Pellas X HYBRID series 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 +5OC 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.