Pellas X M-line M350 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 ..........................................................................4
2.1. Construction of M350 and M500 burners...............................................5
2.2. Quality requirements for pellets fuel.....................................................6
2.3. Burner nameplate template.................................................................6
2.4. Technical data ...................................................................................7
2.5. Safety systems................................................................................ 10
2.6. Technical data of controller, description of functions and burner settings .10
3. INSTALLATION ......................................................................................11
3.1. Chimney .........................................................................................11
3.2. Boiler / oven ................................................................................... 11
3.3. Fuel hopper..................................................................................... 14
3.4. External feeder................................................................................14
3.5. STB protection.................................................................................15
3.6. Boiler temperature sensor................................................................. 15
4. BURNER AND FEEDER ASSEMBLY ............................................................16
4.1. Installation in boiler ......................................................................... 16
4.2. Connecting the feeder ......................................................................17
4.3. Connecting the controller..................................................................17
5. ADDITIONAL CONNECTIONS AND FIRST STARTUP.....................................18
6. EXPLOITATION AND SAFETY REGULATIONS ..............................................18
6.1. Exploitation.....................................................................................18
6.2. Maintenance of furnace ....................................................................18
6.3. Specification of the inspection intervals. .............................................21
6.4. Scope of operational activities ...........................................................22
6.5. Safety regulations referring to installation and exploitation of burner .....22
6.6. Guarantee....................................................................................... 23

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7. SERVICE OF DEVICES ............................................................................23
7.1. Photosensor ....................................................................................23
7.2. Electrical igniter replacement.............................................................24
7.3. Feeder pipe cleaning.........................................................................24
7.4. Burner cleaning ...............................................................................24
8. TROUBLESHOOTING 25
9. ELECTRICAL SCHEMES ...........................................................................26
9.1. Electrical scheme of PellasX controller.................................................26
9.2. Electrical scheme of M350 / M500 burners ..........................................26
10. REPORTS ............................................................................................27
10.1. First start-up report........................................................................27
10.2. Inspection report............................................................................28
11. LIST OF PICTURES AND TABLES ............................................................29
12. NOTES................................................................................................30
The author of this Manual is the company PELLASX 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.
PellasX 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 guaratee.
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.
1.1. Transportation
PellasX burner (with mounting flange and a feeder) is shipped in wooden crate on a 1200x800mm
pallet. Electronic parts (controller and sensors) are packed in separate box. 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
PellasX 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%.
•During storage, the device can not have direct contact with the floor. PellasX 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.

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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.
2. PRODUCT DESCRIPTION
PellasX 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 M solution is the number of the design improvements used as compared to
the burners available previously with the movable combustion chamber. This makes the operation
of M 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.
Movable combustion chamber allows the automatic and constant removal of ash being the residue
of the combustion process to ensure high stability of the combustion itself. With such a solution not
just the pellets, but also oat* or fruit stones are high-efficiency fuels. The chamber structure
ensures higher durability of the bearings and facilitates the quick bearings replacement.
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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The unique solutions employed in the M line burners include:
•Mesh Furnace System – the system of modular heat-resistant plates forming the furnace
ensures the self-cleaning process through the reciprocating movement of the grate. It is
possible to adjust the stroke depending on the type of fuel burned;
•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;
•Cell Feeder System – provides precize dose of fuel at a given burner power. Moreover
provides protection against flashback thanks to the three-section feedeng chamber;
•Overpressure Combustion System –Air is supplied into the combustion chamber at the
central point to increase the flame spin and reduce the backfire.
•Lambda probe –available for all units to improve the combustion process and reduce the
fuel consumption.
PellasX burners are used in households, bakeries, hotels, public utilities, schools and production
halls or warehouses. They are made of heat-resistant acid-proof steel and 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.
*Using oat fuel reduce burner power and result in increased fuel consumption (up to 50%) and
increased ash production.
2.1. Construction of M350 and M500 burners.
Pic. 1. Construction of M350 and M500 burners.
The burner is composed of the following subassemblies:
•combustion chamber consisting of inCrox cast steel grate (1) and ceramic insulation (2);
•blower assembly with steel cover (3) and X.PLUG socket (4) where the controller plug is to
be connected;
•Blowing system (5) located between the blower assembly and the combustion chamber, with
stub pipe (6) where polyurethane pipe from external feeder is to be connected.
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.
ATENTION!
The manufacturer reserves the exclusive right
to implement any modifications in construction
of burner and feeder, its software and wiring,
otherwise it is released from any liability to the
buyer.
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3
4
5
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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 prior to
the hopper filling the pellet temperature is equal to the boiler room temperature.
Table 1. Quality requirements for pellet fuel.
Wooden pellet
Units
CERTIFICATE
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)
Ash melting temperature
-
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
2.3. Burner nameplate template
ATTENTION!
Change of pellets diameter during using of
burner (e.g. from 6mm to 8mm) requires
regulating the controller by a qualified
installer.

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Pic. 2. Burner nameplate template.
2.4. Technical data
Main properties of PellasX burners from M-line:
Safety
•Overpressure Combustion System – flashback protection;
•Burner temperature sensor;
•Polyurethane pellet feeding pipe – melts in case of flashback, cutting the fuel supply.
Reliability
•Movable Grate System – removal of excessive amount of ash from grate without human
intervention;
•Mesh Furnace System – increases the lifetime of grate;
•Cell Feeder System – provides precize dose of fuel at a given burner power. Moreover pro-
vides protection against flashback thanks to the three-section feedeng chamber;
•Hybrid Drive System – supplying fuel and air in a synchronized manner, while reducing
power consumption;
•Automatic start after power failure with memory of the last settings;
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 boilers and with bakery ovens
•Possibility of handling the chimney exhaust fan (the fan works periodically and does not
ventilate the boiler)
Table 2. Technical data.

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Type
M350
M500
Heating power
65 - 350 kW
75 - 500 kW
Power supply
230 V AC / 50Hz
230 V AC / 50Hz
Average power consumption
350 W
350 W
Weight
170 kg
200 kg
Noise emission
73 dB
73 dB
Feeder’s length
3 m
3 m
Fuels
pellet 6-8 mm
pellet 6-8 mm
oat*
oat*
dry pit
dry pit
Burning efficiency
do 99 %
do 99 %
Efficiency in boiler
do 96 %
do 96 %
Power modulation
YES
YES
Lambda probe
YES (optional)
YES (optional)
CH pump service
YES
YES
DHW pump service
YES
YES
Mixer service
YES
YES
Buffer service
YES (optional)
YES (optional)
Additional feeder service (silo)
YES (optional)
YES (optional)
Room temperature sensor
YES (optional)
YES (optional)
Return temperature sensor
YES (optional)
YES (optional)
Fumes temperature sensor
YES (optional)
YES (optional)
Weather automatics
YES (optional)
YES (optional)
*Using oat fuel reduce burner power and result in increased fuel consumption (up to 50%) and
increased ash production.
PellasX burner has simple and compact construction, which allows for easy assembly in boiler’s
door. Pictures below show the dimensions of burner and mounting holes.

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Pic. 3. Dimensions of M350 burner.
Pic. 4. Dimensions of M500 burner.

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2.5. Safety systems
PellasX burner is equipped with following safety systems, which effectively protect the user against
flashback of fire:
1. Burner temperature sensor
The sensor, once it detects temperature over 90°C (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. Cell Feeder System
Cell feeder provides precize dose of fuel at a given burner power. Moreover provides protec-
tion against flashback thanks to the three-section feedeng chamber;
3. Overpressure Combustion System
Air is supplied into the combustion chamber at the central point to increase the flame spin and
reduce the backfire.
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.
Inspection of safety systems - see chapter 6.2: Specification of the inspection interval.
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 PellasX 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 3. Minimum chimney draft.
BURNER TYPE
MINIMUM CHIMNEY DRAFT [Pa]
M350
50
M500
55
3.2. Boiler / oven
PellasX burners can be installed in majority of boilers. The power of burner in relation to boiler or
oven power must be adjusted by installer. The burner is fixed (preferably in boiler’s door) with 4pcs.
M10 screws (dimensions of fixing holes in Pic. 5). The boiler chamber needs to fulfill minimum size
requirements given in tables 4 – 6. If boiler chamber i stoo small, the burner may operate
incorrectly.
Pic. 5. Cut-out dimensions and fixing holes positions.
* - minimal cut-out dimension for
M350/M500 burners.

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Pic. 6. Fixing of burner in the boiler.
Pic. 7. Positioning of burner and direction of flame.
A
H
L
Fix the burner with M10 screws (length of the
screw depends on boiler wall thickness)

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Table 4. Minimum dimensions of furnace chamber.
TYPE OF BURNER
MINIMUM DIMENSIONS OF FURNACE CHAMBER
MINIMUM DIMENSIONS OF
FURNACE CHAMBER [m3]
MINIMUM LENGHT OF
FURNACE CHAMBER [mm]
M350
0,313
1400
M500
0,450
1500
Tabele 5. Exemplary minimum dimensions of rectangular furnace chamber.
TYPE OF BURNER
EXEMPLARY MINIMUM DIMENSIONS OF RECTANGULAR
FURNACE CHAMBER
WIDTH A [mm]
HEIGHT
H [mm]
MINIMUM LENGHT OF
FURNACE CHAMBER L
[mm]
M350
445
500
1400
M500
500
600
1500
Table 6. Exemplary minimum dimensions of cylindrical furnace chamber.
TYPE OF BURNER
EXEMPLARY MINIMUM DIMENSIONS OF CYLINDRICAL
FURNACE CHAMBER
MINIMUM DIAMETER OF
CHAMBER D [mm]
MINIMUM LENGTH OF FUR-
NACE CHAMBER L [mm]
M350
515
1400
M500
620
1500
Table 7. Pressure in burning chamber .
TYPE OF BURNER
PRESSURE IN BURNING CHAMBER [Pa]
M350
50
M500
55

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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.10). 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 ordisintegrating fuel.
It can cause difficulties in operation of burner – burner blockade
3.4. External feeder
Pic. 8. Feeder’s construction.
Fuel feeder connects fuel hopper with burner. It consist of three galvanized steel pipes (1, 2, 3).
Inside the pipe, there is a steel spiral (4), driven by electrical engine (5) with gearbox (6). The
motor is connected to inventer in control cabinet. (see electrical scheme). The lower end of the
feeder is mounted in the lower part of the fuel hopper and its upper part is connected to the burner
with the flexible polypropylene pipe (13).
Feeder assembling scheme (pic. 8):
1. Connect the pipes (1), (2), (3) with two connectors (7) by tightening fixing screws;
2. Inset the pin (8) into the shaft hole (9), then screw the spiral (4) on the pin (8).Secure
the spiral by tightening M12 nut (10) on pin;
1
2
3
4
6
5
7
8
9
10
11
12
13
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3. Put the shaft (9) in the motorgear opening (6). Secure the shaft with M8 screw with
washers (14)
4. Slide the spiral to the pipe. Mount the motorgear (6) on the pipe flange using M10x85
screws (11) and M10 nuts with the washers (12);
ATTENTION: The spiral should end in the middle of opening in the feeder (pic. 9). In case of the
spiral being too long, cut it to proper length.
Pic. 9. Feeder’s spiral position.
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. 10. 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.
4.1. Installation in boiler
Mounting scheme for M350 and M500 burners (pic. 11):
•Make sure that insulation plate [1] is put on furnace pipe.
•Insert the burner’s furnace [2] into the boiler’s mounting hole and fix it with 4pcs M10
screws.
•Because of high weight (170-200kg), montage of the burner should be carried out by more
than one person. For lifting the burner, it is recommended to use a crane or gantry. For this
purpose use lifting eye with M12 male thread (pic. 12) mounted into hole on top of burner
[3]
ATTENTION!
Before starting dismantling
or disassembly entire power supply
must be disconnected.