Greenflame 10kW, 15kW, 25kW, 40kW, 60kW Operating And Service Instructions

Greenflame Eco Installation Manual

1

Installation, Operation and Servicing Instructions

Please read these instructions carefully before installing and

operating this appliance

TO BE RETAINED BY HOUSEHOLDER

Greenflame Eco

Wood Pellet Boiler 10 – 60kW

Greenflame Eco Installation Manual

2

1. General Information:

3

1.1 Introduction:

3

1.2 Applications and Benefits of the Boiler:

3

1.3 Basic Usage Guide:

4

1.4 Users Responsibilities:

4

2. Technical Data:

4

2.1 Fuel parameters:

4

2.2 Connection of the Flue:

4

2.3 Basic Boiler Parameters:

5

2.4 Construction of the Boiler:

6

2.5 Boiler Equipment:

8

3. Setting Up and Installation of the Boiler:

9

3.1 Engineers Responsibilities:

9

3.2 Boiler Room:

9

3.3 Ventilation and Exhaust – Chimney System:

9

3.4Hydraulic and Electrical Schematics:

9 – 15

3.5 Boiler Start-up by the User:

15

3.5.1 Operating the unit:

15

3.5.2 Amount of Air, Lambda Sensor – Power Test Mode:

17

3.5.3 Air During Ignition:

17

3.5.4 Pumps:

17

3.6 Menu Language:

18

3.6.1 Start-up:

18

3.6.2 First Boiler Ignition:

18

3.6.3 Alarms and Safeguards:

18

3.6.4 Programmer Technical Data:

18

3.7 Restarting of the Boiler after Interruption caused by Lack of Fuel:

19

3.8 Final Information Regarding Installation and Boiler Start-up:

19

4. Cleaning and Maintenance of the Boiler:

19

5. Warranty and Guarantee Conditions:

19

Contents

Greenflame Eco Installation Manual

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1. General Information:

1.1 Introduction:

Sustainable heating solutions are at the forefront of

Trianco’s heating product portfolio. The need to increase the

awareness of alternative sources of fuel to fulfil our energy demand has never been so great, not only to alleviate world reliance on fossil fuels but also to encourage more natural

sources of energy supply. Trianco’s renewable portfolio

began with successful introduction of Activair air source heat pumps, the next step naturally pointed to biomass heating systems.

Why Biomass?

Wood is one of the most natural and sustainable fuel sources available to us, it has a carbon neutral cycle as it releases about the same amount of carbon dioxide into the atmosphere through burning, as it absorbs during its growth process. Controlled in a very similar way to an oil or gas boiler, Greenflame Eco biomass boilers have clean burn credentials and super efficiencies in excess of 90%, meaning the range is a more viable option for properties particularly in rural areas that currently have an oil or gas heating system installed. The Greenflame Eco is designed to burn Enplus-A1 pellets which introduce many benefits such as:

 The fuel being from a renewable source; proper

management eliminates the risk of depleting the source;

 Biofuel emits only as much CO

2

that the parent material

absorbs during growth phase;

 Low ash content – 0.3% - 0.5%;  Possibility to use ash as fertiliser;  Low costs involved in operation;  The cost of pellet is independent to the cost of coal;

1.2 Applications and Benefits of the Boiler:

The Greenflame Eco pellet boiler is designed for heating single houses, detached and semi-detached houses, offices, garages, utility buildings, etc. Some of the benefits include:

 Very high efficiency that exceeds 91%, obtained by

modern, precisely tested construction;

 Virtually full automation – the boiler needs to be supplied

with fuel once every couple of days, depending on individual needs and atmospheric conditions. The start and cease of combustion is autonomous;

 Utilisation of Lambda probe, and exhaust probe on the

chimney fitting allows to obtain optimal parameters and high combustion efficiency;

 Novel cleaning system which absolves the user of the

need to clean the exchange element – all that is needed is one general clean per year;

 Low level of hazardous substance in exhaust;  Small amount of ash that can be fully utilised as fertiliser;  Very low costs involved in operations of the device.

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1.3 Basic Usage Guide:

To ensure correct and prolonged operations of the boiler please comply with the following rules:

 Only fuel approved by T R Engineering (ultimately

Enplus-A1) may be used with this appliance;

 It is strictly forbidden to make any changes to the

construction or settings of the boiler; damage of the worm gear supplying the fuel;

 Boiler must always be fitted with water circulation. Not

providing water flow may cause overheating of the boiler, which in consequence may result in injury or damage to material goods;

 Before starting up please make sure that the boiler room

is properly ventilated and that air and exhaust ducts are always clean and permeable;

 It is crucial to follow all rules and instructions regarding

installation (both central heating as well as electrical) and boiler usage;

1.4 Users Responsibilities:

 User is fully responsible for the usage and maintenance

of the boiler;

 Not complying with rules might result in boiler

malfunction, decrease efficiency as well as a shorter life span;

 The boiler should only be operated by a competent

person;

2. Technical Data:

2.1 Fuel Parameters:

Wood pellets are manufactured by hot-extruding compressed sawdust which is produced during the working of natural dried wood. The compactness of the material comes from the lignin which is contained in the wood itself, and allows the production of pellets without the use of glues or binders. The market offers different types of pellet with characteristics which vary depending on what mixture of woods is used. The diameter varies between 6mm and 8mm, with a standard length in the range of 5mm to 300mm. Good quality pellets have a density which varies between 600kg/m3 and 750kg/m3, with a moisture content which varies from 5% to 8% by weight. Besides being ecological fuel (exploiting timber residues to the maximum and achieving cleaner combustion than is possible with fossil fuels), pellets also have technical advantages. While good quality timber has a calorific power of 4.4kW/kg (with 15% moisture, therefore after about 18 months seasoning), the equivalent figure for pellets is

4.9kW/kg. To ensure good combustion, the pellets must be stored in an area that is free of humidity and protected from dirt. The pellets are usually supplied in 10kg bags, so sorting them is

very convenient. Good quality pellets ensure good combustion, thus lowering the emission of harmful agents into the atmosphere.

The poorer the quality of the fuel, the more frequently intervention will be necessary for cleaning the internal parts, such as the grate and the combustion chamber.

The main certification of quality in pellets in the European market is Enplus-A1 and these ensure respect of:

Calorific Power: 4.9kw/kg Water content: max 10% of weight Percentage of ashes: max 0.5% of weight Diameter: 6mm Length: max 30mm Contents: 100% untreated wood. With no added bonding

substances (bark percentage 5% max) Packaging: in sacks made from ecologically compatible of biologically decomposing material.

T R Engineering Ltd recommends using certified fuel in it appliances to Enplus-A1. The use of fuel of inferior quality or not conforming to the specification given above compromises

the running of the guarantee and of the manufacturer’s

responsibility for the product.

T R engineering Ltd’s domestic pellet appliances run

exclusively on pellets with a diameter of 6mm.

2.2 Connection of the Flue:

A full range of straight, offset, elbow and ‘T’ elements are

available to overcome any obstruction which the flue should avoid. The proper draught conditions in the flue are critical for the efficient working of wood pellet boilers. The flue can exit the boiler house/garage through the roof or through the wall by using a bend on the flue. The combustion chamber works in negative pressure. The smoke duct for the discharge of fumes will also be under negative pressure when connected to an efficient flue pipe as directed. All sections of the flue must be capable of inspection and removable to enable periodic internal cleaning. Position the appliance bearing in mind all the instructions and considerations above.

IMPORTANT! All 90° changes in direction in the flue pipe must be either removable or capable of inspection. THE FLUE PIPE RUN MUST NOT INCLUDE MORE THAN 2-3 METRES OF HORIZONTAL PIPE MUST BE AND NOT MORE

THAN THREE 90° ELBOWS (INCLUDING ‘T’s). IT IS ALSO

ADVISABLE NOT TO EXCEED 8 METRES IN LENGTH WITH THE PIPE OF 150mm DIAMETER. The flue connection on the boiler is 146mm. T R Engineering Ltd recommends the use of 150mm diameter flue for use with this appliance.

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2.3 Basic Boiler Parameters:

*= large hopper store capacity

Model

10kW

10kW*

15kW

15kW*

25kW

25kW*

40kW

40kW*

60kW

60kW*

Power (kW)

1-10

1.5-15

2.5-25

3-40

4-60

Weight (kg)

320

335

320

335

320

340

375

400

420

460

Water volume (m3)

72

64

74

91

Flue gas outlet (kz-mm)

153

180

Width (A-mm)

1155

1460

1155

1460

1155

1460

1155

1460

1155

1460

Width (B-mm)

1275

1360

1275

1360

1275

1360

1375

1485

1375

1485

Depth (C-mm)

865

Internal Flue (kW-mm)

146

Minimum height of the boiler room (mm)

1831

1916

1831

1916

1831

1916

1931

2041

1931

2041

Flue gas temp. at minimum operation (°C)

90

Flue gas temp. at nominal operation(°C)

120

Hopper (kg)

100

214

100

214

100

214

127

221

145

292

Working pressure (bar)

2 2 2 2 2 2 2 2 2

2

Chimney draught (mbar)

0.2

Fuel Consumption (kg/hr)

2.2

3.2

5.4

8.6

13

Efficiency (%)

91-95

91

95

91

95

91

95

91

95

91

Dimension (D-mm)

M 1 ¼

Dimension (E-mm)

340

Dimension (F-mm)

235

Dimension (G-mm)

95

155

95

155

95

155

95

155

95

155

Dimension (H-mm)

565

570

565

570

565

570

Dimension (I-mm)

330

Dimension (J-mm)

200

Dimension (L-mm)

885

985

1095

Dimension (M-mm)

485

Dimension (N-mm)

340

Dimension (O-mm)

210

The lids and front doors may need to be removed for access through a standard doorway.

The above parameter comparison for Greenflame Eco pellet boilers is tentative. The manufacturer reserves the right to small variations to some values in the above table.

O

N

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2.4 Construction of the Boiler:

Biomass hopper

Auger feed

Revolving hatch

Igniter

Ash pan

Burner

Separation chamber

Automatic ash removal from fire place

Combustion chamber

Turbulators Exhaust outlet

Lambda probe

Exhaust probe

Automatic heat exchanger cleaning system

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Container cover

Electronics cover

Display

Ash pan

Water flow

Water return

Drain

Central heating sensor

Buffer sensor

External sensor

Room thermostat/Programmer Mixer

DHW pump

Central heating pump

Power supply

If not using either of the pump supplies, terminate to make safe. Cables can be traced back and replaced if necessary, or alternatively extended using a suitable connector and cable.

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The above drawings show the main boiler elements. They have the following specifications:

 Burner – made out of fireproof steel. Its geometry is

result of numerous tests and measures. Equipped with air intakes on various levels which contribute to increased combustion efficiency. Biomass is transported from the hopper to the burner by means of the auger feed. On contact with embers and in connection with air supplied by many ducts the process of pyrolisis of biomass occurs. Exhaust fumes created in the process are directed through the heat exchanger to the chimney outlet through the chimney duct which is enhanced by a fan, which also serves a role of providing a sufficient amount of fresh air for proper combustion. The amount of fuel and fresh air supplied for combustion is automatically matched by the controller based on exhaust fume measurements (oxygen content in exhaust fumes) provided by the Lambda probe.

 Combustion chamber – made out of fireproof steel.

From the moment of starting the ignition process it quickly gains high temperature, which in turn improves the combustion process and reduces the amount of unburnt gas. It is also isolated between the flame and boiler wall.

 Revolving hatch – it is a factory assembled element.

Ensures perfect tightness between the hopper and auger feed. Guarantees very precise dosage of pellets.

 Ignitor – allows for completely automatic ignition of

pellets is controlled by the PCB.

 Turbulator (turbulators) – designed to increase the

effectiveness of heat exchange by momentarily slowing down the speed of the exhaust flow. Additionally, they are periodically, automatically put in motion by this and the heat exchanger is cleared of ash. Releasing the user from performing the task.

 Automatic heat exchanger cleaning system (turbulators

drive) – a reduction unit controlled by automatics of the

boiler, that propels the turbulators.

 Exhaust Outlet – contains a box that can be removed to

gain access to the boiler. On top of the box there is an exhaust outlet and a turbine, responsible for the extraction of exhaust towards the chimney. The electric motor that is driving the turbine is controlled by a microchip via a voltage regulator, which provides voltage based on the measurements provided by the Lambda probe. This solution has been used for many years. Bottom combustion has a lot of benefits, and also prevents the fire getting to the pellet hopper.

 Auger feed – worm-gear that works in a sequential

pattern depending on the demand of the burner. The auger provides a small amount of fuel that is released by the hatch. This allows operation under minimal load.

 The decantation chamber – expanding area located

underneath the heat exchanger allows the deposition of unburned particles and dust hovering due to lower exhaust fume speed.

 Ash pan – located under the burner. Collects ash that is

removed from the burner, ash that drops by force of

gravity, and also ashes that origin from automatic heat exchanger cleaning.

 Automatic removal of ash from fireplace – occurs by the

supplied pellet, and also by fresh air flowing through the burner.

 Lambda probe – located in the exhaust outlet. The

purpose of the Lambda probe is to control the content of oxygen in the exhaust. Using the measurements it allows the optimisation of the combustion process used for fuel. In combination with the temperature probe it guarantees correct boiler operation, and doubles as a safety device.

 Exhaust probe – pilots the ignition and also manages the

power of the boiler. Another role is to protect the boiler from unforeseen temperature raise.

 Display – located on the front of the boiler. Allows

browsing through and editing of the available control parameters.

 Electronics cover – covers the electric box that houses the

heart of the control circuit.

 Pellet hopper – its capacity depends on the power of the

boiler. Theres also the possibility to connect it to an external feeder, which supplies fuel from a repository or large silo.

2.5 Boiler Equipment

A standard Greenflame Eco pellet boiler consists of:

 Burner,  Ignitor,  Lambda probe,  Control M RS 420 controller,  Central heating sensor,  Flue temperature sensor,  Weather sensor,

Additional paid options:

 Pellet silo,  Vacuum system & pneumatic pellet supply.

The ‘vacuum system’ is an optional fuel transportation drive, available on all ‘eco’ models. The system ensures smooth

transportation of pellet from fuel store to boiler. With sensor indication controlling and monitoring the fuel supply. Should the hopper empty the vacuum will automatically refill in defined periods of time. Auger system available upon request.

 Revolving hatch,  Pellet hopper,  Turbine,  Turbine motor,  Cleaner motor reduction unit,  Feeder motor reduction unit.

Greenflame 10kW, 15kW, 25kW, 40kW, 60kW Operating And Service Instructions

Specifications and Main Features

Frequently Asked Questions

User Manual