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

3

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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4

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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5

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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6

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

Greenflame Eco Installation Manual

7

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.

Greenflame Eco Installation Manual

8

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.

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9

3. Setting Up and Installation of the Boiler:

3.1 Engineers Responsibility:

The installation of the boiler can only be performed by qualified biomass engineers, complying with, and in line with all rules, regulations and norms. The installer must also comply with all recommendations, and directions provided by the boiler manufacturer. Specifically this applies to the instruction manual, boiler fitting method and its components and also all hydraulic systems.

For any discrepancies, inconvenience, damage and injuries that result from non-complying with regulations and recommendations found in this manual the installer takes the full responsibility.

3.2 Boiler Room:

Pellet boilers should be fitted in a specifically allocated room (boiler room). The fuel deposit should also be located in an allocated room near the boiler, however, not closer than 400mm from the boiler. To ease access to the boiler and to enable maintenance, there should be at least 400mm of free space around the boiler. The boiler should be positioned on a non-combustible, thermally isolated base, which the dimensions should exceed the dimensions of the boiler by at least 200mm on all sides. If the device should be mounted in a basement it is advisable to put it on at least a 50mm height foundation.

It is mandatory to check if the boiler is perfectly horizontal, and level to prevent air pockets from creating.

During the installation of the boiler it is advisable to provide sufficient distance from inflammable materials, according to the level of flammability. If the level of flammability of material near the boiler is unknown, the safe distance should be doubled (safe distance is 200mm). A permanent air entry air entry opening or openings with a total free area of at least 550mm2 per kW of appliance rated output above 5kW.

It is mandatory to fully follow all instructions and recommendations regarding boiler room contained in this instruction manual as well as in norms and regulations. In case the boiler and its equipment is to be fitted in an open space, where the temperature might drop below 15°C, or if the furnace might be subjected to conditions that might be destructive to the device or any of the additional equipment, such as presence of chlorine, acids or overly humid air, the manufacturer is released from obligation to provide warranty support for any part of the boiler, as well as additional equipment. All doubts regarding the boiler room should be directed to the manufacturer.

3.3 Ventilation and Exhaust – Chimney System

Proper combustion also requires a proper exhaust chimney system. The role of the chimney is to pipe away exhaust

fumes. The chimney required to complete this depends on:

 Temperature difference between exhaust and surrounding

air;

 Usable chimney height;  Diameter of chimney (no less than flue spigot diameter);  Chimney workmanship – as smooth as possible inner

surfaces an air tightness;

Usable chimney height is the difference between the highest point of the fireplace and chimney outlet. This value should be at least 4m for individual chimneys. In case of sloping roofs, chimneys should end around the crest, in the area of smooth wind flow – this way there’s no interruption of air draught. It is always necessary to take into account the location and orientation of the building in relation to surrounding buildings. In most cases, to determine chimney parameters it is enough to use the approximation method, or diagrams would not be sufficient to determine an exhaust system. Chimney parameters should be calculated according to regulations. The cross-sectional area of the chimney should be 160 x 160mm. Improper cross-sectional area selection may cause slowdown of exhaust fumes and in turn, deposition of ash inside the chimney. If exhaust temperatures would drop below the dew point, the water vapours and sulphuric acid might cause damage to the wall. The connection of the boiler and chimney should be made by flue. They can be made as exhaust pipes, or exhaust channels. Exhaust pipes are pipes or forms, which assembled inside room. Exhaust channels usually comply with the fire regulations for chimneys and are made of the same material that the main chimney is made of. The connection between the boiler and chimney should be as short as possible, and assembled in a raising manner to reduce heat loss and additional resistance. They cannot be guided to different floors. Exhaust pipes shouldn’t be mounted in rooms where

fireplaces cannot be located and shouldn’t be placed in walls

and ceilings.

3.4 Hydraulic and Electrical Schematics:

Pellet boilers must be installed according to valid rules and regulations by the authorised installation company. First startup must be performed by a service trained engineer and authorised by T R Engineering Ltd that can show legitimate validation document. The responsibility for proper boiler installation and repairs is held by the installation/servicing company, trained by the manufacturer, and that has validation/authorisation. Any manipulation or changes made in electrical parts of the boiler, or connecting additional controller devices, might result in warranty loss.

Finalisation and test heating must be denoted on the boiler warranty card. Lack of such information about start-up in warranty card might result in warranty loss.

Hydraulic system should comply with BS 7593 and BS 5449 and be executed according to building regulations.

Greenflame Eco Installation Manual

10

Buffer tank (sized 10l per kW of

boiler output)

If not using either of the pump supplies, terminate to make safe. Cables can be traced back

and replaced if required, or alternatively extended using a suitable connector and cable.

Greenflame Eco Installation Manual

11

Exhaust

probe

Buffer

sensor

L

-X1

High

limit

External

sensor

Central

heating

sensor

CS

N

L LAMBDA

MODULE

O

2

0 – 5V

A2

LAMBDA

PROBE

16 17 18 19 IN IN H H

bk gy wh wh

OUT +5V GND bu bu bu bu bu bu bn bn bk bn bn 15 13 14

47nF

1 2 4 3 6 5 7 8 10 9 1 1 12

Room stat.

IN1 AGND IN2 IN3 AGND IN4 IN5 AGND IN6 IN7 AGND +12v IN8 GND

I1 I2 I3 I4 I5 I6 I7 I8

INPUT

Control Panel

1 2 3 4 5 6 7

8

LCD

S+

S-

CM

BUS+ BUS- GND

-G.B

iE5 A B

GND

A B GND

COMMUNICATION PORT

BOILER CONTROLLER

A1

O1 O2 O3 O4 O5 O6 O7 O8 O9 O10 O11 N L

OUTPUT

230V

MO M1 CW CO ZAP ZAS CS NC NC NC POD

N N N N N N N N L

L

N

N1

M

FEEDER

FEE

CLEANING

M

10 9 11

14

-KCS

LAMBDA

MODULE

-M5

A2

A1

A2

A1

VAC

IGN

-M3

-M2

M

VACUUM

IGNITER

CENTRAL

HEATING

PUMP

DHW

MIXER

OPEN

CLOSE

-M1

1 0 6 5 4 3

-X2 N

L

Greenflame Eco Installation Manual

12

CM

S+S-

X2

X1

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PE

1 2 3 4 N PE 5 N PE 6 N PE 7 N PE 8 N PE 9 N PE 10 N PE 11 12 13 N PE 14 15 16 17 N PE

Exhaust

probe

blue

brown

black

grey

white

Buffer

sensor

High

limit

External

sensor

Central

heating

sensor

Room

stat.

Lambda

probe

STB

Mixer

DHW

Pump

Central

heating

pump

Igniter

Vacuum

Cleaning

Feeder

Fan L L L

L

Supply

close

open

Greenflame Eco Installation Manual

13

L N1

N1

N

-X2

1

c

L1 L2

-G.A

U V W G

iE5

11

12

13

U

V

W

M

3 ~

FAN

-M6

N 8 N L N

N

M

-M4 VACUUM

IGNITER

-R

L

-X2

7

IGN

VAC

11

14

11

2

1

L

-X2

-F

D20

-X1

YE / GN

PE

N

-X2

L1 3 X2.5

L1

N

Greenflame Eco Installation Manual

14

Room stat.

Central heating sensor

External sensor

High limit

Buffer sensor

Exhaust probe

N L

IN 1 AGND IN2 IN3 AGND IN 4 IN5 AGND IN 6 IN 7 AGND +12 IN 8 GND 01 02 03 04 05 06 07 08 09 010 011 N N N N N N N

230v ~

IN IN H H OUT +5 GND

CONTROLLER LAMBDA SENSOR N L 230v ~

WHITE

GREY

BLACK

M M

M

IGN

FAN

M0

M1

DHW

heat

IGN

VAC

FAN

FEED

RM2

A2 A1

14 12 11

cϵ cϵ

e

Estyma

www.estyma.pl

electronics

REGULATOR PRACY KOTLA

ESTYMA control M RS

NUMER SERYJNY:

ZASILANIE 230V~50Hz

POBOR MOCY 5VA; T60

e

Estyma

electronics

www.estyma.pl

Greenflame Eco Installation Manual

15

Plug Connection of Water Mixer:

A blending valve can be used for back end protection. This is controlled by the connections above.

Requirements regarding water that is in central heating circuits are the following:

 Water must be clean and treated to BS 7593;  Hardness of water below 20°F;  PH below 8.5

The boiler is dedicated to following electrical parameters 230V/50Hz. Electrical systems should be executed by a qualified person that will create a 230V/10A double pole isolator, in an easily accessible place. Electrical supply of the boiler and lighting should be connected to separate circuits.

3.5 Boiler Start-up by the User

The programmer is a modern microprocessor system which controls not only the boiler, but also the central heating system and Domestic hot water. The unit controls the amount of fuel fed through the auger, and the air supplied to the combustion process. Thanks to solid stat relays (SSRs), the fan has variable speed control and the reliability of the unit controlling the auger motor is greatly increased. Automatic fuel ignition – The control unit provides automatic fuel ignition. Measurement of waste gas temperature – The control unit measures waste gas temperature which is an essential parameter in a boiler with automatic start-up. Waste gas temperature readouts are also very useful when inspecting the boiler and adjusting its operation. Large alphanumeric display – facilitates communication between the unit and the user. Lambda sensor – ensures optimum supply of air to the combustion process, thereby simplifying the work of the operator; it also reduces fuel consumption and improves combustion, reducing emissions of harmful substances to the environment. Pneumatic fuel feeding control system – allows the boiler to operate for long periods of time without the need to add fuel. Heat exchanger cleaning control system – ensures that the boiler retains high efficiency without the need to clean the exchanger.

Thanks to advanced operation algorithm and the possibility of controlling numerous parameters, the unit can be flexibly adjusted to the needs of the heating system. The controller has an output testing function. The function is available in the MAINTENANCE MODE and checks the correctness of electrical connections and the working order of the controlled equipment (pumps, fan, auger, mixing valve actuator) prior to starting the boiler.

3.5.1 Operating the Unit:

MENU NAVIGATION

Press “ENTER” to enter the main menu.

Browse the main menu using and buttons.

Press “ENTER” to enter the selected submenu. Press

“ESC” to enter a higher level. The main menu is shown in

figure 2.

Submenus are used to display and change operation parameters.

In order to change a parameter, press “ENTER” . The

parameter changed is displayed in cycles. In order to edit the

parameter value, press or arrow buttons. When

editing, you may cancel the changes by pressing “ESC” .

Press “ENTER” to approve changes. The boiler submenu

is shown in Figure 3 as an example. The whole menu is shown in

Figure 4.

NOTE!!! Data is saved whenever the main screen is displayed.

4 - ground

1 – neutral

2 -M1 - opening

3 -M0 - closing

MAIN MENU >>BOILER HEATING HOT WATER POWER TEST INPUT LANGUAGE MANUAL MODE (OFF) SERVICE MODE (OFF) TEST (OFF)

BOILER >>mode Summer Boiler progr. 70°C Hysteresis 04°C

Figure 2: Main Menu

Figure 3: Boiler submenu

Greenflame Eco Installation Manual

16

Feeder no 145(s) 09(s) Vacuum syst. no

Set password 100

SERVICE MODE

>>

min. Pumps temp

50°C

igniter[min]

02

flame test[min]

03

bl. Ignites[min]

02

fan at light

90

Talarm boiler

90°C

Tmin boiler

50°C

stop HP/hwp

20

work HP/hwp

05

Pumps rundown

10

Anti-bloc [sec]

20

Tmax. Heating

70°C

Max Fee/10sec

4.0

Min power

20%

Vacuum system [s]

20

Clean. Interval

03

Vacuum syst.

no

POWER TEST

o2=170

>>

power test

no

progr. power

30%

fan at power 20%

15

fan at power 40%

25

fan at power 60%

35

fan at power 80%

45

fan at power 100%

50

oxygen at 20%

190

oxygen at 40%

180

oxygen at 60%

170

oxygen at 80%

160

oxygen at 100%

150

MAIN MENU

>>

BOILER

HEATING

HOT WATER

POWER TEST

INPUT

LANGUAGE

MANUAL MODE (OFF)

SERVICE MODE (OFF)

TEST (OFF) BOILER TEMP.

70°C

HOT WATER

70°C

EXHAUST TEMP.

45°C

ON

fa 30

BOILER

>>

Mode

Summer

Boiler progr.

70°C

hysteresis

04°C

HEATING

>>

Temp. calculat

45°C

reduction

15°C

Curve

0.8

shift

00°C

Feeder no 145(s) 09(s) Vacuum syst. no

HOT WATER

>>

progr. h.w.

70°C

priority

yes

hysteresis

4°C

boiler h.w.

70°C

INPUT

>>

boiler temp.

70°C

hot water temp

70°C

pellets

no

heating temp.

20°C

outside temp.

+24°C

exhaust temp.

20°C

oxygen

155

thermostat

no

LANGUAGE

>>

selected

English

TEST (OFF)

* * *

NOTE: These values will be different for each model Please see below figures as guidance.

10kW

15kW

25kW

45kW

60kW

Bl. Ignites

04

Max Fee/10sec

2.5

3.0

4.5

Figure 4: MENU

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17

3.5.2 Amount of air, Lambda sensor – Power Test Mode:

The combustion process requires the supply of air, the amount of which depends on the type of fuel and the power of the heating unit. Therefore, the optional amount of air should be set for each type of fuel and each burner power level. This should be down by the person who starts up the control unit. The parameters are saved in the non-volatile memory of the control unit. In order to set the optimal amount of air, you should:

 Set the type of fuel corresponding to the fuel to be used,  Turn on the control unit,  Enter the POWER TEST submenu and run the “power

test mode”,

 Set the amount of air for 20, 40, 60, 80 and 100% of the

burner power. The values will be calculated by approximation method from the selected curves. See

figure 6. If the control system includes the optional Lambda module, oxygen values should be set in a similar fashion for the various burner power levels. The parameters should be set in

line with the boiler manufacturer’s specifications, or on the

basis of the results of waste gas analysis at the different burner power levels. If the fan power is controlled using the Lambda sensor module, the fan power may be adjusted within the range ±10 adjustment units. This relationship is shown in Figure 7. NOTE!!! Turn off the chimney sweep mode once you have completed the adjustments. When adjustments are made in the power test mode, automatic burner power control is deactivated so as to allow measurements and analyses at constant burner power.

Figure 5: Power Test submenu

3.5.3 Air during Ignition:

The amount of required air for ignition is set separately because it differs from the amount of air during normal operation of the burner.

Air amount during ignition is set using the “bl.ignites” parameter in the service “SERVICE MODE” submenu. See table on page 16.

3.5.4 Pumps:

In order to be efficient and last long, the boiler must operate within a certain temperature range. This is why the circulation pumps should only run when the temperature exceeds a certain

minimum level. The “min. pumps temp” parameter is available in the “SERVICE MODE” submenu. This should be set to 50°C.

3.6 Menu Language:

The menu of the control unit is available in a number of languages: Polish, English, German and French. The preferred

language may be selected in the “language” submenu. The

default setting is English.

POWER TEST

o2=170

>>

power test

no

progr. power

30%

fan at power 20%

15

fan at power 40%

25

fan at power 60%

35

fan at power 80%

45

fan at power 100%

50

oxygen at 20%

190

oxygen at 40%

180

oxygen at 60%

170

oxygen at 80%

160

oxygen at 100%

150

Figure 6: Blower power curve

Figure 7: Blower power curve with Lambdabased control

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18

3.6.1 Start-up:

Press the “ON/OFF/ESC” button for 3 seconds in order to

turn the control unit on or off. The current status of the unit is displayed on the main screen: OFF – the control unit is turned off (only alarm functions are active while the fan and auger are controlled manually).

ON – the control unit is on. NOTE!!! When off is displayed on the screen, the control unit

is actually in a standby mode and is energised; in case of an alarm, the control unit will initiate the appropriate remedial actions (i.e. it will either turn on the pumps or the auger). If you intend to not use the boiler for a considerable period of time, or to do any maintenance on the boiler, you must de-energise the control unit by isolating the power supply. The display (main screen) shows the current status of the different pieces of equipment. Boilers with the M RS 240M control unit are ideal for domestic hot water both in the heating season and in other parts of the year. Both sensors supplied with the unit, should be installed in the buffer tank and the following settings should be set up.

Figure 8: Boiler submenu

Figure 9: Hot water submenu

If the abbreviation of a particular piece of equipment is displayed, it means that the control unit has turned it on.

ABBREVIATION

DESCRIPTION

HP (not used)

Central heating pump is on

WP

DHW circulation pump is on

Lig

Heating element is on

Fee

Auger is on

Fa20

Fan is on; current fan power level

00

Mixer closing

01

Mixer opening

Table 1: Equipment abbreviations

3.6.2 First Boiler Ignition:

If you work with an auger, you should fill the bin full with fuel then turn the auger on manually in order to feed the

BOILER

>>

Mode

Summer

Boiler progr.

70°C

hysteresis

04°C

HOT WATER

>>

progr. h.w.

70°C

priority

yes

hysteresis

4°C

boiler h.w.

70°C

fuel into the combustion chamber. To do this, you should select the “manual mode” submenu.

Press to turn the auger on/off.

Press to turn the suction on/off.

After you press the button, the auger will run for 30 seconds, filling the burner with pellets about half way. Once this happens, turn the boiler control unit ON; the fuel will ignite automatically.

3.6.3 Alarms and Safeguards:

The flashing of the display screen of the control unit is an alarm

signal. Press “ENTER” to display information about the alarm.

The control unit activates the following types of alarms:

 Boiler overheating; alarm is activated when the boiler

temperature exceeds the “Talarm boiler” which may be set

in the “service mode”. When this happens, the control unit

on the circulation pumps and keeps them running until the

boiler temperature drops, regardless of the operating modes

selected. NOTE!!! The circulation pumps will be turned on and will run in pre-alarm mode when the temperature rises to 2°C less than the boiler alarm temperature. If the temperature does not rise above the alarm level, information on the incident will not be saved in the control unit’s memory.

 No flame/no fuel; the alarm is activated if the suction

system has made three consecutive failed attempts to ignite

the fuel. NOTE!!! Once an alarm has been activated you should determine and eliminate its cause.

 The independent thermal boiler protection (ITBP); is

dependent of the microprocessor system. An independent

thermal switch will cut off the power supply to the fan if the

boiler temperature exceeds 94°C.

3.6.4 Programmer Technical Data:

PARAMETER

VALUE

Power supply

~230V/50Hz ±10%

Power uptake by the controller

<5VA

Carrying capacity of outputs

Central heating pump

100w

DHW pump

100w

Lighter

400w

Blower

150w

Feeder motor

200w

Automatic exchanger cleaning / suction motor

100w

Mixer actuator

50w

Boiler temp. setting range

60-85°C

Domestic hot water setting range

35-70°C

Temperature measurement accuracy

±2°C

Ambient temperature

0-60°C

Humidity

5-95%, no condensation

Boiler alarm temp

80-95%

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

In case of boiler extinguish caused by lack of fuel please follow the instructions below:

 Fill the hopper with fuel;  Using the manual fuel feed, transfer fuel until it reaches

the burner;

 Remove ash arisen from complete burnout of fuel from

the burner;

 Start automatic mode;

3.8 Final Information regarding Installation and Boiler Start-up

To ensure prolonged, failure free operation of the boiler please follow the rules below:

 Supply sufficient chimney draught to allow optimal

combustion;

 Secure the boiler from dampness and lack of chimney

draught by means of an acid-resistant or ceramic

chimney insert along with drainage of condensate to

sewer;

 Position the boiler on thermally isolated flooring to

prevent it from developing water droplets on its walls;

 Make sure that the central heating system is equipped

with a valve positioned on the lowest and as close to the

boiler as possible;

 Remember that the start-up of the boiler should be

performed only by personnel trained by T R Engineering

Ltd with a current authorised service certificate;

 Remember that a heating test must be performed after

boiler installation and must be noted in the warranty

card;

 Remember that the boiler can only be operated by

adults, after reading and understanding this instruction

manual. It is forbidden for children to get close to the

boiler without adult supervision;

 Shut down the boiler if any maintenance /repair work is

performed in the room that would involve gluing,

painting, etc. That might increase the risk of fire or

explosion;

 Shut down the boiler during any periodical service or

boiler maintenance;

 Ignite the boiler using only the automatic ignition

function. It is forbidden to use any solid or fluid

inflammable substance (such as gasoline, kerosene, etc);

 Avoid overheating of the boiler;  Remember not to store any flammable material or

substances in the vicinity of the boiler;

 Remember not to store any flammable material or

substances in the vicinity of the boiler;

 Remember to keep the boiler temperature at 60°C, and

to utilise at least 45°C thermal protection at the water

return duct;

 Remember to thoroughly clean the boiler and exhaust

duct. The boiler room should be kept clean and dry;

 Remember that any intervention with electrical parts or the

construction of the boiler is forbidden and might result in

complete loss of warranty.

4. Cleaning and Maintenance of the Boiler:

In order to prolong the lifespan of the boiler:

 Regularly clean the extracting vent fan – the turbine and

electric motor need to be removed and the dust removed

using a vacuum cleaner;

 Regularly clean the Lambda probe – remove dust using a

vacuum cleaner, and wipe using a soft, dry cloth.

In case of any improper behaviour in the process of combustion please contact your authorised service engineer that will perform complex diagnostics and maintenance of the boiler.

At least once a year please call your authorised service engineer for a service.

5. Warranty and Guarantee Conditions:

WARNINGS AND GUARANTEE / WARRANTY INFORMATION

SAFETY INSTRUCTIONS

Installation of the boiler, making the electrical connections, checking its operation, and maintenance are all tasks which should be carried out by qualified and authorised personnel.

Install the boiler in accordance with the regulations in force in your local area, region and country.

For the correct use of the appliance and to prevent accidents, the instructions given in this booklet must always be followed.

Use, adjustment and programming must be carried out by adults. Errors or incorrect settings may cause hazardous conditions and/or poor operation.

Before beginning any operation, the user, or whoever is preparing to operate on the appliance, must have read and understood the entire contents of this instruction booklet.

All responsibility for improper use is taken entirely by the user and such use relieves T R Engineering Ltd of any civil or criminal responsibility.

Any kind of tampering or unauthorised substitution of nonoriginal spare parts can be hazardous for the safety of the operator and relieves T R Engineering Ltd of any civil or criminal responsibility.

Most of the surfaces of the appliance are extremely hot (the boiler door, the handle, smoke discharge pipes, etc.). Avoid

Greenflame Eco Installation Manual

20

coming into contact with these parts, without adequate protective clothing or suitable implements such as gloves with thermal protection or implements which keep the hands cool.

Carefully explain this hazard to elderly people, disabled people and particularly to all children, keeping them away from the appliance while it is running.

Under no circumstances should the appliance be run with the door open.

Do not touch the appliance with wet hands, in view of the fact that it is an electrical appliance.

Before carrying out any cleaning or maintenance operation, make sure in advance that the appliance is isolated from the mains electricity supply, by removing the mains isolator fuse.

The appliance must be connected to an electrical system which is equipped with an earth conductor, as laid down in directives 73/23 EEC and 93/98 EEC.

The fuse must be of adequate rated capacity for the stated electrical power of the appliance.

Incorrect installation or faulty maintenance (not conforming to the requirements set out in this booklet) can cause harm to people, animals or property. In such cases T R Engineering Ltd is absolved from any civil or criminal responsibility.

Adhesive sealants and paints used in the manufacture of the product are cured and present no known hazards when used in the manner for which they were intended. The appliance contains no asbestos.

OPERATING WARNINGS

Shut the appliance down in the event of a breakdown or bad running.

Pellets must not be fed manually into the burner.

Accumulated un-burnt pellets in the burner after repeated failed ignitions must be removed before re-lighting.

Do not wash the inside of the heat exchanger with water.

Do not wash the appliance with water. The water could get inside the unit and damage the electrical insulation and cause electric shocks.

Do not put any fuel, other than wood pellets, in the hopper.

Install the appliance in a location which is suitable for firefighting, and equipped with all services such as air and electricity supply and provision for discharging combustion gases.

If there is a fire in the flue pipe, extinguish the appliance, disconnect it from the power supply and never open the door. Then contact the competent authorities.

If the appliance is in storage, it should be in a place that is free of damp, and it should not be exposed to extremes of temperature.

It is inadvisable to base the appliance directly on a floor (if located indoors), and if the floor is made of flammable material, it must be suitably insulated.

Do not light the appliance with flammable materials if the ignition system breaks down.

INFORMATION

In case of any problems, get in touch with your dealer, or a qualified engineer authorised by T R Engineering Ltd, and if a repair is necessary, insist on the use of original spare parts.

Use only the fuel recommended by T R Engineering Ltd (EnplusA1) may be used with this appliance.

Periodically check and clean the smoke outlet ducts (connection to the flue pipe).

Accumulated un-burnt pellets in the burner after repeated failed ignitions must be removed before lighting.

Always keep the cover of the fuel hopper closed.

Keep this instruction manual safe, it should stay with the appliance throughout its working life. If the appliance is sold or transferred to another user, always make sure that the booklet goes with the product.

If lost, please contact T R Engineering Ltd or your authorised dealer for another copy.

GUARANTEE CONDITIONS

T R Engineering Ltd offers the following warranties on this appliance:

Leaks in the heat exchanger – 5 years

Faulty electrical components (motors, fan, controller) – 1 year

Pump, ignition element – 1 year

From the date of first ignition of the appliance as proved by a

Greenflame Eco Installation Manual

21

valid commissioning report and the date on which the commissioning report and the date on which the commissioning took place. The guarantee is conditional on the commissioning report being filled in and returned to the manufacturer within 10 days, and requires that the product be installed and commissioned by an approved T R Engineering Ltd installer according to the detailed instructions given in the instruction booklet supplied with the product.

The term “guarantee” is to be understood to denote the free

of charge replacement or repair of parts recognised to have been defective at the start by reason of manufacturing defects.

Limitations

The above guarantee does not cover parts subject to normal wear such as gasket, fibre board on doors and any parts which can be removed from the firebox such as burner pot, baffles and ash box. The replacement parts will be guaranteed for the remainder of the guarantee period starting from the date of commissioning of the product.

Exclusions

The warranty excludes all ancillary products associated with the system (e.g. flue pipes, external circulation pumps, bulk hoppers and augers, plumbing and electrical system). The warranty does not cover issues arising from pellets that do not conform to Enplus-A1. Recommendations advised to the customer to be carried out during commissioning must be completed and advised to your local dealer in order to validate the warranty. The requirement for the flue installation, particularly in relation to draught, is the responsibility of the system owner. Compliance with local building regulations must be adhered to. The warranty does not cover misuse of the product sabotage.

Any consequential loss or damage caused by the failure of a component on this product is not covered.

T R Engineering Ltd refuses to accept any responsibility for any damage which may be caused, directly or indirectly, by persons, animals or things in consequence of the failure to observe all the prescriptions laid down in the instruction booklet, especially those concerning warnings on the subject of installation, use and maintenance of the appliance. Damage caused by transport and/or handling is excluded from the guarantee. The guarantee will be invalidated in the event of damage caused by tampering with the appliance, atmospheric agents, natural disasters, electrical discharges, fire, defects in the electrical system, and caused by lack of fuel, or incorrect maintenance in terms of the manufacturer’s instructions.

CLAIM UNDER THE GUARANTEE

The request for action under the guarantee must be addressed to the Dealer/Retailer, who will forward the claim to T R

Engineering Ltd’s technical assistance service. T R ENGINEERING

LTD DECLARES THAT THE APPLIANCE WHICH YOU HAVE PURCHASED CMPLIES WITH EEC DIRECTIVE 2004/108 EC AND 2006/95 EC AND SUCCESSIVE AMENDMENTS.

T R Engineering Ltd refuses to accept any responsibility in the event that the appliance or any other accessory has been improperly used or modified without authorisation. For all replacement of parts, only original T R Engineering Ltd spare parts must be used.

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22

Date of Repair

Description of Conducted Work

Stamp and Signature of Service Person

Greenflame Eco Installation Manual

23

Date of Repair

Description of Conducted Work

Stamp and Signature of Service Person

Greenflame Eco Installation Manual

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T R Engineering Ltd

Unit 7, Newton Chambers Way

Thorncliffe Industrial Estate

Chapeltown

Sheffield

S35 2PH

Tel: (0114) 2572300

Fax: (0114) 2571419

www.trianco.co.uk

Copyright in this brochure and the drawings and illustrations contained in it is vested in T R Engineering Ltd and neither the

brochure nor any part thereof may be reproduced without prior written consent.

T R Engineering Limited’s policy is one of continuous research and development. This may necessitate alterations to the

specification.

March 2014

Item No. 40000 Issue 2

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

Specifications and Main Features

Frequently Asked Questions

User Manual