Erato Pony PS9 User manual

USER MANUAL
of hot air automated pellet stove
ERATO Pony PS9
http://www.erato.bg

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Thank You for buying hot air automated pellet stove „ERATO Pony
PS9”. This manual will help You to use and maintain the unit
properly.
ATTENTION!
IN INTEREST OF YOUR PERSONAL SECURITY IT IS
OBLIGATORY TO READ THOROUGHLY AND CAREFULLY THIS
INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY
ACTIONS WITH THE BOILER – MOUNTING, CONNECTING, ETC.
IN CASE THAT REQUIREMENTS, DEPICTED IN THIS MANUAL ARE
NOT SATISFIED, FAILURES OF THE UNIT COULD BE EXPECTED,
OR EVEN FATAL CONSEQUENCES, FOR WHICH ERATO
COMPANY DOES NOT TAKE RESPONSIBILITY.
Producer ZMM-Haskovo Ltd
Address Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd.
Phone [phone]
Fax [phone]
e-mail [email protected]
home page http://www.erato.bg/zmm
Hot air automated pellet stove “ERATO Pony PS9” user manual; (document version: 13.03.2011 11:53)

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CONTENTS
Page
1. Description and advantages of hot air automated pellet stove “ERATO Pony
PS9” 5
The unit could utilize following types of fuel:....................................................................5
The unit is equipped with:...................................................................................................5
The unit is supplied with: ....................................................................................................6
2. Technical data of hot air automated pellet stove, “ERATO Pony PS9”.................7
3. Description of the construction of hot air automated pellet stove “ERATO Pony
PS9” 11
4. Installation process.....................................................................................................15
5. Entering the appliance in service..............................................................................23
5.1. Basic fuel requirements. ........................................................................................23
5.2. Starting hot air pellet stove “ERATO Pony PS9” procedure. ...........................24
5.2.1.Interface control board of hot air pellet stove“ERATO Pony PS9” ...................25
5.2.2.Description of the function of the buttons of the interface panel. .......................27
5.2.3.Power supply of the stove........................................................................................29
5.2.4.Turning on the appliance. .......................................................................................29
5.2.5.Set up of the stoves parameters ..............................................................................30
5.2.6.Set up of the stove according to the thermal power needed.................................34
5.2.8.Nominal operation mode of the stove.....................................................................35
5.3. Adjustment of the thermal capacity of the stove.................................................36
5.3.1.Decreasing the thermal capacity of the stove ........................................................36
5.3.2. Decreasing the thermal capacity of the stove......................................................36
5.4. Stopping the operation of the stove. .....................................................................37
5.5. Cleaning the stove...................................................................................................37
5.6. Turning OFF the stove...........................................................................................41
5.7. Showing and teaching the end user about the maintenance and adjustment
procedures...........................................................................................................................42
5.8. Safety and unexpected risks..................................................................................42
5.9. Operation faults and their repairing from the end user.....................................44
5.10. Alarm messages, shown on the display of the stove............................................46
5.11. Operation faults and their repairing from the service personal........................47
5.12. Hot air pellet stove „ERATO Pony PS9” warranty form completion. ...............50
5.13. Actions, after the unit is not in exploitation anymore.........................................50

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6. Electrical scheme of the apliance..............................................................................51
QUALITY CERTIFICATE ..................................................................................................52
WARRANTY CONDITIONS...............................................................................................53
WARRANTY SERVICE PROCEDURES LIST ................................................................54
Declaration of Conformity.....................................................................................................55

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1. Description and advantages of hot air automated pellet stove
“ERATO Pony PS9”.
“ERATO Pony PS9” is steel-plate hot air pellet stove, which uses solid
biomass fuel in shape of pellets. The stove is designed for local heating of
domestic and office spaces. The boiler uses wood pellets, as well as other
type/shape of biomass; the resulting heat energy from thermo-chemical
conversion (i.e. combustion process) is transmitted from the heat-exchanging
surfaces to the surrounding air.
The unit is equipped with:
•Hot air automated pellet stove– 1 ct;
•Battery – Toshiba 23A, 12v, V23GA – 1 ct;
•Remote control - 1 ct;
•Plastic heels M10 X 43 - 4 ct;
•Handel - 1 ct;
•Supply cable PC AC 220V - 1 ct;
•Users guide for “ERATO Pony PS9” – 1 ct;
The unit could utilize following types of fuel:
•Wood pellets, having diameter 6 mm, categorized in the range of: A,
AB, B, (according to the methodology, developed for pellets properties
estimation in ERATO company);
•Other solid biomass based pellets, but confirmation for these fuels
utilization need testing and approval by ERATO company laboratory;
The unit is equipped with:
•Steel plates welded heat exchanger for heating-up the surrounding air;
•Flue gas fan;
•Fan for forced convection of the hot air
•Burner’s ash removal mechanism – removes the ash residuum out of
the burner’s grate;
•Daily fuel hopper with capacity of about 19 kg;
•Programmable operating module, which controls the functions of the
unit and is adjustable to the specific need of the client.
•Ash container with capacity of 0.5 kg;

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The unit is supplied with:
•Automatic fuel ignition system;
•Automatic fuel feeding auger system;
•Remote control;
Unit’s advantages:
•The hot air stove gives you an incredible feel of warmth and comfort due
to a controlled and highly efficient combustion process.
•The hot air stove is designed to utilize solid biomass fuel, making it
environmentally friendly, CO
2
neutral and does not contribute to the
global warming process – result of fossil fuel utilization;
•The specific price of the heat energy, delivered by solid biomass
utilization is less dependent on the world fuel market trends and
practically the heat energy price is competitive to the conventional energy
sources;
•The stove is automatic and the thermal comfort achieved is close to that,
originating from exploitation of fully automatic heaters, (for example
liquid or gas fuel, as well as electric heaters). The stove is equipped with
integrated programmable room thermostat (daily, weekly and weekend
programs);
•The unit is equipped with automatic fuel ignition system and another one
for burner’s ash cleaning;
•High efficiency;
•Low pollutant contents in the flue gases;
•Automatic fuel feeding system, transported from the built-in “daily”
hopper to the burner;
•Simplified maintenance and service procedures;
•Minimized running costs;
•The unit utilizes solid biomass fuel, in shape of pellets (wood pellets),
defined in following norms: ENplus (EN 14961-2:2010), ONORM
M7135, DIN 51731 иDINPlus;

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2. Technical data of hot air automated pellet stove, “ERATO
Pony PS9”
•Thermal and technical data for hot air stove “ERATO Pony PS9”,
utilizing wood pellets are given in Table 2.1;
•Dimensions and technical data for hot air stove “ERATO Pony PS9”,
are given in Table 2.2;
•Recommended solid fuel properties – wood pellets, are given in Table
2.3;
• Pellets classification, considering their physical properties (based on
fuel proximate analysis) are shown in Table 2.4;
Parameter Dimension Value
Nominal thermal capacity kW 9
Thermal capacity operation range kW 3.5 – 9
Utilized solid fuel Wood pellets diameter d+6mm
Utilized pellets, complying ERATO
classification methodology A, AB, B
Wood pellets fuel consumption rate at
nominal thermal capacity kg/h 2.1
kg/h 16 - 18
Fresh air flow rate, required for effective
combustion process and boiler operation m
3
/h 14 - 16
Averaged wood pellets consumption rate kg/h 1.2
Average refueling cycle h Up to 20
Thermal efficiency at nominal capacity ℅Up to 90
Air excess ratio λ 1.6 – 1.9
Flue gases temperature at nominal thermal
capacity ºC 160 – 200
Solid fuel residue ash
The quantity depends
on the ash contents in
the raw fuel, as well
as operating
conditions
Table 2.1 Thermal and technical data for hot air stove “ERATO Pony
PS9”, utilizing wood pellets.

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Parameter Dimension Value
Weight kg 91
dm³ 29Fuel hopper capacity
kg 19 kg wood pellets
d=6mm
Overall dimension of the unit (WxDxH) mm 470x612x1083
Class (according to EN 303-5) - 3
Recommended air temperature in the heated
space ºC 20
Minimum air temperature in the heated
space ºC 14
Draught Pa 4-10
Fresh air channel mm
35
Connections Flue gases duct mm 80
Electrical supply - 50Hz; 230V
Electrical power VA <100
< 350 (at ignition
process)
- IP20
Table 2.2 Dimensions and technical data for hot air stove “ERATO
Pony PS9”, utilizing wood pellets.
The recommended fuel for hot air stove “ERATO Pony PS9”, utilizing pellets
is: wood pellets with specific size – diameter 6 mm. Main characteristics of the
fuel are given in the next table.

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Parameter Dimension Value
Pellet’s characteristic size mm 6
Pellet’s characteristic length mm Max 30
MJ/kg >17.2Recommended fuel net calorific value (low
heating value) kWh/kg >4.7
Wood pellets category A, AB, B
Ash content % See Table 2.4.
Moisture content % Max. 8 – 10%
Table 2.3 Recommended solid fuel properties – wood pellets
Pellet’s category A
d
DU
A
%6.0≤
d
A %0.97
≥
DU
AB
%6.0≤
d
A %0.97
<
DU
B
%0.16.0 ≤<
d
A %0.97
≥
DU
BC
%0.16.0 ≤<
d
A %0.97
<
DU
C
%0.2%0.1 ≤<
d
A %0.97
≥
DU
CD
%0.2%0.1 ≤<
d
A %0.97
<
DU
D
%0.3%0.2 ≤<
d
A %0.97
≥
DU
DE
%0.3%0.2 ≤<
d
A %0.97
<
DU
E
%0.3>
d
A %0.97
≥
DU
EF
%0.3>
d
A %0.97
<
DU
Table 2.4 Pellets classification, considering their physical properties
(based on fuel proximate analysis) – according to fuel evaluation
methods, developed and applied in ERATO company;
where:
A
d
– ash contents, dry basis, [%];
DU – mechanical durability, [%];

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The European wood pellets standard EN 14961-2:2010
defines wood pellets certificate ENplus for pellets, utilized in
boilers and appliances for domestic heating systems. The
certificate EN-B is applied for pellets, utilized in industrial
boilers. In principal the ENplus standard defines two quality
classes: А1 иА2. The class А1 is highly restricted,
considering the ash content. The class А2 the limit of the ash content of the
wood pellets is higher – up to 1.5%. For industrial boilers the certificate EN-B is
applicable, which defines fewer restrictions on the pellets quality.
Parameter Dimension ENplus-A1 ENplus-A2
Diameter mm 6 (± 1) 6 (± 1)
Length mm 3,15 ≤L ≤40
1)
3,15 ≤L ≤40
1)
Bulk density kg/m³ ≥600 ≥600
Low calorific value MJ/kg ≥16.5 ≥16.5
Moisture content % ≤10 ≤10
Dust % ≤1
3)
≤1
3)
Mechanical durability % ≥97.5
4)
≥97.5
4)
Ash content %
2)
≤0,7 ≤1.5
Ash melting point temperature °C ≥1200 ≥1100
Cl %
2)
≤0.02 ≤0.03
S %
2)
≤0.05 ≤0.05
N %
2)
≤0.3 ≤0.5
Cu mg/kg
2)
≤10 ≤10
Cr mg/kg
2)
≤10 ≤10
As mg/kg
2)
≤1 ≤1
Cd mg/kg
2)
≤0.5 ≤0.5
Hg mg/kg
2)
≤0.1 ≤0.1
Pb mg/kg
2)
≤10 ≤10
Ni mg/kg
2)
≤10 ≤10
Zn mg/kg
2)
≤100 ≤100
1) not more that 1% of the wood pellets should be with length of 40 mm, the maximal pellet
length is 45 mm ;
2) determined on dry mass;
3) the particles are <3.15 mm, fine particles, before fuel delivery;
4) in case the test measurements are performed with Lignotester, than the limit value is ≥
97.7% m.w.;
Table 2.5 ENplus - European standard for wood pellets;

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3. Description of the construction of hot air automated pellet
stove “ERATO Pony PS9”
The heat exchanger of the stove complies with the acting requirements for
such kind of units, defined in operating norm: EN 303-5/2000 – „Heating
boilers for solid fuels, hand and automatically fired nominal heat output up to
300 kW. Terminology, requirements, testing and marking”.
The unit consists of:
•Main part of the unit is heat exchanger. In the combustion chamber of
this exchanger is mounted specialized grate burner, designed for
horizontal fuel feeding;
•The heat exchanger is welded construction of carbon steel plates. The
lower part of the exchanger is designed as combustion chamber. The
burner is mounted in this chamber and under is the ash container.
•Combustion chamber: It is designed to provide conditions for optimal
burning process and helps for complete burning of the fuel. The chamber
is closed by a door with heat-prove glass, giving the possibility to see the
burning process ant also provides direct heat radiation to the surrounding
objects.
•Stainless steel burner, mounted in the combustion chamber of the heat
exchanger;
•Ash container, positioned in the lower part of the combustion chamber,
below the burner;
•Fuel hopper is mounted right behind of the stoves’s burning chamber. In
the hopper (in the center and on angle) is mounted a fuel-auger separator.
•Fresh air for burning is provided by a pipe. The air for burning needs to
be with room temperature. Do not connect the pipe directly to the outside
of the building.
•Flue gases exit duct is positioned in the lower rear side of the heat
exchanger (after the flue gases fan, concerning the flue gases track),
utilized for forced flue gases extraction;
•Control unit it is placed in a cool zone of the stove and provides save
function of the appliance. The control is equipped with a lithium battery,
which has a live time of 5 years – it is used for memorizing the settings of
the control in cases of interrupted main power supply. In order to maintain
save function the stove is supplied with a pressure gadget for monitoring
the functionality of the chimney. In cases of malfunction of the chimney,
that pressure gadget stops the stove immediately, preventing damages to

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the appliance and emergency situations. Also the stove is monitoring the
temperature of the smoke gases. In cases of increased temperatures, above
the save a limit, the stove goes in minimum power, or in critical values
shuts down itself.
•Interface panel is used for set up of the control unit. And to monitor the
work parameters and massages.
•The heat exchanger, fuel hopper and other modules of the stove are
covered with decorative covers painted in different colors.
Figure 3.1. External view and description of the main modules of hot air stove
“ERATO Pony PS9”;
Interface panel of the control
module of the stove
Fuel hopper cover
Decorative guiding screen for
the hot air
Door with fire-prove glass
Handel
Cover for the ash container

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Main dimensions of hot air stove “ERATO Pony PS9” are given in figure 3.2.,
3.3 and 3.4.
Figure 3.2. Front and back view of hot air
stove “ERATO Pony PS9”;
Figure 3.3.Top and left-hand side view of hot air stove “ERATO Pony PS9”

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Main modules/elements of hot air stove “ERATO Pony PS9” are given in figure
3.4.
Figure 3.4. Cross section view and description of the main modules/elements of
hot air stove “ERATO Pony PS9”
Fuel hopper
Fuel-auger
Interface panel of the control
module of the stove
Fuel-auger motor
Pipe for fresh air
Hot air fan
Stainless-steel burner
Flue-gas channel
Flue-gas fan
Ash container
Door of the burning chanber
Guiding plate – back of the burning chamber

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4. Installation process.
Norms and recommendations.
In order to meet the safety requirements is necessary to meet the following:
•At least two people are needed to unpack, move and install the stove. Be
careful not to damage the covers of the stove or the stove itself.
•During transportation you need to take in count the information provided
on the package.
•The moving and placing of the stove needs to be done with proper
equipment, following the safety requirements.
•If lifting equipment is used (cranes, forklifts), do not life the stove close
to them.
•In case of using ropes during transportation, take in count their strength
and condition.
•During transportation keep the stove as straight as possible; do not tilt it
too much.
•During unpacking of the stove be careful not to damage the side covers of
the stove or the stove itself.
•After unpacking take out, of the burning chamber, all the accessories (if
there are any). Also take out all elements used for safe transportation of
the stove (pasteboard, cardboard, plastic)
ATTENTION: Keep all packing materials out of reach of children.
Throw them away in the designated for that purpose places.
Requirements during installation of hot air stove “ERATO Pony PS9”
•The room, dedicated to mount the stove, should be supplied with fresh air
supply duct, necessary for optimal combustion process as well as room
ventilation. Place the stove where it will be easily checked, maintained or
repaired.
PROHIBITED is installing the stove in bedrooms, bathrooms and rooms in
which is installed other heat source without a vent (open fire place for
instance)
•Installation and service procedures should be performed by authorized
qualified and certified personal ONLY;

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•The Stove needs to be installed on a floor with required strength and fire-
resistance. In case of not meeting these requirements you need to chose
other place for installing the stove or to take the necessary actions in order
to improve the place for installation in order to meet the requirements.
Most often the stove is installed on fire-proved floors with size larger than
the stove itself so safety operation is ensured and possibility of fire is
taken to the minimum and also provides easy access for cleaning and
maintenance. The minimum size of the fire-proved floor needs to be
150mm from the sides of the stove and at least 300mm in front of the
stove. In case of using a metal sheet for meeting above mentioned safety
requirements it needs to be at least 2mm thick.
•It is strongly recommended burning objects (wood beams, furniture,
curtains and flammable liquids) to be placed on distance at least 1meter
from the zone of intensive heat radiation. In cases that such objects are
near to the stove, you need to protect them with a lair of fire-prove
insulating material. If the floor is made of flammable material (wood) it is
necessary in front of the stove to be placed protective sheet with size
300mm minimum.
•Before entering the stove in service you need to check the draught of the
chimney and to ensure that the stove is properly connected to the
chimney.
•Maintenance procedures of the boiler should be performed by trained
adult persons, which have read the user manual of the unit;
Installation procedure of the stove requires engineering project for the
heating system, prepared according to the acting local norms and
recommendations as follows:
•To the heating system - EN 303-5/2000 - „Heating boilers. Part 5 :
Heating boilers for solid fuels, hand and automatically fired, nominal
heat output of up to 300 kW. Terminology, requirements, testing and
marking”;
•To the chimney;
•Fire prevention requirements;
•To the power circuit - EN 60335-1/1997- “Household and similar
electrical appliances – safety, Part 1 – General requirements”;

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•Appliance positioning in order to achieve comfortable maintenance.
oMinimal distance of 500mm in front of the unit and any wall should be
provided;
oMinimal distance of 150mm from the rear wall of the unit and any wall
should be provided;
oMinimal distance of 600mm from the right hand side of the unit and
any wall should be provided, in order to guarantee easy access to the
stoves modules;
oUnder the stove is required an unburying stand.
oMinimal distance of 600mm above of the unit and any ceiling(wall)
should be provided, in order to guarantee easy access to the fuel’s
hopper, as well as enough room for cleaning purposes of the heat
exchanger body as well as fuel hopper charging;
oMinimum distance in which can be TEMPORARY placed flammable
materials is 1500mm.
EXPLANATION: The exact distances from flammable objects and
materials must be determent after a consultation with a specialist when are
taken in fact the exact positioning of the stove in the room and the level of
flammability of the surrounding materials and objects.

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During exploitation of the stove the outer services of the appliance get hot
and the surface temperature can exceed the safety limits and to cause skin
burns in contact. The zones with high surface temperatures are shown in
the figure below.
Figure 4.1. Outer view of hot air stove “ERATO Pony PS9” with marked hot
zones which must be taken in count during exploitation (Marked zones are with
temperatures exceeding the safe values and it is possible to cause burns in
contact;
Zone
1
Zone
2

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EXPLANATION: The surface temperature of the marked zone 1can exceeds
80
o
C, the temperature of the glass (marked as Zone 2) of the burning chamber
can rich 280-300
o
C;
•Placing the stove according connection to the power supply: Place the
appliance so a free connection to a power outlet can be easily made
(230V/50Hz). It is prohibited the stove to be installed in room with power
installation mounted on the floor.
•Before connecting the stove to the chimney you must check if the chimney is
cleaned, with the required debit and if it ensures the required draught. Make
the chimney air tide to prevent the possibility of flue gases escaping. The use
of heat resisting silicon is recommended. It is prohibited the use of cement or
cement based materials for packing the chimney. In case of using an existing
chimney it needs to be thoroughly checked for functionality and safe work,
because some untied places can cause flue gases to escape to living area and
to harm the health of the inhabitances. In case of the existing chimney not
being air tide you need to fix so it will be safe to use.
ATTENTION: It is prohibited the direct exhaust of flue gases thru a wall.
The use of chimney is obligatory. The chimney exhausts the flue gases to a
safe height away from the inhabited zone.
In cases of using external chimney (Chimney which is not a part of the
building and it is mounted independently to a side wall of the building.), you
must check the following:
•You must use pre insolated chimneys (“Double pipe”), mounted to the
side of the building;
•In the base of the chimney you must install an opening for cleaning
and maintenance;
•The chimney must be well placed and mounted protected from storms,
wind and rain. Also it needs to meet the minimum distance from the
highest point of the roof.

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EXPLANATION:
•It is recommended the stove to be placed as close to the chimney as
possible so you can minimize the use of elbows and fittings.
•It is prohibited the use of the stove connected to a chimney already used
by another appliance. The stove must be connected to independent
chimney.
•When making the smoke exhaust tract you must check the following.
oThe connecting tract must be with cylindrical shape. The
diameter of the tract must be equal or larger that the diameter of
the exhaust of the stove. The chimney and the tract must be well
insulated in order to prevent cooling of the smoke gases and
decrease in the draught.
oYou must check the strength of the tract. It needs to be without
holes or cracks.
oThe inside surface of the tract needs to be as smooth as possible.
If you use elbows they must be with the maximum possible
radius of curvature, not smaller than twice the diameter of the
tract. In cases of use of long curvatures they need to be with
minimum difference from the straight shape.
oWhen building the chimney you need to make it easy for
disassembly for cleaning and you need to install condense tubs.
oThe exit section of the chimney must be realized in a way
preventing entering of hail, snow or other. And also in event of
strong wind to prevent returning of smoke gases to the building.
oThe chimney needs to be wind-proof. The exit must be above
the highest point of the roof. The exit of the chimney needs to be
away of other buildings.
•The automated hot air pellet stove „ERATO Pony PS9” is different
from the stoves with manual fuel loading – the stove is equipped
with flue gas fan creating under pressure in the burning chamber.
The exit of the chimney is with over pressure, this requires the
chimney to be well packed with heat resistant silicon (up to 250
o
C). The connection with the chimney must be done in a way that in
cases of cleaning and maintenance will not require to be removed.
It is recommended the tract to be made from stainless steel. (Mark
AISI 316) with minimum thickness of 1.0mm. The diameter is
recommended to be 80 or 100mm. It is also recommended the use
of pre insolated pipes (double wall pipes). The making of doors,