Greenflame 18kw Slim Installation Manual
Contents
1. L1 12 L3 L4 L5 6 L7 L8 L9 MNO L11 L112 n sc A P2 C Ps P3 C C2 P6 FUNCTION DESCRIPTION ON OFF Function Ignition Extinguishing by pushing the button for 3 seconds until the acoustic signal UNBLOCK Function Unblock When the system is in block by pushing the button for 3 seconds until the acoustic signal MODIFY WA US In modify mode change menu and INTO MENU submenu values B O U In menu run or submenu and menu AND SUBMENU ESC Function Exit managed by pushing the D button if in a menu or a submenu Out of menu Pump Test MENU Function Enter in menu or in a submenu MODIFY Enter in modify mode into a menu SET Save date in a menu Aasi loe In Chrono menu gt Chrono Program PROGRAMMING enables the selected program KEYBOARD To lock keyboard keys keep this button KEYLOCK pressed for 3 seconds To unlock repeat the same procedure GREENFLAME BIOMASS a Chrono System State Locked Buttons eefe T ignitidh ens tne me oe ee ll Flame 65 Status A SS SSeS Exhaust Boiler Boiler enable Day and Time Temperature Temperature Thermostat 7 1 Error Codes ERRORS DESCRIPTION DISPLAY Error activation thermostat high voltage Eo TE roa Exhaustovertemperature SEO Water pressure low Waterpressurehigh TEL Real time clock error Eri O Ignition failed CSC Accidental extinguishing for low exhaust temperature ras Error activation pre2. and a buffer tank to protect the boiler from water boiling in the central heating system 6 7 Water Connections The diagram below indicates the plumbing connections at the rear of the boiler The return connection is factory fitted with a 15 60 standard pump N Incorrectly sized expansion vessel will invalidate the warranty A minimum 18 litre is recommended for the boiler plus additional expansion for heating and domestic hot water system A Ensure that the pre charge in the vessel is equal to the initial system fill pressure of between 1 1 5bar The boiler can be plumbed into either an open vented system the maximum static head of water permissible is 90ft 27 44m or a sealed system If plumbed into a sealed system an appropriately sized expansion vessel should be used and installed as per manufacturer s instructions The expansion vessel should be sized based on the water capacity in the boiler and the water in the entire heating system The pump is on the return pipe work just before the boiler It is recommended that a by pass pipe between the flow and return is used with a valve to regulate the temperature of the water returning to the boiler Also the system designed should ensure that there is adequate provision in the system for heat dissipation from the boiler during the shut down extinguishing phase An automatic 12 Greenflame Slim Wood Pellet Boiler 18kW air vent and pressure relief valve must be fit
3. ask T R Engineering Ltd or your authorised dealer for another copy 2 3 Guarantee Warranty Information T R Engineering Ltd offers the following warranties on this appliance Leaks in the heat exchanger 5 years Faulty electrical components motors fan controller 1 year Pump ignition element 1 year From the date of first ignition of the appliance as proved by a valid commissioning report which gives the name of the installer commissioning engineer and the date on which the commissioning took place The guarantee is conditional on the commissioning report being filled in and returned to the manufacturer within 10 days and requires that the product be installed and commissioned by an approved T R Engineering Ltd GREENFLAME BIOMASS BOILERS installer according to the detailed instructions given in the instruction booklet supplied with the product The term guarantee is to be understood to denote the free of charge replacement or repair of parts only recognised to have been defective at the start by reason of manufacturing defects 2 3 1 Limitations The above guarantee does not cover parts subject to normal wear such as gaskets fibre board on doors and any parts which can be removed from the firebox such as burner pot baffles and ash box The replacement will be guaranteed for the remainder of the guarantee period starting from the date of commissioning of the product 2 3 2 Exclusions The warranty excl
4. workshop or tool shed is prohibited The floor of the room where the appliance is to be installed must be strong enough to take its weight If the walls are flammable position the appliance with a clearance to the rear of 450mm 300mm on the sides and 1500mm at the front If the flooring is made of wood provide a floor protection surface in compliance with current national standards BH Service Clearances The minimum service clearances around the appliance are as follows Rear 50mm Nominal Ends 300mm Front 600mm Concrete plinth should extend 300mm past the front and ends 5 4 Connection of the Flue The proper draught conditions in the flue are critical for the efficient working of wood pellet boilers The flue can exit the boiler house garage through the roof or through the wall by using a bend on the flue The combustion chamber works in negative pressure The smoke duct for the discharge of fumes will also be under negative pressure when connected to an efficient flue pipe as directed All sections of the flue must be capable of inspection and removable to enable periodic internal cleaning Position the appliance bearing in mind all instructions and considerations above IMPORTANT All 90 changes of direction in the flue pipe must be A either removable or capable of inspection For locating gt the boiler against a wall ensure adequate flue support using approved wall brackets THE FLUE PIPE
5. 1 Error Codes Boiler Operation and Maintenance 8 1 Turning ON and OFF the Boiler 8 2 Emptying the Ash Pan 8 3 Filling the Hopper with Fuel Technical Data 10 Maintenance Schedule 11 Service Log GREENFLAME BIOMASS BOILERS 3 go D pa e NNNO OQI UUUHunH PH HBwWWw i W N UI oO o 00 oo a 11 12 11 11 11 11 12 12 12 13 13 14 15 14 14 15 15 16 17 Greenflame Slim Wood Pellet Boiler 18kW 1 Introduction Dear Customer We wish to thank you for choosing this Greenflame wood pellet boiler product from T R Engineering Ltd In order to get the best performance from your appliance we recommend that you read this booklet carefully before lighting the appliance for the first time While thanking you again may we remind you that the appliance MUST NOT be used by children and that they must always be kept at a safe distance from it Revisions to the publication In order to improve the product to keep this publication up to date the manufacturer reserves the right to make notifications without any advanced notice Any reproduction even part in part of this manual without the consent of T R Engineering Ltd is prohibited Care of the manual and how to consult it e Take good care of this manual and keep it in a place which can easily and quickly be reached e If this manual should be lost or destroyed or if it is in poor condition ask for a copy from your retailer or directly from the manufacturer pro
6. isolation fuse is accessible IMPORTANT A The boiler must be connected to a flue pipe or vertical duct which can discharge the fumes at the highest point of the building The fumes are however derived from the combustion of wood products and if they come into contact with or close to walls they can cause smoke staining Also take care because the fumes are very hot and almost invisible and can cause burns on contact 5 3 Operating Area For proper functioning the appliance should be positioned in a location where it is able to take in the air necessary for combustion of the pellets about 40m h must be available as laid down in the standard governing the installation and in accordance with local national standards All louvers on the external casing of the boiler must be un obstructed at all times as these allow air for combustion 6 Greenflame Slim Wood Pellet Boiler 18kW and for cooling to enter the appliance enclosure Heavy snowfall can also obstruct the air in take louvers and cause the appliance to not burn clean Smoke emanating from the flue is a symptom of this Snow must be cleared from around the appliance at the earliest opportunity Where the appliance is to be installed indoors it is not permissible to install the appliance where another heating appliance is installed fireplace stove etc which does not have its own independent air in take Locating the appliance in a room with an explosive atmosphere e g
7. on your time clock it is recommended that you program the clock for long runs instead of short runs This gives the boiler time to settle and match the heat demand of the property It is also when the boiler is most efficient e If the boiler is not being controlled by a time clock then it can be turned on and off locally at the display on the boiler control panel Hold the ON OFF button for 3 seconds to start the boiler Hold the ON OFF button for 3 seconds to turn off the boiler 8 2 Emptying the Ash Pan e The boiler contains two areas where ash needs to be removed at regular intervals e The primary ash pan is located in the main combustion chamber The frequency of emptying the ash pan is determined by the length of time the boiler has been running and under what load conditions Once the ash in the ash pan has reached the top then it should be emptied A daily check during the first few days of operation will give an indication as to when it needs to be emptied Always make sure that before you open the main combustion chamber door that the boiler has been switched off and has been allowed to cool down sufficiently so as to not cause injury Always empty ash into a metal container as ash which may appear cool could be hot in the centre Never use plastic brushes or dust pans to clean ash from the boiler Always use heat resistant gloves when handling the ash pan or cleaning the boiler GREENFLAME BIOMASS BOILERS 4 Whe
8. the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England In Scotland and Wales this power rests with ministers in the devolved administrations for those countries Separate legislation the Clean Air Northern Ireland Order 1981 applies in Northern Ireland Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been authorised in regulations and that appliances used to burn solid fuel in those areas other than authorised fuels have been exempted by an Order made and signed by the secretary of State or minister in the devolved administrations Further information on the requirements of the Clean Air Act 1993 can be found here http smokecontrol defra gov uk Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision 2 5 Customer Handover After every commission the customer MUST be provided with training by the commissioning engineer The following is a list of items which should be covered during the product induction with the customer e Provide a general overview of the product and identify the main components and their function e Illustrate how to turn on and off the appliance and adjust water temperature through the user menu e Demonstrate where and how to fill the appliance with fuel and advise of the correct quality of fuel to be used e Demonstrate how to clean down th
9. x2 The user manual pack includes a user manual quick step user instructions commissioning report keys for lockable doors and heat proof gloves Elue components listed above may vary depending on where the boiler is being installed Please check with the installer Hopper Hopper Supplied in separate packaging 6 2 Preparing the Base Careful planning at an early stage will greatly help the installation process and make sure that all required clearances are adhered to for servicing and that any potential issues with the routing of the flue can be resolved The Greenflame pellet boiler should be positioned on a concrete plinth at least 50mm high and should project a minimum 300mm beyond the sides and front of the appliance The plinth must be capable of supporting the weight of the appliance when full with fuel and the plumbing system has been filled with water Use the template below for constructing the plinth and for positioning the flow and return pipe work and electricity supply A Refer to the service and access clearances around the appliance on Page 7 GREENFLAME BIOMASS BOILERS Base BACK FRONT 6 3 Electrical Connections Electrical installations should only be carried out by suitably qualified and certified electricians If in doubt on any issue relating to the electrical connections on the appliance contact T R Engineering Ltd technical support or your local dealer for guidance before carr
10. Probe Greenflame Slim Wood Pellet Boiler 18kW 6 5 Auger Set Up Optional S i S23 azn HEF gagag B28 BASS ZF FFF meenomen FNLI r22 AQKRARARRAS zau V V zu SES T 25 zi s5 8e2 4 PINO ZLYNI HYNI SING 9170 uno gino 61NO OMNO HNO ZNO a 3 2 32 Brg a a ore 68 N 3 i ono 35 67 F s amp s 36 6N z l cn 37 or 8 ses 38 64 e ono 39 esl z B o 40 omo 41 S eo 42 s7 S 5 j i i i fee ee Blue Configure Controller to Operate Motor In System Menu gt Default Settings gt set P50 2 to activate the Loading Motor Function In System Menu gt Timers gt Set T24 to 300 seconds Set T23 to 600 for the amount of time to fill hopper Re set Er18 if showing on the display Press and hold power button to re set if required Run outputs test on auxiliary output to prime auger This will take several attempts due to maximum run time of 90 seconds per test Greenflame 25 wait 30 seconds for Belimo valve to open Alternatively connect auger to temporary power supply and run until pellet appears at auger outlet anid GREENFLAME BIOMASS BOILERS Relay Contactor Brown Motor Supply MCB Sized to Suit Motor Blue Please ensure you check the grub screw is correctly fitted between the auger screw and motor 10 Greenflame Slim Wood Pellet Boiler 18kW 6 6 Vacuum System Set Up Optional 6 6 1 Description Feeder Feeder addition
11. RUN MUST NOT INCLUDE MORE THAN 2 3 METRES OF HORIZONTAL PIPE AND MORE THAN THREE 90 ELBOWS INCLUDING T s IT IS ALSO ADVISABLE NOT TO EXCEED 8 METRES IN LENGTH WITH THE PIPE DIAMETER OF 100mm DIAMETER SONA EOLERS e 5 5 Operating Problems Caused by Draught Defects in the Flue Of all the weather and geographical conditions which affect the operation of a flue pipe rain fog snow exposure to sunlight direction of facing the wind is unquestionably the most decisive In fact along with thermal depression caused by the difference in temperature inside and outside of the chimney there is another type of depression or over pressure dynamic pressure caused by the wind An up draught always increases depression provided the cowl has been installed properly A down draught always decreases depression at times inverting it Least favourable points WIND H Y Ato N 24 A fe _ E itt oe e High pressure Low pressure zone ms N Downdraft d A i if N T f l j Besides the direction and force of the wind the position of the flue and cowl with respect to the roof of the building and surrounding landscape is important The Greenflame air flow regulation system is equipped to deal with the conditions referenced above by regulating the air flow through the combustion chamber an air flow sensor is mounted on the air in take duct and measures the volume of air dr
12. al Top sensor Bottom sensor ON OFF Exit settings cancellation Entrance to menu Minus down 6 6 2 Installation 1 Remove 2 pin plug from power lead and connect to the power connections of the controller Supply must come from a 13A switched fused spur settings to approval i Fower Feeder jAddtensiivedes Ce NIL ke NIL ee MN AN n 2 Connect vacuum motor cable to feeder connections 3 Using the sensor bracket and back nuts fit the low sensor 250mm from the bottom of the hopper and the high sensor should be approximately half way up the hopper high and low sensors can be identified from the controller connections 4 Fit vacuum pipe supplied with the unit to the motor connection on the back of the unit 6 6 3 Controller Functions Main Page The main page is shown in the LCD display during normal operation with the following data displayed on it e Current time e Feeder current mA e Icon if the night mode is active F GREENFLAME BIOMASS BOILERS By pressing the MENU button the sub menu is entered or the selected option is activated Press the EXIT button to exit the menu or cancel the setting Manual Operation The controller is equipped with the manual operation mode for user s convenience When using that function each is turned on off independently from the others By pressing the MENU button of the selected unit feeder additional feeder or alarm i
13. aning or maintenance operation make sure in advance that the appliance is isolated form the mains electricity supply by removing the mains isolator fuse The appliance must be connected to an electrical system which is equipped with an earth conductor as laid down in directive 73 23 EEC and 93 98 EEC The fuse must be of adequate rated capacity for the stated electrical power of the appliance Incorrect installation or faulty maintenance not conforming to the requirements set out in this booklet can cause harm to people animals or property In such cases T R Engineering Ltd is absolved from any civil or criminal responsibility 0 Adhesive sealants and paints used in manufacture of the product are cured and present no known hazards when used in the manner for which they were intended The appliance contains no asbestos 2 2 Operating Warnings Shut the appliance down in the event of a breakdown or bad running Greenflame Slim Wood Pellet Boiler 18kW Pellets must not be fed manually into the burner Accumulated un burnt pellets in the burner after repeated failed ignitions must be removed before re lighting Do not wash the inside of the heat exchanger with water Do not wash the appliance with water The water could get inside the unit and damage the electrical insulation and cause electric shocks Do not put any fuel other than wood pellets in the hopper Install the appliance in a location which is suitable fo
14. annual services Appliance Serial No Cust ID No Installation Date Commissioning Date lt Service Centre and Technical Support Tel 0114 257 2300 Fax 0114 257 1419 Hours of Business Monday Thursday 8 30am 17 00pm Friday 8 30am 14 30pm 4 How Your Greenflame 18kW Pellet Boiler Operates The Greenflame 18kW user interface has been designed to allow the user to carry out the basic operational and maintenance functions while an advanced digital control system operates in the background controlling combustion temperature control and modulation within the pre determined safety parameters Each Operational cycle has several distinct phases Greenflame Slim Wood Pellet Boiler 18kW Run mode Modulation Be SN SK AS Ignition Ignition Ignition is the phase where the initial ignition of the fuel takes place and develops a fire bed with enough heat and intensity to enter run mode Sub stages within the ignition are Pre Heating During this stage the heating resistance heats up to a temperature to ignite the fuel Pre Load A starting charge of fuel is introduced into the burner Variable Ignition Ignition of the fuel is attempted by directing hot air at the fuel If a flame is detected by the end of this stage it enters the last stage of ignition Stabilisation This final ignition stage aids further development of the flame before allowing the system to e
15. awn through the burner pot by the exhaust fan If down draught conditions are present and air flow increases the exhaust fan increases speed to maintain the required air flow The opposite reaction occurs in up draught conditions IMPORTANT In areas of extreme weather especially wind additional measures may need to be provided for in consultation with T R Engineering Ltd Flue draught stabilisers will be required where natural draught of gt 100Pa is present or anti downdraught cowls will be required where down draught of gt 10Pa exists 5 6 Plumbing Connections Important The connection of the boiler to the plumbing system must be carried out ONLY by specialised personnel who are capable of carrying out installation properly in compliance with current standards in the country of installation If the installation of the boiler will involve interaction with another pre existing system complete with heating equipment gas boiler methane boiler fuel oil boiler etc it is even more advisable to call in qualified personnel who subsequently will be responsible for conformity of the system with current applicable law T R Engineering Ltd will not be held responsible for damage to persons or things in the event of failed or incorrect operation if the aforementioned warnings are not complied with For connection of the plumbing system to the appliance the user should refer to Chapter 4 INSTALLATION AND ASSEMBLY specifically parag
16. e combustion chamber by removing and replacing the baffles emptying the ash containers in the main combustion chamber and lower ash chamber e Explain how to remove the burner grate and clear the air holes to ensure good combustion e Explain the various error codes that may appear and provide instruction on how to manage and clear messages Provide warnings on which error codes are system critical codes and should not be reset by the customer e The customer must be warned of the safety implications when handling hot ash and that heat proof gloves should be used The product warranty must be explained to the customer and they Shall sign the commissioning card confirming that they have received instructions on how to operate the appliance understand the risks when handling hot ash and agree to the product warranty The warranty card and commissioning report shall be returned to T R Engineering Ltd by fax email or post within 30 days from the commissioning date 3 After Sales Service Information A qualified field service engineer is available to attend a breakdown occurring during the boiler s guarantee period GREENFLAME BIOMASS BOILERS The boiler must be made available for attendance during normal working hours Monday to Friday 3 1 How to Report a Fault Step 1 Contact your installation or service engineer who should assess the unit and works carried out on the appliance prior to requesting the attendance of an
17. ean the flue gas thermocouple e Remove the fans and check for dust Never touch the wires and only clean with an air blow e Completely clean the flue through the inspection door e Remove the burner pot and remove any loose ash in the pot holder e Ensure all air holes in the burner pot are clear and check the rope seal that it maintains a seal when replaced in the holder e Replace the Ignitor and adjust accordingly e Check sealing rope and tape on the lower ash pan door and main combustion door that it maintains a good seal Replace if necessary e Check the ceramic board on the combustion chamber door and replace if necessary e Disconnect and remove the auger motor e Remove the auger and clear out any debris Refill with fuel and re prime the auger e Check auger calibration e Check all outputs tests as per commissioning guide Heat Exchanger Clean e Remove and empty both ash containers e Remove baffles and completely clean down heat exchanger surfaces e Remove the burner pot and remove any loose ash in the pot holder e Ensure all the air holes in the burner pot are clear and check the rope seal that it maintains a seal when replaced in the holder e Check sealing tape and rope on the lower ash pan door and main combustion chamber door respectively and check that it maintains a good seal Replace if necessary Emptying of Ash Containers and Clean Down of Boiler Surfaces e Remove and empty the main ash conta
18. econds before switching on again Er18 Lack of Pellet When the pellets reach the pellet sensor in the hopper the system extinguishes to prevent having to re prime the auger Refill the hopper and hold button B for 3 seconds Turn off the time clock for 10 seconds before switching on again Er34 Low Vacuum Pressure Clear the error by holding button B for 3 seconds Turn off the time clock for 10 seconds before switching on again Er35 High Vacuum Pressure Clear the error by holding button B for 3 seconds Turn off the time clock for 10 seconds before switching on again 8 Boiler Operation amp Maintenance The Greenflame 18kW slim has been developed to ensure that the user is able to carry out the most basic functions in a safe and convenient manner Once the installation has been successfully carried out the user interaction is quite simple from a regular inspection on the combustion chamber to removing ash to filling the hopper with pellets 8 1 Turning ON and OFF the Boiler e It is recommended that your boiler is controlled by an external time clock The time programs should be set to times that heat is required at different periods throughout the day You should also make allowance for the ignition time of the appliance i e the time it takes from when the time clock signals the boiler to start until the flame has fully developed in the appliance usually approx 10 20 minutes e When choosing your programs
19. ee GREENFLAM TRIAN BIOMASS BOILERS Greenflame Slim Wood Pellet Boiler 18kW Internal amp External Installation operation and Servicing Instructions PLEASE NOTE This product MUST be commissioned by a T R Engineering Ltd representative Please contact T R Engineering Ltd to arrange the commission immediately after install Please read these instructions carefully before installing and operating this appliance TO BE RETAINED BY THE HOUSEHOLDER Greenflame Slim Wood Pellet Boiler 18kW Contents 9 Introduction Warnings and Guarantee Warranty Information 2 1 Safety Instructions 2 2 Operating Warnings 2 3 Guarantee Warranty Information 2 3 1 Limitations 2 3 2 Exclusions 2 4 Clean Air Act 1993 2 5 Customer Handover After Sales Service Information 3 1 How to Report a Fault 3 2 Technical Assistance How Your Greenflame 18kW Pellet Boiler Operates Pre Installation Considerations 5 1 Pellets 5 2 Considerations for Installation 5 3 Operating Area 5 4 Connection to the Flue 5 5 Operating Problems Caused by Draught Defects in the Flue 5 6 Plumbing Connections Installation and Assembly 6 1 Unpacking 6 2 Preparing the Base 6 3 Electrical Connections 6 4 Control Panel Schematic 6 5 Auger Set Up Optional 6 6 Vacuum Set Up Optional 6 6 1 Description 6 6 2 Installation 6 6 3 Controller Functions 6 6 4 System Menu 6 6 5 Technical Data 6 6 6 Assembly 6 7 Water Connections Control System 7
20. engineer from T R Engineering Ltd Step 2 Please note that upon attendance by T R Engineering Ltd engineer a charge will be made where The engineer finds no fault with the boiler The cause of the breakdown is due to parts of the system not manufactured or supplied by T R Engineering Ltd The boiler has not been installed in accordance with these instructions The boiler has not been commissioned by a qualified engineer The boiler has not been serviced annually since installation The breakdown occurs outside the guarantee period The appliance has not been maintained correctly The breakdown occurs as a result of work on the appliance by an unauthorised third party Important Invoices for attendance and repair work by any third party will not be accepted unless authorised in advance by T R Engineering Ltd 3 2 Technical Assistance A team of trained technical advisors are available to discuss any problem with the appliance In many cases the problem may be solved over the telephone eliminating the need for an engineer s visit Before making contact please have the following information ready The appliance serial number or your unique customer identification number issued upon registration of the appliance with T R Engineering Ltd A description of the fault and any unusual behaviour by the boiler before the failure occurred The installation and commissioning dates and the details of any
21. ents natural disasters electrical discharges fire defects in the electrical system and caused by lack of or incorrect maintenance in terms of the manufacturer s instructions Claims under the Guarantee o The request for action under the guarantee must be addressed to the dealer retailer who will forward the claim to T R Engineering Ltd s technical assistance service T R ENGINEERING LTD DECLARES THAT THE APPLIANCE WHICH YOU HAVE PURCHASED COMPLIES WITH THE EEC DIRECTIVE 2004 108 EC AND 2006 95 EEC AND SUCCESSIVE AMENDMENTS A T R Engineering Ltd refuses to accept any responsibility in the event that the appliance or any other accessory has been improperly used or modified without authorisation For all replacement of parts only original T R Engineering Ltd spare parts must be used Greenflame Slim Wood Pellet Boiler 18kW 2 4 Clean Air Act 1993 Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area It is an offence to emit smoke from a chimney of a building from a furnace or from any fixed boiler if located in a designated smoke control area It is also an offence to acquire an unauthorised fuel for use within a smoke control area unless it is used in an exempt appliance exempted from the controls which generally apply in the smoke control area The secretary of State for Environment Food and Rural Affairs as powers under
22. h a moisture content which varies from 5 to 8 by weight Besides being ecological fuel exploiting timber residues to the maximum and achieving cleaner combustion than is possible with fossil fuel pellets also have technical advantages While good quality timber has a calorific power of 4 4kW kg with 15 moisture therefore after about 18 months seasoning the equivalent figure for pellets is 4 9kW kg To ensure good combustion the pellets must be stored in an area that is free of humidity and protected from dirt The pellets are usually supplied in 10kg bags so storing them is very convenient Good quality pellets ensure good combustion thus lowering the emission of harmful agents into the atmosphere The poorer the quality of fuel the more frequently intervention be necessary for cleaning the internal parts such as the grate and the combustion chamber Standby Extinguishing GREENFLAME BIOMASS BOILERS The main certifications of quality for pellets in the European market are ENplus A1 these ensure respect of Calorific Power 4 9kW kg Water Content max 10 of weight Percentage of Ashes max 0 5 of weight Diameter 6mm Length max 30mm Contents 100 untreated wood with no added bonding substances bark percentage 5 max Packaging in sacks made from ecologically compatible or biologically decomposing material A T R Engineering Ltd recommends using certified fuel in its appliances to ENplus A1 The use
23. iner every week or more frequently if required e Clean down boiler surfaces when emptying main ash container e Remove and empty the secondary ash container every 2 weeks or more frequently if required Ensure that the secondary ash pan door is fully secured and air tight 16 Greenflame Slim Wood Pellet Boiler 18kW 11 Service Log Service Provided Service Provided Service Provided Service Provided Service Provided Service Provided Service Provided Service Engineer Service Engineer Service Engineer Service Engineer Service Engineer Service Engineer Service Engineer GREENFLAME BIOMASS BOILERS 17 TRIANCO T R Engineering Ltd Unit 7 Newton Chambers Way Thorncliffe Industrial Estate Chapeltown Sheffield S35 2PH United Kingdom Tel 0114 257 2300 Fax 0114 257 1419 E mail info trianco co uk Web www trianco co uk OT R Engineering Ltd Copyright in this brochure and the drawings and illustrations contained in it is vested in t R Engineering Ltd and neither the brochure nor any part thereof may be reproduced without prior consent T R Engineering Ltd s policy is one of continuous research and development This may necessitate alterations to this specification 400008 April 2014
24. invalidate the warranty Always close the lid to the hopper once it has been filled with pellets Never leave the hopper lid open for prolonged periods as rain or moisture can affect the pellet Always supervise children when the hopper is open in case foreign material is placed into the hopper or children climb into the hopper DD DBD DDD e DDD ODD DDB 1075mm 15 Greenflame Slim Wood Pellet Boiler 18kW 1140mm 935mm 10 Maintenance Schedule ensure that your Greenflame wood pellet boiler appliance is at its highest efficiency and trouble free operation it is essential that the following maintenance schedule is adhered to by a QUALIFIED SERVICE ENGINEER Full System Service by Service Provider Every 12 months or 1200 running hours whichever comes first recommended just before the heating season i e October Heat Exchanger Clean by Service Provider 6 months after a full service recommended March after winter season Emptying of Ash Containers by Operator Weekly Clean Down of Boiler Services by Operator every 2 weeks GREENFLAME BIOMASS BOILERS Full Service e Remove baffles from main combustion chamber and clean down all heat exchanger surfaces e Remove turbulator cleaning mechanism from the boiler and clean heat exchanger tubes e Empty ash containers e Remove exhaust fan motor and clean flue gas passage ways to the flue outlet e Remove and cl
25. ler making electrical connections checking its operation and maintenance are all tasks which should be carried out by qualified and authorised personnel Install the boiler in accordance with the regulations in force in your local area region and country For the correct use of the appliance and to prevent accidents the instructions given in this booklet must always be followed Use adjustment and programming must be carried out by adults Errors or incorrect settings may cause hazardous conditions and or poor operation Before beginning any operation the user or whoever is preparing to operate on the appliance must have read and understood the entire contents of this instruction booklet All responsibility for improper use taken entirely by the user and such use relieves T R Engineering Ltd of any civil or criminal responsibility Most of the surfaces of the appliance are extremely hot the boiler door the handle smoke discharge pipes etc Avoid coming into contact with these parts without adequate protective clothing or suitable implements which keep the hands cool Carefully explain this hazard to elderly people disabled people and particularly to all children keeping them away from the appliance while it is running Under no circumstances should the appliance be run with the door open Do not touch the appliance with wet hands in view of the fact that it is an electrical appliance Before carrying out any cle
26. n the combustion chamber door is opened even with the boiler in the OFF position the combustion fan will run at full power Always allow to cool down before opening the combustion chamber door Unscrew the two fixing knobs on the ash pan Carefully remove the ash pan and dispose of the ash into a metal container 14 Greenflame Slim Wood Pellet Boiler 18kW 9 Technical Data kW 4 6 18 5 0 19 8 90 7 EG 120 140 C 70 90 Pa 10 g s 3 3 10 6 If the burner pot contains ash remove the pot for the holder and 10 8 12 7 scrape the contents into a container Also make sure that the air C 50 85 holes are clear Carefully replace the pot ensuring that it is properly bar kPa 3 269 seated ae 15 i inch Failure to replace the pot correctly can cause damage T A and invalidate the warranty Your installer will show you inch how to do this correctly oC eae Class 6 3 Filling the Hoper with Fuel Say Rats watts 448 e The boiler indicates when the level of pellets reaches a low watts 164 level The system will shut down and will wait for the hopper to 25 be refilled 1 2 e Open the pellet lid and carefully pour approved pellets into the hopper e Never fill the hopper above the guard mesh across the opening of the hopper Flue Height Determined on Site Never allow any foreign material to enter the hopper This will lead to malfunction of the auger system and could cause damage to the appliance and
27. nter run mode Run Mode The system runs at full power until it reaches a pre determined water temperature below the set point Once it exceeds the temperature it enters the modulation phase Modulation This phase allows the system to slow down and find the optimum running conditions and temperature to match the load of the property Once the water temperature finally reaches the set point the system enters a standby stage Standby Extinguishing Standby is reached when there is no further heat demand by the property and extinguishing of the fire bed is required to stop further heat generation Once the fire bed has been extinguished the system waits in standby until such time as the water temperature drops below a pre determined level below the set point Once this temperature is reached the cycle is repeated 5 Pre Installation Considerations 5 1 Pellets Wood pellets are manufactured by hot extruding compressed sawdust which is produced during the working of natural dried wood The compactness of the material comes from lignin which is contained in the wood itself and allows the production of pellets without the use of glues or binders The market offers different types of pellet with characteristics which vary depending on what mixture of woods is used The diameter varies between 6mm and 8mm with a standard length in the range 5mm to 30mm Good quality pellets have a density which varies between 600kg m and 750kg m wit
28. of fuel of inferior quality or not conforming to the specification given above compromises the running of your appliance and can therefore lead to the termination of the guarantee and of the manufacturer s responsibility for the product T R Engineering Ltd domestic pellet appliances run exclusively on pellets with a diameter of 6mm It is recommended that the brand of pellets used during commissioning are used during normal operation If you change your pellet supplier or brand re calibration may be necessary and a call out charge will apply i The Greenflame 18kW Slim has been recommended as suitable for use in smoke control areas when burning ENplus A1 wood pellets 5 2 Considerations for Installation IMPORTANT Installation and assembly of the appliance must be carried out by qualified personnel The appliance must be installed in a suitable position to allow the normal operations of opening and ordinary maintenance The sire must be e Capable of providing the environmental conditions for operation e Equipped with power supply 230V 50Hz EN73 23 e Capable of taking an adequate system for smoke discharge e Provided with external ventilation if located indoors e Provided with an earth connection complying with CEI 64 8 The appliance must be connected to a flue pipe or internal or external vertical duct conforming to current standards UNI129 7131 9515 The boiler must be positioned in such a way that the power
29. per Sensors Both these values should be set NPN Protections To ensure safe and failure free operation the controller is equipped with a number of protections When an alarm occurs the buzzer goes off and a corresponding message appears on the display Feeder Protection Where the auxiliary hopper is not filled for a long period e g due to lack of pellet the controller will turn the feeder off and an alarm will be activated Fuse The controller is equipped with a 10A fuse to protect the controller CAUTION This must be protected by a 13A fuse from a switched fuse spur Maintenance The pellet loader controller must be checked for any damage to its wires before and during the heating season You should also check the mounting of the controller clean it of dust and other contamination 6 6 5 Technical Data Specification Power Supply 230V 50Hz 10 Max Power Consumption 2000 Ambient Temperature 5 50 Feeder Output 7 Feeder Additional Output 1 Load Fuse Insert 10 Height Width Depth Weight Cee GREENFLAME BIOMASS BOILERS 7 A 6 6 6 Assembly NOTE Installation should be performed by a fully qualified engineer DO NOT install the unit with the power on make sure that the plug is disconnected from the mains supply NOTE Incorrect wiring may damage the controller The controller cannot be operated in a closed central heating system The installation must include safety valves pressure valves
30. r fire fighting and equipped with all services such as air and electricity supply and provision for discharging combustion gases If there is a fire in the flue pipe extinguish the appliance disconnect it from the power supply and never open the door Then contact the competent authorities If the appliance is in storage it should be in a place that is free of damp and it should not be exposed to extremes of temperature It is inadvisable to base the appliance directly on a floor if located indoors and if the floor is made of flammable material it must be suitably insulated Do not light the appliance with flammable materials if the ignition system breaks down 0 Information In case of any problems get in touch with your dealer or a qualified engineer authorised by T R Engineering Ltd and if a repair is necessary insist on the use of original spare parts Use only fuel recommended by T R Engineering Ltd ENplus A1 may be used with this appliance Periodically check and clean the smoke outlet ducts connection to the flue pipe Accumulated un burnt pellet sin the burner after repeated failed ignitions must be removed before lighting Always keep the cover of the fuel hopper closed Keep this instruction manual safe because it must stay with the appliance throughout its working life If the appliance is sold or transferred to another user always make sure that the booklet goes with the product If it gets lost
31. raph 4 7 WATER CONNECTIONS 7 Greenflame Slim Wood Pellet Boiler 18kW A It is recommended that a suitable anti freeze solution is added to the heating system to prevent the freezing of water within the boiler in case of a power outage The boiler has an anti freeze function which activates the pump in the event of the temperature in the boiler dropping below 5 C 6 Installation and Assembly 6 1 Unpacking The Greenflame 18kW Slim pellet boiler will come packaged on a single pallet The flue will be packaged separately The materials which make up the packaging are 100 recyclable Their storage or recycling is therefore the responsibility of the final user in compliance with Local Regulations Do not store the boiler without its packaging Remove the nylon strapping cardboard packaging and bubble wrap and recycle in the appropriate manner When unpacking the boiler use the checklist below to ensure that all the required components to complete the kit have been supplied In the unlikely event of an omission you must notify the manufacturer within 48 hours of delivery The manufacturer reserves the right to charge for items deemed lost after 48hrs Unpacking List RECEIVED YES NO ITEM Koreio Combustion chamber Combustion chamber Combustion chamber Baffle set 2pcs Burner Pot User Manual Pack Stainless Flue Support Brackets x2 Single Twin Wall Flue Adaptor Rain Cap Hopper Flue Straight Lengths 1m
32. s activated and stays on until the MENU button is pressed again Clock The user may define the current time by setting the clock Clock setting is necessary for proper operation Day from This function is used to define the time when the controller will switch Night from This function is used to define the time when the controller will switch to night mode The controller will start the main hopper filling process half an hour before switching to the night mode Language This function is used to select the language version of the controller menu 6 6 4 System Menu To access the system menu enter the password 5162 Low Current Threshold To set this monitor manual operation and when the vacuum store is full take note of the mA value on the main screen i e 7078mA A This needs to be set at 72 x 100mA so that when the value drops below this the vacuum will turn off after the low current time 11 Greenflame Slim Wood Pellet Boiler 18kW Low Current Time This should be set at 4s so when the mA value drops below the threshold for 4 seconds the vacuum stops Pause Time This should be set at 30s and is the time between cycles of the vacuum this is when the vacuum store drops its pellets into the main hopper Protection Time This should be set at 5 mins so if the vacuum does not turn off after this time an alarm will show this is usually due to lack of pellet Feeder protection Lower and Up
33. ssure switch only with exhaust fanon Erl4_ Lack of Voltage Extinguishing for lack of pellet Vacuum error below the minimum threshold Vacuum error above the upper threshold In the unlikely event that the appliance fails to start or shuts down unexpectedly then the error code shown on the display will give an indication as to the potential cause of the problem Some of the errors can be cleared by the householder and they are Er01 Water Safety Thermostat Press the reset button A and then hold button B for 3 seconds to clear the error from the controller A B Er04 Water Over Temperature Hold button B for 3 seconds If the problem persists contact your service engineer Er05 Exhaust Over Temperature Check that the baffles are in position and clean inside the combustion chamber Er09 Low Water Pressure Contact your installer Er10 High Water Pressure Contact your installer Er12 Failed Ignition Empty any un burnt pellets from the burner pot and hold button B for 3 seconds to clear the error Er13 Accidental Extinguishing for Low Exhaust Temperature Empty any un burnt pellets from the burner pot and hold button B for three seconds 13 Greenflame Slim Wood Pellet Boiler 18kW Er15 Loss of Voltage Usually occurs after a power cut Empty any un burnt pellet from the burner pot and hold button B for 3 seconds Turn off the time clock for 10 s
34. ted to the flow pipe work immediately outside the boiler The pressure relief valve should be piped to drain to prevent injury to the user or service technicians if it is activated All unused connections should be sealed with blanking plugs A non return valve should be fitted to prevent back siphonage Once the plumbing has been completed the system should be fully flushed to clear any debris which may become lodged in the pipe work The system should generally be filled from the lowest point on the system to force any air to the highest point where it can be vented The flue flow pipe on the boiler is fitted with a manual air vent for venting air from the boiler The system must then be filled and the pump can be run continuously for a few hours to completely de aerate the system Hold the ESC button on the controller for 3 seconds to activate the pump Repeat the procedure to turn it off Only when the system has been fully vented can the boiler be commissioned The installation and the design of the central heating system must be in accordance with BS EN 14336 2004 Heating Systems in Buildings Installation and Commissioning of Water based Heating Systems BS EN 12828 2003 Heating Systems in Buildings Design of Water based Heating Systems BS EN 12831 2003 Heating Systems in Buildings Method for Calculation of the Design Heat Load Always ensure that all connections are making a watertight seal 7 Control System CONTROL PANEL
35. udes all ancillary products associated with the system e g flue pipes external circulation pumps bulk hoppers and augers plumbing and electrical system The warranty does not cover third party damage to the product or damage caused by the plumbing an example would be an inappropriately sized expansion vessel or electrical system Warranty does not cover issues arising from pellets that do not conform to ENplus A1 Recommendations advised to the customer to be carried out during commissioning must be completed and advised to your local dealer in order to validate the warranty The requirement for the flue installation particularly in relation to draught is the responsibility of the system owner Compliance with Local Building Regulations must be adhered to He warranty does not cover misuse of the product or sabotage Any consequential damage caused by the failure of a component on this product is not covered T R Engineering Ltd refuses to accept the responsibility for any damage which may be caused directly or indirectly by persons animals or things in consequence of the failure to observe all prescriptions laid down in the instruction booklet especially those concerning warnings on the subject of installation use and maintenance of the appliance Damage cause by transport and or handling is excluded from the guarantee The guarantee will be invalidated in the event of damage caused by tampering with the appliance atmospheric ag
36. viding product identification data e Information which is essential or that requires special attention is shown in bold text e Italic text is used to call your attention to other paragraphs in the manual or for any additional clarifications ATTENTION This warning sign indicates that the message to which it refers should be carefully read and understood because failure to comply with what these notices say can cause serious damage to the boiler and put the user s safety at risk INFORMATION This symbol is used to highlight information which is important for proper boiler operation Failure to comply with these provisions will compromise use of the boiler and its operation will not be satisfactory OPERATING SEQUENCES Indicates a sequence of buttons to be pushed to access menus or make adjustments MANUAL Indicates that you should carefully read this manual or the related instructions T R Engineering Ltd T R Engineering Ltd operates a policy of continuous development and improvement of our products and welcomes any feedback from our customers Please forward your comments to T R Engineering Ltd Unit 7 Newton Chambers Way Thorncliffe Industrial Estate Chapeltown Sheffield S35 2PH Tel 0114 257 2300 Fax 0114 257 1419 E mail info trianco co uk Web www Trianco co uk GREENFLAME BIOMASS BOILERS 2 Warnings and Guarantee Warranty Conditions 2 1 Safety Instructions A Installation of the boi
37. ying out any connections The Greenflame boiler must be supplied with a 230V 50Hz electrical supply via a two pole isolation switch rated for Overvoltage Category Ill and protected with a 6A circuit breaker Also the unit shall have a 30mA RCD installed into the mains supply It is recommended that a power isolation switch is located adjacent to the boiler isolate the power during servicing and maintenance but also out of the reach of children and to prevent accidental turning off to the mains power Room thermostats shall be supplied controlled by safety extra low voltage Black Permanent Live Brown Time Clock Control Live Blue Neutral Green Yellow Earth Only authorised T R Engineering Ltd personnel may open the control panel on the boiler Any interference with the wiring in the control panel will invalidate the warranty The boiler and complete plumbing system must be adequately earthed and bonded in accordance with Local Building Regulations and Bye Laws 8 eel GREENFLAME Greenflame Slim Wood Pellet Boiler 18kW BIOMASS BOILERS 6 4 Boiler Control Panel Schematic Electrical Connections 62 366 61 Sx 60 sec 59 ano Pump 5g sec A pm Domestic Water Valve Pump GND AR Burner Cleaning Motor 52 E 51 s Fo 22 ra 2 e COM 24 5 NO 25 NC 26 a Belimo Valve Pellet N 29 Loading Pellet Motor Flussostat Or Butter Prote input 3 F 30 Pellet Light deperdieg on pararneter P35 Exhausting
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