Pelltech PV1000agri User manual

PV1000agri pellet burner
User manual
POOLELI - DRAFT
DK9401A1

PV1000agri pellet burner
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1 Contents
2 Description ............................................................................................................................................ 4
2.1 Main components ......................................................................................................................... 5
2.2 Specifications................................................................................................................................. 7
3 Installation........................................................................................................................................... 10
3.1 Prerequisites................................................................................................................................ 10
3.2 Burner .......................................................................................................................................... 11
3.3 Water sprinkler............................................................................................................................ 20
3.4 External auger ............................................................................................................................. 21
3.5 Pellet storage............................................................................................................................... 22
3.6 Electrical connections.................................................................................................................. 22
3.7 Commissioning ............................................................................................................................ 27
4 Operation and maintenance ............................................................................................................... 28
4.1 User interface.............................................................................................................................. 28
4.2 Starting and stopping .................................................................................................................. 30
4.3 Statuses and parameters............................................................................................................. 30
4.4 Cleaning ....................................................................................................................................... 38
4.5 Replacing components ................................................................................................................ 38
5 Optional components.......................................................................................................................... 40
5.1 GSM Modem ............................................................................................................................... 40
5.2 Flue gas fan.................................................................................................................................. 41
6 Common problems and solutions ....................................................................................................... 42
7 Annex A –Parameters ......................................................................................................................... 43
8 Annex B –Burner status change logic ................................................................................................. 47
9 Annex C –Controller board description .............................................................................................. 49

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Tables
Table 1 PV1000agri connectors ( * optional extras) ................................................................................... 22
Table 2 Info menu description .................................................................................................................... 30
Table 3 Summary of burner statuses .......................................................................................................... 30
Table 4 List of tests in TESTING status......................................................................................................... 31
Table 5 Cleaning parameters....................................................................................................................... 31
Table 6 Loading parameters........................................................................................................................ 32
Table 7 Ignition parameters ........................................................................................................................ 33
Table 8 Pre-burn parameters ...................................................................................................................... 33
Table 9 Heat-up parameters ....................................................................................................................... 34
Table 10 Power levels.................................................................................................................................. 34
Table 11 Hold flame parameters................................................................................................................. 36
Table 12 End burn parameters.................................................................................................................... 37
Table 13 End blow parameters.................................................................................................................... 37

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2 Description
PV1000Agri is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. Due to the
unique design of the burning chamber you can use industrial pellets to fuel the burner. You cannot use
any other form of fuel to run this burner.
The construction of the burner allows it to be used with different boilers: liquid fuel, solid fuel and
universal boilers. The burner is connected to the boiler using a connection plate.
The burner is equipped with a safety thermostat, a melting hose, temperature sensor, sprinkler system
(optional) and auxiliary battery for protection against back-burning.

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2.1 Main components
14
15
13
5
15
1
2
3
4
5
6
7
16
17
5
18
20
7
12
11
10
9
8
19
21

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No
Name
Description
1
Burning chamber
The part of the burner that is inside the boiler and where pellets are burnt.
2
Burner body
The part of the burner that is outside the boiler.
3
User interface
Screen, navigation buttons and indication lights. For more information, please see chapter
4.1
4
Control box
Contains inverters, fuses, relays, main controller board etc.
5
Water sprinkler
Sprinkler system will spray water to extinguish the fire in case of back burning. The sprinkler
system is only activated when the temperature of inner auger rises dangerously high.
6
Grate cleaning
motor
Linear motor moves the grates in burning chamber and pushes ash out from burning
chamber. This cleaning cycle is made periodically. The interval between cleaning cycles can
be managed by parameter 48. In each cleaning cycle, the linear motor pulls grates back then
pushes the grates completely out and then pulls the grates on the half way. The linear motor
has 75mm stroke and end switches for stop. Linear motor current limit can be set by
parameter 47. There is also fuse F10 installed on the controller board (board version BBB
v2.1)
7
Igniter
Igniter´s purpose is to ignite loaded fuel making the burning process start. Igniter is installed
on the burner together with igniter holding pipe. PV1000agri has total four igniters.
8
Brick temperature
sensor
A sensor to adjust burner start up speed according to temperature rise. Brick temperature
rise speed must be controlled to extend its lifetime.
9
Cleaning hatch
Hatch below burning chamber to ease the removal of ash under grates.
10
Grates support
frame
Holds moving and stationary grates in correct position.
11
Grates
Cast iron grates form fire bed and distribute combustion air through holes in grates. Some of
the grates are moving to periodically clean the burning chamber.
12
Fire bricks
Heat resistant bricks that cover the burning chamber. Bricks are necessary for proper airflow
and combustion.
13
Flame sensor
Photocell´s purpose is to recognize flame in the burning chamber.
14
Level sensor
Optical fuel level sensors recognize the fuel level in the vertical pipe. Fuel is recognized when
pellets pass the optical beam between sensors.
15
Combustion air
fans
Left –primary
Right - Secondary
Primary fan delivers main burning air needed for gasification of the fuel. Primary air is also
used to burn the gasified fuel (charcoal) and to ignite the pellets together with igniters.
Secondary fan blows air through burning chamber back-wall and holds burning quality and
optimal flue gas content. If oxygen sensor (optional) is used the secondary fan speed is
regulated by oxygen level in flue gases.
Both fans rotation speed is measured by sensor, installed near the impeller axle. The sensor
is reading magnetic field changes caused by magnet installed on the impeller axle.
16
Controller board
Controller board controls the burner´s burning process, by calculating fuel amount also
feeder and auger work during burning process. Depending on the input signals from the
sensors, controller makes necessary changes to the output states to maximize burning
efficiency. Controller has a single control board.
17
GSM modem
(optional)
A GSM modem enables burner to send SMS messages with various information of burner´s
operating states (errors). GSM modem is located in controller unit. More information in
chapter 5.1
18
Internal feeder
motors
Internal feeders are used to deliver correct amount of fuel into burning chamber. Delivered
fuel amount is regulated by periodical work of feeder gear motors.
24V DC motors are supplied from backup battery to empty feeder tubes in case of power
failure.
19
Battery
When there is no power from the main power supply then the burner is operating on battery
power. PV1000 uses two 12V 3,4 Ah batteries. Because the battery is a safety element, the

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burner checks batteries condition and does not start the next working cycle if the batteries
voltage is too low.
20
Internal feeder
screw
Hollow spiral connected to feeder motor to transport pellets into burning chamber. Screw is
not tightened to motor, but has small slack. It lowers the mechanical stress and expands
gearmotor lifetime.
21
Pressure sensor
connection
Metal tube to connect pressure sensor input. Pressure sensor measures draught in burning
chamber and enables the controller to regulate flue gas fan speed.
2.2 Specifications
Parameter
Unit
PV1000agri
L total length
mm
1300
L1 burner body length
mm
630
L2 burning chamber length
mm
690
H total height
mm
620
H1 burner chamber height
mm
550
W total width
mm
710
W1 burner housing width
mm
620
Mass
kg
290
Supply voltage
VAC
0
Power max
W
620
Power at standby
W
7
Noise
dB
58
Emission class1
-
5
Operating temperature
Co
-10…40
Nominal heat input
kW
1000

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Figure 1 Dimensions
Figure 2 Dimensions

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Figure 3 Dimensions

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Prerequisites
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3 Installation
3.1 Prerequisites
In order to install the burner, the boiler must meet to the following requirements:
 Recommended to use three pass boilers.
 The construction of the boiler must make it possible to open the door of the boiler with the
burner connected and removing ash from the furnace. If the door of the boiler is too narrow for
opening it with the burner, then extra hinges must be installed.
 If there is not sufficient (less than 5Pa) negative pressure in the furnace, a draught fan should be
installed for the exhaust gases.
 The boiler must be positioned in a way that there is enough space for cleaning the burner, the
boiler, the smoke pipe and removing the ash.
 The burning chamber must not touch the bottom of the boilers furnace (min 10cm distance
needed).
 The boiler room where the burner is installed must fulfill all rules and recommendations given by
local authorities.
 Boiler room must provide constant air supply of 1500 m³ per hour (ca. 1600 cm2 air inlet
opening).
In order to install the burner to the boiler door, there must be
mounting holes as shown below.
Figure 4 Boiler door mounting hole
Note: If the burner is installed to the boiler, the door or the
installation flange´s thickness should be 8-14mm.
Unit PV 1000
mm 400
mm 490
mm 6x13
deg 30
angle between bolt holes 60
⌀D hole for burning chamber neck
⌀D1 flange bolt ring diameter
⌀D2bolt holes
a bolt hole offset angle
deg

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3.2 Burner
Figure 5
Mount the burning chamber on the
inner side of the boiler door.
Figure 6
Use 6 M12x60mm bolts, spacers
and distance nuts respective to the
bolts

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Figure 7
Install the insulation rope between
the burning chamber and the boiler
door. The rope must be installed
near the outer perimeter of the
burning chambers back wall.
Figure 8
Grate holders installation
Install the burning chambers
bottom panel (15x15mm insulation
rope must be inserted to the slot in
the panel) with 6 M8x16mm bolts.
Install the burning chambers front
panel (heat shield), use M8x16mm
bolts.

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Figure 9
Connect the static grate holders
with the side stone holders
separately and install them
together into the burning chamber
as a frame. Fix them with
M8x16mm bolts to the burning
chamber.
Figure 10
Connect the moving grate holders
with M6x12mm bolts.

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Figure 11
Install the burning chambers front
brick holders, use M8x16mm bolts.

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Figure 12
Release the igniter tube screws and
while inside the holders pull the
tubes out about half of the total
length.
Move the air separator to its
correct position (according to the
boiler door thickness) and fix it
with screws.

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Figure 13
Install the ceramic sealing strips on
the boiler door. Fix them
temporarily in position with any
ordinary cellophane tape (scotch).
Cut away the excessive sealing on
the perimeter of the air chamber.
Figure 14
Mount the burner body on the
boiler door, using 4 M12x70mm
bolts and respective washers.

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Figure 15
Push the igniter tubes through the
burning chambers back wall and fix
them in position with M4 screws.
Figure 16
Connect the linear actuator with
the moving grate holder. Use
27x2,5mm pipe (length 240mm),
M8x45mm bolt for the burning
chamber side and a M6x25 socket
set screw (DIN914 45H) on the
actuator side.

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Figure 17
Push the stone temperature sensor
through the hole in the burner
body and the pipe on the burning
chambers back wall, isolate it from
the air flow (accessible from the
burning chamber side) with
ceramic sealing to prevent cold air
from tampering with the
measurements.
Figure 18
Install the 8 lower position grates
with 5mm holes.
Install the 8 higher position grates
with 7mm holes.

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Figure 19
Install the ceramic paper on the
back wall of the burning chamber.
Install the back wall stones on the
burning chambers back wall.
ATTENTION!: Care must be taken
not to damage the temperature
sensor!
Push the stone temperature sensor
into the opening in the back wall
stone.
Figure 20
Install the upper grate holder and 2
upper grates. Fix the holder with
M10 wing nuts

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Water sprinkler
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Figure 21
Install the 6 side bricks.
Install the 6 arc-stones.
ATTENTION!: The arc-stones are
numbered, they must be installed
as pairs!
3.3 Water sprinkler
Water sprinkler is main safety element against back burning. It is strongly recommended to install
sprinkler system. In Figure 22, water supply line and pressure switch is used. Pressure switch allows
starting the burner only if water supply is present. If no water is available on installation site, reservoir
can be filled manually. In this case, pressure switch is not connected to safety circuit as there is no
pressure in water system.
In case of back burning, sprinklers will open and extinguish fire in feeder tubes. Flow control valve limits
the amount of water flowing into burner after the reservoir is emptied. The burning chamber must be
cleaned from wet ash and pellets before turning the burner back on again.