Pelltech PV1000agri User Manual [en, fr]

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PV1000agri pellet burner

User manual

POOLELI - DRAFT

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Description

Main components

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1 Contents

2 Description ............................................................................................................................................ 4

2.1 Main components ......................................................................................................................... 5

2.2 Specifications ................................................................................................................................. 7

3 Installation ........................................................................................................................................... 10

3.1 Prerequisites ................................................................................................................................ 10

3.2 Burner .......................................................................................................................................... 11

3.3 Water sprinkler ............................................................................................................................ 20

3.4 External auger ............................................................................................................................. 21

3.5 Pellet storage ............................................................................................................................... 22

3.6 Electrical connections .................................................................................................................. 22

3.7 Commissioning ............................................................................................................................ 27

4 Operation and maintenance ............................................................................................................... 28

4.1 User interface .............................................................................................................................. 28

4.2 Starting and stopping .................................................................................................................. 30

4.3 Statuses and parameters ............................................................................................................. 30

4.4 Cleaning ....................................................................................................................................... 38

4.5 Replacing components ................................................................................................................ 38

5 Optional components .......................................................................................................................... 40

5.1 GSM Modem ............................................................................................................................... 40

5.2 Flue gas fan .................................................................................................................................. 41

6 Common problems and solutions ....................................................................................................... 42

7 Annex A – Parameters ......................................................................................................................... 43

8 Annex B – Burner status change logic ................................................................................................. 47

9 Annex C – Controller board description .............................................................................................. 49

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Tables

Table 1 PV1000agri connectors ( * optional extras) ................................................................................... 22

Table 2 Info menu description .................................................................................................................... 30

Table 3 Summary of burner statuses .......................................................................................................... 30

Table 4 List of tests in TESTING status ......................................................................................................... 31

Table 5 Cleaning parameters ....................................................................................................................... 31

Table 6 Loading parameters ........................................................................................................................ 32

Table 7 Ignition parameters ........................................................................................................................ 33

Table 8 Pre-burn parameters ...................................................................................................................... 33

Table 9 Heat-up parameters ....................................................................................................................... 34

Table 10 Power levels .................................................................................................................................. 34

Table 11 Hold flame parameters ................................................................................................................. 36

Table 12 End burn parameters .................................................................................................................... 37

Table 13 End blow parameters .................................................................................................................... 37

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Main components

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2 Description

PV1000Agri is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. Due to the unique design of the burning chamber you can use industrial pellets to fuel the burner. You cannot use any other form of fuel to run this burner.

The construction of the burner allows it to be used with different boilers: liquid fuel, solid fuel and universal boilers. The burner is connected to the boiler using a connection plate.

The burner is equipped with a safety thermostat, a melting hose, temperature sensor, sprinkler system (optional) and auxiliary battery for protection against back-burning.

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2.1 Main components

1 2 3

5 6 7

17 5 18

10 9 8

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Description

Main components

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Name

Description

Burning chamber

The part of the burner that is inside the boiler and where pellets are burnt.

Burner body

The part of the burner that is outside the boiler.

User interface

Screen, navigation buttons and indication lights. For more information, please see chapter

4.1

Control box

Contains inverters, fuses, relays, main controller board etc.

Water sprinkler

Sprinkler system will spray water to extinguish the fire in case of back burning. The sprinkler system is only activated when the temperature of inner auger rises dangerously high.

Grate cleaning motor

Linear motor moves the grates in burning chamber and pushes ash out from burning chamber. This cleaning cycle is made periodically. The interval between cleaning cycles can be managed by parameter 48. In each cleaning cycle, the linear motor pulls grates back then pushes the grates completely out and then pulls the grates on the half way. The linear motor has 75mm stroke and end switches for stop. Linear motor current limit can be set by parameter 47. There is also fuse F10 installed on the controller board (board version BBB v2.1)

Igniter

Igniter´s purpose is to ignite loaded fuel making the burning process start. Igniter is installed on the burner together with igniter holding pipe. PV1000agri has total four igniters.

Brick temperature sensor

A sensor to adjust burner start up speed according to temperature rise. Brick temperature rise speed must be controlled to extend its lifetime.

Cleaning hatch

Hatch below burning chamber to ease the removal of ash under grates.

Grates support frame

Holds moving and stationary grates in correct position. 11

Grates

Cast iron grates form fire bed and distribute combustion air through holes in grates. Some of the grates are moving to periodically clean the burning chamber.

Fire bricks

Heat resistant bricks that cover the burning chamber. Bricks are necessary for proper airflow and combustion.

Flame sensor

Photocell´s purpose is to recognize flame in the burning chamber.

Level sensor

Optical fuel level sensors recognize the fuel level in the vertical pipe. Fuel is recognized when pellets pass the optical beam between sensors.

Combustion air fans

Left – primary

Right - Secondary

Primary fan delivers main burning air needed for gasification of the fuel. Primary air is also used to burn the gasified fuel (charcoal) and to ignite the pellets together with igniters.

Secondary fan blows air through burning chamber back-wall and holds burning quality and optimal flue gas content. If oxygen sensor (optional) is used the secondary fan speed is regulated by oxygen level in flue gases.

Both fans rotation speed is measured by sensor, installed near the impeller axle. The sensor is reading magnetic field changes caused by magnet installed on the impeller axle.

Controller board

Controller board controls the burner´s burning process, by calculating fuel amount also

feeder and auger work during burning process. Depending on the input signals from the sensors, controller makes necessary changes to the output states to maximize burning efficiency. Controller has a single control board.

GSM modem (optional)

A GSM modem enables burner to send SMS messages with various information of burner´s

operating states (errors). GSM modem is located in controller unit. More information in chapter 5.1

Internal feeder motors

Internal feeders are used to deliver correct amount of fuel into burning chamber. Delivered fuel amount is regulated by periodical work of feeder gear motors.

24V DC motors are supplied from backup battery to empty feeder tubes in case of power failure.

Battery

When there is no power from the main power supply then the burner is operating on battery power. PV1000 uses two 12V 3,4 Ah batteries. Because the battery is a safety element, the

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burner checks batteries condition and does not start the next working cycle if the batteries voltage is too low.

Internal feeder screw

Hollow spiral connected to feeder motor to transport pellets into burning chamber. Screw is not tightened to motor, but has small slack. It lowers the mechanical stress and expands gearmotor lifetime.

Pressure sensor connection

Metal tube to connect pressure sensor input. Pressure sensor measures draught in burning chamber and enables the controller to regulate flue gas fan speed.

Parameter

Unit

PV1000agri

L total length

1300

L1 burner body length

630

L2 burning chamber length

690

H total height

620

H1 burner chamber height

550

W total width

710

W1 burner housing width

620

Mass

290

Supply voltage

VAC

Power max

620

Power at standby

Noise

Emission class1

Operating temperature

-10…40

Nominal heat input

1000

2.2 Specifications

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Figure 1 Dimensions

Figure 2 Dimensions

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Specifications

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Figure 3 Dimensions

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Prerequisites

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3 Installation

Unit PV 1000

mm 400 mm 490 mm 6x13 deg

angle between bolt holes 60

⌀D hole for burning cha mber neck ⌀D1 flange bolt ring diameter ⌀D2bolt holes

a bolt hol e offset angle

deg

3.1 Prerequisites

In order to install the burner, the boiler must meet to the following requirements:

 Recommended to use three pass boilers.  The construction of the boiler must make it possible to open the door of the boiler with the

burner connected and removing ash from the furnace. If the door of the boiler is too narrow for opening it with the burner, then extra hinges must be installed.

 If there is not sufficient (less than 5Pa) negative pressure in the furnace, a draught fan should be

installed for the exhaust gases.

 The boiler must be positioned in a way that there is enough space for cleaning the burner, the

boiler, the smoke pipe and removing the ash.

 The burning chamber must not touch the bottom of the boilers furnace (min 10cm distance

needed).

 The boiler room where the burner is installed must fulfill all rules and recommendations given by

local authorities.

 Boiler room must provide constant air supply of 1500 m³ per hour (ca. 1600 cm2 air inlet

opening).

In order to install the burner to the boiler door, there must be mounting holes as shown below.

Figure 4 Boiler door mounting hole

Note: If the burner is installed to the boiler, the door or the installation flange´s thickness should be 8-14mm.

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Burner

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3.2 Burner

Figure 5

Mount the burning chamber on the inner side of the boiler door.

Figure 6

Use 6 M12x60mm bolts, spacers and distance nuts respective to the bolts

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Burner

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Figure 7

Install the insulation rope between the burning chamber and the boiler door. The rope must be installed near the outer perimeter of the burning chambers back wall.

Figure 8

Grate holders installation

Install the burning chambers bottom panel (15x15mm insulation rope must be inserted to the slot in the panel) with 6 M8x16mm bolts.

Install the burning chambers front panel (heat shield), use M8x16mm bolts.

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Burner

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Figure 9

Connect the static grate holders with the side stone holders separately and install them together into the burning chamber as a frame. Fix them with M8x16mm bolts to the burning chamber.

Figure 10

Connect the moving grate holders with M6x12mm bolts.

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Burner

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Figure 11

Install the burning chambers front brick holders, use M8x16mm bolts.

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Burner

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Figure 12

Release the igniter tube screws and while inside the holders pull the tubes out about half of the total length.

Move the air separator to its correct position (according to the boiler door thickness) and fix it with screws.

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Burner

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Figure 13

Install the ceramic sealing strips on the boiler door. Fix them temporarily in position with any ordinary cellophane tape (scotch).

Cut away the excessive sealing on the perimeter of the air chamber.

Figure 14

Mount the burner body on the boiler door, using 4 M12x70mm bolts and respective washers.

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Burner

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Figure 15

Push the igniter tubes through the burning chambers back wall and fix them in position with M4 screws.

Figure 16

Connect the linear actuator with the moving grate holder. Use 27x2,5mm pipe (length 240mm), M8x45mm bolt for the burning chamber side and a M6x25 socket set screw (DIN914 45H) on the actuator side.

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Burner

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Figure 17

Push the stone temperature sensor through the hole in the burner body and the pipe on the burning chambers back wall, isolate it from the air flow (accessible from the burning chamber side) with ceramic sealing to prevent cold air from tampering with the measurements.

Figure 18

Install the 8 lower position grates with 5mm holes.

Install the 8 higher position grates with 7mm holes.

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Burner

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Figure 19

Install the ceramic paper on the back wall of the burning chamber.

Install the back wall stones on the burning chambers back wall.

ATTENTION!: Care must be taken not to damage the temperature sensor!

Push the stone temperature sensor into the opening in the back wall stone.

Figure 20

Install the upper grate holder and 2 upper grates. Fix the holder with M10 wing nuts

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Water sprinkler

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Figure 21

Install the 6 side bricks.

Install the 6 arc-stones.

ATTENTION!: The arc-stones are numbered, they must be installed as pairs!

3.3 Water sprinkler

Water sprinkler is main safety element against back burning. It is strongly recommended to install sprinkler system. In Figure 22, water supply line and pressure switch is used. Pressure switch allows starting the burner only if water supply is present. If no water is available on installation site, reservoir can be filled manually. In this case, pressure switch is not connected to safety circuit as there is no pressure in water system.

In case of back burning, sprinklers will open and extinguish fire in feeder tubes. Flow control valve limits the amount of water flowing into burner after the reservoir is emptied. The burning chamber must be cleaned from wet ash and pellets before turning the burner back on again.

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Installation

External auger

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Figure 22 Sprinkler installation

3.4 External auger

The external auger transports pellets from the pellet container to the burner. The burner controls the work of the auger. The auger is connected to the burner with a special hose (∅ 80), which is made from easily melting material that acts as a safety measure against back-burning. PV1000Agri pellet burner´s fuel consumption at full power is about 208-222 kg of pellets per hour ( 3,3-3,7 kg per minute ). External auger´s productivity must be at least 270kg of pellets per hour. The auger can be fixed to the storage or a ceiling depending on the conditions at the installation site.

Requirements for auger installation:

 The raising angle of the auger must not exceed 45°  The end of the exit tube of the auger and the input of the burner must not be aligned. The

recommended minimal horizontal distance is 20cm.

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Pellet storage

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 The distance between the input of the burner and the exit tube of the auger must be at least

Nr.

Name

Color, type

Signals

X11

Power, thermostat

black F/ brown F

230V 3A, 230V

X12

Main Power supply

black F

3x380V 16A

X13

Safety circuit

white M

230V

X14

Pellet auger 1

black M

3x380V 0,55kW 1,6A

X15

Ash augers

white M

230V 90W

X15*

Pellet auger 2

black M

3x380V 0,55kW 1,6A

X16

Secondary fan

white M

3x230V 0,18kW 1,4A

X17

Ignitors

black M

2x500W 2,2A

X21

Fluegas fan

white M

3x230V max 1,5kW

X21*

Fluegas inverter

brown M

0...10V, 24V DC

X22

Modbus

Brown M

24V DC

X23

Pt100/4..20mA sensors

Green M

24V DC

X24*

Level sensors

Brown M

24V DC

X25*

by request

X26

Primary fan

white M

3x230V 0,18kW 1,4A

X27

Ignitors

black M

2x500W 2,2A

60cm vertically – recommended distance is 80-200cm.

 Hose between auger and burner must be tight, otherwise pellets will block the auger. Falling

angle must me between 65° and 85°.

Figure 23 External auger installation

3.5 Pellet storage

Pellets must be stored in a dry and ventilated room that is separated from the boiler room. A purpose built silo is recommended. All safety regulation must be taken into consideration according to the local laws. It is recommended to wear a respirator when handling pellets. Refilling must be carried out before the storage runs empty.

3.6 Electrical connections

Table 1 PV1000agri connectors

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Electrical connections

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* optional extras

0 % O² - 4

25 % O² - 20

mA mA

Figure 24 Connector markings

Burner is designed to work at 230V. Boiler should be equipped with thermostat or external switch between plug X11 pin T1 and T2 for turning on/off the pellet burner.

Internal feeder is equipped with motor thermal protection, which prevents motor from overheating. As soon as the nominal trip temperature (TNF) of the sensor set point is exceeded, the relay detects this variation and the output relay cuts off the power to the motor.

Burner can be equipped with optional lambda sensor. It provides efficient control for optimal performance concentrating emissions and burning efficiency. Lambda sensor output range has linear relationship with following points:

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Installation

Electrical connections

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Installation

Electrical connections

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Installation

Electrical connections

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Installation

Commissioning

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3.7 Commissioning

Prior to the initial start-up of the burner make sure that:

 The burner is connected to the boiler  The boiler thermostat is installed and is functioning properly  The feeding auger of the burner is installed and connected to the burner  The smoke duct is connected to the chimney, the dampers for smoke gases are open and there is

sufficient draught. When the burner is operating, the negative pressure inside the furnace must stay between 5-20 Pa

 Sprinkler system is connected and pressure switch connected to safety circuit (chapter 3.3).

 Phase and neutral wires in power cable are connected properly.

.....................................

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Operation and maintenance

User interface

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4 Operation and maintenance

4.1 User interface

The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log etc. Yellow light (2) shows the presence of flame in burning chamber. Or if blinking, the burner is out of normal operation. Status can be seen on log screen. Green light (3) indicates if there is fuel in the burner. Navigation buttons enable to move in menus and make changes in parameters setup.

Burner on/off switch (4) can be used any time to turn on or off the burner. Using this switch, the burner will make all necessary action to safely stop or start the burning process.

Figure 25 User interface

1 – 4x20 character display 2 – Yellow LED, indicates if flame is detected in burning chamber 3 – Green LED, indicates if pellets are present in internal feeder 4 – Burner on/off switch with power indication light. 5 – Burner operation light, showing if the boiler thermostat sends a signal to the burner. 6 – Fault light 7 - GSM modem antenna

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Operation and maintenance

User interface

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Figure 26 Main menu structure

Status info screen displays last events (burner states) and their duration. The duration is in form mm:ss

(’m’ in the middle) or hh:mm (’h’ in the middle). For example “Igniting 01m25 means the burner ignition

state lasted 1minute and 25 seconds. Last row of the log shows current state. To reach the last row,

press the “down” button, until you reach the current state. The duration of current state updates every

second or minute.

Info menu

Info menu is useful to troubleshoot various problems. It gives access to some input signals and internal parameters. Use up and down arrows to scroll through info menu.

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Operation and maintenance

Starting and stopping

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Note: Comma “,” is used as decimal separator.

Screen text

Description

Pwr 00/550 kW

Current and maximum power. Max power can be changed from main menu.

Tstn=1810C T1=26850C

Tstn – fire brick temperature, T1 - PT

Fan=10/13±2 14/15

10 – primary fan actual speed, 13 – primary fan setpoint speed. Actual speed is controlled to match setpoint speed. ±2 - Base air value. Controller tries to keep speed setpoint + base air. In this case controller keeps speed 15rps. Speed unit is rps (revolutions per second). 14/15 – same as above for secondary fan. Base air setting is same ±2

Δp=-0,2/-15Pa

Burning chamber pressure value. -0,2 is current measured pressure and -15 is setpoint. Controller regulates flue gas fan speed to keep this pressure. Depends also on PAR60 value.

Total=10 kg

Roughly the amount of pellets burnt. It is measured by counting internal feeder rotations. Number is reset by firmware upgrade

Count=12,1 kg 180/254

Roughly the amount of pellets burnt, resettable by user.

U=25V68 I=0.0A

U - DC power voltage 25V68 means 25.68V. I – Feeders and/or grate motor current

Ver=2.02c 19/12/12

Firmware version and date

Status

Short description

Waiting

Waiting signal from boiler thermostat

Testing

Thermostat is switched on, testing battery, fans, feeder, level sensors, draft

Cleaning

Ash removing from burning chamber

Loading pellets with auger into burner and by feeder into burning chamber

Igniting

Igniter is turned on, pellets igniting

Pre-burn

Flame is recognized, small amount of pellets is added by feeder

Heat up

Burning chamber Ceramic is heated up

Burning

Normal burning operation

Hold flame

Thermostat is switched off, small flame is held alive

End burn

Thermostat is switched off, feeder is cleaned up

Table 2 Info menu description

4.2 Starting and stopping

To turn on the burner, switch on boiler main switch. If burner displays ’Stopped’, then go to STATUS menu and change parameter ’Burner’ from ON to OFF. The display shows ’Waiting’. Now turn boiler

thermostat to desired temperature. The burner will go to Loading-state. If this is the first run, external auger needs to fill up with pellets. It can take as long as 20minutes.

4.3 Statuses and parameters

PV1000agri pellet burner operates in many different states, which are called “Status”. Current and previous statuses can be seen from user interface panel (chapter 4.1). Burner changes its status based on input signals from sensors and user. Below are given the statuses in order of typical working cycle.

Table 3 Summary of burner statuses

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Statuses and parameters

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End Blow

Pellet coals in burning chamber is burned, flame has disappeared

Waiting

Wait signal from boiler thermostat

Test name

Par nr.

Value

Unit

Test conditions

Battery voltage

22 V Battery loading is turned OFF and feeder is turned ON - voltage must be greater than 12V

Feeder current

Par 46

3..6

Feeder is turned ON – feeder current must be smaller than Par 46

Draft

Par 62

+10

All fans are turned on. Draft must be under Par 62

Primary fan

Par 4

rot

Fan must rotate faster than 35rot = 38 (Par4) - 3

Secondary fan

Par 4

rot

Fan must rotate faster than 35rot = 38 (Par4) - 3

Par name

Par nr.

Value

Unit

Test conditions

Cleaning cycle interval

Par 48

0...250

min

„Burning“ time between „Cleaning“ cycles. If 0 then cleaning is turned off. If burned longer then 2x Par 48 then forced cleaning is made.

Actuator max. current

Par 47

0.2..6

Actuator maximum current level. If greater, then actuator is stopped and cleaning cycle is started

Waiting

In this status, the burner is waiting signal from boiler thermostat. There is no limit time for waiting status. Only internal feeder is working periodically at “Waiting” time – ½ rotations after every 2 minutes. When signal comes from the thermostat, burner will go to “Testing”.

Te sting

At “Testing” time, burner integrity and important device functioning is checked.

Table 4 List of tests in TESTING status

Cleaning

In “Cleaning” cycle, the linear actuator moves the grates and pushes out from burning chamber the ash and residues. The cleaning cycle has been divided into 3 steps:

1. Grates are pulled fully in to actuator end limit.

2. Grates are pushed fully out to actuator end limit.

3. Grates are pulled in, actuator works 4 seconds.

Table 5 Cleaning parameters

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Operation and maintenance

Statuses and parameters

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again.

Actuator min. current

0.1 A If smaller, then actuator is stopped and running direction can be changed.

Max. move time

sec

Maximum time to move actuator to one direction.

Max. cleaning time

100

sec

Maximum „Cleaning“ cycle time

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 24

Loading feed

35..40

rot

Feeder rotations neede to load pellets into burning chamber. Depends from burner model.

Par 25

Loading 2 feed

rot

Feeder rotations for second loading.

Max loading time

min

Maximum regular loading time

First loading time after manual start

min

Maximum loading time after manual start.

Auger start

sec

Auger Start delay if no fuel in burner

Auger stop

sec

Auger Stop delay if fuel in burner

Feeder start

sec

Feeder Start delay if fuel in burner

Feeder stop

rot

Feeder rotations made without fuel level before stopped

In the “Loading” cycle, pellet auger is turned on. When pellet level in the burner reaches to level sensors, internal feeder is started. Feeder loads correct amount of fuel into burning chamber needed for ignition. Loaded fuel amount is measured by counting internal feeder rotations. Loading cycle is ended when feeder is made correct amount of rotations, fixed in parameter nr.24 (loading feed rot.)

Table 6 Loading parameters

At the “Loading” time, external auger holds permanent fuel level in the feeder tube. Depending of the level sensor signal, the auger is turned ON or OFF.

Internal feeder work is also depending on fuel level sensor signal.

Maximum loading time is limited by 20 minutes after manual (first) start because extra time for external auger filling is needed. In next loadings, maximum time is limited by 5 minutes.

If maximum loading time is exceeded and silo selection on burner is used, the pellet delivery will be switched on other auger. In single pellet delivery system “No pellets” error will occur.

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Operation and maintenance

Statuses and parameters

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Igniting

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 24

Fan @ignition

rps

Primary fan speed at ignition

Max ignition time

255

sek

Maximum ignition time

First loading time after manual start

min

Maximum loading time after manual start.

Auger start

sec

Auger Start delay if no fuel in burner

Auger stop

sec

Auger Stop delay if fuel in burner

Feeder start

sec

Feeder Start delay if fuel in burner

Feeder stop

rot

Feeder rotations made without fuel level before stopped

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 8

Fan@ignition

rps

Primary fan speed at ignition and preburn

Par 39

Fan 2 min

rps

Secondary fan minimum speed. Used at “Ignition”, “Preburn”, “Heat up”, “Hold flame” and “End blow” time.

Par 41

Preburn time

Delay between pellet feedings at Preburn

Par 42

Preburn cycles

Number of pellet feeding cycles at Preburn

Preburn feed

1/2

rot

Feeder turns at each feeding

In ignition cycle the igniter is heated up and fan blows hot air thru pellets in burning chamber. Hot air ignites pellets. Igniter is working periodically at ignition time to avoid overheating.

Igniter is preheated already in the end of loading cycle. When internal auger has made 10 rotations (full load rotations* - 12) the igniter is turned on for preheating. If the igniter has been turned on more than 1 minute at loading time, the igniter is turned off.

Table 7 Ignition parameters

Pre-burn

The purpose of pre-burn status is to get correct burning and flame after ignition. There is minimum fuel amount added periodically at pre-burn time. Fans are working with same speed as at ignition.

Table 8 Pre-burn parameters

Heat up

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Operation and maintenance

Statuses and parameters

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“Heat up” cycle is needed for slow heating of the burning chamber and to minimize thermal stress in

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 70

Heat up time

min

Maximum cycle time

Par 71

Heat up power

30...70

Depends from burner model

Par 72

Heat up temperature

500

°C

Ceramic stone minimum temperature

Power

level

Level

type

Power by burner model (kW)

Air parameters

PV350

PV500

PV700

PV1000

Primary

Secondary

main

100

160

200

250

Par 1

Par 31

virtual

120

200

250

320 - -

main

150

240

300

400

Par 2

Par 32

virtual

170

280

350

470 - -

main

200

320

400

550

Par 3

Par 33

virtual

220

360

450

620 - -

main

250

400

500

700

Par 4

Par 34

virtual

270

440

550

770 - -

ceramic stones.

“Heat up” mode is selected from main menu between “ON”, “OFF” or “AUTO”.

Table 9 Heat-up parameters

When “Heat up” is mode is “ON” - burner will leave from “Heat up” cycle after heat up time is exceeded (stone temp. is not measured)

When “Heat up” is mode is “AUTO” - burner will leave from “Heat up” cycle after heat up time is exceeded or stone temp. is higher than setpoint (PAR72)

Burning

This is main operation status in burner operation.

Burner can operate on 11 different fixed power levels. There are 6 main power levels, which can be selected and adjusted. Virtual power levels (between main levels) are for smoother operation – they can't be adjusted or selected.

For every power level, the primary fan speed is fixed in parameters 1...6 and secondary fan speed in parameters 31...36. The fan speed for virtual levels is calculated as average from previous and next main level speed.

Table 10 Power levels

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Operation and maintenance

Statuses and parameters

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main

300

480

600

850

Par 5

Par 35

virtual

320

520

650

920 - -

main

350

560

700

1000

Par 6

Par 36

Figure 27 Burning at fixed power

Power level can be selected in main menu. Power level selection for burning time can be automatic or fixed on some main level. When power level is fixed, the power is slowly raised to selected level and will be there until boiler thermostat is switched off.

Power

level

Burning time

min

Par 17

3 2 1

2 2 2

Selected power

Power level

Time(min)

Par 17

Par 15

Max power (par 14)

Par 15

3 2 1

2 2 2 30 30

Operation power

“End burn“ „End Blow“ „Waiting“

„Burning“

“Testing“ „Loading“ „Igniting“ „Pre-burn“

Thermostat ON

OFF

„Burning“

New operation power

Par 15

In Automatic Power mode (POWER = AUTO in main menu), the operation power is selected automatically depending of burning cycle length.

Figure 28 Burning when power selection = AUTO

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Operation and maintenance

Statuses and parameters

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Slow down

Par

Nr.

Parameter name

Default

value

Unit

Comment

Power

level

Status/time

Par 18

3 2 1

Operation power

Thermostat OFF

„Burning“

„Slow down“

„Burn end“

„Hold flame“

Thermostat ON

„Slow down“

„Burning“

Par 17

In “Slow down” mode, the burner power is reduced step-by-step to 1 level after boiler thermostat is switched OFF. This mode can be used only is systems with high and stable power demand. Using “Slow down” mode in systems with low thermal inertia or unstable power demand, there will be risk of system overheating. The “Slow down” mode is recommended to use together with “Hold flame”. “Slow down”

mode can be switched ON or OFF from main menu.

Figure 29 Slow down mode

Hold Flame

“Hold flame” mode purpose is to avoid burner start-up procedures every time when burner is switched on from boiler thermostat. In “Hold flame” mode, minimum fuel and air amount is delivered into burning chamber. “Hold flame” mode can be switched from burner main menu to ON, OFF or AUTO. When “Hold flame” is selected as AUTO then burner will turn the mode on or off depending of “Waiting” time:

 If “Waiting” (time between “End blow” and thermostat ON) is shorter then Par 11, then “Hold

flame” mode is switched on.

 If “Hold flame” is longer than Par 12, hold flame mode is turned off

“Hold flame” is also used as intermediate state before cleaning or after “Slow down”

Table 11 Hold flame parameters

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Operation and maintenance

Statuses and parameters

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Par 8

Fan @hold flame

rps

Primary fan speed at hold flame

Par 39

Fan 2 min

rps

Secondary fan minimum speed. Used at “Ignition”, “Preburn”, “Heat up”, “Hold flame” and “End blow” time.

Par 11

Hold flame ON

min

Short “Waiting” limit.

Par 12

Hold flame OFF

min

Maximum time in “Hold flame”

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 26

End burn feed

50..80

rot

Feeder rotations neede to clean feeder pipe. Depends from burner model.

Minimum feed

rot

If less rotations maid and boiler thermostat is switched ON then back to “Burning”

Par

Nr.

Parameter name

Default

value

Unit

Comment

Par 9

Fan @end blow

rps

Fan speed at “End blow”

Par 39

Fan 2 min

rps

Secondary fan minimum speed. Used at “Ignition”, “Preburn”, “Heat up”, “Hold flame” and “End blow” time.

Par 27

End blow time

min

Time to blow air after flame is disappeared

Max. “End blow” time

min

Maximum time when flame must disappear in “End Blow”

End burn

The “End burn” cycle is needed to stop the burner. All pellets inside the burning chamber and feeder

tubes are burned. Pellet feeding frequency and fan rotation speed (power level) is same as in “Burning” status. If burner goes to “End burn” from other states (example “Hold Flame”), first power level is selected. Burner works in “End burn” until feeder tube is empty - feeder has made as many turns as selected in Par 26. “End burn” is used in case of some errors.

Table 12 End burn parameters

End blow

The “End blow” cycle is needed to finish unburned pellet coals in the burning chamber. Burner will wait

the flame disappearing in burning chamber. In Par 27 is fixed the time, how long the fans continue to blow after flame disappearing.

Table 13 End blow parameters

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Operation and maintenance

Cleaning

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External au ger control

4.4 Cleaning

Pellet burner requires systematic maintenance. The maintenance period depends on the quality of the pellets and heating intensity.

To clean the burner:

1. Turn off the burner by turning the thermostat to 0.

2. Let the burner cool down for at least 1 hour.

3. Open the boiler's door to gain access to the burning chamber

4. Remove the grates and clean them from any residues. Make sure all holes on the grates are clean.

5. Remove the bottom panel to gain access under the grate movers to clean the ash from the burning camber.

6. Reattach the bottom panel.

7. Clean the boiler. The frequency of cleaning the boiler depends on the type of the boiler and heating intensity. For more information about cleaning the boiler, please see boiler's user manual.

8. Put back the grates.

9. Close the boiler's door to finish the maintenance and turn the thermostat to desired temperature.

The connection between the boiler and chimney must be completely airtight. There mustn't be any extra draught in the smoke draft of the boiler. All cleaning and maintenance openings must be closed with covers.

4.5 Replacing components

Step by step, how to replace igniter etc

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Operation and maintenance

Replacing components

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.................................

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Optional components

GSM Modem

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5 Optional components

Figure 30 Modem

Figure 31 SIM card insertion

5.1 GSM Modem

Modem enables users to receive burner error messages via SMS. Boiler room must have GSM coverage in order to use the modem.

Preconfiguring S IM ca rd

Before inserting the SIM card to burner, SIM card must be preconfigure. That can be done by inserting the SIM card to a mobile phone and making following actions:

 SIM card must the activated by the mobile operator  SIM card pin code must be turned off  Mobile operator´s messaging center number must be correct  In SIM card´s phonebook, there must be only the numbers, where the messages from the burner

will be sent. The number of receiving contacts is limited to 5.

Insertion and remo val o f the SIM card

The terminal has a built-in toggle spring (Push-Push) SIM holder, accessible through a slot in the panel at the antenna side of the housing. Do not insert or remove the SIM when the product is in power saving mode.

To insert and remove the SIM, a plastic strip of the same width of the SIM and appropriate length of ca. 50-100 mm shall be prepared as a tool. The figure printed on the panel shows the position of the cut edge and the direction, how

the SIM shall be inserted.

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Optional components

Temperature sensor

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Insert the SIM and push it with the tool slightly inside until the spring snaps in. Removing the tool, the

LED status Device Status

permanently on a call is active fast interrupt sequence Net search / Not registered / turning off (period 0,5s, Ton 1s)

slow interrupt sequence Registered full service (period 0,3s, Ton 3s) permanently off device off

SIM shall remain inside the GT863-PY. For removing the SIM, push the tool slightly inside until the spring is released so that it pushes the SIM outside when the tool is retracted.

Burner´s GSM modem menu can be accessed in the PARAMETERS menu, parameter no. 52

LED indicators

The GT863-PY Terminal has 2 LED indicators, one for Power, one for Status.

Power LED When on, the green Power LED indicates that the supply voltage is arriving at the GSM Engine inside the GT863-PY Terminal.

Status LED: Indication of network service availability. The red Status LED is connected internally to the STAT_LED output of the module by an inverting circuit. In addition to the status information obtainable via AT commands, this LED shows information on the network service availability and Call status.

Status LED indications

5.2 Temperature sensor

Temperature sensor can be resistive PT100 type or mA output type. In

5.3 Flue gas fan

Schematics, instructions for set up.

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Common problems and solutions

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6 Common problems and solutions

Problem description

Possible cause and solution

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Annex A – Parameters

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7 Annex A – Parameters

Par Nr

Parameter name

Unit

Burner model

Default

Min.

Max.

Description

Par 1

FAN @level 1

rps

PV350

PV500

PV700

50 PV1000

Par 2

FAN @level 3

rps

PV350

36 PV500

PV700

PV1000

Par 3

FAN @level 5

rps

PV350

PV500

50 PV700

50 PV1000

Par 4

FAN @level 7

rps

PV350

PV500

PV700

50 PV1000

Par 5

FAN @level 9

rps

PV350

50 PV500

PV700

PV1000

Par 6

FAN @level 11

rps

PV350

PV500

50 PV700

50 PV1000

Par 7

FAN START

% 170

240

Initial speed for prim., sec. and flue gas fan to start. 0=100%, 255=0%

Par 8

FAN IGNITION

rps 20

35 Par 9

FAN BURN END

rps 20

Par 10

FAN HOLD FLAME

rps 10 7 14

Par 11

HOLD FLAME ON

min 15 5 30 Par 12

HOLD FLAME MAX

min 60

Par 13

MIN POWER

PV350

100

100/150/200/250/300/350

PV500

160

160/240/320/400/480/560

PV700

200

200/300/400/500/600/700

PV1000

250

250/400/550/700/850/1000

Par 14

MAX POWER

PV350

350

100/150/200/250/300/350

PV500

560

160/240/320/400/480/560

PV700

700

200/300/400/500/600/700

PV1000

1000

250/400/550/700/850/1000

Par 15

POWER UP

min 15 5 120 Par

POWER DOWN

min 30

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Annex A – Parameters

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Par 17

UP CYCLE

min 2 1 3 Par 18

DOWN CYCLE

min 2 1 3

Par 21

PELLET NORMAL

g/n

PV350

100

PV500

160

120

250

PV700

160

120

250 PV1000

160

120

250

Par 22

PELLET LIGHT

g/n

PV350

100 PV500

150

120

250

PV700

150

120

250

PV1000

150

120

250

Par 23

PELLET HEAVY

g/n

PV350

100 PV500

170

120

250 PV700

170

120

250

PV1000

170

120

250

Par 24

LOADING FEED

rot

PV350

PV500

PV700

80 PV1000

Par 25

LOADING 2 FEED

rot 5 1 15

Par 26

BURN END FEED

rot

PV350

PV500

120

PV700

120 PV1000

120

Par 27

END BLOW TIME

min 2 1 15 Par 30

FAN 2 ON

AUTO

ON/OFF/AUTO

AUTO for normal operation

Par 31

FAN 2 @level 1

rps

PV350

15 5 80

PV500

15 5 80

PV700

13 5 80

PV1000

16 5 40

Par 32

FAN 2 @level 3

rps

PV350

20 5 80 PV500

20 5 80 PV700

23 5 80 PV1000

22 5 50

Par 33

FAN 2 @level 5

rps

PV350

30 5 80

PV500

30 5 80 PV700

32 5 80 PV1000

30 5 55

Par 34

FAN 2 @level 7

rps

PV350

36 5 80

PV500

36 5 80

PV700

39 5 80

PV1000

38 5 55

Par

FAN 2 @level 9

rps

PV350

40 5 80

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Annex A – Parameters

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PV500

40 5 80

PV700

41 5 80

PV1000

42 5 55

Par 36

FAN 2 @level 11

rps

PV350

46 5 80 PV500

46 5 80 PV700

43 5 80

PV1000

46 5 55

Par 38

FAN 2 BASE

% 100

140 Par 39

FAN 2 MIN

rps 7 5 20

Par 40

PHOTOCELL LEVEL

% 90

100

Photocell sensitivity 100% = infinity flame Par

PRE-BURN TIME

s 25

80 Par 42

PRE-BURN CYCLE

x 6 2 10

Par 46

FEED CURRENT

PV350

3,0

1,0

9,9

Feeder max. Current.

PV500

6,0

1,0

9,9

PV700

6,0

1,0

9,9

PV1000

6,0

1,0

9,9

Par 47

GRATE CURRENT

A 2,0

0,2

6,0

Grates actuator max. Current

Par 48

CLEANING CYCLE

min 30 0 250

Cleaning cycle delay.

Par 50

ERROR RELAY

ON/OFF

Error relay action at error: ON-contact closed at error (NO), OFF-contacts opened at error (NC)

Par 52

SMS COUNT

x 1 0 5

Par 53

TEMP TYPE

0 0 2

Temp. Sensor action type: 0-no sensor, 1overheat sensor, 2-temp. holding sensor

Par 54

TEMP LEVEL

°C 70

105

Temp. Holding setpoint

Par 55

TEMP HYST

°C 5 2 10

Temp. Holding hysteresis

Par 58

BASE FREQUENCY

Hz 50

Power grid frequency (for triac operated fans)

Par 60

FLUEGAS TYPE

2 0 2

Flue gas fan/ underpressure control type: 0

- no-fan, no-control, 1 - no-fan but controlled underpressure, 2 - inverter, 3 230V triac

Par 61

DRAFT SET

-Pa 8 0 250

Draft setpoint

Par 62

DRAFT ERROR

+Pa 10 0 20

Draft error level

Par 63

DRAFT BASE

% 110

150

Draft sensor calibration value

Par 70

HEAT UP TIME

min 20 0 60

Max. Time for „HEAT UP“ cycle.

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Annex A – Parameters

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Par 71

HEAT UP POWER

PV350

100

Power at „HEAT UP“

PV500

100

PV700

100

PV1M

150

Par 72

HEAT UP TEMP

°C 500

250

900

Stone temperature to reach at „HEAT UP“ Par

TEMP BASE

°C 20 0 100 Par 99

BURNER TYPE

PV350

PV350/PV500/PV700/PV1M

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Annex B – Burner status change logic

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8 Annex B – Burner status change logic

Status

Next Status

Change conditions

Waiting

Testing

Signal from boiler thermostat

Testing

All tests are done successfully

Battery error

Battery voltage is too low

Fan error

Fan does not reach 40* rps at pre-burn

Level error

The level sensor recognizes pellets in the feeder

Ignition

Loading (22* rot.) made by feeder

No pellets

Maximum loading time (5 or 20 min.**) is reached

Burn end

Flame detected and unknown start conditions

Loading 2

Ignition

Previous state was ignition and rotations (3* rot.) made by feeder

Pre-burn

Previous state was hold flame and rotations (3* rot.) made by feeder

Ignition

Pre-burn

Flame recognized

Loading 2

Max ignition time (255* sec) is reached and load 2 is not done

Ignition error

Max ignition time (255* sec) is reached and load 2 is done

Pre-burn

Burning

Pre-burn cycles (3*x40*sec.) is done and continuous flame is recognized more than 10 seconds

Loading 2

Pre-burn cycles is done and flame is NOT recognized and load 2 is NOT done

No flame

Pre-burn cycles is done and flame is NOT recognized and load 2 is done

Burning

Burn end

NO Signal from boiler thermostat (hold flame is NOT allowed)

Hold flame

NO Signal from boiler thermostat (hold flame is allowed)

Burn end

Maximum burning time (4 hours) is reached

Burn end -> End blow ->Level error

Fuel level is continuously detected in time of 8 feeder rotations

Burn end -> End blow ->No pellets

Fuel level is not detected in 4 min.

No flame

No Flame more than 2 minutes

Hold flame

Loading 2

Signal from boiler thermostat

Burn end

Max keep flame time (1 hour) is reached

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Annex B – Burner status change logic

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Burn end

End blow

Burn end (15*rot. + 10rot.) plus time 30sec. is reached

Burning

Signal from boiler Thermostat, feeder made less than 8 rot and previous state was BURN

End Blow

Waiting

No Flame 1 min. and RUN command is active

Stopped

No Flame 1 min. and RUN command is NOT active

No flame

Max cleaning time (5 min.) is reached

Level error

No Flame 1 min. and error is set From: Burn-> Burn end-> End blow>Level error

No pellets

No Flame 1 min. and error is set From: Burn-> Burn end\-> End blow>No pellets

No Power

Wait

Power exist and RUN command is active

Stopped

Power exist and RUN command is NOT active

Burning

If Burned before No Power and less than 15 min in No Power

Any other

Waiting

RUN command is activated

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Annex C – Controller board description

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9 Annex C – Controller board description

Fuses F4=6A, F10=2A

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Annex C – Controller board description

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Connector

Description

LoPr 

Boiler pressure sensor connection. Must be connected to tube on left feeder tube.

FANx-1

Prim/sec fan speed sensor +5V power

FANx-2

Prim/sec fan speed sensor GND

FANx-3

Prim/sec fan speed sensor digital input

MOD1-1

Modem interface +5V output, fused through F9

MOD1-2

Modem interface Rx input

MOD1-3

Modem interface Tx output

MOD1-4

Modem interface GND

TMP1-1

Temperature sensor power +5V

TMP1-2

Temperature sensor GND

TMP1-3

Temperature sensor signal 0 – 2.5VDC

RSV-1

Level sensor receiver diode cathode

RSV-2

Level sensor receiver diode anode

TRS-1

Level sensor transmitter LED anode

TRS-2

Level sensor transmitter LED cathode

X1-1

+27VDC power output, fused through F1

X1-2