Trianco GREENFLAME 55 User guide

GREENFLAME 55/85/100/125/199 kW
Commercial Wood Pellet Boiler System
INSTALLATION, OPERATION AND
SERVICING INSTRUCTIONS
Please read these instructions carefully before installing
and operating this appliance.
TO BE RETAINED BY THE HOUSEHOLDER

TR Engineering Ltd
TR Engineering Ltd operates a policy of continuous development and improvement of our
products and welcome any feedback from our Customers. Please forward your comments
to :
TR Engineering Ltd
Unit 7 Newton Chambers Way
Thorncliffe Industrial Estate
Chapeltown
Sheffield
S35 2PH
United Kingdom
Tel: [phone]
Fax: [phone]
E-mail: [e-mail]
Web: www.trianco.co.uk
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This symbol is used to
highlight important
information
SAFETY NOTICE
PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE YOUR
NEW BOILER.
THIS APPLIANCE MUST BE INSTALLED BY APPROVED AND COMPETANT
PERSONNEL ONLY. FAILURE TO INSTALL THE APPLIANCE IN ACCORDANCE
WITH THE MANUFACTURERS INSTRUCTIONS AND LOCAL BUILDING
REGULATIONS AND BY-LAWS WILL INVALIDATE THE WARRANTY.
Manual Edition : GREENFLAME Commercial Series May 2012

Table of Contents
1General Information 5
1.1 Important note for efficient and low-emission operation
of your Greenflame biomass heating system. 6
2 Safety Information 7
2.1 Greenflame Safety Guidelines 7
3 Greenflame System Features 9
3.1 Greenflame Boiler Features 10
3.2 Fillomatic Pellet Transport Features 11
3.3 Self Cleaning Burner Features 12
3.4 Control System 13
4 Installation 14
4.1 Setting out the boiler location 14
4.2 Unpacking 15
4.3 Assembly 16
4.4 Flues 17
4.5 Flue Pipe 17
4.6 Flue Requirements 19
4.7 Air Supply 22
4.8 Water Connections 24
4.9 Electrical Connections 28
4.10 Self Cleaning Burner Electrical Schematic 29
4.11 Boiler Control Panel Electrical Schematic 30
5 Digital Control System 31
5.1 Buttons 31
5.2 LED’s 32
5.3 LCD Display 32
5.4 Power Display 34
5.5 Error Messages 34
5.6 Menus 35
5.6.1 User Menu 35
5.6.1.1 Power Menu 37
5.6.1.2 Boiler Thermostat Menu 37
5.6.1.3 Chrono Menu 37
5.6.1.4 Time & Date 37
5.6.1.5 Monitor 38
5.6.1.6 Load Menu 38
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5.6.1.7 Language Menu 38
5.6.2 Keyboard Menu 39
5.6.3 Secret Menu 39
6 Troubleshooting 40
7 How Does My Wood Pellet System Work 43
7.1 Sensors 43
7.2 Combustion Process 43
7.3 What Happens When I Turn On My Boiler 45
7.3.1 Check-Up 45
7.3.2 Pre-Heating 45
7.3.3 Pre-Load 45
7.3.4 Variable Ignition 46
7.3.5 Stabilisation 46
7.3.6 Run Mode 47
7.3.7 Modulation Mode 47
7.3.8 Standby / Extinguishing / OFF 48
7.3.9 Pump Management 48
7.3.10 Extinguishing When Boiler Is In The OFF State 48
8 Operation 50
9 Maintenance 51
10 Commissioning 52
11 Warranty Information 55
12 Fuel 56
13 Technical Data 57
13.1 Boiler Dimensions 58
13.2 Boiler Section 59
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Table of Contents

1. General Information
Dear Customer,
We would like to congratulate you on choosing this high-quality product from TR
Engineering Ltd. The Greenflame range of wood pellet boilers for commercial / light
industrial applications are designed specially with aim of maximising efficiency, reduced
CO2 emissions, compact design for installation in the smallest of plant rooms and cutting
edge system management features with remote access through the cellular network for
remote routine maintenance, as standard. Due to the low-emissions and CO2-neutral heat
produced by renewable fuels, you are making a considerable contribution to the protection
of the environment and its resources.
You have also chosen a product with an elegant line, a refreshing design and perfect
workmanship. The outer surfaces require minimum care in day-to-day life and are easy to
clean. On the inside, however, is a carefully designed and ultra efficient heat exchanger
which has been developed from TR Engineering Ltd’s 40 years of boiler manufacturing
experience.At the centrepiece of the system is a self cleaning pellet burner which is at the
cutting edge of combustion technology and innovation which guarantees low emissions and
high efficiency by maintaining the combustion area in a clean condition. The mastermind of
the system is the TR Engineering Ltd Boiler Management System (BMS) control which sets
the standard in control engineering. The LCD display with generous graphics and clear-text
user management provides brilliantly simple and easy-to-use operation.
This new-generation control system together with the self-cleaning mechanism and the
automatic de-ash system makes sure that under normal operating conditions (except for
boiler maintenance) only occasional emptying of the ash box is necessary –no other tasks
are required. This instruction and maintenance manual contains all the information required
for trouble-free operation and handling of the system. Please read it carefully.And if you
still have any questions, please contact your sales partner. No claims for damages incurred
as a result of misuse of the safety, operating or maintenance notes can be accepted.
We wish you many years of heating pleasure with your new TR Engineering Ltd
Greenflame biomass heating system.
Best regards from your TR Engineering Ltd team,
We provide heating with a clear conscience!
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1.1 Important note for efficient and low-emission
operation of your TR Engineering Ltd biomass heating
system.
For efficient and low-emission operation of your TR Engineering Ltd heating system,
please follow these instructions:
• Only use the fuels specified in this TR Engineering Ltd instruction manual. Only then can
a low-emission, economic and trouble-free operation of your heating system be
guaranteed. (Section 12)
• Carry out maintenance and cleaning work recommended by TR Engineering Ltd on your
heating system at regular intervals. Details can be found in the instruction manual in
section 9. By doing this, you will not only be ensuring the operational reliability of the
heating system but also its efficient and low-emission operation. The best way of caring for
your heating system is by taking out a TR Engineering Ltd maintenance contract. Your TR
Engineering Ltd Agent will be happy to give you information about this.
• Your TR Engineering Ltd heating boiler is adjustable within an output range of 30 to
100% of the boiler’s rated power.
A buffer tank / thermal store is recommended and should be correctly sized by your
heating engineer. This ensures efficient and low-emission operation of your TR
Engineering Ltd heating system.
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2. Safety Information
In the design of the TR Engineering Ltd biomass system, special attention has been
placed on safety. However, since the system contains elements which can reach high
temperatures, it is essential that several simple, but important rules, are adhered to by
the user.
2.1 TR Engineering Ltd Safety Guidelines
Please read the instruction manual carefully before
starting the system for the first time, and pay special
attention to the safety instructions. If something is not
clear, please look it up in this operating manual.
•Ensure all maintenance doors are closed tightly.
•The boiler room should always be locked.
•When opening the boiler door make sure that no flue gases or sparks come out. Never
leave the boiler door open without supervision.
•Make sure that there is sufficient supply of fresh air to the boiler room and avoid frost.
•Carry out maintenance work regularly or call your Agent to arrange to have this done.
•Always make sure the power is isolated when carrying out maintenance work or
opening the control system.
•Combustible materials (including fuel) should not be stored in the boiler room, other
than the fuel that is required for the operation of the boiler.
•Fire extinguishing apparatus should be located near the door of the boiler room.
•The boiler may only be run on wood pellet fuel as prescribed in the fuel section of this
manual.
• Do not carry out any unplanned changes to the settings; do not modify the system in
any way without first consulting your local dealer.
• The boiler should be switched off the before refilling the fuel silo using a pump truck for
blowing pellets into the storage hopper.
• In the case of any problems contact your Agent or for Troubleshooting visit
www.trianco.co.uk .
Legislation stipulates certain devices should be used with automatic pellet boilers which
prevent back-burn along the conveying troughs into the fuel store. The following safety
precautions are implemented in TR Engineering Ltd systems:
• A cell wheel is located between the head of the conveying auger and the combustion
area thus helping to prevent back burn.
•If the temperature in the pellet feed pipe exceeds an pre-determined safety
temperature the a high temperature safety thermostat will send a signal to the controller
that a high temperature has been reached and will initiate a safety shut down sequence.
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HEALTH AND SAFETY PRECAUTIONS
Special care must be taken when installing the boiler such that the requirements of the
Health and Safety at WorkAct are met.
Handling
Adequate facilities must be available for loading, unloading and site handling.
Fire Cement
Some types of fire cement are caustic and should not be allowed to come into contact with
the skin. In case of contact wash immediately with plenty of water.
Asbestos
This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the
course of installation then please seek specialist guidance and use appropriate protective
equipment.
Metal Parts
When installing or servicing this boiler care should be taken to avoid the possibility of
personal injury.
In all cases the installation must comply with current Building Regulations, LocalAuthority
Bye-laws and other specifications or regulations as they affect the installation of the boiler.
It should be noted that the Building Regulations requirements may be met by adopting the
relevant recommendations given in British Standards BS 8303, BS EN 15287-1:2007 as an
alternative means to achieve an equivalent level of performance to that obtained following
the guidance given in Approved Document J.
Please note that it is a legal requirement under
England and Wales Building Regulations that
the installation of the boiler is either carried
out under Local Authority Building Control
approval or is installed by a Competent Person
registered with a Government approved
Competent Persons Scheme. HETAS Ltd
operate such a Scheme and a listing of their
Registered Competent Persons can be found
on their website at www.hetas.co.uk.

3. Greenflame System Features
The data plate contains important information on the type designation of the
appliance. You will find this on your system mounted on the control panel cover .
The boiler is located on the left hand side of the unit with the burner located
underneath the integral storage hopper.
The fuel is loaded in the integral hopper which has a capacity of 125 kgs, the
TR Engineering Ltd Fillomatic pellet transport system which will fill the integral
hopper from a remote bulk storage silo.
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RemovableAccess Panel
Vacuum Cyclone Unit
Ash Containers

3.1 Greenflame Boiler Features
The heat exchanger has been designed and developed to provide maximum efficiency
and combustion quality as well as not having to compromise on space. The compact
nature of it’s design has allowed the integral hopper to be incorporated as part of the
overall unit. The secondary heat exchanger is cleaned by mechanically operated
spirals which actuate vertically at pre-determined intervals to clean the tubes.
The drop feed burner is fitted to the side of the boiler where the flame fires in a
horizontal direction across the combustion chamber. The flue gases are then forced
to rise to the top of the chamber and are forced down behind the refractory board
which aids in the complete combustion of the flue gases. The flue gases must then
rise again through 12 vertical pipes before exiting through the flue chamber at the rear
of the boiler and are eliminated through the flue. The flue has an exhaust fan which
aids in providing the ideal draft conditions for the appliance to work efficiently and
safely. The flue fan is controlled automatically by a vacuum sensor in the combustion
chamber which will automatically adjust the exhaust fan to provide the optimum under-
pressure conditions in the combustion chamber.
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3.2 Fillomatic Pellet Transport Features
The integral hopper has a capacity of up to 125 kgs of pellets. Filling of the hopper
is carried out automatically by the Fillomatic pellet transport system.
The pellets are auger fed from the base of the hopper to the top of the drop feed
pipe where the pellets free fall into a cell wheel and down into the pellet burner.
Located in the hopper is a pellet level sensor which lets the system know when the
level of pellets has reached a low level and allows the system to re-fill automatically.
The design of he Fillomatic system means that pellets can be transported up to 45m
horizontally with a 2.4m vertical rise. For each additional 2.4m vertical rise, 10
meters must be taken off the horizontal travel.
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Bulk Storage
Hopper
Auger
Vacuum Feed
Hose

3.3 Self Cleaning Burner Features
The self cleaning burner system allows the burner to maintain optimum combustion
by maintaining the combustion tube in a clean condition. The cleaning process is
activated after each time the system goes into an extinguishing phase (or after a
number of run cycles as required). The controller can also be programmed that after
a pre-determined number of hours running the system can shut down, clean and
then restart . This will prevent any “clinker “ build up in the combustion tube.
Cleaning of the burner tube is carried out by compressed air.A mini air compressor
charges a storage tank of air and when this has reached the correct pressure a
solenoid valve releases a short high pressure jet of air into the burner which clears
any clinker or debris into the de-ash augers.
If the temperature in the pellet feed pipe reaches a high temperature a safety
thermostat will signal the controller to shut down and signal an error “Er 03” on the
LCD display to warn of a high temperature occurrence.
The combustion fan of the burner regulates the combustion quality and is controlled
automatically. The ignition element creates the initial combustion during start up
and will turn off when a full flame is detected in running mode.
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Burner Cleaning Air Tubes
Air Accumulator
Tank

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3.4 Control System
The TR Engineering Ltd Greenflame Control System leads the way in combustion
efficiency
and control and is also at the cutting edge in communications technology and
providing the user with useful information related to their Greenflame system.
The main features of the Greenflame control system include :
•Combustion regulation through control of the combustion fan, exhaust fan
and auger interval settings.
•Safety sensors on the boiler combustion chamber doors, water overheat
thermostat and pellet feed pipe safety thermostat.
•Pellet level sensor
•UPS switch to provide electrical back-up to the Greenflame in the event of
a power cut.
•Photocell for flame recognition.
•Optional heating system or buffer tank management
•02 visualisation through lambda sensor.
•Auto-regulation of the draught in the combustion chamber through a
vacuum sensor.
•Boiler and burner cleaning management. De-Ash management.
•Integrated modem for remote access and maintenance and well as
providing the user with ON/OFF features and system status though GSm
message.

4. Installation
Careful consideration and time spent planning the boiler room and fuel store will
prevent delays when it comes to installing the system. It is recommended that a
survey of the plant room should be forwarded to TR Engineering Ltd for review so
they can advise the best solution for locating the boiler and fuel transport systems.
Contact your local TR Engineering Ltd Representative who will be happy to advise
what information the survey should contain.
4.1 Setting out the boiler location
The Greenflame system requires minimum clearances around the appliance for
servicing and maintenance. These are detailed in the figure below. A minimum of
600mm is required in front of the boiler in order to safely remove the ash pan from
the boiler or to clean the combustion chamber.
The boiler must be located on a non-combustible base that is capable of holding the
weight of the boiler when full (1700 kg)
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250mm
300mm
750mm
400mm

4.2 Unpacking
The TR Engineering Ltd Greenflame Pellet Boiler System is delivered in a single crate.
Remove the wooden crate, cardboard packaging, polystyrene packing, and bubble wrap
packaging and recycle in the appropriate manner.
The following items should accompany you Greenflame pellet boiler system :
Fillomatic Pellet Transport System
Pellet cyclone c/w door flap sensor.
40-65mm hose clamps to connect flow and return vacuum feed pipes.
Auger system –either the Fillomatic standard auger or the Fillomatic floor track
system.
De-Ash Box
Boiler scraper tool
Burner scraper tool
A4 Manual pack
Installation and User Manual
Product Registration Card
Foil tape to blank de-ash outlet
Chimney pipe gasket
Hopper/Boiler fixing bolts x 2
Cable ties to tidy cable runs after installation.
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In the unlikely event that an item is missing then yourAgent should be notified within 5
working days in order to issue replacement parts. Missing or mislaid parts notified after
5 working days will incur a charge plus postal costs.
The following guidelines should be followed to ensure that the installation of the boiler
is carried out in a trouble free manner.
Be careful when moving or lifting the boiler as it is heavy
and could cause an injury. Use appropriate lifting
techniques and equipment for the individual weights of
these sections. Take all necessary precautions to prevent
damage to external casing.

4.3 Assembly
The Greenflame is supplied fitted to it’s base permanent base for ease of lifting and
assembly. The Greenflame boiler is “plug and play” with just the connection of the flue,
hydraulic system and electrical system. The only items that need to be fitted to the
Greenflame are the ash box, exhaust fan housing and the pellet cyclone.
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Commissioning of the Greenflame may only be
carried out by TR Engineering Ltd trained
personnel or their authorised representatives.

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4.4 Flues
Use stainless steel twin walled insulated flue pipe to flue your Greenflame.
An exhaust fan is used to extract the combustion gases from the firebox. This
creates a negative pressure in the firebox and a positive pressure in the flue system.
The longer the flue pipe and more elbows used in the system, the greater the flow
resistance. Because of these facts we recommend using as few elbows as possible
and 10 meters or less of flue pipe. Be sure to use wall and ceiling pass through
fittings (which are approved for pellet vent pipe ) when going through combustible
materials. Be sure to use a starting collar to attach the flue system to the boiler. The
starting collar must be sealed to the boiler flue collar with high temp silicone caulking
or aluminium tape
Any exterior flues (flue pipe exposed to outside ambient temperatures) should
be kept to a minimum, due to potential condensation problems.
This is especially important in high humidity cold weather climates, such as maritime
areas, lake shores, and low river valleys.
4.5 Flue Pipe
A flue pipe suitable for use with a class 1 appliance (i.e. an appliance burning solid fuel).
is constructed of two layers with insulation between the layers. This insulation reduces
the outside surface temperature to allow a minimum clearance to combustibles of
50mm.
The sections of pipe lock together to form an air tight seal in most cases; however, in
some cases a perfect seal is not achieved. For this reason and the fact that the TR
Engineering Ltd operates with a positive vent pressure, we specify that all joints within
the structure should also be sealed with clear silicone.
NOTE:. Be sure to inspect and clean the exhaust flue system frequently.
It is not recommended that the flue has 90 elbows or
horizontal sections.If the flue must pass through a wall only
45 elbows may be used
NOTE: Read and follow all of the flue pipe manufacturers’ instructions on
the proper installation and support of the vent pipe. Adhere to all
clearances.
TR Engineering Ltd recommend the use of the Therminox range of flues for use
With the TR Engineering Ltd pellet boiler system.

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Chimneys taller than 6m above the connection will require a draft test to determine if
the draft is too high.
Note: The High Burn Draft should not exceed 50Pa. A draft stabiliser is fitted to the
starter flue to counteract a certain amount of excessive draft but additional measures
may be required.
Creosote Formation and Need for Removal - When wood is burned slowly, it
produces tar and other organic vapours, which combine with expelled moisture to
form creosote. The creosote vapours condense in the relatively cool chimney flue of a
slow-burning fire. As a result, creosote residue accumulates on the flue lining. When
ignited, this creosote makes an extremely hot fire. The pellet flue pipe should be
inspected at least twice monthly during the heating season to determine if a creosote
build-up has occurred. If creosote has accumulated it should be removed to reduce
the risk of a chimney fire.
Guidance on minimizing creosote formation and the need for periodic creosote
removal: The chimney should be inspected during the heating season to determine if
a creosote build-up has occurred. If a significant layer of creosote has accumulated
(3mm or more) it should be removed to reduce the risk of a chimney fire.
The TR Engineering Ltd Boiler may be used and installed into an existing masonry or
a flue pipe suitable for use with a class 1 appliance (i.e. an appliance burning solid
fuel).
It can not be installed in a chimney serving another appliance.
The chimney should be cleaned and or inspected before installation.
WARNING
Keep combustible materials such as grass, leaves, etc. at least 3 feet away
from the point directly under the flue termination. (between the flue and the
ground)
CAUTION
KEEP COMBUSTIBLES AWAYFROM FLUE OUTLET.
INSTALLATION IS TO BE PERFORMED BY A QUALIFIED INSTALLER.
DO NOT INSTALL A FLUE DAMPER IN THE EXHAUST FLUE SYSTEM
OF THIS UNIT.
DO NOT CONNECT THIS UNIT TO A CHIMNEY FLUE SERVING
ANOTHER APPLIANCE.

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4.6 Flue Requirements
A natural draught must exist in the boiler when
connected to the flue and this will be checked by the
Commissioning Engineer before the burner is run. If this
is not the case then the customer must take the necessary
measures to ensure a draught like increasing the flue
height or fitting an anti downdraught cowl.
The proper draught conditions in the flue is critical for the efficient working of wood pellet
boilers. TR Engineering Ltd recommend that it’s Therminox range of stainless steel twin-
walled insulated flue pipe is used with its “TR Engineering Ltd” boilers. A draught
stabiliser is fitted as standard to the short section of flue pipe that connects to the boiler.
This will help stabilise draught in average wind conditions. The flue can exit the boiler
house/garage through the roof or through the wall by using a bend on the flue. The
following diagram indicates recommended flue layouts. Installation must comply with the
current Building Regulations and local by-laws and it is the Installers responsibility to
ensure that the flue is installed safely and to the appropriate regulations.
In order to avoid down draught, the chimney or flue must terminate in a position at least
600mm higher than the highest point on a roof, tree or building within a distance of
9 meters (30 ft.). Down draughts will affect the performance of the boiler and may cause
some of the safety features to come into operation.
Down Draught:
If the proper flue height cannot be achieved the commissioning engineer may refuse to
commission the boiler. Whenever possible, the flue should terminate above the apex of the
roof; if this is not possible, use a cowl that is specified as anti-downdraught by the cowl
manufacturer. Use as few bends as possible but when necessary 135º bends are
recommended. In cases where the boiler is commissioned with a lower height flue the
necessary draught conditions are achieved on the day of commissioning, the customer
must sign the Commissioning Report stating that any issues arising from the flue not to the
required height will not be covered under warranty.
NOTE: Read and follow all of the flue pipe manufacturers’ instructions on the
proper installation and support of the flue pipe. Adhere to all clearances.
Reference : BS EN15287-1:2007; Chimneys –Design, installation and
commissioning of chimneys; Part 1: Chimneys for non-room sealed heating
appliances

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The chimney or flue must have a cross-sectional area throughout its whole length that is
at least the area of flue outlet of the boiler and must be sealed to the boiler with fire clay
or other suitable compound.
The chimney or flue should be of sufficient height to provide draught of min. 25Pa
measured at the test hole in the top of the boiler. Draught conditions that are excessive,
measured at the test hole in the top cleaning door of the boiler, due to chimney height or
location should be controlled by means of the draught stabiliser fitted to the chimney to
ensure a draught of not more than 40 Pa exists. In some instances where the boiler is
located in exposed sites a second stabiliser may be required where natural draught
exceeds 40 Pa.
The newly developed design of the regulator makes it possible to install it on the flue
pipe in all possible positions, angled, vertically as well as horizontally. The regulator can
be fitted the short flue section supplied with the boiler. Possible leaks can easily be
sealed off with a gasket, putty or other suitable sealing substances.
Counterbalancing the flap
After installation the two screws should be loosened and the balance spindle should be
turned to a horizontal position when the flap is closed. Tighten screws.
Adjustment of Under-pressure
Adjustment of the under-pressure opening the flap is made by pressing the clamp on
which the weight is fitted and move it along the spindle. The under-pressure is changed
approx. 1 Pa every 2mm the weight is moved, see fig. 2. The values are approximate
and must be controlled with a draught indicator if exact under –pressure is required. The
flap is set at 25Pa on delivery.