Technical manual PV-50
Contents
1. s pelltech PV50b pellet User manual DK9802A2 PV50b pellet burner p 1 24 Description 2 5 6 Specifications 1 Contents SiO US 3 2 1 PECA 3 7 3 1 Hic NE Ue 7 3 2 Installing burner to the boiler i ke keke kK 10 3 2 1 Peller NER 11 3 2 2 Daran UE 12 3 3 CONECO nen Do TOL SE 13 3 4 COMTE STONN Jg2 13 Operationand EVIE CV NEN aces ba y N w b dul 14 4 1 err T 14 4 1 1 Status messages sa REH HHHH 16 4 1 2 GOWN CTA m u 17 4 2 dz inre o ERRORI mn 17 4 3 Cy E 17 4 4 wo mmmmrm ym MM 19 4 5 Iesuldr mmalltelldiibB 19 4 6 FRED FAC IN COMO 19 Problem and SOJ V d 070 22 Annex Electrical lt 24 9296 3533 pelltech DK9801A2 www pelltech eu PV50b pellet burner p 2 24 Description Specifications 2 Description PV50b is wood pellet burner for domestic and industrial use Typical setup includes2. check battery maybe too old www pelltech eu PV50b pellet burner p 22 24 Problem and solutions No power No mains power check power connector cables Safety thermostat is turned off the power check safety thermostat backburn check burner for backburn 9296 92229 pelltech DK9801A2 www pelltech eu ese PV50b pellet burner p 23 24 6 Annex A Electrical schematic F1 F2 F3 F4 F6 F8 F10 3A 2A 1A 2A 6A 1A 6A Ilgnitor Error pump Auger Fluegas fan Fans and grate Feeder Battery Main wiring diagram on the next page pelltech DK9801A2 Annex A Electrical schematic www pelltech eu Annex A Electrical schematic p 24 24 PV50b pellet burner THERMOSTAT INFRARED RECEIVER RSV INFRARED TRANSMITTER TRS TEMPERATURE SENSDR EU 1 RR FAN n omma See Ea i 1 FLAMELED _ USER INTERFA FEEDER RIRATIIN SENSOR www pelltech eu DK9801A2 pelltech
3. external pellet storage 1 external auger to transport pellets from storage to burner 2 boiler 3 and PV50b burner 4 mounted onto the boiler 233 Figure 1 Typical installation PV 50b is a pellet burner that is intended to be used with 6 or 8mm wooden pellets You cannot use any other fuel to run this burner The unique construction of PV 50b allows it to be used with different boilers liquid fuel solid fuel and universal boilers The PV 50b burner is connected to the boiler with a 90 mm flange similar to oil burners The burner is equipped with a safety thermostat a melting hose temperature sensor and auxiliary battery for protection against back burning e Methods of control of pellet burner modulating burner e Means of ignition Hot air element Without integral fuel hopper e Automatic ash cleaning system e Hold flame function e Optional oxygen sensor interface e Optional communications module interface 2 1 Specifications L total length mm 560 L1 burner body length mm 175 L2 burner head length mm 260 D burner head width mm 180 201 burner head neck diameter mm 90 202 internal feeder inlet diameter mm 60 2 pelltech 522 DK9801A2 www pelltech eu PV50b pellet burner H total height H1 burner housing height W total width W 1 burner head width Mass Supply voltage Power max Power average Power at standby Noise Emission class Operating temperature Nominal
4. heating element to heat up air and ignite pellets in burning chamber Connector for power supply flue gas fan thermostat AC DC converter to supply internal controller board feeder motor fans and sensors Internal auger temperature sensor to detect back burning before safety thermostat cuts mains power Backup battery to enable safe shut down in case of mains power interruption Internal auger motor with rotation feedback to transport controlled amount of pellets to burning chamber Quick connector to connect external auger Electronic control unit to turn on off burner switch external auger regulate combustion air supply etc Optical sensor to detect the presence of pellets in internal auger inlet Normally external auger is switched on if no pellets detected Replaceable cover to increase combustion quality DK9801A2 www pelltech eu o O 5 T QO QO 2 5 o Q E e N N lt b L CO O lt Q Lum E 5 5 Q ee 99220 S en e od D o0 at PV50b pellet burner 6 24 Installation Prerequisites 3 Installation 3 1 Prerequisites Following tools are needed in order to install the burner e Spanner no 13 for fixing the flange of the burner to the boiler e Spanner no 10 for connecting the body of the burner with the burning camber e Cross head screwdriver for fixing the cove
5. d to burning chamber The amount of pellets is adjustable in parameters menu Igniters are switched on first time in loading status to preheat the ignition system Igniters are periodically switched on and off to keep them from overheating It can take several minutes for the hot air to ignite pellets Signal from flame sensor marks the end on igniting and burner enters into PRE BURN status The purpose of this status is to allow build up flame before starting to add more fuel Next status BURNING is the normal operating state of the burner Here fuel is periodically added according to current power level If enabled from menu burner can make cleaning cycle after fixed time intervals Cleaning during burning is preceded by short HOLD FLAME status to burn the pellets before dumping ash to boiler Burning can be ended by turning burner off from menu or button on user interface but normally the burning status ends by receiving boiler thermostat signal In all three cases the next status is END BURN No more pellets are added anymore but the combustion air is still kept as in burning status It allows remaining pellets to burn End burn lasts until no flame is detected by flame sensor The burning cycle ends by END BLOW status Here only small amount of air is supplied to completely burn all embers Next status can be waiting again or HOLD FLAME if it is enabled from menu Hold flame reduces the number of ignitions and allows the burner to operat
6. e controller board to completely remove upper cover from the burner lgniter 1 Disconnect burner from the power network 2 Open burner body 3 Disconnect igniter wiring from the control board X1 connector 1 and 2 4 Loosen igniter fixation screw 11 using cross head screwdriver 5 Remove igniter from the burner body 6 Install and connect new igniter vice versa from removing www pelltech eu PV50b pellet burner 20 24 pelltech DK9801A2 Operation and maintenance Replacing components Battery 1 Disconnect burner from the power network 2 Open burner body 3 Disconnect battery wiring 4 Install new battery redo wiring redo burner cover and connect burner to the network Note It is recommended to use two sided tape to secure battery in place www pelltech eu PV50b pellet burner 21 24 5 Problem and solutions Error status Stopped No pellets No flame Overheat Ignition error Level error Feeder error Fan error Battery low 2 pelltech Cause This is actually not an error condition Burner is turned OFF from menu Maximum loading time is reached 5 or 20 minutes and not enough fuel from external auger for ignition is loaded Fuel level is not detected in 4 minutes at burning time Flame disappeared at preburning time Flame is disappeared at burning time Flame dose not disappeared in end blow cycle Burner internal temperature is reached over set poi
7. e smoothly Here only minimal pellets and air is supplied to keep the flame alive 9 52252 pelltech DK9801A2 www pelltech eu PV50b pellet burner 18 24 Operation and maintenance Refilling fuel storage 4 4 Refilling fuel storage The fuel storage must be refilled before it runs empty Fuel can be added at any time during the operation To add fuel simply pour a new bag of pellets into your fuel storage If the storage runs empty before new fuel is added the external auger must be loaded again by switching burner OFF and back ON from menu Failing to do so will result Fuel error due to fuel loading timeout 4 5 Regular maintenance Following maintenance procedures must be carried out on regular basis Once a week ash removal from boiler Once a year cleaning of grate power screw 4 6 Replacing components 4 SN lt open cover loosen burner cover s middle 8 and bottom 9 screw Then pull the cover towards direction shown in picture 9 There is no need to remove screws 52252 pelltech DK9801A2 www pelltech eu E PV50b pellet burner 22 pelltech p 19 24 DK9801A2 Operation and maintenance Replacing components In order to remove burner upper cover first open burner lower cover Then remove upper cover s screws 10 Pull the cover upwards direction shown in the picture NOTE it may be necessary to remove user interface buttons from th
8. er door 25222 pelltech DK9801A2 Installation Prerequisites www pelltech eu PV50b pellet burner p 9 24 Installation Installing burner to the boiler I 3 2 Installing burner to the boiler z a 5 u 1 burning chamber from the body by loosening burning chamber bracket bolts 1 There is no need to completely remove brackets or bolts Figure 8 2 Remove upper grate 2 and then the lower grate 3 from the burning chamber 3 Remove burning by pulling it while pushing linear actuator rod 4 upwards through the burning chamber back wall Figure 9 o9 9222 pelltech DK9801A2 www pelltech eu ege PV50b pellet burner 10 24 Installation Figure 10 Igniter Figure 11 Igniter correct position 3 2 1 Pellet storage Installing burner to the boiler 4 Fix the flange 4 of the burner to the door of the boiler 5 Make sure that the opening of the flange and the opening of the boiler door are aligned 5 Fix the burning chamber 6 For that you need to put a ceramic seal 7 on the narrower side of the burning chamber and then put the chamber through the door of the boiler in a way that the rearward wall of the burning chamber would lean on the door of the boiler Fixate the burning chamber with two grub screws to the flange 6 Connect the body of the burner to the burning chamber like it was done before disassembling in step 1 7 Make sure when
9. er object nearby with delivered chain Figure 12 shows correct position for external auger As the hose is a safety device it must be placed strictly as described below The vertical distance between auger outlet and burner inlet must be in range of 40 to 70 cm and horizontal displacement 10 to 20 cm typical auger angle 30 45 External auger cannot be installed in position with angle greater than 457 The hose must be in angle of 50 or more to ensure free falling of the fuel Auger cable must be connected to the left of the burner Make sure the connector is fully inserted into socket 30 70 cm Uu Figure 12 External auger installation pelltech DK9801A2 www pelltech eu PV50b pellet burner p 12 24 Installation Electrical connections 3 3 Electrical connections The burner is equipped with a standard oil burner plug that has 7 contacts There will be different connection schemes used for different boilers Usually the burner is connected to the boiler with a 5 wire cable It is also possible to connect with a 4 wire cable Auger motor wiring connection for the 3 contact plug Flue gas fan wiring connection for the 7 contact plug Tt Boiler temperature thermostat Figure 13 Electrical wiring Caution All electrical connections of the burner must be made by a qualified professional 3 4 Commissioning Before starting the burner for the first time please check that e Burner body and burning chambe
10. heat input Min heat input Figure 2 Dimensions p 3 24 Description opecifications 275 230 240 168 17 220 240 570 25 40 7 52 5 0 60 50 20 Main parts of the burner a shown on Figure 3 and listed below 8 pelltech DK9801A2 www pelltech eu PV50Ob pellet burner Table 1 Main components list p 4 24 Description opecifications E Spare part code 10 11 12 13 14 15 16 17 18 19 Burning chamber Burner body User interface Internal auger inlet Internal auger feed screw Burning chamber back wall Grates set of two Igniter Boiler connector Power supply Temperature sensor Battery Feeder motor Primary fan External auger connector Secondary fan Controller board Fuel level sensor Burning chamber cover 3 83 pelltech Pellets are burned inside the burning chamber grate The half of the burner that is located outside the boiler Incorporates feed screw internal auger fans controller etc LCD screen LED indicators and navigation buttons to show burner status and change settings External fuel supply line hose is connected here Transports pellets from inlet to the burning chamber Internal auger is switched by controller board Replaceable stainless steel wall that separates hot and cold surfaces and reduces heat transfer through boiler door Moving grates where burning takes place Air is supplied through holes in grates Electric
11. hed on and waiting for command from the thermostat of the boiler Testing the fan battery and feeder Loading pellets into burner for ignition after the command from boiler thermostat Second try if the first ignition was not successful Loaded amount of pellets are in the burning chamber igniter and fan are working till photocell recognizes flame Only the fan is working the igniter is off Pellets start burning properly Status of normal working External auger works by level sensor internal auger and fan are working by Photocell must see the flame Boiler has reached an estimated temperature and boiler thermostat switched off pilot flame is held in the burning chamber Boiler has reached an estimated temperature and boiler thermostat switched off the burner The external auger has stopped the internal feeder and fan are still working until all fuel is burned When photocell doesn t see any flame only the fan keeps on working with minimum speed in order to make sure there is no fuel in burner Level sensor does not detect pellets There is no flame in the burner more than 120 seconds during burning Temperature in the burner has reached preset temperature and burner turned off Flame is not recognized after ignition Level dose not reached or level dose not disappear at burning time Jam in feeder or feeder rotation is not detected Fan rotation problem Battery is not connected or empty Supply power is not detected burner work
12. looking through the burning chamber the igniter end tip is at the same level with the back wall The tube of the inner auger must reach through its opening Caution After the installation of the burner always make sure that the end of the igniter is positioned through its opening and not stuck behind the back wall The burner the auger and the pellet container are a common system The size and the location of the pellet container depend on the needs and possibilities of the specific boiler room While choosing the pellet container you must keep in mind that e lf the pellet container is in the same room as the boiler then the size of the pellet container must not exceed 500 liters approx 350kg e The container must be made of fireproof materials Thecontainer must be positioned in a way that the raising angle of the feeding auger does not exceed 45 refer to Figure 12 e advisable to use a container that can be closed with a cover 92252 pelltech DK9801A2 www pelltech eu PV50b pellet burner 11 24 Installation Installing burner to the boiler 3 2 2 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 The hose is made of melting material that acts as a safety measure against back burning The upper side of auger with motor must be fixed to the storage or to some oth
13. ned without removing the burner The minimum boiler opening radius depends on the position of door hinges and vice versa Figure 3 below illustrates the situation Point C is critical In order to keep door width minimum and boiler opening small a double hinge solution can be used As double hinges add another degree of freedom door must be fastened on both sides Slide out doors with guide rails is also an option 9 92229 pelltech DK9801A2 www pelltech eu ede PV50b pellet burner p 7 24 Installation Prerequisites Figure 4 Hinge position and boiler opening size Figure 5 Double hinges considerations Boiler firebox length L Figure 6 should be at least 2 5 x the length of the burning chamber For PV 50b minimum of 640mm is acceptable leaving L1 approx 380mm The height under the burner H1 should be enough for about 100mm of ash Minimum dimensions L and for PV 50b L2640mm H2400mm Figure 6 Boiler firebox requirements Burners are mounted to door using supplied oil burner flange Bolt hole circle diameter and bolt sizes can be customized by using custom flanges D1 and D2 given in Table 2 are only valid with supplied flanges ae 9222 pelltech DK9801A2 wWw pelltech eu PV50b pellet burner p 8 24 Table 2 Mounting holes for boiler door Dimension D hole for burning chamber neck D1 flange bolt ring diameter 130 150 OD2 bolt holes 8 9 Figure 7 Mounting holes with supplied flanges for boil
14. nt as fixed in setup menu Possibly back burning is happened Flame is not detected at ignition time Fuel level in the burner dose not disappeared at burning time Feeder did not make any rotations in 8 seconds at its running time Feeder motor current reached 0 75A permanently in 0 2 second time Fan did not reach 40 rps in 7 seconds at testing time with full power Fan did not reach to needed speed at burning time in 20 sec Battery voltage is less than 12V with load working feeder DK9801A2 Problem and solutions Action To turn burner on hold down OK at least 3 sec or change BURNER from OFF to ON in setup menu check fuel in storage check auger and auger connection to burner check the level sensors clean them check the level sensors clean them check photocell clean it check burner temp from INFO menu check temp sensor connection check burning chamber and clean it check the chimney and pressure in the boiler check the internal feeder screw connection and rotation check igniter and igniter fuse check photocell Check the level sensors clean them check feeder sensor connection check magnet on the feeder shaft check feeder screw connection feeder can be stuck check fan sensor connection check fan power connections check magnet on the fan shaft check fan bearings and rotation If there was power failure then just wait when it is loaded
15. ore than 20minutes to complete Warning Never turn off a working burner from the main switch of the boiler i e by cutting the mains supply Use the thermostat switch for that purpose In order to stop safely let the burner burn empty 4 3 Description of a working cycle When the burner is switched on for the first time it displays STOPPED After turning on the burner chapter 4 2 the burner enters into WAITING status Now the burner is ready to start if boiler thermostat signal is received electrical connections chapter 3 3 9 92229 pelltech DK9801A2 www pelltech eu ede PV50b pellet burner p 17 24 Operation and maintenance Refilling fuel storage Burner starts TESTING if boiler thermostat signal is received Combustion air fans battery voltage is tested and measured Upon completion of testing the burner starts CLEANING during which grates are moved back and forth do remove the ash After cleaning the burner is ready to load pellets into burning chamber In LOADING status external auger starts to transport pellets into burner Internal feeder loads pellets into burning chamber Internal feeder starts only when there is a signal from level sensor The signal is needed to ensure that the internal tube is filled with pellets This way the amount of pellets entering into burning chamber is roughly proportional to the number of rotations that internal feeder makes IGNITING starts when predetermined amount of pellets is loade
16. r are securely connected by brackets e grates are installed in burning chamber e Igniter can be seen from burning chamber and it is not stuck behind back wall of the burning chamber Figure 11 e Boiler thermostat is connected to the burner Figure 13 e External auger is connected to burner and auger position is according to requirements in Figure 12 e Boiler is connected to chimney dampers are opened and there is enough draught 4 6Pa minimum e No additional air valves are opened in boiler All combustion air must come from the burner 42225 pelltech DK9801A2 wWw pelltech eu ese PV50b pellet burner p 13 24 Operation and maintenance User interface 4 Operation and maintenance 4 1 User interface User interface allows starting and stopping changing parameters and view statistics about burning process Main parts of the interface are listed below 1 Flame indicator Yellow LED to indicate if flame detector has detected flame in burning camber 2 LCD screen 3 Fuel indicator Green LED to indicate if there are pellets in internal auger inlet 4 Navigation buttons to change parameters and control the burner Figure 14 User interface Up and down arrow keys enable to move up and down in menus also change parameter value in editing mode OK and back arrows have different actions depending on the context Table 3 Buttons Push time OK less than 3s Enter submenu Confirm settings
17. r of the burner e 4mm hex wrench for fixing the boiler to the flange Warning If flue gas temperature at the top of the chimney is less than 80 there is a risk of condensation In this case a pipe should be installed throughout the length of the chimney Note It is recommended to use a flue gas analyzer for adjusting the burner The burner must be adjusted using the flue gas analyzer also when you change the size or the quality of the pellets Boiler requirements In order to install the burner the boiler must correspond to the following requirements e door of the boiler must have a 90 mm opening placement opening for the oil burner The thickness of the boiler door must be less than 100mm 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 draught the furnace a draught fan should be installed for the exhaust gases e The boiler room where the burner is installed must fulfill all rules and recommendations given by authorities The boiler must be positioned in a way that there is enough space for cleaning the burner the boiler and the smoke pipe and removing the ash Pellet burners need regular cleaning and therefore boiler construction must allow the door to be ope
18. s on battery DK9801A2 www pelltech eu PV50b pellet burner p 16 24 Operation and maintenance Starting and stopping 4 1 2 Info menu Content of info menu is following TOTAL total amount of pellets burned with this burner Amount is updated after every 10 kg COUNT amount of pellets burned since last zero Amount is updated after every 0 1 kg To zero the amount be sure you are in this menu and hold down OK for 5 sec FAN fan rotation speed as it is fan rotation speed as it should be base air selected base air in the main menu P currently working power power as it should be T burner internal temperature U Battery voltage level Feeder current DRAUGHT when pressure sensor is connected draught is shown 4 2 Starting and stopping To turn on the burner switch on boiler main switch If burner displays Stopped then go to settings menu and change parameter Burner from OFF to ON The display shows Waiting Now turn boiler thermostat to desired temperature The burner will go to Loading state If this is the first run external auger needs to be filled with pellets It can take up to 20 minutes To stop the burner there are two options e Turn boiler thermostat to lowest point Or e Goto menu and change Burner from ON to OFF In both cases it takes some time before all pellets inside the burner are burnt Status changes BURNING gt BURN END BLOW gt WAITING or STOPPED It can take m
19. when blinking OK more than 3s in MF menu Pellet counter reset OK more than 3s not in menu Error status reset OK more than 3s in state Switch off the burner cut battery lt less than 35 Move back from menu Discard changes in setting when blinking more than 3 Burner reset By default the status screen is displayed with time counter 1111 2 reads as 1 minute and 12 seconds imiz and 2 means hours and 24 minutes 9 92229 pelltech DK9801A2 www pelltech eu ede PV50b pellet burner p 14 24 Main menu in Figure 1Figure 15 can be accessed by pressing OK button Status info STATUS BURNER idi HOLD FLAME or PELLETS POWER BASE AIR LANGUAGE Fi rna Figure 15 Menu layout 3533 pelltech 9 DK9801A2 9e Operation and maintenance User interface www pelltech eu PV50b pellet burner p 15 24 Operation and maintenance User interface 4 1 1 Status messages During operation the burner displays several status messages Short explanation is given below Table 4 Burner status messages Status Description Message STOPPED WAITING TESTING LOADING LOADING2 IGNITION PREBURN BURNING HOLD FLAME BURN END END BLOW NO PELLETS NO FLAME OVERHEAT IGN ERROR LEVEL ERR FEEDER ERR FAN ERROR BATTERY LOW NO POWER 3338 pelltech The burner is not switched on The burner is switc
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