Pellas X HYBRID series, HYBRID 44, HYBRID Mini, HYBRID Mini35 User Manual

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TABLE OF CONTENTS

1. GENERAL INFORMATION ..................................................................................... 3

1.1. Transportation ............................................................................................. 3

1.2. Storage ...................................................................................................... 3

1.3. Control of burner's delivery ........................................................................... 4

1.4. Free space around burner ............................................................................. 4

2. PRODUCT DESCRIPTION ..................................................................................... 5

2.1. Construction of burner .............................................................................. 5

2.1.1. HYBRID Mini and HYBRID Mini 35 models .................................................... 6

2.1.2. HYBRID model .......................................................................................... 6

2.2. Quality requirements for pellets fuel .............................................................. 8

2.3. The pattern of the burner nameplate .............................................................. 9

2.4. Technical data of burner ................................................................................ 9

2.5. Safety systems of burner ............................................................................. 12

2.6. Technical data of controller, description of functions and burner settings ............. 12

3. INSTALLATION ................................................................................................. 13

3.1. Chimney .................................................................................................... 13

3.2. Boiler / oven .............................................................................................. 13

3.3. Fuel hopper ............................................................................................... 15

3.4. External feeder ........................................................................................... 16

3.5. STB protection ........................................................................................... 17

3.6. Boiler temperature sensor............................................................................ 17

4. BURNER AND FEEDER ASSEMBLY ........................................................................ 18

5. ADDITIONAL CONNECTIONS AND FIRST START-UP ............................................... 22

6. EXPLOITATION AND SAFETY REGULATIONS .......................................................... 22

6.1. Exploitation ................................................................................................ 22

6.2. Specification of the inspection intervals ......................................................... 24

6.3. Safety regulations referring to installation and exploitation of burner ............... 24

6.4. Guarantee ................................................................................................. 25

7. SERVICE OF DEVICES ........................................................................................ 26

7.1. Photosensor ............................................................................................... 26

7.2. Electrical igniter replacement ........................................................................ 26

7.3. Feeder pipe cleaning ................................................................................... 27

7.4. Burner cleaning .......................................................................................... 27

8. REASONS OF IMPROPER OPERATION ................................................................... 28

9. ELECTRICAL SCHEMES ...................................................................................... 29

10. REPORTS ....................................................................................................... 30

10.1. First start-up report .................................................................................. 30

10.2. Inspection report ...................................................................................... 31

11. LIST OF PICTURES AND TABLES ........................................................................ 32

12. NOTES ........................................................................................................... 33

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The author of this Manual is the company PELLAS X Sp. z o.o. Sp.k.

The use of part or all of this manual in other publications is possible only with the

written permission of the author.

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1. GENERAL INFORMATION

Read carefully the user’s manual before activating burner.

Pellas X burner requires installation according to this user’s manual. Following advice
included in this USER’S MANUAL will guarantee safe functioning and installation of the

device. All doubts and ambiguities as to condition of equipment or given functions of
parts of burner should be reported to the seller in order to get explanations.

Installation of burner should be carried out by a service person who is authorized and
trained by the producer.

Improper installation may lead to loss of guarantee.

Every user of heating boiler devices should know and comply to all local rules of law.
Particularly before activating a heating installation in accordance with construction
law.
The seller does not bear any responsibility for burner installation which is not in
accordance to valid local regulations and for lack of required protocols and permissions.

1. Transportation

Pellas X burner is packed in a carton with a divider (burner with a controller, mounting
flange and a feeder). The device must be carried in packaging, according to markings on
the parcels. During transportation it should be protected against unfavorable environmental
conditions (snow, rain, dust) and it should not be exposed to shocks, hits and the packaging
should be protected against damages.

Loading and unloading must be carried out in a way which does not expose the devices to
shocks. Improper loading, unloading and transportation (throwing, rapture sliding, crushing
with other heavy goods) can be a cause of damage to the product.

In case of damage of the packaging or product, the device should be subjected to control in
operation. In case when improper work of a fan or feeder motor is observed (loud work,
rubbing), possibly other faults, e.g. electronics (vanishing of characters on display of LCD
display) the burner should be sent to the service team in order to carry a reparation.

Consignments delivered by forwarding companies should be checked in presence of
the courier when the goods are delivered. In case of any incompatibilities a
protocol should be prepared.

1.2. Storage

Pellas X burner should be stored in environmental conditions in accordance to following
guidelines:

 Dry and draughty rooms, free from substances like gases, corrosive liquids and

fumes, which are harmful to burner. Burner and feeder can not be stored in rooms where
artificial fertilizers, chlorinated lime, acids, chemicals etc. are kept.

 Best storage temperature +5

O

C to +40OC. Relative humidity should not exceed 70%.

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 During storage, the device can not have direct contact with the floor. Pellas X

burner until final assembly should be kept in carton and on a pallet. Burners can be
stored and transported in three layers maximum.

 In case when a burner is stored for over 2 years from its production date or in

environmental conditions not similar to above description, before installing it should
be subject to activating - test by an authorized service person. To testify proper
quality and safety of a burner, the above inspection will be documented by service person
in the guarantee card.

1.3. Control of burner’s delivery

Before commencing assembly activities check the following: condition of packaging, make
sure that there are no visible damages and if delivery is complete and not damaged.
Possible reservations and problems should be reported to the supplier immediately. He is
responsible for insuring the merchandise.

1.4. Free space around burner

According to local safety regulations referring to heating devices, provide free space

around burner, at least 1 m around boiler and space for service of burner.

The boiler room should be clean, dry and well aired. Airflow to the boiler should be at
least equal to exhaust of fumes through the chimney.

ATTENTION!

Controller and all devices cooperating with it should be installed on the boiler or its

area, in places where the temperature is the lowest (below 50⁰C). Electronic devices

operating at high temperature may be damaged or not work properly.

ATTENTION!

In order to minimize the risk

of fire is not allowed to store

flammable materials

near the burner

(minimal length 1m).

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2. PRODUCT DESCRIPTION

Pellas X is a brand under which since 2001 burners for biomass have been produced.
These products are characterized with stepless regulation of settings allowing for usage in all
types of ovens or heating boilers. In case when exchange of burner is done in an old
boiler, then it is not necessary to make changes in existing installation. Firing up, sustaining
fire after reaching preset temperature and feeding fuel is automatic.

The uniqueness of the HYBRID solution is the number of the design improvements used as
compared to the burners available previously with the stable combustion chamber. This makes
the operation of HYBRID line burners reliable and free of technical problems. Significant changes
in the technological parameters and the components used have been introduced which makes the
economic attractiveness and the environmental usability of the technology considerably better
with the burner being one of the most modern solutions in the world

The unique solutions employed in the HYBRID line burners include:
 Hybrid Drive System. Fuel and air are supplied in a synchronized manner i.e. the fuel is

supplied according to the air supply rate and vice versa;

 Overpressure Combustion System. Air is supplied into the combustion chamber at the central

point to increase the flame spin and reduce the backfire.

 Wide range Lambda probe available for all units to improve the combustion process and

reduce the fuel consumption.

Pellas X burners are used in households, bakeries, hotels, public utilities, schools and
production halls or warehouses. They are made of acid-proof steel and they are equipped in best
quality parts available on the market. The product which you have at your disposal is the
highest quality, most technologically advanced burner available on the market.

2.1. Construction of burner

HYBRID line burners are divided into 2 groups:

1. HYBRID Mini and HYBRID Mini35 models

2. HYBRID 44 model

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2.1.1. HYBRID Mini and HYBRID Mini 35 models

Pic. 1. Construction of HYBRID Mini and HYBRID Mini 35 burners.

The burner is composed of the following subassemblies:

 Combustion chamber including: furnace (1) made of the highest quality steel heat-

resisting steel and a covering pipe (2),

 Blowing assembly including a cover made of non-combustible ABS V0 (3), X.PLUG socket

(4) located to the right of the burner where the controller plug is to be connected,

 Blowing system (5) located between the blowing assembly and the combustion chamber

with a quick-coupling in the upper part (6) to be attached to the feeding pipe by turning it
clockwise (detaching is carried out in the reverse direction). Afterwards the pipe which
connects the burner with the fuel feeder is connected to the quick coupling.

The cover of burner does not have any protruding nor sharp parts. It does not threat one’s health.
The temperature of burner’s cover during operation should not exceed 60ºC with exception of
places of raised temperature, i.e. bakery.

2.1.2. HYBRID 44 model

Pic. 2. Construction of HYBRID 44 burner.

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The burner is composed of the following subassemblies:

 Combustion chamber including: furnace (1) made of the highest quality steel heat-

resisting steel and a covering pipe (2),

 Blowing assembly including a cover made of non-combustible ABS V0 (3), X.PLUG socket

(4) located to the right of the burner where the controller plug is to be connected,

 Blowing system- is located underneath the cover and it is a connector between the blowing

assembly and the combustion chamber. The upper part of the chamber houses the feeding
pipe and a chimney with a barrier (6) where the pipe connecting the burner to the fuel
feeder is attached. The chimney is mounted to the rectangular opening in the upper part
of the burner chamber. A steel barrier with a counterbalance is installed inside the
chimney. The barrier prevents backfire that would result in the fire entering the feeder. It
is important that the counterbalance is not locked.

The cover of burner does not have any protruding nor sharp parts. It does not threat one’s health.
The temperature of burner’s cover during operation should not exceed 60ºC with exception of

places of raised temperature, i.e. bakery.

ATTENTION!

The producer reserves the only right

to implement from any changes in

construction of burner and feeder,

its software and wiring, otherwise he is

freed responsibilities to the buyer.

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2.2. Quality requirements for pellets fuel

In table below given requirements as to quality of pellet fuel are shown. Using fuel which complies
to DIN 51731 or DIN PLUS certification or meet the rules of EN-14961-2 norm, extends
longevity of burner. The pellet storage location should be dry and well-ventilated. It is important
that before the hopper filling the pellet temperature is equal to the boiler room temperature.

Table 1. Quality requirements of pellet fuel.

Wooden pellet

Units

NORM

Quality criteria

DIN plus

DIN 51731

Diameter

mm

4≤d<10(6)

4≤d<10(6)

Length

mm

5 x D(3)

<50

Density

kg/dm³

1,12

1,0< Density <1,4>

Ash % <0,5(1);(7)

<1,50

Humidity % <10

<12

Humidity when delivered

%

Not specified

Not specified

Caloric value

MJ/kg

>18(1)

17,5<HW<19,5(2)

Sulphur % <0,04(1)

<0,08

Nitrogen % <0,3(1)

<0,3

Chlorine % <0,02(1)

<0,03

Dust collected % <2,3

-

Additives facilitating
pressing

%

<2(8)

(4)

Temperature of melting
ash

-

Not specified

Not specified

Arsenic

mg/kg

<0,08

<0,08

Lead

mg/kg

<10

<10

Cadmium

mg/kg

<0,5

<0,5

Chrome

mg/kg

<8

<8

Copper

mg/kg

<5

<5

Quicksilver

mg/kg

<0,05

<0,05

Zink

mg/kg

<100

<100

Halogens

mg/kg

<3

<3

(1)

Dry weight

(2)

Free from water and ash

(3) No more than 20% of pellets can be as long as 7,5 x diameter

(4)

DIN forbids to use additives. This ban is not valid to small heating systems.

(5)

In warehouse of the producer

(6)

Tolerance in differences in diameter 10 %

(7)

Allowed content of dust up to 0,8%, if it is naturally higher, specific for given sort of wood

(8)

Only natural additives from biomass are allowed

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2.3. The pattern of the burner nameplate

Pic. 3. The pattern of the burner nameplate.

2.4. Technical data of burner

Main properties of Pellas X burners from HYBRID line:

Safety

 Technology of overpressured burning and the built-in firewall with counterweight – no risk

of backfiring

 Burner temperature sensor
 Flexible pellet feeding pipe – is melted when backfire occurs and fuel is not fed to the

burner

Reliability

 Hybrid Drive System – lower electricity consumption costs and full synchronization of fuel

feeding into the air.

 Automatic start after voltage failure – memory of recent settings
 Furnace made of highest quality heat-resistant steel

Modern controlling system

 Automatic operation: firing up, cleaning, flame control
 Stepless (electronical) power regulation
 Possibility of control over burning process by broadband lambda probe (optional)
 Low emission of CO and CO₂
 Low consumption of electricity
 Low heat inertia
 High burning efficiency – up to 99 %
 Very precise flame sensor
 Fully compatible with automatics of oil and gas boiler and with bakery oven
 Possibility of handling the chimney exhaust fan (the fan works periodically and does

not ventilate the boiler)

ATTENTION!

Change of pellets diameter during

using of burner (e.g. from 6mm to 8mm)

requires resetting the controller

by a qualified installer.

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Table 2. Technical data.

Type:

HYBRYD Mini

HYBRYD Mini 35

HYBRYD 44

Power:

5 - 26 kW

8 - 35 kW

10 - 44 kW

Currency:

230 V AC / 50Hz

230 V AC / 50Hz

230 V AC / 50Hz

Average consumption of electricity:

35 W

35 W

35 W

Weight:

15 kg

17 kg

24 kg

Noise emission:

63 dB

63 dB

63 dB

Feeder’s length:

2 m

2 m

2 m

Fuels:

pellet 6-8 mm

pellet 6-8 mm

pellet 6-8 mm

oat

oat

oat

dry pit

dry pit

dry pit

Burning efficiency:

to 96 %

to 96 %

to 99 %

Efficiency in boiler:

to 96 %

to 96 %

to 96 %

Power modulation:

YES

YES

YES

Lambda probe:

YES (optional)

YES (optional)

YES (optional)

CH pump service:

YES

YES

YES

HUW pump service:

YES

YES

YES

Mixer service:

YES

YES

YES

Buffer service:

YES (optional)

YES (optional)

YES (optional)

Additional feeder service (silo):

YES (optional)

YES (optional)

YES (optional)

Room temperature sensor:

YES (optional)

YES (optional)

YES (optional)

Return temperature sensor:

YES (optional)

YES (optional)

YES (optional)

Fumes temperature sensor:

YES (optional)

YES (optional)

YES (optional)

Weather automatics:

YES (optional)

YES (optional)

YES (optional)

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Pellas X burner has simple and compact construction, which allows for easy assembly in boiler’s
door. Below in the table: the dimensions and drawings of mounting holes for given types
of burners.

There are 2 groups of burners from HYBRID line:

Group 1

 HYBRID Mini
 HYBRID Mini 35

Group 2

 HYBRID 44

Table 3. Dimensions of burners.

Type of

burner

Picture of mounting holes

Dimensions

Group

HYBRYD

Mini

HYBRYD Mini

D - Ø155
A - 215

B - 456

C - 126

HYBRYD Mini

35

D - Ø173
A - 234

B - 477

C - 144

Type of

burner

Picture of mounting holes

Dimensions

HYBRYD 44

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2.5. Safety systems of burner

Pellas X burner is equipped with following safety systems, which effectively protect the user
against backburning:

1. Burner temperature sensor

The sensor, once it detects temperature over 90OC (setting: alarm temperatures may
be modified depending on the conditions in which the device operates i.e. bakery
ovens or dryers; please note that such changes can only be done by an authorized
service person) goes from work mode into burning off mode, at the same time it
switches off the external feeder and sets the fan for 100% power.

2. Technology of burning in overpressure

Burning in overpressure is founded on physical phenomenon which takes place in inner
feeder of burner.

3. Chimney for pouring fuel

In upper part of the burner there is a chimney for pouring fuel. It is equipped with a barring
hatch with a counterweight. In case of backfire the hatch closes inlet and also
prevents fire against reaching the fuel hopper.

4. Flexible pouring pipe

Flexible pouring pipe is an elastic connection between external feeder and burner. Its main
function is delivering fuel to burner, additionally it also protects against backfiring.
Under influence of high temperature pipe starts to deform and extend which makes fuel
delivering impossible.

Safety systems control- see chapter 6.2: Specification of the inspection intervals

2.6. Technical data of controller, description of functions and burner settings

See User’s manual of controller.

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3. INSTALLATION

3.1. Chimney

The parameters of chimney should be adjusted to requirements of heating device, of
which fumes are led away to chimney. The chimney can be made of ceramics or steel.
Chimney should be clean, and its draft sufficient for Pellas X burner operating with heating
device in scope of preset power output. In case when chimney draft is not sufficient, it is
possible to install a mechanical fumes exhaust. Before operation chimney should be checked and
approved by a qualified chimney-sweeper.

It should be remembered that a high chimney with big capacity of fumes needs more
heat and temperature of inner part of it should not be lower than 80ºC, 1m below the top to avoid
condensation on top of the chimney. To reduce the inner profile of the chimney, a steel pipe with
proper diameter can be installed. All advice referring to chimney duct should be taken from
a professional company. Strong wind, too high or too low chimney have influence on efficiency
of burner and its settings. In such cases it is advised to install a stabilizer of chimney
draft which will ventilate chimney and help in maintaining stable draft. If chimney is too small,
then burner may not work correctly, in such case it is necessary to install a mechanical fumes
exhaust.

Table 4. Minimum chimney draft.

TYPE OF BURNER

MINIMUM CHIMNEY DRAFT [Pa]

HYBRID Mini

15

HYBRID Mini 35

15

HYBRID 44

20

3.2. Boiler / oven

Pellas X burner can be installed in majority of boilers. The power of burner in relation to boiler or
oven power must be adjusted by installer. It is the best to mount the burner in boiler’s
door, just above grate or in side wall if it is possible. The diameters of mounting holes of Pellas
X burner are given in table 3. The length of pipe in boiler is regulated by installer with usage of a
connector – mounting flange – similar as in oil boilers or directly into door of boiler with 4
M8 screws. Thanks to connector it is possible to regulate length of furnace pipe of burner
in boiler. If boiler chamber is too small, burner may operate incorrectly.

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Pic. 4. Positioning of burner and direction of flame.

Table 5. Minimum dimensions of furnace chamber.

TYPE OF BURNER

MINIMUM DIMENSIONS OF FURNACE CHAMBER

MINIMUM DIMENSIONS
OF FURNACE CHAMBER

MINIMUM LENGHT OF

FURNACE CHAMBER [mm]
HYBRID Mini

0,023

400

HYBRID Mini 35

0,030

520

HYBRID 44

0,038

520

Table 6. Exemplary minimum dimensions of rectangular furnace chamber.

TYPE OF BURNER

EXEMPLARY MINIMUM DIMENSIONS OF RECTANGULAR

FURNACE CHAMBER

WIDTH A [mm]

HEIGHT H [mm]

WIDTH A [mm]

HYBRID Mini

218

262

400

HYBRID Mini 35

218

262

520

HYBRID 44

273

327

520

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Table 7. Exemplary minimum dimensions of cylindrical furnace chamber.

TYPE OF BURNER

EXEMPLARY MINIMUM DIMENSIONS OF CYLINDRICAL

FURNACE CHAMBER

MINIMUM DIAMETER OF

CHAMBER [mm]

MINIMUM LENGTH OF

FURNACE CHAMBER [mm]

HYBRID Mini

270

400

HYBRID Mini 35

270

520

HYBRID 44

337

520

Table 8. Pressure in burning chamber.

TYPE OF BURNER

PRESSURE IN BURNING CHAMBER [Pa]

HYBRID Mini

10

HYBRID Mini 35

15

HYBRID 44

20

3.3. Fuel hopper

Fuel hopper can be made of any non-flammable material, i.e. steel. It can have any
capacity and should be located in proper distance from burner (Pic.7). In lower part of
fuel hopper a spiral feeder in covering pipe is mounted. The slope of feeder should not
be bigger than 45° in relation to the floor. Fuel hopper must be covered with a lid which
would protect rotating screw of the feeder against damage by leftovers.
It is forbidden to manipulate on the bottom of the hopper during operation of feeder. It is a threat
to body injury – particularly to fingers. It must be remembered to refill the fuel hopper
with pellets type fuel before activating the burner. Never pour the fuel hopper with damp or
disintegrating fuel. It can cause difficulties in operation of burner – burner blockade.

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3.4. External feeder

Pic.5. Feeder’s construction.

Fuel feeder connects fuel hopper with burner. It is made of steel pipes, galvanized or
stainless steel with diameter 60mm or 76mm and 2m or 3m long (it is related to the size of
burner). There is a steel spiral inside the pipe driven by electrical engine 230V AC with gearbox.
The motor is connected using the power suitable socket located on the burner’s controller. The
feeder lower part is mounted in the lower part of the fuel hopper and its upper part is connected
to the burner with the flexible polypropylene pipe.

Feeder assembly:

1. Connect both pipes (1) and (2) with the bolt M8 (3) and nut M8 (4);

2. Insert the pin (6) in the shaft hole (8), and then screw the spiral (5) onto the pin (6)

and tighten with the nut (7);

3. Put the feeder’s cap (10) onto the motor pin (9);

4. Slide the shaft (8), including the mounted spiral, onto the motor pin (9) and secure

with the set screw (11);

5. Slide the spiral into the pipe inside so that it terminates at the half of the inlet hole

(figure below) and screw the motor (9) to the pipe flange with the bolts (12) and nuts
(13).

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Pic.6. Feeder’s auger installation.

Fuel dosing is done automatically. Feeder operation is cyclic and is operated by outer controller.
Feeder should be positioned at maximum 45º angle in relation to the floor. Flexible, antistatic
polyurethane pipe must not be directed vertically above the pouring chimney of burner, but at
least 30 cm away from it. In case of pipe overheating (back burning) or its melting, pellet fuel will
not be falling onto burner. Lack of fuel supply will cause burning off. It prevents against spreading
fire on fuel hopper and on the rest of boiler room.

NOTE: Before starting the burner, fill the hopper with pellets and fill the feeder until
pellets will start falling into the burner.

3.5. STB protection

In case when oven or boiler does not have its own STB protection, a thermostat with a
capillary on clips is added to the set. Capillary sensor should be permanently mounted in water
coat of the boiler. After reaching critical (95oC) temperature of boiler, fuel feeder is cut off. In case
of restarting the burner the switcher on cover should be reset, before that the cause of
switching off due to boiler overheating should be checked, assessed and right steps to solve the
cause of the problem should be taken.

3.6. Boiler temperature sensor

Burner is provided together with boiler temperature sensor. Its task is to control firing up and
burning off process in burner. It does not refer to burner version destined for bakery
ovens.

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4. BURNER AND FEEDER ASSEMBLY

Pic. 7. Scheme of installation in boiler room.

Burner and feeder are delivered in ready-made state, ready for installing. They are packed
in cardboard boxes, which have to be unpacked with care.

ATTENTION!

Before starting dismantling

or disassembly entire power supply

must be disconnected.

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1. HYBRID line burners installation in boiler

To perform correct installation, isolate thermally the burner from the boiler door (2) [isolation pad
is not a part of the set].

Scheme of assembly HYBRID line burners in a boiler:

 Insert the burner’s furnace pipe in the boiler mounting hole and fix with the bolts M8 (1).

Pic. 8. Installation of HYBRID Mini and HYBRID Mini 35 burners.

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Pic. 9 Installation of HYBRID 44 burner in boiler’s door.

2. Assembling the chimney for pouring fuel

In top part of burner (model HYBRID 44), insert the chimney in vertical position and press
it until it properly fits in the socket.

3. Assembling the feeder Pic. 5

 Attach with joint flexible pouring pipe, long enough to connect with upper part of the

feeder, no less however than 30 cm from vertical pouring axis of burner. Second
part of flexible pipe insert onto vertical pipe of chimney for pouring fuel of burner and

ATTENTION!

When assembling burner in boiler which

does not have outer thermo-isolation in

place of mounting, isolation pad

should be used to protect burner against

influence of boiler temperature.

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tighten it with a band.

 Insert lower part of feeder pipe in fuel hopper, remember that hole for

sucking granulate must be directed upwards.

 Fill the hopper with fuel. Approval for fuel should be made available by the seller.

Specification of fuels is shown in Table 1.

 Join feeder with burner by electrical wire providing power to feeder and stick plug into

proper socket on the controller. Remember about zeroing wiring for cover of burner, it
can not be damaged and must be tightly screwed to the cover.

 In case when oven or boiler does not have its own STB protection, a capillary

thermostat with fastener should be added to the set. A capillary sensor should be installed
permanently in water coat of boiler, together with temperature sensor of boiler

4. Connecting the controller

Attach the cover of controller by screws on isolated wall of the boiler or on the wall
of the boiler-room. The wire of a multicoupler should be attached to proper socket on the
right side of burner.

ATTENTION!

Feeder should be positioned at angle

no bigger than 45 O in relation to the floor.

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5. ADDITIONAL CONNECTIONS AND FIRST START-UP

1. Additional connections of the burner are described in the controller manual.

2. Determination of the supplied pellet capacity

a) Before starting the balancing procedure, make sure that the feeder is filled with

pellets.

b) Put an empty bag (e.g. pellet bag) under the feeder and start the feeder for 15

minutes. The pellet amount collected in the bag must be weighed.

c) The value being the result should be used in the FEEDER EFFICIENCY

PARAMETER since the value is required by the controller during the initial start­up.

d) Enter the maximum operating power of the burner in the next step.
e) The controller will adjust the necessary pellet quantity automatically.

6. EXPLOITATION AND SAFETY REGULATIONS

6.1. Exploitation

Before starting up burner’s operation all connections and joints with feeder should be
checked. Mounting screws, which join burner with boiler should be checked, as well as thermal
seals between burner and boiler.

Burner is started up according to user’s manual after connection to electricity by power cord with

zeroed plug. In order to ensure correct operation of burner, depending on quality of fuel, the
inside of burner should be cleaned from fouling and slag.
Depending on a group of burners, there are different ways of conducting the maintenance of
furnace plate:

a) Maintenance of furnace plate in HYBRID Mini and HYBRID Mini35 burners

The Mini-series burners are equipped with the removable furnace.

ATTENTION!

Pellas X burners can only be handled

by adults. It is mandatory to be

acquainted with user’s manual before

servicing the burner.

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Rys. 10. How to remove furnace in burners HYBRID Mini and HYBRID Mini35.

Before removing the furnace, clean it thoroughly to prevent ash from getting into the airflow
chamber during its removal, then you can remove the furnace and clear the airflow holes. After
cleaning the furnace, insert the furnace correctly in the burner. The furnace lock must be
precisely located in the burner seat. It is presented in figure below.

Rys. 11. Correct positioning of furnace in burner HYBRID Mini and HYBRID Mini 35.

b) Maintenance of furnace plate in HYBRID 44 burner

Palniki HYBRID 44 wyposażone są w rurę paleniskową umieszczoną w rurze osłonowej. Aby
dostać się do paleniska należy powtórzyć operacje 1 i 2 ze schematu montażu palnika HYBRID 44
w drzwiczkach kotła (patrz strona 20).

Po upływie okresu gwarancyjnego, a następnie raz w roku kontrolować stan techniczny palnika

poprzez uprawnionego serwisanta.

UWAGA! Zewnętrzną rurę osłonową należy okresowo (w zależności od ilości popiołu w paliwie),
najlepiej 1 raz w miesiącu, odpiąć od korpusu palnika w celu usunięcia popiołu.

ATTENTION!

Maintenance of burner must always

be conducted on cold burner.

UWAGA!

Palenisko po wygaszeniu palnika może

być jeszcze gorące, dlatego do

wyjmowania zawsze używaj narzędzi np.

kombinerek.

24 | P a g e

6.2. Specification of the inspection intervals.

Table 9. Specification of the inspection intervals.

Power rating

6 months from

installation

date

12 months

from

installation

date

18 months

from

installation

date

24 months

from

installation

date

30 months

from

installation

date

5 – 50 kW

1. Expanded

2. Expanded

51 – 150 kW

1. Expanded

1. Basic

2. Expanded

2. Basic

The inspection interval date starts from the installation and start-up of device by the authorised

service company having the suitable manufacturer’s certificates. The inspections must be

performed not earlier than one month before and not later than one month after its scheduled
date.

Scope of operational activities:

For basic operation inspection:

 Check of setting of the automatic
 Check of safety devices (STB, boiler and burner temperature sensors)
 Check and cleaning of the flame sensor
 Check of the firewall with counterweight condition (if any)
 Fumes analysis and chimney draught measuring
 Record of service counters status
 Cleaning of the blowing nozzles and burner furnace
 Check of the fixing mechanism and furnace condition
 Calibration of lambda probe (if any)

Additional operations when extended inspection is performed:

 Test of transmitters
 Check of the burner tightness
 Check of the electrical connections condition
 Check of the igniter condition

6.3. Safety regulations referring to installation and exploitation of burner

Before starting installation and exploitation of burner, the chimney shaft and boiler to
which burner will be connected should be thoroughly cleaned (see page 14). Check if there is
enough liquid in heating installation, and if pouring device works correctly.

 Burner can only be handled by adults who are acquainted with user’s

manual.

 Children can not be allowed to be close to the burner.
 It is forbidden to put a hand inside the feeder pipe and burner pouring

pipe, this is a risk of an injury and disability.

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 It is forbidden to open boiler’s door during operation of burner.
 Opening the door of the boiler is allowed only after extinguishing the burner and

disconnect of electric power.

 Burner is designed for burning dry biomass, i.e. “pellets” in boilers operating in central

heating system.

 Obligatorily burner must be electrically zeroed and connected to a socket with

zeroing pin 230V AC.

 Electrical installation must be done accordingly to current safety rules and

regulations. Electrical installation powering a burner must be done in TN-S system and
protected by a RCD – residual current device 6A/30mA. For making an installation a
professional electrician must be responsible.

 Installation of a burner must be executed by an authorized installer trained

by PELLAS X sp. z o.o. sp. k. (The Producer) and the Acceptance Report should
be written – which is included in User’s Manual.

 Any sort of works and reparations of a burner or a feeder must be done with

disconnected powering cable from electricity.

 The room in which a burner works must be well and constantly aired.
 Exploitation can not be done in improper environmental conditions, i.e. too high

temperature, above 45ºC, in presence of aggressive compounds, dirt, bad
ventilation, etc.

 Following items must be connected to the boiler: capillary safety sensor STB and boiler

temperature sensor outgoing from a burner.

Failure in observing by the user – owner of a burner the above SAFETY
REGULATIONS releases The Producer – PELLAS X sp. z o.o. sp. k. from any responsibility
for improper work of a burner and results in loss of the warranty.

If the user executes the installation of a burner not in accordance with
instructions and recommendations of the producer or when he does not have the
„Collection Report” written during first firing-up of a boiler by authorized installer
and confirmed with the signature of the user, then he or she loses the right to warranty
for burner faults. Also the guarantee is lost then.

6.4. Guarantee

Details in the GUARANTEE CARD attached to the User’s Manual.

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7. SERVICE OF DEVICES

7.1. Photosensor

Photosensor in a burner should be cleaned from time to time with a damp, soft rug,
similarly to oil or gas burners. After removing the cover of a burner, the photosensor
should be removed from the socket (1), then it should be cleaned and installed again. After
executing the above activities, the cover of a burner should be mounted.

Frequency of cleaning the photosensor:

 Bakeries- once a month
 Boiler rooms – every 3 months

Pic. 12. Position of photosensor in HYBRID burners.

7.2. Electrical igniter replacement.

When the igniter does not heat even though the “firing up” message is shown, it is probably

damaged. To replace the igniter, remove the burner cover. On the right side of the fan, there is a

ATTENTION!

Servicing of devices can only be

executed by switched off electrical

powering of a burner and a boiler.

27 | S t r o n a

steel sheath, where the electric igniter is located. Disconnect the igniter electric cables from the
terminal block, loosen the bolt mounting the steel sheath case and remove the igniter. Follow the
above procedure in reverse order to mount a new igniter and the burner cover.

7.3. Feeder pipe cleaning

If a string from the pellet bag or other object clogging the feeder operation gets into the feeder
pipe, then the feeder motor will overheat and circuit-breaker will be switched off by the
temperature sensor located in the motor.
In order to remove an object from the feeder pipe, the powering wire should be removed from the
socket inside the controller, unscrew the screws mounting the gear motor to feeder pipe,
remove the spring from the pipe and remove the object which was the cause of breakdown. Then
the feeder should be assembled and checked.

7.4. Burner cleaning

One of the reasons of lack of firing-up of a burner may be a slag filling in the burner chamber. The
igniter will not ignite the fire when there is a slag in its way. Slag does not burn itself.
As we are unsure as to the quality of fuel, that is why initially every day, later every now and then
we clean furnace pipe of a burner from slag and ash. After removing a burner, the
remnants of slag and ash should be cleaned with a wire-brush or a small poker. Common
cause of accumulating a slag is switching off a burner with the main switch. Too abrupt
removal of air-flow (oxygene) to the furnace causes unburning of fuel remnants. By another
firing up of a burner, without cleaning it from slag and ash, a smoke can come out from a
burner as the openings in it are blocked with slag. Burner is not aired enough. Therefore:

Before switching off the power of a burner, burning off process should be conducted.

In case of serious breakdowns an installer should be contacted.

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8. REASONS OF IMPROPER OPERATION

Burner does not fire up the fuel:

Reasons:

 No fuel – check the fuel hopper and the feeder, if it is not blocked
 Too small startup dose – check the startup dose
 Burnt igniter – check the igniter
 Defective drive motor - check motor thermistors

Burner fires up but does not go into the first power

Reasons:

 Improper start-up dose – check the start-up dose
 Dirty or faulty photosensor – clean it or replace it
 Damaged outer thermostat in oil boilers or bakery ovens

Photosensor checking

See page 26.
Measuring readings:

 In darkness 0-5 units
 In full light 100 units

Overheating of inner feeder.

Reasons:

 Burner dirty with slag
 Weak chimney draft – chimney exhaust fan should be used

Damage of the feeder sensor– alarm can not be cancelled

Reasons:

 The most common reason of this breakdown is damage of thermo protection of a sensor,

which results in overheating of measuring part. Despite burner cooling off, the fault can
not be cancelled, in this case the measuring sensor should be replaced. In order to
verify if the sensor is faulty indeed, its resistance should be checked, it should be between
1-5 Ω. The resistance of a damaged sensor is about 100 kΩ.

Feeder filling
The inner feeder is designed to mix and feed fuel evenly. The reason of filling the inner
feeder can be:

 Bad setting of the inner feeder in relation to outer feeder – increase capacity of inner

feeder (service menu/ burner feeder)

 Gearmotor damage – replace the gearmotor
 Badly adjusted interval of feeder work – this value should not exceed 20s. (service menu /

burner interval)

Blower damage

Reasons:

 Blockade of blower blades – unscrew the blower cover and check if they are not blocked

mechanically

 Check the voltage on blower wires
 Check the capacitor of blower motor

29 | S t r o n a

9. ELECTRICAL SCHEMES

Electrical scheme of Pellas X controller

See controller’s user’s manual

Electrical scheme of HYBRID burners

Pic. 13. Electrical scheme of HYBRID burners.

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10. REPORTS

10.1. First start-up report

Table 10. The pattern of the first start-up.

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10.2. Inspection report

Table 11. The pattern of first inspection report.

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11. LIST OF PICTURES AND TABLES

33 | S t r o n a

List of pictures:

Pic. 1. Construction of HYBRID Mini and HYBRID Mini 35 burners. 6

Pic. 2. Construction of HYBRID 44 burner. 6

Pic. 3. The pattern of the burner nameplate 9

Pic. 4. Positioning of burner and direction of flame. 14

Pic. 5. Feeder’s construction. 16

Pic. 6. Feeder’s auger installation. 17

Pic. 7. Scheme of installation of boiler room 18

Pic. 8. Installation of HYBRID Mini and HYBRID Mini 35 burners. 19

Pic. 9. Installation of HYBRID 44 burner in boiler’s door. 20

Pic. 10. Maintenance of HYBRID Mini and HYBRID Mini 35 burners. 22

Pic. 11. Correct positioning of furnace in burner HYBRID Mini and HYBRID Mini 35. 23

Pic. 12. Position of photosensor in HYBRID burners. 26

Pic. 13. Electrical scheme of HYBRID burners. 29

List of tables:

Table 1. Quality requirements of pellet fuel. 8

Table 2. Technical data. 10

Table 3. Dimensions of burners. 11

Table 4. Minimum chimney draft. 13

Table 5. Minimum dimensions of furnace chamber. 14

Table 6. Exemplary minimum dimensions of rectangular furnace chamber. 14

Table 7. Exemplary minimum dimensions of cylindrical furnace chamber. 15

Table 8. Pressure in burning chamber. 15

Table 9. Specification of the inspection intervals. 24

Table 10. The pattern of the first start-up. 30

Table 11. The pattern of first inspection report. 31

12. NOTES

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NOTES

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NOTES

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