Pelltech PV1000agri User manual

PV1000agri pellet burner
User manual
POOLELI - DRAFT
DK9401A1

PV1000agri pellet burner
p 1/ 50
Description
Main components
DK9401A1
www.pelltech.eu
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

PV1000agri pellet burner
p 2/ 50
Description
Main components
DK9401A1
www.pelltech.eu
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

PV1000agri pellet burner
p 3/ 50
Description
Main components
DK9401A1
www.pelltech.eu
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.

PV1000agri pellet burner
p 4/ 50
Description
Main components
DK9401A1
www.pelltech.eu
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

PV1000agri pellet burner
p 5/ 50
Description
Main components
DK9401A1
www.pelltech.eu
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

PV1000agri pellet burner
p 6/ 50
Description
Specifications
DK9401A1
www.pelltech.eu
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

PV1000agri pellet burner
p 7/ 50
Description
Specifications
DK9401A1
www.pelltech.eu
Figure 1 Dimensions
Figure 2 Dimensions

PV1000agri pellet burner
p 8/ 50
Description
Specifications
DK9401A1
www.pelltech.eu
Figure 3 Dimensions

PV1000agri pellet burner
p 9/ 50
Installation
Prerequisites
DK9401A1
www.pelltech.eu
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