. The reason for the emergency situation has to be determined and the relevant corrective measures have to be performed. The emergency thermostat has to be switched back manually, in order to supply the burner with power again.

In case the burner’s pellet feeding inlet pipe has been overheated (also treated as an emergency situation) the sensor, which monitors the temperature in this zone and protects the transport auger from the so called “back fire”, activates. After cooling of the burner’s main module the cause for the emergency has to be determined and the relevant corrective actions have to be performed. After removing the reason for emergency, in this case overheating of the burner’s fuel inlet pipe, the security sensor in that zone might be damaged, as it may requires replacement.

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

6.6. MENU DISPLAYING A LIST WITH THE LAST FAILURES, OCCURRED DURING

OPERATION OF A PELLET BURNER FROM SERIES “GP XX SC”.

To check the last failures that have occurred during operation of the burner it is necessary to enter the menu “LOG”.

The menu LOG shows a list only with the last 10 failures, which have occurred during operation of the burner. In case a new failure occurs it replaces the oldest one in the list.

Figure 6.13. The controller’s display panel shows the chosen menu “LOG” together with the

failure sequence number and code.

To exit this menu press the button “ESC”. Table 7.2 provides information about the failure code and its explanation.

6.7. RESTART OF THE PELLET BURNER OPERATION.

The burner restarting is necessary in situations when there is assignment for operation, but the control module has switched to secured mode and the burner is not operating. The display panel shows a message with the failure code. The reason for the failure has to be determined and the relevant corrective measures performed. After that the burner has to be restarted – it can be performed by switching OFF and then back ON the electrical supply of the main module (for example through the main switch of the control board to which the burner is connected).

6.8. DESCRIPTION OF THE TEMPERATURE STICKERS FUNCTION FOR

MONITORING OF THE SYSTEM’S CONDITION.

The temperature sticker is used for measurement of the burner temperature in specific zone. Through such measurement the system’s condition can be determined, as well as the necessity for prevention and servicing actions to the appliance, to which the burner is mounted and/or to the flue tract and more specifically the chimney.

LOG error: 1: 22

EXIT

ESC

Pellet burner GP xx sc 29

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Figure 6.14. View of the reversible (self-restoring) temperature sticker, used to indicate the

operational temperature in the burner’s zone, to which it is stuck up – the example shows

condition of increased temperature within a range of 60 – 65

Figure 6.15. View of the reversible (self-restoring) temperature sticker, used to indicate the

operational temperature in the burner’s zone, to which it is stuck up – the example shows

condition of increased temperature within a range of 65 – 75oC.

Figure 6.16. View of the reversible (self-restoring) temperature sticker, used to indicate the

operational temperature in the burner’s zone, to which it is stuck up – the example shows

condition of increased temperature within a range of 75 – 85oC.

The reversible temperature sticker condition has to be checked every time when the burner or the consuming appliance have been attended. It indicates the current temperature during burner operation, provides information about the appliance’s ash contamination level, indicates about necessity for cleaning, as well as information about the chimney draught and its influence over the operation of the system – pellet burner – consuming appliance – chimney.

Figure 6.17. View of the irreversible (not self-restoring) temperature sticker – the example

shows its normal condition, i.e. the temperature of the pellets inlet pipe has not been

exceeded over the limit value – 104 oC.

Figure 6.18. View of the irreversible (not self-restoring) temperature sticker – the example

shows its emergency condition, i.e. the temperature of the pellets inlet pipe has been

exceeded over the limit value – 104 oC.

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The activation of the irreversible temperature sticker is indication that the pellets inlet pipe of the burner has been overheated. The original condition of the sticker can’t be restored. It is necessary to determine the cause for its activation, to perform the relevant corrective measures and after that to replace the sticker with new one – to be performed by a servicing technician. The activation of this sticker might occur in cases of increased resistances in the chimney tract or decreased chimney draught, as well as by presence of hot flue gasses in the flexible pipe between the auger and the burner’s main module. Such situations are considered as emergencies and are not covered by the burner’s warranty.

6.9. CLEANING AND MAINTENANCE OF A PELLET BURNER FROM SERIES “GP XX

SC”.

The automatic cleaning system of a pellet burner from series “GP xx sc” includes selfcleaning mechanism consisting of:

 Moving grate mechanism;  Actuator that provides motion to the moving grate mechanism;  PC board that controls the actuator.

Figure 6.19. Self-cleaning mechanism of a pellet burner from series “GP xx sc”.

The automatic cleaning of the pellet burner is performed through a designed algorithm. It activates when:

 The burner has been started, after final combustion;  The burner has been stopped, including when the assigned circulations water

temperature has been reached;

 The burner is normally operating, after defined intervals of time.

The adjustment of the automatic cleaning system of a pellet burner from series “GP xx sc” must be performed by a certified staff.

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The parameters: time between two cleaning procedures (“Max comb. Time”), number of cleanings (“Iterations”) and other parameters, can be found in ”Advanced menu” (the access is password protected). Example for typical settings:

 Time between two cleanings (“Max comb. Time”) - 4 hours;  Number of cleanings (“Iterations”) - 2.

These settings should be changed when using fuels with higher ash content – the time between two cleanings should be decreased.

6.10. USER INTRODUCTION WITH THE MAINTENANCE AND ADJUSTMENTS

PROCEDURES OF A PELLET BURNER FROM SERIES “GP XX SC”.

The users must read in details the presented manual book for operation of the burner, as well as how it operates, the methods for adjustment of its heating output level and with the methodic for maintenance.

Figure 6.20. A pair of working gloves, provided by the manufacture company to the end

users, for easier and safe maintenance of the pellet burner.

It is necessary to clean the flexible connection tube from the dust separated by the fuel, because when the auger transports fuel the dust from it gathers in the flexible pipe. As a result the fuel feeding could be troubled and also the dust might fire in case of emergency situation, in which the hot flue gasses are passing through the flexible tube.

Regular cleaning of the burner’s modules and components ensures it’s reliable and economic operation for long time.

6.11. SAFETY AND UNPREDICTED RISKS. RISKS RELATED WITH THE USAGE OF A PELLET BURNER FROM SERIES “GP xx

sc”.

The automated pellet burner from series “GP xx sc” is designed and manufactured in compliance with the main safety requirements of the acting European standards and provisions. Dangerous conditions might occur in the following situations:

 The automated pellet burner from series “GP xx sc” has been used incorrectly;

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 The pellet burner has been installed by unqualified staff;  The guides for safe usage, presented in this manual book, have not been observed;

UNPREDICTED RISKS.

The automated pellet burner from series “GP xx sc” is designed and manufactured in compliance with the acting safety standards. Although all possible risky situations are preliminary considered, resulting from incorrect operation, the following risks might occur:

 Risk from burning, caused by high temperatures from the burning process in the

combustion chamber;

 Risk from electrical shock by indirect contact. The pellet burner is connected to the

power supply network and the controlling modules are positioned in specially designed section, all equipped with the necessary components for overload and short circuit protection. The ground connection of the burner is mandatory and must be performed by an authorized technician. Opening of the protection cover panel of the burner by unauthorized staff is forbidden;

 Risk from fingers injuries during maintenance and cleaning. It is recommended to use

proper individual protection equipment;

 Risk from strangulation in case of insufficient chimney draught to the consuming

appliance, to which the burner from series “GP xx sc” is mounted or bad sealing of the flue extraction tract;

6.12. COMPLETION OF THE BURNER’S WARRANTY CARD.

The attached WARRANTY CARD must be completed by filling the required information in its fields, as the signature and stamp fields must be completed too, in order to ensure the WARRANTY CARD VALIDITY of the pellet burner from series “GP xx sc”.

6.13. ACTIONS AFTER EXPIRY OF THE LIFE CYCLE OF A PELLET BURNER FROM

SERIES “GP XX SC”.

After expiry of the product’s life cycle, its termination must be environmentally friendly and protective. For that purpose the burner has to be disassembled and its modules and components have to be delivered to waste disposal offices, by observing the principles for separate collection of wastes.

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7. FAILURES AND TROUBLESHOOTING. Table 7.1. Description of the failures in the operation of a pellet burner from series “GP xx sc”

and methods for troubleshooting.

Nо. FAILURE CAUSE TROUBLESHOOTING

In case the burner is mounted to a hot water boiler and the temperature in the heated premises is too low

In case the burner is mounted to a hot water boiler and the temperature in the heated premises is too high

The burner is switched ON but there is no burning process Difficult pellets ignition

The fuel ignition is accompanied by abnormal noise

Overheating of the appliance, to which the burner is mounted

No fuel ignition No pellets in the fuel

Insufficient heating output The assigned temperature is low

Low temperature assignment by the room thermostat (if connected) Heating output, exceeding the consumption

The assigned temperature is high

High temperature assignment by the room thermostat (if connected) No assignment for operation

The pellets are with low quality

Insufficient chimney draught

No heating load or incorrectly adjusted heating output level of the burner, or of the heat energy consuming appliance

hopper No pellets in the

burner’s combustion chamber Presence of nonignited or burned pellets over the burner’s fire-grate, but there is no burning process

It is necessary to adjust the burner’s heating output level. It is necessary to check the circulations water temperature assignment in the burner’s control module. It is necessary to increase the room thermostat temperature assignment.

It is necessary to increase the burner’s heating output level.

It is necessary to decrease the assigned temperature

It is necessary to decrease the room thermostat temperature assignment

Check the assignment for operation by the burner’s control module.

It is required to change the fuel, as its water content is probably higher by the values needed for normal operation of the appliance. It is necessary to check the condition of the chimney and of the appliance, to which the burner is mounted and to clean the ash deposits. After cleaning it might be necessary to adjust the operational parameters of the system – ask for servicing assistance. Check the heating system - burner - appliance for correct operation and eventually adjust the operation parameters – to be performed by servicing specialist. After the consuming appliance cools down and the failure has been removed deactivate the emergency thermostat (unscrew the protection cover cap, press the button and screw the cap back), after that restart the burner. The hopper from which the burner’s transport auger intakes fuel must be refueled.

The process of primary fuel ignition can be restored by restarting the pellet burner.

Clean the gathered fuel from the burner’s firegrate. If the ignition heating element is damaged or inactive it must be replaced.

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Incorrect operation of

To be performed by servicing technician:

the burner’s photic sensor, which monitors the burning process

The photic sensor for monitoring of the burning process has to be re-adjusted or replaced – to be performed by a servicing specialist.

10.

11.

12. Heating of the pellet

13. Heating of the pellet Low chimney draught Clean the appliance and eventually the chimney.

The burner does not start or stops during operation

The flame from the burning process is dim and the chimney smokes too much.

The burner starts, but can’t transit to stable operation mode

The burner operates unstable

burner’s fuel feeding inlet pipe

No power supply Check the operation of the burner’s display panel

and its indications. Check the working order of the power supply of the appliance, to which the burner is mounted and which provides voltage with parameters 220V, 50Hz – to be performed by servicing technician. Check the burner’s electrical connections, according to the attached wiring diagram. Check for loose electrical connections – to be performed

by servicing technician. No starting signal submitted to the burner

The burner does not operate, although there is starting signal

Blown fuses

Pellets with low quality

Improper adjustment of the pellet burner’s operational parameters Improperly oriented photic sensor

The photic sensor’s surface is dirty The photic sensor has defected – its surface seems to be burned Malfunction of the photic sensor The control module’s operational parameters have been changed

Insufficient chimney draught or not cleaned burner

Check if the burner receives starting signal and

the working orders of the electrical connections of

the burner’s module, which submits signal for

operation – to be performed by servicing

technician;

Check for loose electrical connections.

Check the working order of the burner’s control

module, which provides voltage with parameters

220V, 50Hz – to be performed by servicing

technician.

Check for activated alarm – check the list with

alarm codes in the controller and their indications,

as presented in the next table.

check the fuses condition and if necessary

replace them with new fuses, but only from the

same type.

Change the pellets as their water content is

probably higher than the required for normal

operation.

Re-adjust the burner’s operational parameters –

to be performed by a servicing specialist.

Change the photic sensor’s position for

monitoring of the burning process by turning it

around its longitudinal axis.

Clean the contaminations (dirt) from the photic

sensor carefully.

Replace the photic sensor with new one – ask for

servicing assistance.

Check the photic sensor’s working order

Check the burner’s heating output level

adjustment.

Check the controller’s adjustments – to be

performed by servicing technician.

Clean the appliance and eventually the chimney.

Possible solution is to install additional flue gas

extraction fan and/or to change the chimney*.

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burner’s fuel feeding inlet pipe and activation of its emergency thermostat

14. High temperature indicated by the reversible temperature sticker

15. Activation of the irreversible temperature sticker, positioned on the pellets inlet pipe of the burner

16. Dirty and/or melted photic sensor

17. Presence of unburned fuel in the ash tray

18.

19. A failure code,

20. The burner has

Too many slag deposits in the burner’s combustion chamber (melted mineral mass)

indicated on the controller’s display panel

stopped, but after a new start it operates again

or dirty appliance from the ash

Increased resistance in the flue extraction tract or insufficient chimney draught

Increase of the operational temperature in this pipe, which in most cases is caused by hot gasses passing through it Improper stopping of the burner’s operation

Inefficient fuel combustion

The used fuel is with high ash content and does not comply with the requirements of the appliance The burner operates in a mode with heating output higher than its nominal output Trouble in the operation of the burner

The photic sensor submits faulty information to the controller

It is necessary to restart the burner. Possible solution is to install additional flue gas extraction fan and/or to change the chimney**.

It is necessary to clean the appliance and/or the chimney from the ash residues. In case the chimney draught is insufficient it is necessary to install additional flue gas extraction fan and/or to change the chimney - to be performed by specialist. It is necessary to clean the appliance from the ash residues, to check and clean the chimney tract and to check the pellet burner condition - to be performed by specialist.

It is necessary to clean the photic sensor’s surface or to replace it with new one. The burner’s stopping procedure, as presented in this manual book, must be observed. It is necessary to adjust the appliance’s operational parameters – ask authorized servicing technicians for consultation and/or to perform adjustments. Change the fuel with type which complies with the requirements for reliable operation of the burner.

Decrease the heating output of the burner by changing its output level.

Check the meaning of the indicated failure code in the next table. If necessary look for consultation/intervention by servicing technician.

Check the fuel quantity over the fire-grate. Look for assistance or consultation by servicing technician.

21. High temperature of the flue gas (if a thermometer is installed)

22. Smoke in the boiler room after a certain period of operation

23. Another, not described failures

Dirty heat exchanging surfaces, depending on the consuming appliance type and the operation modes Dirty or clogged from dust flue extraction tract of the heat energy consuming appliance Ask for assistance by servicing specialist or

It is necessary to clean the appliance’s heat exchanging surfaces.

Clean the heat energy consuming appliance from the ash deposits.

company.

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* The heating of the pellets inlet pipe in most cases is caused by contamination of the heat exchanging surfaces of the appliance, to which the pellet burner is mounted;

** In case of insufficient chimney draught it is recommended to look for servicing assistance in order to solve the problem – cleaning or change of the chimney might be required, as well as installation of additional flue extraction fan or another solution.

Table 7.2. Description of the failures, saved in the “LOG” menu of the pellet burner’s from

series “GP xx sc” controller.

No.

FAILURE

CODE

10 Unsuccessful fuel ignition Clean the burner’s fire-grate.

11 The burner loses flame during 12 Failure in the photic sensor 13 The motherboard temperature is

14 The temperature sensor has

15 The temperature sensor has

FAULT DESCRIPTION TROUBLESHOOTING

Check for presence of fuel. Look for consultation by servicing technician. Look for servicing assistance.

operation

Look for servicing assistance.

operation

Switch the burner OFF and leave it to cool

too high

measured a value under 5oC

indicated a value over 120oC

down. Look for servicing assistance. The circulations water temperature is dangerously low and can freeze. Look for servicing assistance to check the heating installation. The circulations water temperature is dangerously high. Overheating of the heating system and the appliance might occur. Look for servicing assistance to check the heating installation.

10.

11.

12.

13.

14.

16 Motherboard failure Look for servicing assistance. 18 The fan’s relay is out of order Look for servicing assistance. 19 The fan is not rotating Look for servicing assistance. 20 The fan is not rotating with the

required speed

21 Primary ignition failed Check for presence of fuel in the hopper and

22 Failure of the external auger Look for servicing assistance. 23 The photic sensor does not

darkens during the final combustion phase

24 The photic sensor loses light

during operation and unsuccessful firing after the ignition phase

Look for servicing assistance.

check the auger’s operation. Look for servicing assistance.

Look for servicing assistance.

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Table 7.3. Description of the failures indicated on the display panel of the pellet burner from

series “GP xx sc”.

MESSAGE INDICATED

No.

1. IGNITION FAILED Ignition failure Check for presence of fuel and also the

ON THE DISPLAY

PANEL

LOST FIRE IN COMBUSTION STOKER FAULT The auger connection

TEMP- SENSOR LOW The temperature

PHOTOSENS Photic sensor failure Check the photic sensor condition, replace it

TEMP SENSOR OVERHEAT

MEANING

Loses flame during burning

is interrupted

sensor is switched OFF

High temperature indicated by the temperature sensor

TROUBLESHOOTING

auger’s operation. If there is fuel - look for servicing assistance. Check the auger’s connection, restart the burner. Check the auger’s power supply. Power supply cut off might occur if the pellets inlet pipe has been overheated – check the temperature stickers. Check connection of NTC sensor.

if necessary – to be performed by a servicing technician. Check the hot water boiler’s condition, cool the appliance down.

8. WIRING DIAGRAM OF AN AUTOMATED PELLET BURNER“GP XX SC”.

The connectors and the NTC sensor are installed in the hot water boiler. TD – thermo-disc (installed on the pellet burner’s fuel inlet pipe) - 950C.

Remove the connector’s bridge connection when using a room thermostat. Use the room thermostat’s socket only. Do not supply external voltage! See the wiring diagram!

Figure 8.1. Wiring diagram of a pellet burner from series “GP xx sc”.

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The manufacture company guarantees correct and failsafe operation of a pellet burner from series “GP xx sc”, only when the requirements for installation and operation are observed during initialization to operation and maintenance.

The warranty start date of the automated pellet burner from series “GP xx sc” is considered from the date of completion and stamping of its warranty card.

The pellet burner’s warranty start date is considered from the date of its initiation to operation, but no later than 6 months from the date of purchase.

The warranty period validity of the pellet burner is 24 (twenty four) months. The warranty is valid only if an invoice and original warranty card have been presented.

THE WARRANTY OF THE PRODUCT IS INVALID in the following cases:

 Damages of the pellet burner caused by improper storage, transport and/or

unloading, not performed by the manufacturing company;

 Emergencies caused by natural disasters (earthquakes, fire, floods and etc.);  The requirements for installation, operation and periodical maintenance,

presented in the present manual book, are not observed;

 Attempts to recover defects, performed by the buyer or by other unauthorized

persons;

 Changes in the pellet burner’s modules construction;  Incorrect technical project for installation and operation of the burner;  Damages or failures caused by reasons for which the manufacture company is

not responsible or can’t perform control;

 Interferences and failures not caused by the pellet burner from series “GP xx sc”,

but have led to failures/damages in its construction;

 If the irreversible temperature sticker has been colored (activated) or in case it

has been removed, torn, detached or destroyed. Every warranty repair must be registered in the product’s warranty card. The warranty period is stopped for a term considered from the date of a registered warranty

claim until the date of removing the failure.

WARRANTY CONDITIONS

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