Full Manual PV700
Contents
1. 25 Figure 11 Burning at fixed 9 0 30 Figure 12 Burning procedure when power selection 31 Figure 13 Electrical 1 1 111 3 0 0 39 Figure 23 3133 7 3 111 59 40 Figure 2323333 3 1313 1 1 1 1111111 1 111 1 1 41 02320 sssss pelltech DK9501A1 www pelltech ee PV500 pellet burner p 3 45 Safety precautions Do not start the burner before it is connected to the boiler and the boiler is connected to the chimney e Itis recommended to wear a respirator while handling pellets boiler room where the burner is installed must fulfil all rules and recommendations given by authorities All electrical connections must be done by trained professionals e No flammable materials must be stored near the burner Warnings e Changing the construction of the burner without written permission from the manufacturer is for bidden Useonly 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 Donotopen any boiler door while the burner is in operation Notice e Manufacturer of burner has right to make changes in construction of burner and its fir2. Installation commissioning date Owners contacts Installers name and signature Name 1111 1 1 11 1111 90 City village 211 Street House 2 Warranty ticket Burners model PV500 Productnumber 1 1 1 1 1 1 5 5 esaeetiteeinitote tien enin es eds sie Poena Salesdate Installation commissioning date Owners contacts Installers name and signature 7 1 11 Phonemt 0 3 111 0 7 111 0 Street HOUSE 3331 313 entente Warranty is valid only if the bottom half of the warranty ticket is filled in and sent or brought to the office of Pelltech OU Sara tee 3 Peetri Rae vald 75312 Harjumaa ESTONIA Ph 372 677 5277 www pelltech ee info pelltech ee
3. 1 n ot ot ot ec 2 ps ps ps ps ps ps ps ec X A A in C C 2 Pa N N N N Oje D jw Un w A 170 40 3 70 3 20 25 32 39 41 43 00 7 3 5 2 1 3 70 5 50 1 10 10 1 1 A o N ee sssss 9e DK9501A1 www pelltech ee PV500 pellet burner p 43 45 PAR66 OXYGEN TYPE Type of oxygene sensor 0 no sensor 1 4 25mA 0 25 2 4 20mA 0 2096 PAR67 OXYGEN SET Oxygen level setpoint PAR70 HEAT UP TIME Initial heat up time for burners with ceramic burning chamber PAR71 HEAT UP POWER Initial heat up power for burners with ceramic kW burning chamber 10 Annex 5 List of statuses Status External auger Feeder auger Fan Ignitor WAITING rot 127s TESTING 2 rot Maximum 10 sec LOADING By level 21 rot 30 60 sec LOADING 2 3 rot rps ign IGNITION rps ign 30s on 20s off PREBURN rps ign BURNING By level By power By power HOLD FLAME By level 7 rot 127s rps hold END BURN By power By power END BLOW rps end STOPPED rot 127s NO PELLETS rot 1275 NO FLAME rot 127s OVERHEAT 1275 IGNITION ERROR rot 127s LEVEL ERROR rot 1275 FEEDER ERROR rot 127s FAN ERROR z 7 rot 127s BATTERY LOW rot 127s NO POWER 7 rot 12
4. 8 pelltech PV500 PELLET BURNER DK9591A1 USER MANUAL PV500 pellet burner p 1 45 Table of contents Table Of contents nce 3 5 Safety precaution Sisir 3 9 303 WAFMINES ERES 7 77 1 11 0 1 SetOF components 7 7 79 7 7 7 8797777 7 2 General 3 13 1 2 nnns 2 1 M in COMPONENTS 3 33 0111 2 2 Safet TT 2 3 dcm 3 JnstallatiOD od pea tenet 3 1 Pre requisites to boiler and boiler 3 2 Burner installation aceto cutie ceed 3 3 enne nnne nnne 3 4 External 0 3 5 Pellet storage 3 3 3 3 De 3 6 X Electrical 6 6 2222 6 3 7 Initial 3 11 11 1 11 1 4 Optional 6 200 43 0 70 7 7 7 7777 7 1 a 4 2 Error OUTPUT TS 4 3 4 4 Oxygen am
5. 353 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 38 45 7 Annex2 Electrical diagramm Flies felti TERR REEF Figure 13 Electrical diagram 388 pelltech eee DK9501A1 www pelltech ee PV500 pellet burner p 39 45 8 Annex 3 Controller board x1 ERR UU Uu Uu Uu Uu Uu TT Wu WV X2 X2 qd 01060606606 d 0 98 8 6 5 3 2 E cq cq a q q q qd 4 TMP1 FAN TMP2 R36 d TMP3B EO O Wem 5 UT 2010 ei O FDR 44 il 9 1516 R51 R82 0000999990900000 BE PROG TRS RSV Figure 14 Controller board X1 Connector terminal ERR Error output X2 Connector terminal TMP1 Feeder auger temperature sensor FAN Fans rotation sensor TMP2 Connected to TMP3 on ext board TMP3 Connected to TMP3 on ext board BUT Control button connector FDR Feeder augers control pelltech RSV Fuel level sensor s signal receiver White marked TRS Fuel level sensor s signal transmitter Black marked CONTR LCD contrast adjustments PROG Programming outlet UART RS232 Modem connector DK9501A1 www pelltech ee PV500 pellet burner p 40 45 Table 25 Controller board connector terminals X1 and X2 Description X2 Description 1 Igniter 1 Ash removal 2 Igniter 2 Ash removal 3 IN 3 Battery positive terminal 4 Flu
6. ESC To move back in menu by one level To cancel change in parameter edit mode OK ESC gt 35 To reset burner 5 2 Starting and stopping To turn on the burner turn on the boiler main switch If burner displays STOPPED then go to STATUS menu and change parameter BURNER from ON to OFF The display shows WAITING Now turn boiler thermostat to desired temperature The burner will go to TESTING and then to LOADING state If this is the first run external auger needs to fill up with pellets It may take as long as 20minutes To stop the burner set in main menu BURNER from ON to OFF Now the burner will burn all pellets in burning chamber and turn safely to standby STATUS menu displays the changes BURNING gt END BURN END BLOW gt WAITING gt STOPPED The stopping procedure may take up to 30 minutes Attention If necessary the boiler s thermostat can be turned on off from burner red switch with power indication light Caution Do not turn off mains power to terminate burning process Use the boilers thermostat for that In order to complete burning procedure safely let the burner to burn all fuel in burning chamber Never leave burner unattended when you had to stop boilers work turning boiler off from mains switch in any reason 5 3 Fuel refilling Fuel container has to be refilled before its runs out The fuel can be added any time to container If con tainer runs out before refilling refill it and restart the burner The s
7. 5 Set point hysteresis PAR55 Shows weather actual temperature is increasing or decreasing 200 Forecasted temperature in 10min 5 Operation and service 5 1 User interface 1 2 row LCD display 2 Yellow LED indicates presence of flame in the burning chamber 3 GSM modem antenna option 4 Orange burner operation light in dicates if the boiler s thermostat is switched on or off 5 Red burner on off switch with power indication light Enables to switch boilers thermostat on off 6 Green LED indicates existence of the fuel in the burner Figure 10 User interface The burner is controlled via user interface on the front panel Figure 10 LCD screen 1 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 6 indicates if there is fuel in the burner To move in menus use up and down buttons to change parameter press OK to go back to STATUS MENU press ESC button Functionality of buttons depends on time of pushing See Table 9 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 25 45 Table 9 User interface controls Button Push time Action OK 3s To enter to submenu To confirm settings in parameter edit mode OK gt 35 reset error resume normal operation To reset counter only in counter screen in INFO menu
8. pre set in parameter PAR24 loading feed LOADING parameters are described in Table 13 Table 13 LOADING parameters and timing PAR Parameter name Default Unit Comment No value PAR24 Loading feed 35 40 rot Feeder rotations needed to load pellets into burning chamber Depends from burner model PAR25 Loading 2 feed 5 rot Feeder rotations for second loading Max loading time 5 min Feeder auger s maximum regular loading time First loading time 20 min Feeder auger s maximum loading time after manual after manual start start Auger start 3 sec Auger Start delay if no fuel in burner Auger stop 3 sec Auger Stop delay if fuel in burner Feeder start 1 sec Feeder auger Start delay if fuel in burner Feeder stop 4 rot Feeder auger rotations made without fuel level before stopped At the LOADING time external auger holds permanent fuel level in the feeder auger s tube Depending on the level sensor signal the external auger is turned on or off Feeder auger s work depends also on fuel level sensor signal Maximum loading time is limited by 20 minutes after manual initial start up because extra time for ex ternal auger filling is needed In next loadings maximum time is limited by 5 minutes If maximum loading time is exceeded and silo selection on burner is used the pellet delivery will be switched to other external auger In single pellet container
9. Point C is critical point In order to keep door width minimum and boiler s door opening small a double hinge solution can be used As double hinges add another degree of moving freedom door must be fastened on both sides Slide out doors with guide rails is also an option Double hinges 3 2 Burner installation 1 Install the burning chamber to the boiler door or to the flange using M12x45 bolts distance washersbolts and coupling nuts Do not tighten the bolts 233 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 12 45 2 Install the sealing rope 15x15mm between the burning chamber and the boiler door or flange Use heat resistant sealant between flange and boiler Tighten the bolts Notice One attachment for the bolt and the distance nut is positioned under the burning chamber 233 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 13 45 3 Install the backside using M12x70 bolts and washers to the burning chamber coupling nuts Ceramic sealing must be placed between pellet burner and boiler door or flange The feeder tube must go through the hole on the back wall of burning chamber N Air separator devides primary and secondary air fan s air flow to the burning chamber Air separator must be regulated towards the burning chamber wall that there would be no gap between air separator and burning chamber
10. delivery system NO PELLETS error will occur At IGNITING cycle the igniter is heated up and fan blows hot air on pellets in burning chamber Hot air ignites pellets Igniter is working periodically at ignition time in order to avoid its overheating pelltech DK9501A1 www pelltech ee PV500 pellet burner p 28 45 Igniter is pre heated already in the end of loading cycle When internal auger has made 10 rotations full number of load rotations is 12 the igniter is turned on for pre heating If the igniter has been turned on more than 1 minute at LOADING time then it will be turned off IGNITING parameters are described in Table 14 Table 14 Ignition parameters and timing PARNo Parameter name Default Unit Comment value PAR8 FAN IGNITING 25 rps Primary fan speed at ignition Max ignition time 255 sek Maximum ignition time Time of first loading 20 min Maximum loading time after manual start Auger start Auger stop Feeder start Feeder stop sec Auger Start delay if no fuel in burner sec Auger Stop delay if fuel in burner sec Feeder Start delay if fuel is in burner rot Feeder rotations made without fuel before stopped By The purpose of PRE BURN status is to create stabile flame and assure effective pellets burning procedure after ignition Minimum fuel amount is added periodically at pre burn time Fans are working with same speed as at IGNITION Feeder
11. fan speed must be connected with inverter analog input Inverter setup Inverter parameters are set up at factory for automatic control To test flue gas fan manually 1 Press Easy button on inverter 2 Press dial button and change settings CNOd 0 FNOD 0 F174 0 4 4 Oxygen amount sensor Following instruction is applicable for firmware version 3 88 or later Oxygen amount sensor oxygen sen sor allows the burner to keep predefined oxygen levelin flue gas what increases the efficiency of the burning procedure In order to implement sensor what measures the amount of oxygen in flue gas Oxygen amount sensor two parameters PAR66 and PAR67 in parameters menu have to be set up according to Table 7 Table 7 PAR66 and PAR67 set up Parameter Description Unit No Name Def Min Max PAR66 OXYGEN TYPE 0 no sensor 0 0 2 1 4 20mA 0 25 oxygen 2 4 20mA 0 20 oxygen PAR67 OXYGEN SET Oxygen level set point 6 4 12 For oxygen amount sensor EPOO06 in parameters menu the PAR66 value has to be set to 1 Some third party oxygen amount sensors use 4 20mA output for 0 20 oxygen In this case value 2 must be se lected If PAR66 is set to 0 no sensor secondary fan is driven by air table set in PAR31 PAR36 Secondary fan also switches back to air table if oxygen level reading is below 396 or over 1996 Oxygen sensor is located inside the burni
12. heavier than normal weight pellets are selected PAR24 LOADING FEED Number of feeder auger rotations in LOADING state Bud PAR25 LOADING 2 FEED Number of feeder auger rotations in LOADING2 state PAR26 END BURN FEED Number of feeder auger rotations in END BURN state PAR27 END BLOW TIME Fan s END BLOW time after flame is disappeared EA PAR30 FAN 2 Secondary fan control ON OFF not used in PV50b S 1 PAR31 FAN 160 Secondary fan speed at 1 power level r r r r r S m 120 200 2 2 PAR38 FAN 2 BASE Changing amount of secondary fan base air with flue gas fan speed setting in all power levels PAR39 FAN 2 MIN Secondary fan minimal speed PHOTOCELL LEVEL Flame sensor sensitivity Higher number means that flame is recognized when less light N w N N o 0 0 PAR42 PRE BURN CYCLE Number of PRE BURN cycles Total length of PRE BURN cycles is length of one cycle times number of cycles PAR46 FEED CURRENT Preset feeder auger motors current Overcurrent protection threshold PAR47 GRATES CURRENT Grate motor overcurrent protection threshold PAR48 CLEANING CYCLE Pre set time between two cleaning cycles O CLEANING OFF PARSO RELAY ERROR ERR output function selection PAR52 SMS COUNT Selecting number of phones receiving alert SMS PAR53 TEMP TYPE Determines temperature sensor type plugged in TMP1 connector PAR54 TEMP LEVEL Set point value for temperature sensor plugged to E TMP1 HE ZN
13. level up when burning time has been less than 30 minutes PAR 16 next time burner takes one power level down pelltech DK9501A1 www pelltech ee PV500 pellet burner p 32 45 5 6 Main menu and settings To enter to main menu press To move in main menu use J 7 buttons To enter to menu parameter press OK To change paramerer press 4T buttons To confirm change press OK To go back to main menu press ESC button Main menu is depicted in Table 21 Table 21 Main menu Menu Menu para Description Default Options nr meter ENG settings 1 STATUS gt Submenu with status info 2 INFO gt Burner s info 3 BURNER Burner s turning ON OFF OFF ON OFF 4 HOLD FLAME Hold flame allowed OFF ON OFF AUTO 5 PELLETS Fuel quality options NORM NORM LIGHT HEAVY 6 POWER Power level selection AUTO PV500 AUTO 560 480 400 320 240 160 7 BASE AIR Fan speed change at once 0 2 1 0 1 2 3 4 5 for all power levels 8 LANGUAGE Language options ENG Annex 6 List of languages 9 PARAMETERS Parameters menu Annex 4 List of parameters Info screen in STATUS menu displays last events burner statuses and their duration The duration is in form mm ss m in the middle or hh mm h in the middle For example Igniting 0125 means that the burner ignition state lasted 1minute and 25 seconds Last row of the log shows current state The duration of current state updates every second or minute INFO m
14. shows placement of the error output It is allowed to switch up to 5A 230VAC device to circuit PAR50 in burner s parameters menu defines weather the error circuit is open or closed when error occurs 1 means ON opened when error and 2 means OFF closed when error occurs See Table 6 Table 6 PAR50 value 1 Normally open circuit Turns ON when error occurs 2 Normally closed circuit Turns OFF when error occurs 3 Turns ON in IGNITING HEAT UP BURNING and HOLD FLAME statuses 4 Not in use 5 Not in use 02820 sssss 90569 p DK9501A1 www pelltech ee PV500 pellet burner p21 45 K5 Figure 9 ERROR output 4 3 Flue gas fan The burner needs stable under pressure in burning chamber for its correct operation Simplest way to assure this is to use the flue gas fan between boiler and chimney With flue gas fan the burner can control and hold constant under pressure In order to control flue gas the PAR6O value has to be set to 2 ON Selected flue gas fan must provide transmission of the maximum flue gas amount and exceed the pressure provided by boiler ash cyclone and chimney The flue gas capacity for burned pellets can be calculated by simplified formula PM Tg Th 00 V V Capacity range in m h P Burner max power in kW Tg Flue gas absolute temperature in Toom Room absolute temperature in K lambda Excess air ratio PV burners are des
15. their thermal stress and thus prolong their lifetime BURNING END BURN Boiler s thermostat is NOT switched on HOLD FLAME is NOT allowed HOLD FLAME Boiler s thermostat is NOT switched on HOLD FLAME is AUTO mode END BURN Maximum continuous burning time 4 hours is reached END BURN gt Fuel level is continuously detected at time of 8 feeder auger rotations END BLOW gt LEVEL ER ROR END BURN gt Fuel level is not detected in 4 min END BLOW gt NO PELLETS NO FLAME Flame is not detected more than 2 minutes HOLD FLAME LOADING 2 Boiler thermostat is switched on END BURN Max KEEP FLAME 1 hour is reached END BURN END BLOW Flame is not recognised in 1 min and boiler s thermostat is switched off BURNING Boiler thermostat is switched on feeder auger has made less than 8 rotations and previous state was BURNING END BLOW WAITING Burning end Feeder auger has made 15 10 rot and blowing time 60 sec is reached STOPPED Flame is not recognised in 1 minute and burner is not switched on NO FLAME In Burning status flame misses more than 1 minute LEVEL ERROR In Burning status level of fuel in feeder s inlet doesn t decrease NO PELLETS No pellets recognised in feeder s inlet NO POWER WAITING Power exists and boiler s thermostat is switched off STOPPED Power exists and burner is not switched on BURNING If status before No Power was Burning and No Power didn t last more than 5 min
16. working time is much longer than stand by time For example 1 hour of working time and 10 minutes of waiting time In HOLD FLAME status the fan rotates slowly PAR10 and small quantities of fuel are added to burner Existence of flame is not checked Such status lasts max one hour after what burner ends usual cycle and stands by If signal from boilers thermostat arrives before hour burner goes to state BURNING If HOLD FLAME is set to AUTO it activates if two stand by times have been shorter than set value in PAR11 HOLD FLAME turns off if flame has been hold more than PAR12 value Menu PELLETS enables to select between 3 pre set fuel quality options Depending on fuel quality the mass of fuel could differ in same amount That s why the calorific value of same amount may differ By default burner calculates that one rotation pushes 160 grams pellets PAR21 to burning chamber If pel lets density is smaller i e they are lighter then with one rotation less pellets will be delivered into burning chamber Such mistake has to be compensated by choosing LIGHT from PELLETS menu Now burner calcu lates that one rotation equals with 150 grams of pellets PAR22 and makes more rotations In general case there is no need to make change in PELLETS menu Menu POWER determines caloric productivity of burner in kilowatts Power is calculated by reading the rotations of the feeder auger taking into account average caloric value of 1 kg of pellets It is pos
17. www pelltech ee PV500 pellet burner p 30 45 In Automatic Power mode POWER AUTO in main menu the operation power is selected automatically depending on burning cycle length A Max power par 14 5 8 Thermostat ON New operation power 7 pr e QA 6 5 Operation power 4 3 lon 2 Par 15 Par 15 igniting 1 End burn Pre burn Par 17 Blow Burning Waiting i Burning gt T T T T 222 30 30 Time min Figure 12 Burning procedure when power selection AUTO The purpose of HOLD FLAME mode is to avoid burner start up procedures i e TESTING CLEANING LOAD ING IGNITING etc every time when burner is switched on from boiler thermostat In HOLD FLAME mode minimum fuel and air amount are delivered to burning chamber HOLD FLAME mode can be switched on from burner main menu When HOLD FLAME is set to AUTO burner will turn the mode ON or OFF de pending on WAITING time e f WAITING time between END BLOW and boiler thermostat switched on is shorter than set in PAR 11 then HOLD FLAME mode will be switched on e f HOLD FLAME time is longer than set in PAR12 HOLD FLAME mode is switched off HOLD FLAME is also used as intermediate state before CLEANING or after SLOW DOWN Table 18 HOLD FLAME parameters PARNo Parameter name Default Unit Comment value PAR10 FAN HOLD FLAME 10 rps Primary fan speed at HOLD FLAME PAR3
18. 7s 353 pelltech DK9501A1 www pelltech ee PV500 pellet burner 11 44 45 Annex 6 List of languages ENG English ESP Spanish EST Estonian FIN Finnish FRA France GER German GRE Greece HRV Croatian LTU Lithuanian LVA Latvian NLD Dutch PRT Portuguese RUS Russian SLO Slovenian SRB Serbian SVK Slovakian SWE Swedish 02820 33338 pelltech DK9501A1 www pelltech ee Warranty Warranty objects in this context are pellet burner PV500 and supplied auger Producer gives 2 years warranty from the date of sale for the PV500 burner and supplied auger Exception is ignition element igniter for this item warranty is 1 one year Warranty is valid when user had not made changes in the construction and setup of the burner Warranty does not cover defects caused by an accident misuse abuse improper installation or operation lack of reasonable care unauthorized medication loss of parts tampering attempted repair by a not au thorized person mains errors or using poor quality fuel Warranty is valid only if the bottom half of the warranty ticket is filled in and sent or brought to the office of Pelltech OU Sara tee 3 Peetri Rae vald 75312 Harjumaa ESTONIA Ph 372 677 5277 www pelltech ee info pelltech ee Warranty ticket Burners model PV500 Product number esses nennen en nennen nnne nns Salesdate
19. 9 FAN 2 MIN 7 rps Minimum speed of secondary fan Used at IGNITION PREBURN HEAT UP HOLD FLAME and END BLOW statuses PAR11 HOLD FLAME ON 15 min If two consecutive WAITING states have been short er than 15 min HOLD FLAME will be activated PAR12 HOLD FLAME OFF 60 min Maximum time when burner holds flame The END BURN cycle helps securely to stop burning procedure in burning chamber of burner All pellets inside the burning chamber and feeder tubes will be burnt Amounts of pellets delivered and fan rotation pelltech DK9501A1 www pelltech ee PV500 pellet burner p 31 45 speed power level are same as in BURNING status If burner goes to END BURN from other states e g HOLD FLAME the first power level is selected Burner works in END BURN until feeder tube is empty feeder has made as many rotations as selected in PAR26 END BURN can be used in case of some occurred errors e g If pellets have run out and NO PELLETS is displayed the burner stops safely normal BURNING cycle Table 19 END BURN FEED parameters PAR No Parameter name Default Unit Comment value PAR26 END BURN FEED 50 80 rot Feeder auger rotations to clean up feeder s pipe Minimum feed 20 rot If fewer rotations are made and boiler thermostat is switched on then burner goes back to BURNING state The END BLOW cycle is needed to burn finally all unburned pellet coals in the burning chamber Burner will wait f
20. AR17 Following actions must be done to enable temperature hold mode THM 1 Mount external temperature sensor to boiler according to boiler manufacturer instructions 2 Connect the sensor to TMP1 connector on controller board 3 Choose PAR53 value sensor type according to Table 8 4 Set requested temperature PAR54 It should be lower than boiler thermostat temperature Oth erwise the boiler thermostat would force the burner to turn off before reaching PAR54 value 5 Optionally PAR55 the hysteresis of requested temperature can be changed THM activates if PAR53 value is larger than 1 and BURNING status has lasted longer than set in PAR15 typically 30min The burner will change its output power according to current measured temperature and the rate of temperature change New power level is selected after every time interval specified in PAR17 s pelltech DK9501A1 www pelltech ee PV500 pellet burner p 24 45 Table 8 PAR53 values PAR53 Sensor type Temp min Temp max Function 0 No sensor 1 0 2 5V 096 0 5V 1252C 1 75V Burner s existing internal over temperature sen sor Overheat value to be set PAR43 2 0 2 5V 0 0 5V 1252C 1 75V Boiler temperature control with external sensor After activating THM following row is displayed on INFO screen e g T 22 3 70 5 4 200 It means fol lowing 22 3 Actual measured temperature 70 Set point temperature PAR54
21. AR70 is exceeded or stone temperature is higher than set in PAR72 Temperature of stones is not measured directly BURNING is main action status in burner s every day s operation Burner can operate on 11 different fixed power levels There are 6 main power levels which can be select ed and adjusted 5 virtual power levels between main power levels are for smoother operation they can t be adjusted or selected For every power level the primary fan speed is fixed in PAR1 PAR6 and secondary fan speed in PAR31 PAR36 The fan speed for virtual levels is calculated as average from previous and next main level speed Power levels are represented in Table 17 Table 17 Power levels Power level Level type PV350 Primary fan Secondary fan 1 main 100 Par 1 Par 31 2 virtual 120 3 main 150 Par 2 Par 32 4 virtual 170 5 main 200 Par 3 Par 33 6 virtual 220 7 main 250 Par 4 Par 34 8 virtual 270 9 main 300 Par 5 Par 35 10 virtual 320 11 main 350 Par 6 Par 36 level Power level can be selected in main menu Power level selection for burning time can be automatic or fixed on some main level When power level is fixed the power is slowly raised to selected level and will be there until boiler thermostat switches off _ Selected power A Power Par 17 Burning time p gt Figure 11 Burning at fixed power Su pelltech DK9501A1
22. Loading pellets with auger into burner and by feeder into burning chamber IGNITING Igniter is turned on pellets are ignited PRE BURN Flame is recognized small amount of pellets are added by feeder auger HEAT UP Burning chamber ceramic stones are heated slowly up BURNING Normal burning operation HOLD FLAME Thermostat is switched off small flame is held alive END BURN Thermostat is switched off feeder is burned up END BLOW Pellet coals in burning chamber are burnt flame has disappeared WAITING Burner waits when boiler s thermostat switches on At WAITING status the burner waits for boiler s thermostat switching on There is no time limit for WAIT ING status Only feeder auger is working periodically at WAITING status and makes rotations after every 2 minutes With this feeder augers spiral cleans feeder s tube from wastes When boilers thermostat switches on burner will go to TESTING At TESTING status burner s integrity and important device functioning are checked List of tests is given in Table 11 Table 11 List of tests in TESTING status PAR No Test name Test conditions Battery voltage Battery charging is turned OFF and feeder auger is turned ON Battery voltage must be greater than 24V PAR46 Feeder auger s Feeder is turned ON feeder current must be smaller than set in PAR46 current PAR62 Draught All fans are turned on Draft must be under PAR 62 PARA Primary fan Fan must rot
23. ariation and the output relay cuts off the power to the motor Burner can be equipped with optional lambda sensor It pro vides efficient control for optimal performance concentrating emissions and burning efficiency Table 4 Sockets on control panel Socket Description Color of poles Data Y1 Power input Black brown 7 poles 230V 16A Y2 Power input Black 4 poles 3x380V 4A Y3 External auger 1 Black 4 poles 0 55kW 1 6A Y3 1 External auger 2 Black 4 poles 0 55kW 0 65A YA Secondary fan White 4 poles 0 15kW 0 65A Y5 Primary fan White 4 poles 0 15kW 0 65A Y6 Lambda sensor Green Y7 External inverter or ash re White moval Y8 Flue gas fan White 3x230V 0 75kW max 4A Y9 Igniters Black 3 poles 2x500W 2 2A ssess Delitech 9e DK9501A1 www pelltech ee PV500 pellet burner p 18 45 3 7 Initial start up 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 functioning properly The external auger of the burner 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 suffi cient draught When the burner is operating the negative pressure inside the furnace must stay be tween 5 20 Pa Sprinkler system is connected and pressure switch connected to safety circuit Phase L and neutral N wires in power cable are connected pr
24. ate faster than 37rot 40 3 PAR34 Secondary fan Fan must rotate faster than 37rot 40 PAR34 3 At CLEANING status the linear motor actuator moves the grates and pushes the ash and residues out of burning chamber CLEANING parameters are desctibed in Table 12 The CLEANING cycle might be divided into 2 steps 1 Grates are pulled fully in to end of burning chamber s burner side 2 Grates are pushed fully out to end of boiler s side Attention Depending on polarity of connection of linear motor steps can be changed ss pelltech DK9501A1 www pelltech ee PV500 pellet burner p 27 45 Table 12 CLEANING parameters PAR No PAR name Value Unit Test conditions PAR48 Cleaning cycle 0 250 min BURNING time between CLEANING cycles If set to 0 interval then CLEANING is turned off If BURNING has been longer than 2x Par 48 set then extraordinary cleaning will made PAR47 Linear motor s 0 2 6 A Linear motor s maximum current level If greater then max current motor is stopped and cleaning cycle is started again At the LOADING status external auger is turned on When pellet level in the burner reaches to level sen sors feeder auger is started Feeder auger loads necessary amount of fuel needed for ignition into burning chamber Amount of loaded fuel is measured by counting rotations of feeder auger LOADING cycle is end ed when feeder has made exact number of rotations
25. auger makes rotations at every 25 sec up to 6 rotations achieved PRE BURN parameters are described in Table 15 Table 15 PRE BURN parameters PAR No Parameter name Default Unit Comment value PAR8 FAN IGNITIG 20 rps Primary fan speed at IGNITING and PREBURN PAR39 FAN2 MIN 7 rps Secondary fan s minimum speed Used at IGNITING PRE BURN HEAT UP HOLD FLAME and END BLOW statuses PAR41 PRE BURN 25 S Length of one PRE BURN cycle PAR42 PRE BURN CYCLES 6 x Number of PRE BURN cycles Pre burn feed 1 2 rot Number of feeder auger s rotations at each PRE BURN cycle HEAT UP cycle is needed to slow down heating up of the burning chamber s ceramic stones in order to minimize their thermal stress and thus prolong their lifetime HEAT UPparameters are described in Table 16 Table 16 HEAT UP parameters No Parameter Default value Unit Comment PAR70 HEAT UP TIME 20 min Initial heat up time of ceramic stones PAR71 HEAT UP POWER 30 70 kW Initial heat up power of ceramic stones PAR72 HEAT UP TEMPERATURE 500 Ceramic stone minimum temperature zd 3 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 29 45 When HEAT UP is in mode ON burner stops HEAT UP cycle after heat up time set in PAR7O is exceeded Temperature of stones is not measured directly When HEAT UP is in AUTO mode burner stops HEAT UP cycle after time set in P
26. e gas fan 4 Battery negative terminal 5 Mains transformer 5 Flame sensor 6 Mains transformer 6 Flame sensor 7 Fan 7 Feed screw black 8 IL 8 Feed screw red 9 Thermostat 9 Mains transformer 10 External auger 10 Mains transformer Table 26 Fuses F1 0 5A quick External auger F2 0 5A quick Fan F3 0 5A quick Flue gas fan FA 3A quick Igniter F5 2A quick Controller and feeder motor Table 27 Extension board connector terminals X1 and X2 X1 Description 1 Lambda a 2 Lambda v C 3 27 2V e 4 Ground m 5 Inverter R10 lt gt 6 o 7 Inverter CC a 8 Inverter VIA R5 gog e 2L esa x TMP24 PELLTECH OU SEB ver1 8 amp 2011 Figure 15 Extension board s pelltech DK9501A1 www pelltech ee PV500 pellet burner p41 45 9 Annex 4 Table of parameters retsuk 1 57 Cea FAN 240____ Fanspeedat2 powerlevel m Ami FANG320 Fanspeedat3 powerlevl m para FANG400 Fanspeedatd powerlevl m PARS FANG4B0 FanspeedatS powerlevl pars FANG560 Fanspeedat6 powerlevel m PART ANSTANT FanspeedatTETING PARS FAN IGNITING Fan speed at IGNITING and PREBURN ms PARS FAN ENDBURN FanspeedattNDBURN 77 77 m TwerobnaMt Fan speed tow ME me PAR11 HOLD FLAME ON HOLD FLAME funct
27. enu displays following main burner s indicators See Table 22 Table 22 INFO menu Screen text Description P 00 480 kw Actual and maximum power Max power can be changed from main menu T 181 C T Fire brick temperature 10 13 2 14 15 10 Primary fan s actual speed 13 Primary fan s set point speed Actual speed is controlled to match set point speed 2 Base air value Controller tries to keep speed set point base air In this case controller keeps speed 15 rps Speed unit is rps rotations per second 14 15 Same as above for secondary fan Base air setting is same 2 Ap 0 2 15Pa Pressure value of burning chamber 0 2 is currently measured pressure and 15 is set point in Pa Controller regulates flue gas fan speed to keep this pressure Depends also on PAR6O value pelltech 9501 1 www pelltech ee PV500 pellet burner p 33 45 Total 10 kg Roughly total amount of pellets burnt It is measured by counting internal feeder rotations Resettable by firmware upgrade Count 12 1 kg 180 254 Roughly the amount of pellets burnt resettable by user U 25V68 1 0 0 U DC power voltage 25V68 means 25 68V Feeders and or grate mo tor current Ver 3 88 12 11 13 Firmware version and date Menu BURNER enables to turn burner ON or OFF The main idea of HOLD FLAME function is to reduce permanent ON OFF cycles This function is useful if burner s
28. er and external auger can t reach the pellets Remove sawdust e Flame is disappeared at pre burning time or at burning time oFuel level sensor is dirty or broken Check sensor clean or replace if needed oFlame sensor is dirty or smelt Clean or replace sensor e Appears in screen for some seconds when turning on the burner olf me t disar b front panel e Feeder otations in 8 seconds at its running time oFeeder auger motor s rotation sensor is too far from magnet Check sensor s placement It has to be located maximally on magnet and not far than 2 3 mm Sensor has not to touch rotating parts of motor oFeeder motor s reducer may be broken if motor makes noise Replace both e Feeder auger motor current has reached its limit and over current protection applied oFeeder auger may be blocked or jammed by foreign object Remove obstacle e Fan has not reached enough speed at testing time Fan motor s rotation sensor is too far from magnet Check sensor s placement It has to be located maximally on magnet and not far than 2 3 mm Sensor has not to touch rotating parts of motor oFan doesn t rotate Bearings too dusty or fuse blown Clean bearings or replace fan oFuse has blown Replace fuse e The mains supply doesn t reach controller oBack burning and safety thermostat have turned mains off Possible reasons are poor draught too much ash in burner or in boiler or poor burning procedure Improve draught remove ash use o
29. igned to work at lambda values 1 2 1 5 for calculations choose value of 1 5 Flue gas fan must be installed between boiler and chimney If ash cyclone is used then flue gas fan must be installed between ash cyclone and chimney to avoid overpressure in cyclone and smoke leakage Burner setup Depending on burner s configuration weather inverter included or not the electrical connections may be different In case the frequency inverter has already been installed in factory to the burner the flue gas fan can be directly connected to the burner through connector Y8 Fan must be connected to burner with 3 wire cable 3x1 5mm Internal inverter output is x 230V If flue gas fan motor is a three phase motor 3 x 230 380V then it has to be connected as triangle In case the burner has on inverter the external inverter for flue gas fan can be used Inverter must be selected according to fan motor s parameters and available power supply The inverter must be switched to sink logic negative common To connect the external inverter with burner there is connector Y7 with 3 output signals sssss Delitech ege DK9501A1 www pelltech ee PV500 pellet burner p 22 45 T1 burner DC common ground must be connected with external inverter input common S3 inverters run command must be connected with F forward pin inverter input Burner will connect this pin to ground when fan must run B4 0 10V output for
30. ion is activated if two consecutive WAITING states have been shorter than set in this parameter Applies in AUTO status only PAR12 HOLD FLAME OFF Max time when burner holds flame HOLD FLAME function has to be set to AUTO PAR13 MIN POWER Minimum power level up to what burner decreases kW output power Applies in AUTO status only PAR14 MAX POWER Maximum power level up to what burner kW increasesoutput power Applies in AUTO status only PAR15 POWER UP Timeframe to burner to increase power to one level up if BURNING state lasts longer than set with this parameter Applies in AUTO status only PAR16 POWER DOWN Timeframe to burner to decrease power to one level down if BURNING lasts less than set with this parameter Applies in AUTO status only PAR17 UP CYCLE Pace of increasing targeted power level party steps PAR18 DOWN CYCLE Pace of decreasing targeted power level party steps PELLETS NORMAL Determines how many grams of pellets feeder g rot auger transports to burning chamber with one full rotation when PELLET NORM ie normal weight pellets are selected Determines how many grams of pellets feeder g rot auger transports to burning chamber with one full rotation when PELLET LIGHT ie lighter than normal weight pellets are selected DK9501A1 www pelltech ee PV500 pellet burner 42 45 PAR23 PELLETS HEAVY Determines how many grams of pellets feeder g rot auger transports to burning chamber with one full rotation when PELLET HEAVY ie
31. lets must be stored in a dry and ventilated room that is separated from the boiler room A tailor made silo for particular storage is recommended All safety regulation must be taken into consideration according to the local laws It is recommended to wear a respirator when handling pellets Refilling must be carried out before the storage runs empty 3 6 Electrical connections Following connections must be done by the electrical installer e 1 phase supply and boiler s thermostat to socket Y1 e 3 phase supply to socket Y2 e External auger to socket Y3 233 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 17 45 3 amp c amp 2 The burner is equipped with a standard oil burner plug that has 7 contacts Usually the burner is connected to the boiler with a 5 wire cable according to Figure 5 Tt bolier s thermostat It Boiler Figure 5 Thermostat connection Burner is designed to work at 230V single phase supply socket Y1 External auger is supplied by separate 3 phase 3x380V power socket Y2 Boiler should be equipped with thermostat or external switch what has to be connected to pins T1 and T2 in 7 pole plug Y1 for turning on off the pellet burner Feeder auger s motor is equipped with motor thermal protection which prevents motor from overheating As soon as the nominal trip temperature TNF of the sensor set point is exceeded the relay detects this v
32. llets together with ignitors Primary fan is located at left side of burner Fan has single phase motor with capacitor located in motor connection box For fan rotation speed measurement there is installed magnet on fan axle and hall effect sensor near it Primary fan power supply is connected through connector Y5 with control cabinet Power supply line is modified with triac relay to regulate the power delivered to fan motor Fan speed is depending about the delivered power Fast melting fuse F2 on control board is used for protection Rotation sensor is connected to connector FAN on control board Secondary fan 2 also delivers main burning air needed for gasification of the fuel Rotation sensor is connected to connector FDR on control board Secondary fan is connected through connector Y4 Igniter Igniter s main purpose is to ignite loaded fuel making the burning process start Igniters electrical supply for PV700 is connected through connector Y9 PV500 has 2 igniters su pelltech DK9501A1 www pelltech ee PV500 pellet burner p 7 45 Linear motor Linear motor moves the grates in burning chamber It s purpose is to move ash and half burnt pellets away from igniters and feeder Photocell Photocell s purpose is to recognize if there is flame in the burning chamber which gives signal to the controller to start igniters or not Level sensors Optical fuel level sensors recognize the fuel level in the
33. mware Burner corresponds to following directives and standards Directive 2004 108 EC Directive 2006 95 EC Directive 2001 95 EC Directive 2006 42 EC EN 15270 2008 EN 230 2005 EN 60370 2 5 2002 233 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 4 45 1 Set of components Part Quantity Burner s housing 1 Burning chamber frame Ceramic sealing Sealing rope Burning chamber bricks Side bricks Backside wall brick Front bricks Upper arc bricks Grate ladder Grate box Burning chamber grates Washer 13mm Distance nut 14mm M12x70 bolt M12x45 bolt M12x36 coupling nut Sprinkler connector 6 6 DID AD oD Notice Burner is delivered to client in fully put together 2m polyurethan hose and 2 fixating brackets are separately in set ssess Delitech 9e DK9501A1 www pelltech ee PV500 pellet burner 2 General description PV500 is a burner of wooden pellets sawdust granules that is intended for heating of the industrial agri cultural and public buildings Only wooden pellets with diameter 6 or 8mm can be used to run this burner You cannot use any other form of fuel Unique design of the burning chamber allows using industrial pel lets run the burner The construction allows burner to be used with different boilers liquid fuel solid fuel 5 45 and universal boilers The bu
34. nditions have changed in boiler s combustion chamber There are several reasons for such changes In order to secure operational and fire safety the burner PV500 is equipped with following safety devices e Back up batteries Enable to finish safely burning procedure in normal conditions or during unex pected black out in mains supply e Melting hose The external auger is connected to the burner with a special hose 76mm which is made from easily melting polyurethane material that interrupts when back burning takes place Such measurement avoids entrance of the flame from burner into external auger and pellets container e Thermostatic sprinkler valve Enables to extinguish the fire in feeder s augers tube by spraying water into it when burner is overheated due to possible back burning or any other reason e Firesafety water pressure control switch Enables to keep necessary water pressure in water reservoir and to ensure with that successful extinguishing procedure when needed Pressure control switch allows starting the burner only if water supply is present and pressure exists 2 3 Pellets Wooden pellets or saw dust granules are concentrated and homogenized wooden 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 neutral renewable fuel Its burn ing doesn t spoil CO balance in the atm
35. ng chamber Oxygen level control starts 5min after burner enters into BURNING status It can take about 10min for oxygen level to stabilize Oxygen level can be seen in INFO menu next to pressure reading The value on the screen must be divided by 10 to get the real value For example 02 113 means oxygen level value 11 3 ssess Delitech 9e DK9501A1 www pelltech ee PV500 pellet burner p 23 45 4 5 Ash removal system The burner can control external ash removal motor via grate motor connector 24V NO normally open relay must be connected in parallel to grate motor During cleaning cycle the relay is powered and switch es on external boiler ash removal motor FUEL FEEDERS Ash removal motor control LINEAR mG 4 6 External boiler temperature sensor TMP1 External temperature sensor enables the burner to maintain constant boiler s water temperature For that external temperature sensor has to be installed to relevant place on boiler existing burner s temperature sensor to be disconnected from TMP1 connector on controller s board and external sensor to be connect ed to connector TMP1 In parameters menu PAR53 value has to be chosen 2 When temperature holding status is activated then burner will change its capacity according to water temperature and speed of temperature changing Burner starts to change its capacity when BURNING status has lasted longer than set in PAR15 Capacity is changed after time set in P
36. ning the burner the boiler the smoke pipe and removing the ash e Boiler door must have openings for feed screw air holes etc and four 13mm holes for fixing the burner See and Figure 1 and Table 3 e boiler room where the burner is installed must fulfil all rules and recommendations given by local authorities e Boiler room must provide constant air amount of 1500 m per hour i e ca 1600 cm air inlet opening is needed Note If the burner is installed to the boiler the door or the installation flange s thickness should be 8 14mm Table 3 Diameters of holes Unit PV500 D hole for burning chamber neck mm 350 D 1 flange bolt ring diameter mm 400 D2bolt holes mm 6x13 a bolt hole offset angle deg 15 angle between bolt holes de g 60 Figure 1 Placement of mounting holes 02820 sssss segee p DK9501A1 www pelltech ee PV500 pellet burner p11 45 Boiler firebox depth must be at least 2 times longer than length of the burner s burning chamber The min imal length of the firebox L has to be 1200 mm The height of firebox must leave at least 100 mm for ash below burning chamber Minimum dimensions for height 560mm Pellet burners need regular cleaning and therefore boiler construction must allow easy opening of boiler s door without removing the burner The minimum size of opening in boiler s door depends on the position of door hinges Figure 2below illustrates the situation
37. nly quality pellets Poor burning may be caused by big amount pellets feed heavy pellets or poor stream of the air Change PAR23 heavier oGeneral blackout Wait for end Restart burner e Burner internal temperature reached over set point as fixed in setup menu e Possibly back burning is happened oBad connection of temperature sensor Check and improve if needed olnsufficient entrance of fresh air into the boiler room Draught to wrong direction Ensure availability of fresh air and improve draught s pelltech DK9501A1 www pelltech ee PV500 pellet burner p 36 45 GRATE ERROR Over current of grate movers motor has exceeded value set in PAR47 and over current protection has applied Ash removing grate has jammed before reaching extreme point Remove reason e Motors power screw got dirty and stops rotation Clean the screw Screen empty backlights on Screen empty no backlights e Controller error or screen error o Replace respective component e The contrast of screen is poor Contrast can be adjusted with small screwdriver by turning the resistor CONTR on down edge of controller In one extreme the screen displays nothing and in other extreme screen is filled with black rectangles e No mains supply oFuse F5 is blown only for controller SBB ver3 2 Replace fuse Annex 1 Burner status change logic Table 24 Burner change logic Status Ne
38. operly Extension board is connected to main controller by 2 wires TMP2 and TMP 3 as shown Figure 6 below Figure 6 Extension board connection Su pelltech es DK9501A1 www pelltech ee PV500 pellet burner p 19 45 4 Optional components 4 1 GSM modem Modem enables users to send up to 5 phone numbers the SMS messages with burner s error or status info on 8 rows Following products are needed to set up modem 1 Modem signal converter 005 connected between modem and UART plug See 2 Modem EP0007 3 Modem power cable 001 E X2 8 at x White af X2 4 C c Brown f alee ij B n o 9996 od b UART e 8 MU PT f 9999 GND _ a Rx 45V 7 o Figure 7 GSM modem connection Modem is connected according to diagram in Figure 7 Power supply cable is connected to pins X2 8 and X2 4 Adaptor EPOOOS is connected with modem and controllers UART plug Depending on the location of the modem extension cables may be needed Before inserting the SIM card to burner the following actions have to be done 1 SIM card must by activated by the mobile operator 2 PIN code request has to be switched out 3 Check by using mobile phone that it is pos
39. or flame disappearing in burning chamber In PAR27 is fixed the end blow time i e the time how long the fans continue to blow after flame s disappearing Table 20 END BLOW parameters Parameter name Default Unit Comment value PAR9 FAN END BURN 20 rps Fan speed at END BURN PAR39 FAN 2 MIN 7 rps Minimum speed of secondary fan Used at IGNITION PREBURN HEAT UP HOLD FLAME and END BLOW statuses PAR27 END BLOW TIME 2 min Time to blow air after flame is disappeared Max END BLOW 15 min Maximum time when flame must disappear at END time BLOW 5 5 Output power levels Burner has 6 pre set output power levels For every level the program calculates correct fuel amount what depends on fuel s calorific value and burner s internal feeder productivity The feeder productivity for normal light and heavy pellets can be changed from main menu For normal pellets it is 80 grams per rota tion PAR21 Calculated amount of fuel is divided into periodic feeding cycles In every normal cycle inter nal feeder makes half rotation If the calculated time of cycle comes too short then the cycle length will doubled and fuel will loaded with full rotation of feeder For every power level there is different pre set fan rotation speed PAR1 PAR6 Burner chooses the output level between pre set min and max powers When burning time has been more than 30 minutes PAR 15 next time burner takes one power
40. osphere Only premium ENplus A1 pellets can be used in PV500 Pellets must be stored in a dry and ventilated room Some key data for industrial and premium wooden pellets are given in Table 2 Table 2 Pellets key data Premium pellets Industrial pellets Raw material Stem wood wood processing whole trees bark logging resi industry residues dues Calorific value 4700 5100 kWh ton ca 4700 kWh ton Volume weight ca 650 670 kg m gt 675 kg m Volume of 1 ton pellets 1 5 1 6 m 1 5 m Diameter 6 10 mm 6 12 mm Length 3 5 x diameter ca 4mm Water content 8 10 96 ca 5 96 Ash content ca 0 596 ca 296 To replace 1000 light oil ca 2 tons or 3 m ca 2 tons or 3 m 8 pellbech e oso DK9501A1 www pelltech ee PV500 pellet burner p 10 45 3 Installation 3 1 Prerequisites to boiler and boiler house In order to install the burner the boiler must meet to the following requirements ltis recommended to use three pass boilers e 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 e If there is not sufficient less than 5Pa negative pressure in the furnace a draught fan should be installed for the exhaust gases e boiler must be positioned in a way that there is enough space for clea
41. ount 3 3 3 3 3 331 4 5 Ash removal system 2 6 4 6 External boiler temperature sensor 1 5 Operation and service 2 6 5 15 USER IMEE GEA CO 7 7 1 10 5 2 Starting and Stopplhp nere 5 3 Fuel re bi nc 5 4 Statuses and parameters sess enne nnne 523 pelitech eie DK9501A1 www pelltech ee PV500 pellet burner p 2 45 G Problems and solutions reusind 35 Annex 1 Burner status Change logic 2 6 37 7 JAnnex2 Electrical diagrams tete 3 111 1111 ERES 39 8 3 3 33 133 11 1313111111 l
42. ply Pressure hose Pressure switch Figure 3 Water sprinkler connection 233 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 16 45 3 4 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 80 which is made from easily melting material that acts as a safety measure against back burning PV500 fuel consumption at full power is 146 156 kg of pellets per hour 2 4 2 6 kg per minute External auger s productivity must be at least 190kg of pellets per hour The auger can be fixed to a storage container or a ceiling depending on the conditions at the installation site e While installing the auger you must keep in mind that e The raising angle of the auger must not exceed 45 e The end of the exit tube of the auger and the input of the burner must not be aligned The recommended minimal horizontal distance is 20cm e distance between the input of the burner and the exit tube of the auger must be at least 60cm vertically recommended distance is 80 200cm e Hose between auger and burner must be tight otherwise pellets will block the auger Falling angle must me between 65 and 85 All critical requirements to installation of external auger are depicted in Figure 4 Mo T oa Figure 4 External auger connection 3 5 Pellet storage Pel
43. quires systematic maintenance The maintenance period depends on the quality of the pellets and heating intensity The boiler must be cleaned weekly For more information about cleaning the boiler please see boiler s user manual The burner should be cleaned about two times in a heating season To clean the burner 1 Turn off the burner by turning the boiler s thermostat to O 2 Letthe burner cool down for at least 1 hour 3 Open the boiler s door to gain access to the burning chamber 4 Remove the grates and clean them from any residues Make sure that all air holes on the grates are clean 5 Remove the bottom panel to gain access under the grate movers to clean the ash from the burning chamber Place back the bottom panel 7 Place back the grates Make sure the stopper of grate is touching the burning camber from inside Misaligned base plate will interfere the air flow and reduce burning efficiency 8 Close the boiler s door to finish the maintenance and turn the thermostat to desired temperature The connection between the boiler and chimney must be completely airtight There mustn t be any ex tra draught in the smoke draft of the boiler All cleaning and maintenance openings must be closed with covers 6 Problems and solutions Table 23 Problems and solutions Message on Reason and solution screen BATTERY LOW e Battery voltage is less than 24V with load working feeder motor oWhen there was blackout then just wait when battery
44. recharges itself oReplace battery IGN ERROR e No flame detected at ignition time olgniter is out of order or fuse is blown Usually fuse blows when igniter is broken or its body is in short circuit Replace fuse or igniter oFlame sensor is dirty or smelt Clean or replace sensor if needed oAmount of pellets for igniting is too small If error is frequent increase amount of pellets PAR24 STOPPED e Burner is turned OFF from menu oTo turn burner on hold OK button down 3 seconds or set in BURNER menu OFF to ON ssess Delitech 969 DK9501A1 www pelltech ee PV500 pellet burner p 35 45 LEVEL ERROR NO PELLETS NO FLAME FEEDER ER ROR FAN ERROR NO POWER OVERHEAT e Feeder auger doesn t rotate oRemowve plastic hose and check is there any foreign object or very tall pellet jammed the feeder auger Remove obstacle e A fuel level sensor is dirty or melt Clean or replace sensor if needed oPoor draught dirty sensor Check sensor clean if needed Improve draught e Max loading time is reached but level sensor hasn t detected enough fuel in feeder or in burning state during 4 minutes no pellets detected oNo pellets in container Check existence of pellets refill container oExternal auger is broken Check fuse and connection with burner Replace fuse or auger oFuel level sensor is broken or short In this case transparent tube has to be filled with pellets Replace sensor oToo much sawdust in contain
45. rner is connected to the boiler by using a connection plate The burner is equipped with a safety thermostat a melting hose temperature sensor sprinkler system with pressure switch and auxiliary battery for protection against back burning Main technical data are given in Table 1 Table 1 Technical data Parameter Unit PV 500 Fuel Wood pellets 6 8 mm Input power burning at maximum kW 560 burning at minimum kW 160 holding flame kW 40 Power supply 230 240V 50 60Hz 16A Electrical power consumption burning at maximum W 600 burning at minimum W 160 igniting W 1100 standby W 20 Overall dimensions length mm 1065 width mm 606 height mm 523 Burning chamber dimensions length mm 585 width mm 506 height mm 452 Burner weight kg burning chamber frame kg 30 grates kg 18 ceramic tiles kg 53 burner body kg 32 Burner weight with package kg 130 RR pelltech tege DK9501A1 www pelltech ee PV500 pellet burner p 6 45 2 4 Main components Internal feeder Internal screw feeders are used to deliver correct amount of fuel into burning chamber Delivered fuel amount is regulated by periodical work of feeder gear motors Air fans Primary fan 1 delivers main burning air needed for gasification of the fuel Primary air is also used to burn down the gasified fuel charcoal and to ignite the pe
46. sible to pre set particular 160 240 or else power level value or AUTO automatically selected value In AUTO status burner selects necessary power level depending on time what is needed to achieve pre set temper ature Burner changes its capacity what is determined by parameters MIN POWER PAR13 and MAX POWER PAR14 If burner cannot achieve pre set temperature in certain time PAR15 it will raise its pow er automatically by one level and continues rising power up to reaching maximum level PAR14 or boiler has achieved pre set temperature If boiler achieves pre set temperature faster than set in PAR16 burner will work one power level lower in next cycle Power will be reduced as long as burner has reached minimal power level PAR13 Menu BASE AIR increases or decreases speed of fan in all power levels by same number It is reasonable to use base air to balance different characters of particular heating systems For example if draught is very strong the fan can work at lower speed and thus reduce the draught Menu LANGUAGE enables user to select between 17 languages List of languages is in Annex 3 Menu PARAMETER gives overview of burner s default and minimal maximal settings The menu enables fine tuning of the burner what in general is not necessary Short description of burner s parameters is given in Annex 3 ee sssss pelltech ege DK9501A1 www pelltech ee PV500 pellet burner p 34 45 5 7 Regular maintenance Pellet burner re
47. sible to send SMS with this SIM card 4 In SIM card s phonebook must be only the numbers where to the messages from the burner will be sent s pelltech DK9501A1 www pelltech ee PV500 pellet burner p 20 45 To insert the SIM card the modem has to be discon nected from supply mains To insert the card push it into a slot as long as its spring clicks See Figure 8 To remove card push it in as long as spring clicks and pushes it out In order to activate SMS sending in burners menu PAR52 has to be changed Value shows for how many numbers the message will be sent 0 means no mes sages to be sent 2 means that messages will be sent to 2 first recipients in SIM card Figure 8 SIM card insertion SIM card connector Modem has two indicators Green one shows that modem is turned on Red one shows modem status Modem s statuses are described in Table 5 Table 5 Modem statuses Red LED indicator Modem status Permanently on Sending message on going call Fast interrupt sequence period 0 5 s Ton 1s Net search Not registered Turning off Slow interrupt sequence period 0 3s Ton 3 sec Registered full service Permanently off Device is turned off 4 2 Error output It is possible to connect to burner additional device like pump or modem what switches a device on or off when error occurs in burner The error output is marked with ERR and is located on controllers upper part Red arrow on Figure 9
48. t lt 40 9 Annex4 Table 5 111641 1 0 42 10 Annex List of StatUses 44 11 1 3333331333133111 11 uas 45 ME rr H 46 Figure 1 Placement of mounting holes 6 11 Figure 2 The burner has to reach out of boiler esses esee eene ener esent enn 12 Figure 3 Water Sprinkler COMMECtION icc 3 3 111 90 16 Figure 4 External auger conrectiOD 17 Fig re 5 Thermostat COnFiection 3 33 7377 111111111 18 Figure 6 Extension board connection ete 3 111 09 19 Figure 7 GSM modem connection otro verde 3131111 11111 1111111111 20 Fig re 8 SIM 33 3 33 33 3 3 001 21 Fig re 9 ERROR output 7 1 0 22 Figure 10 User interface on
49. tart up takes now longer about 20 minutes because external auger has to be filled with pellets like in initial start up Turn burner from BURNER menu ON Vice versa the LEVEL ERROR is displayed because loading time is exceeded 5 4 Statuses and parameters PV350 pellet burner operates in many different states which are called Status Log screen STATUS menu displays last and actual events burner statuses and their duration Burner changes its statuses based on received input signals from sensors and values set by user The statuses in typical working order of cycles are given in Table 10 The duration of all actions are in form mm ss m in the middle or hh mm h in the middle For example IGNITING 01m25 means the burner ignition state lasted 1 minute and 25 second Lower row of the log shows burner s current state To reach the lower row press the down 4 button until you reach the lower row with current state The duration of current state updates every second or every minute Changed data blinks sssss pelltech ege DK9501A1 www pelltech ee PV500 pellet burner p 26 45 Table 10 Summary of burner statuses Status Short description WAITING Waiting when boiler s thermostat switches on TESTING Boiler s thermostat is switched on testing the battery fans feeder level sensors and draught in progress CLEANING Ash removing from burning chamber LOADING
50. vertical pipe Fuel is recognized when pellets pass the optical beam between optical sensors Water sprinkler pelitech DK9501A1 www pelltech ee PV500 pellet burner p 8 45 The sprinkler system is only activated when the temperature of inner auger rises dangerously high Sprinkler system will spray water to extinguish the fire The burning chamber must be cleaned from wet ash before turning the burner on again Pressure hose and reservoir should be used with water supply connection to the sprinkler is designed to be made with threaded 1 2 inch connection System should stay active even when there is a power failure Battery When there is no power from the main power supply then the burner is operating from battery power PV700 uses two 12V 3 4 Ah batteries with 6 3A fuse F6 Because battery is a safety element burner controls batteries condition and does not start next working cycle if the batteries voltage is too low Inverter for flue gas fan optional Inverter is an electrical device that converts direct current DC to alternating current AC The converted AC can be at any required voltage and frequency with the use of appropriate devices example flue gas fan for PV burners e 383 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 9 45 2 2 Safety devices The back burning is the biggest danger risk at burners working procedure Back burning appears when usual pressure or draught co
51. wall 233 pelitech DK9501A1 www pelltech ee PV500 pellet burner p 14 45 4 The tips of the igniters must reach as deep into the burning chambers internal feeding screw Ensure the tips of the igniters are not touching any metal parts in side the burning chamber Fix the igniters in place with a screw Notice The tips of igniters have to be on same level with tubes ends hold ing them Su pelltech DK9501A1 www pelltech ee PV500 pellet burner p 15 45 5 Install the ceramic tiles and the grates on to the burning chamber in order as shown in figure 3 3 Water sprinkler Principal chart of water sprinkler installation is depicted in Figure 3 Water sprinkler is main safety element against back burning It is strongly recommended to install sprinkler system 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 auger s tube Flow control valve limits the amount of water flowing into burner after the reservoir is emptied Caution The burning chamber must be cleaned from wet ash and pellets before turning the burner back on again Water reservoir Water sup
52. xt Status Change conditions WAITING TESTING Boiler s thermostat switches on TESTING LOADING All tests are passed successfully BATTERY Battery voltage is less than 24V in burdened status ERROR FAN ERROR Fan does not reach 40 rps at PRE BURN LEVELERROR The level sensor recognizes pellets in the feeder LOADING IGNITING Feeder makes loading rotations 40 rot min PAR24 NO PELLETS Maximum loading time 5 min normal or 20 min initial is reached END BURN Flame detected and unknown start conditions LOADING restarts LOADING 2 IGNITING Previous state was ignition and feeder made 3 rotations PRE BURN Previous state was hold flame and feeder made 3 rotations IGNITING PRE BURN Flame recognized by flame sensor LOADING 2 Max ignition time 255 sec is reached and load 2 is not done IGN ERROR Max ignition time 255 sec is reached and load 2 is done PRE BURN BURNING 3 pre burn cycles each 40 sec are done and continuous flame is recog nized more than 10 seconds LOADING 2 Pre burn cycles are done and flame is NOT recognized and load 2 is NOT done 02220 20900 pelltech DK9501A1 www pelltech ee PV500 pellet burner p 37 45 NO FLAME Pre burn cycles are done and flame is NOT recognized and load 2 is done HEAT UP BURNING Pellets are burning power is added step by step in order to slow down heating up of the burning chamber s ceramic stones in order to mini mize
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