Pelltech PV 20a User manual

Pellet burner PV 20a
User manual

PV 20a
Table of content
Table of content.....................................................................................................................................2
Description.............................................................................................................................................4
Fuel.....................................................................................................................................................7
Installation..............................................................................................................................................7
Boiler requirements................................................................................................................................8
Burner............................................................................................................................................... 0
Pellet container................................................................................................................................
External auger.................................................................................................................................. 2
Electrical connections....................................................................................................................... 2
Operation............................................................................................................................................. 4
Starting............................................................................................................................................. 5
Log.................................................................................................................................................... 5
Settings............................................................................................................................................. 6
Info Menu......................................................................................................................................... 7
Languages......................................................................................................................................... 7
Refilling fuel...................................................................................................................................... 8
Maintenance.................................................................................................................................... 9
Working principle.................................................................................................................................2
Testing..............................................................................................................................................2
Loading.............................................................................................................................................2
Igniting..............................................................................................................................................2
Preburn.............................................................................................................................................2
Burning.............................................................................................................................................22
Auger control................................................................................................................................22
Fuel level detection......................................................................................................................22
Output power levels ....................................................................................................................22
Hold flame........................................................................................................................................22
End burn...........................................................................................................................................23
End blow...........................................................................................................................................23
Controller board description................................................................................................................24
Problems and solutions........................................................................................................................26
Warranty..........................................................................................................................................27
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PV 20a
Safety precautions
Do not start the burner before it is connected to the boiler and the boiler is connected to the
chimney.
It is recommended to wear a respirator while handling pellets.
The boiler room where the burner is installed must fulfill all rules and recommendations given by
authorities.
All electrical connections must be done by trained professionals.
No flammable materials must be stored near the burner.
Warnings
Changing the construction of the burner without written permission from the
manufacturer is forbidden.
Use only spare parts provided or approved by the manufacturer in order to avoid
any damage to the burner and dangers resulting from it
Welding is allowed only after disconnecting the burner from electric supply. The
circuit board must be removed from the burner.
Do not open any boiler door while the burner is in operation.
The burner complies with following directives and standards
Directive 2004/ 08/EC
Directive 2006/95/EC
Directive 200 /95/EC
Directive 2006/42/EC
EN 5270 2008
EN 230 2005
EN 60370-2-5 2002
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PV 20a
Package content
The burner is shipped with following components included:
. Grate
2. Burner
3. Brackets for hose ( x)
4. Flange
5. Ceramic seal
6. 7-pole boiler connector
7. Hose
8. User manual
Description
PV 20a is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. You cannot use
any other fuel to run this burner.
The unique construction of PV 20a allows it to be used with different boilers: liquid fuel, solid fuel
and universal boilers. The PV 20a burner is connected to the boiler with a 90 mm flange (similar to oil
burners).
The burner is equipped with a safety thermostat, a melting chute, temperature sensor and auxiliary
battery for protection against back-burning.
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PV 20a
Burner main components are shown on Figure
1. Burning chamber
. Feed screw
3. Safety cut off thermostat
4. Mains transformer
5. User interface joystick
6. User interface screen
7. Auxiliary battery
8. Connectors
9. Feed screw motor
10. Fan
11. Fuel level sensor
1 . Mounting nut
13. Flame detector
14. Igniter
15. Grate
Figure 1 Burner main components
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PV 20a
Figure Dimensions
Table 1 Specification
Unit PV 0a
L total length mm 530
L1 burner body length mm 230
L burning chamber length mm 70
⌀D burning chamber diameter mm 46
⌀D1 burning chamber neck diameter mm 88.9
⌀D internal feeder inlet diameter mm 60
H total height mm 250
H1 burner housing height mm 200
W total width mm 220
W1 burner housing width mm 204
Mass kg .2
Supply voltage VAC 220-240
Power max W 570
Power average W 25 - 40
Power at standby W 7
Noise dB 52
Emission class1- 5
Operating temperature Co0-60
Nominal heat input kW 20
Min heat input kW 0
. According to EN 5270
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PV 20a
Fuel
PV 20a uses premium wooden pellets as fuel. Wood pellets are concentrated and homogenized fuel
made from sawdust and cutter shavings. Pellets are pressed with high temperature. No extra
materials are added, pellets are held together by a natural ingredient found in wood – lignin. Pellets
are CO2-neutral, renewable fuel. Pellets must be stored in a dry and ventilated room. It is
recommended to wear a respirator when handling pellets.
Only premium class pellets can be used with PV 20a. Refilling must be carried out before the storage
runs empty. In case it happened, burner has to be restarted and the loading time can be up to 20
minutes that external auger has enough time to refill itself.
Table Pellet properties
Raw material sawdust and cutter shavings
Calorific value 4700-5 00 kWh/ton
Volume weight ca 650-670 kg/m3
Volume of 1 ton .5- .6 m3
Diameter 6- 0 mm
Length 3-5 x diameter
Water content 8- 0 %
Ash content Ca 0.5%
To replace 1000 l light oil ca 2 tons or 3 m3
Installation
You will need the following tools in order to install the burner:
•Spanner no. 3 for fixing the flange of the burner to the boiler
•Spanner no. 0 for connecting the body of the burner with the burning camber
•Cross-head screwdriver for fixing the cover of the burner
•4 mm hex wrench for fixating the boiler to the flange
In order to install the burner, the boiler must correspond to the following requirements:
•The door of the boiler must have a 90 mm opening (placement opening for the oil burner).
•The thickness of the boiler door must be less than 00mm
•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 room where the burner is installed must fulfill all rules and recommendations
given by authorities.
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PV 20a
•The boiler must be positioned in a way that there is enough space for cleaning the burner,
the boiler and the smoke pipe and removing the ash.
If flue gas temperature at the top of the chimney is less than 80Co, there is a risk of condensation. In
this case a pipe should be installed throughout the length of the chimney.
Note: It is recommended to use a flue gas analyzer for adjusting the burner. The burner must be
adjusted using the flue gas analyzer also when you change the size or the quality of the pellets.
Boiler requirements
Pellet burners need regular cleaning and therefore boiler construction must allow the door to be
opened without removing the burner. The minimum size of opening in boiler depends on the
position of door hinges and vice versa. Figure 3 below illustrates the situation. Point C is critical.
In order to keep door width minimum and boiler opening small, a double hinge solution can be used.
As double hinges add another degree of freedom, door must be fastened on both sides. Slide-out
doors with guide rails is also an option.
Figure 3 Hinge position and boiler opening size considerations
Figure 4 Double hinges
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PV 20a
Boiler firebox length L (Figure 5) should be at least 2,5 x the length of the burning chamber. For PV
20a, minimum of 420mm is acceptable (leaving L approx. 250mm). The height should be enough to
leave H below the burner about 00mm for ash.
Minimum dimensions L and H for PV 20a: L≥420mm; H≥350mm.
Figure 5 Boiler firebox requirements
Burners are mounted to door using supplied oil burner flange. Bolt hole circle diameter and bolt sizes
can be customized by using custom flanges. D and D2 given in Table 3 are only valid with supplied
flanges.
Table 3 Mounting holes for boiler door
Unit
⌀D hole for burning chamber neck mm 90
⌀D1 flange bolt ring diameter mm 30.. 50
⌀D bolt holes mm 8..9
Figure 6 Mounting holes with supplied flanges for boiler door
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PV 20a
Burner
In order to install the burner properly, you must go through the following steps:
. Remove the cover of the burner by loosening 4 screws of the cover. There is no need to remove
the screws.
2. Remove the burning chamber from the burner by releasing the M6 nut that connects the halves of
the burner. Separate the halves of the burner by pulling the burning camber and slightly rotating it at
the same time.
3. Fix the flange (2) of the burner to the door of the boiler ( ). Make sure that the opening of the
flange and the opening of the boiler door are aligned.
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PV 20a
4. Fix the burning chamber (8). For that you need to put a ceramic seal (4) on the narrower side of
the burning chamber and then put the camber through the door of the boiler in a way that the
rearward wall of the burning chamber would lean on the door of the boiler. Fixate the burning
chamber with two grub screws ( 0) to the flange.
Caution! The burning camber must be placed in a way that the burning grate will be as horizontal as
possible. The connection between the burner and the boiler must be tight in order to avoid any
leakage of smoke gases.
5. Connect the body of the burner to the burning chamber like it was done before disassembling in
step 2.
6. Fixate the halves of the burner with a M6 nut (9). The nut has to be rolled tight but not too hard.
The halves of the burner are connected correctly when there is no space between the mark on the
connecting tube (a line drawn on the tube with a dark marker) and the body of the burner.
7. Make sure the halves of the burner are connected correctly. Make sure that when looking through
the fire tube the igniter end tip is at the same level with the wall. The tube of the inner auger must
reach through its opening.
Caution! After the installation of the burner always make sure that the end of the igniter is
positioned through its opening and not stuck behind the dividing wall.
Pellet container
The burner, the auger and the pellet container are a common system. The size and the location of
the pellet container depend on the needs and possibilities of the specific boiler room. While choosing
the pellet container you must keep in mind that:
•If the pellet container is in the same room as the boiler, then the size of the pellet container
must not exceed 500 liters (approx. 350kg).
•The container must be made of fireproof materials.
•The container must be positioned in a way that the raising angle of the feeding auger does
not exceed 45°.
•It is advisable to use a container that can be closed with a cover.
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PV 20a
External auger
A feeding 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. The hose is made of
melting material that acts as a safety measure against back-burning. The uppon side of auger (with
motor) must be fixed to a storage or to some other object nearby (with delivered chain) .
Figure 7 shows correct position for external auger. As the hose is a safety device, it must be placed
strictly as described below. The vertical distance between auger outlet and burner inlet must be in
range of 40..70cm and horizontal displacement 0..20cm (typical auger angle 30o..45o). External
auger cannot be installed in position with angle greater than 45o. The hose must be in angle of 50o or
more to ensure free falling of the fuel.
Figure 7 External auger installation (units in mm)
Electrical connections
The burner is equipped with a standard oil burner plug that has 7 contacts. There will be different
connection schemes used for different boilers. Usually the burner is connected to the boiler with a 5-
wire cable. It is also possible to connect with a 4-wire cable.
Caution! All electrical connections of the burner must be made by a qualified professional.
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Figure 8 Burner 5-wire connection Figure 9 Burner 4-wire connection
Chs – Chassis grounder R – Flame sensor
M – Fan SBB – Controller board
M2 – Flue gas fan* Se – Igniter
M3 – External auger TR – Transformer
M4 – Internal feeder Tt – Boiler thermostat
Ot – Safety thermostat
*Flue gas fan M2 is installed only if there is not enough draught. The flue gas fan is not included with burner.
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PV 20a
Operation
The burner is controlled via user interface on the front panel. LCD screen ( ) 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. To move in menus, use up and down buttons (4), to change parameter, press
OK, to go back to LOG press “ESC” button.
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PV 20a
Figure 10 Front panel
Starting
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 boiler thermostat is turned to lowest temperature
•The external auger 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
boiler must stay between 4-6 Pa
To turn on the burner, switch on boiler main switch. If burner displays ’Stopped’, then go to settings
menu and change parameter ’Burner’ from OFF to ON. The display shows ’Waiting’. Now turn boiler
thermostat to desired temperature. The burner will go to Loading-state. If this is the first run, extern-
al auger needs to be filled with pellets. It can take up to 20 minutes.
To stop the burning, turn boiler thermostat to lowest point. The burner will now finish the process
after all fuel is burnt.
Caution! Never turn off a working burner from the main switch of the boiler. Use the thermostat
switch for that purpose. In order to stop safely, let the burner burn empty. Do not leave the burner
unattended when it has been necessary to use the emergency stop.
Log
Log screen displays last events (burner states) and their duration. All states are described in Table 4.
The duration is in form mm:ss (’m’ in the middle) or hh:mm (’h’ in the middle). For example ’Igniting
0 m25 means the burner ignition state lasted minute 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.
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Table 4 Burner states
Status Description
STOPPED The burner is not switched on.
WAITING The burner is switched on and waiting for command from the thermostat of the
boiler.
TESTING Testing the fan, battery, feeder.
LOADING Loading pellets into burner for ignition after the command from boiler thermostat.
LOADING Second try if the first ignition was not successful.
IGNITION Loaded amount of pellets are in the burning chamber, igniter and fan are working till
photocell recognizes flame.
PREBURN Only the fan is working, the igniter is off. Pellets start burning properly.
BURNING Status of normal working: External auger works by level sensor, internal auger and
fan are working by. Photocell must see the flame.
HOLD FLAME Boiler has reached an estimated temperature and boiler thermostat switched off,
pilot flame is held in the burning chamber.
BURN END Boiler has reached an estimated temperature and boiler thermostat switched off the
burner. The external auger has stopped, the internal feeder and fan are still working
until all fuel is burned.
END BLOW When photocell doesn`t see any flame only the fan keeps on working with minimum
speed in order to make sure there is no fuel in burner.
NO PELLETS Level sensor does not detect pellets
NO FLAME There is no flame in the burner more than 20 seconds during burning.
OVERHEAT Temperature in the burner has reached preset temperature and burner turned off.
IGN.ERROR Flame is not recognized after ignition
LEVEL ERR Level dose not reached or level dose not disappear at burning time
FEEDER ERR Jam in feeder or feeder rotation is not detected
FAN ERROR Fan rotation problem
BATTERY LOW Battery is not connected or empty
NO POWER Supply power is not detected – burner works on battery
Settings
To enter settings menu, press OK. To go back to log screen, press ESC.
Table 5 Main menu
Men
u nr
Menu
parameter ENG
Description Default
value
Selection list
STATUS-> Submenu for status information *
2 INFO-> Information from burner devices *2
3 BURNER Turn burner ON/OFF OFF ON/OFF
4 HOLD FLAME Flame holding allowed *3OFF ON/OFF/AUTO
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5PELLETS Select fuel quality NORMAL NORMAL/LIGHT/HEAVY
6POWER Actual power level AUTO AUTO/ 0/ 2/ 4/ 6/ 8/20
7BASE AIR Fan speed correction for all fan
speeds
0 -2/- /0/+ /+2/+3/+4/+5
8LANGUAGE Language selection *4ENG See language list
9PARAMETERS -> Parameter setup menu
*1 – see “Status menu description”
*2 – see “Info menu description”
*3 – see “H LD FLAME” status description
*4 – see “Languages” chapter
Info Menu
To enter info menu, move in the main menu until the row INFO and press OK. Content of info menu
is following:
TOTAL = total amount of pellets burned with this burner. Amount is updated after every 0 kg.
COUNT = amount of pellets burned since last zero. Amount is updated after every 0, kg. To zero the
amount, be sure you are in this menu and hold down OK for 5 sec.
FAN = fan rotation speed as it is / fan rotation speed as it should be ± base air (selected base air in
the main menu)
P = currently working power/ power as it should be
T = burner internal temperature
U = Battery voltage level
I = Feeder current
DRAUGHT = when underpressure sensor is connected, draught is shown.
Languages
To change the burner language, move in the main menu until the row LANGUAGES and press OK.
Choose the requested language and press OK. Burner has following languages: english (ENG),
estonian (EST), finnish (FIN), french (FRA), german (GER), greek (GRE), latvian (LAT), lithuanian (LIT),
dutsch (NED), portuguese (POR), russian (RUS), serbian (SRB), spanish (SPA), slovakian (SLV), swedish
(SWE).
Table 6 Parameters menu
Parameter Description Unit Value
Nr Name Default Min. Max.
BURN AIR @ 0kW Fan speed at power level rps 22 20 24
2 BURN AIR @ 2kW Fan speed at power level 2 rps 25 23 27
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PV 20a
3 BURN AIR @ 4kW Fan speed at power level 3 rps 27 25 29
4BURN AIR @ 6kW Fan speed at power level 4 rps 30 28 32
5BURN AIR @ 8kW Fan speed at power level 5 rps 34 32 36
6BURN AIR @20kW Fan speed at power level 6 rps 38 36 40
7 TESTING AIR Fan speed for testing rps 42 38 50
8IGNITION AIR Fan speed during ignition cycle rps 25 20 35
9BURN END AIR Fan speed durinf end blow cycle rps 20 0 30
10 HOLD FLAME AIR Fan speed during hold flame cycle rps 0 7 4
11 HOLD FLAME ON In case of Hold flame is set on AUTO,
flame holding activated after 2 waiting
session, both less then 5 min.
min 5 5 30
1 HOLD FLAME OFF In case of Hold flame is set on AUTO,
there is maximum time for flame
holding cycle.
min 60 30 90
13 MIN POWER Minimum power level kW 2 0 20
14 MAX POWER Maximum power level kW 8 0 20
15 AUTO POWER UP min 60 30 20
16 AUTO POWER
DOWN
min 30 5 45
1 PELLET NORMAL Internal feeder production g/rot 33 28 38
PELLET LIGHT Internal feeder production g/rot 3 28 38
3 PELLET HEAVY Internal feeder production g/rot 35 28 38
4 LOADING FEED Feeder turns during loading cycle rot 2 20 24
5 LOADING 2 FEED Feeder turns during second loading
cycle
rot 3 8
6 BURN END FEED rot 5 0 20
30 SMOKEFAN ON 0- OFF, - ON 0/ 0 0
31 SMOKEFAN Smokegas fan speed for ignition, end
blow, burn at power level and 2
% 40 0 00
3 SMOKEFAN 2 Smokegas fan speed for burn at power
level 3 and 4
% 60 0 00
33 SMOKEFAN 3 Smokegas fan speed for burn at power
level 5 and 6
% 80 0 00
40 PHOTOCELL Photocell sensitivity % 84 50 00
41 PREBURN TIME Preburn cycle lenght s 50 30 00
4 PREBURN CYCLES n 2 4
43 OVERHEAT TEMP Maximum allowed burner
temperature
°C 50 20 70
50 ON ERROR RELAY Error output relay contacts (ON - NO
or OFF -NC)
ON ON/OFF
99 MODEL VERSION Load default settings for chosen
burner model or change model type
0 20a 20a/30a/50a/
00a
Refilling fuel
The fuel storage must be refilled before it runs empty. Fuel can be added at any time during the
operation. To add fuel, simply pour a new bag of pellets into your fuel storage.
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PV 20a
If the storage runs empty before new fuel is added, the external auger must be loaded again as
described in chapter Starting. Failing to do so will result ‘No Pellets’ due to fuel loading timeout.
Maintenance
Pellet burner PV 0a requires systematic maintenance. The maintenance period depends on the
quality of the pellets and heating intensity. The average maintenance period is week. The burner
needs cleaning when the ash layer on the grate is thicker than .5-2 cm. As even high quality pellets
contain 0.3-0.5% ash, then the burning grate must be cleaned at least once a week. Depending on
the quality of the pellets, it might be necessary to clean the burner more frequently.
To clean the burner:
. Turn off the burner by turning the thermostat to 0.
2. Let the burner cool down for at least hour.
3. Open the boiler's door to gain access to burning chamber
4. Remove the grate and clean it from any residue. Make sure all holes on the plate are clean.
5. Remove ash from burning chamber.
6. 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.
7. Put back the grate. Make sure the stopper of grate is touching the burning camber from
inside. Misaligned base plate will change the air flow and reduce burning efficiency.
8. Close the boiler's door to finish the maintenance and turn the thermostat to desired
temperature.
NB! The burner grate must be checked and cleaned once a week. This assures trouble-free and
effective operation of the burner.
The connection between the boiler and chimney must be completely tight. All cleaning and
maintenance openings must be closed with covers.
Feed screw motor
The condition of the feeding screw motor is crucial for safety. Therefore the motor must be replaced
after every 2000 working hours or after 40-50 tons of pellets are burned or when the burner gives
warning. Burnered pellets amount (in kg) is accessible from info-menu.
Battery
Battery must be replaced when the burner gives warning message or after 5 years. As the battery is
also safety device, burner monitors the state of battery and blocks next work cycle if battery voltage
is not within limits.
Fan
The air in boiler room contains dust that can deposit on fan bearings. The best cure is to keep boiler
room as clean as possible. Otherwise the fan bearings can get stuck after several years of working
and must be replaced.
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Resetting safety thermostat
In case of overheating the burner flashes yellow indicator and displays message OVERHEAT. The
safety thermostat must be reset manually. Thermostat is located on the horizontal tube of inner
auger.
. Make sure the burner has cooled down and disconnected from power supply.
2. Remove the cover by loosening 4 screws (2 on both sides)
3. Press small button on thermostat.
4. Connect power supply
5. Press OK for 5s
6. If indicator keeps flashing, you need to replace the thermostat.
Figure 11: Resetting the
safety thermostat
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