USER MANUAL
Contents
1. 19 5 2 5 Adjustment process of the boiler according to the thermal load of the building consumer seen 20 5 2 6 Changing the working parameters of the process control module SER ib cubo tit eot Rees E eoe ie epe Le conta 22 5 2 7 Nominal operation mode of the boiler 24 5 3 Adjustment of the thermal capacity of the boiler 25 Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 3 38 5 3 1 Decreasing the thermal capacity of the boiler 26 5 3 2 Increasing the thermal capacity of the boiler 26 5 4 Stopping the hot water boiler essen 26 5 5 Turning OFF the boiler sssseeeneenneennn 27 e Accidental boiler stop seen 27 5 6 Showing and teaching the end user about the maintenance and adjustment procedures 28 5 7 Safety and unexpected risks 28 5 8 Operation faults and their 30 5 9 Hot water boiler warranty form completion 33 5 10 Actions after the unit is not in exploitation anymore 33 QUALITY CERTIFICATE noeneen et C RR a eR 34 WARRANTY nho2. 2 ERATO Pelletherm 25 automatic hot water boiler technical data e Thermal and technical data for hot water pellet boiler ERATO Pelletherm 25 automatic utilizing wood pellets are given in Table 1 e Dimensions and technical data for hot water pellet boiler ERATO Pelletherm 25 automatic are given in Table 2 e Recommended solid fuel properties wood pellets are given in Table 3 e Pellets classification considering their physical properties based on fuel proximate analysis are shown in Table 4 Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 7 38 Parameter Dimension Value Nominal thermal capacity kW 25 Thermal capacity operation range kW 15 25 Utilized solid fuel e Wood pellets e Pre dried cherry nuts e Other dried nuts Utilized pellets complying ERATO A AB B BC C CD D DE classification methodology Wood pellets fuel consumption rate at kg h 6 nominal thermal capacity Fresh air flow rate required for effective kg h 45 50 combustion process and boiler operation mU 40 45 Averaged wood pellets consumption rate the kg h 4 unit is operating in a popular heating system Thermal effectiveness at nominal capacity 89 Air excess ratio A 1 6 1 8 Flue gases temperature at nominal thermal 155 165 capacity Solid fuel residue ash The quantity depends on the ash contents in the raw fuel as
3. THE WARRANTY OF THE UNIT IS NOT VALID in case one of the following is fulfilled e Unit damages caused by incorrect handling transport and or loading unloading which are not organized by the producer e Failures caused by natural disasters Earth quakes fires floods etc e Unsatisfied installation maintenance and service requirements which are described in this manual and its annex e Repairing of any failure of the unit performed by unauthorized technicians or the end user e Any changes in the design of the boiler e Incorrect heating system design e Failures caused by factors for which the producer could not be blamed and or has no control over them e Any malfunctions or damages which are not caused by the operation of the boiler itself but result in unit damages and its functionality Every warranty service operation should be noticed in its warranty service procedures list The warranty period of the unit is interrupted by the period during which the unit is warranty serviced by authorized technicians the period between failure notification and its repairing The warranty period of the unit is 24 months The warranty of the unit is valid when the original invoice document and the original warranty form are presented only Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 36 38 WARRANTY SERVICE PROCEDURES LIST Entry date of unit in the service
4. company Description of the failure Date of delivery back to the end user Signature of the technician which repaired the unit Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 37 38 CONFORMITY DECLARATION We ERATO Product Ltd bul Saedinenie 67 6300 Haskovo Bulgaria declare our own responsibility that the unit hot water pellet boiler ERATO Pelletherm 25 automatic for which the current DECLARATION states is in compliance and conformity with all requirements of standards or other normative documents according to EN 303 5 Heating boilers for solid fuels hand and automatically fired nominal heat output of up to 300kW Terminology requirements testing and marking Generated in Haskovo Executive director Date 10 12 2008 ERATO Product Ltd eng D Panayotov Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 38 38
5. Adjustment process of the boiler according to the thermal load of the building consumer It is recommended to make appropriate adjustments of the process control module parameters in order to obtain high efficiency and reliable performance of the boiler considering the thermal load that should be Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 20 38 supplied by the boiler The required heat capacity for heating purposes of a common house could be assumed to be a linear function of the temperature gradient AT the difference between the mean value of temperature level in the heated rooms and the ambient temperature level Thus the optimal operation process of the boiler requires regular adjustment of the heat capacity parameters of the unit Explanation the data shown in the following table are calculated on the assumption that the mean temperature level in the heat supplied rooms of the building is Toom 20 C If any other value is the case than refer the temperature gradient instead T anibientair AT Ratio T4 Heat T4 T6 capacity seconds kW 15 35 0 7000 14 0 25 0 10 30 0 6067 10 3 21 6 5 25 0 5133 12 1 18 3 0 20 0 4200 8 4 15 0 Table 6 Appropriate adjustments of heat capacity parameters T4 and T6 according to the thermal load of the boiler where mean value of the temperature in the hea
6. B BC C CD E EF Ash content See Table 4 Moisture content Max 8 10 Table 3 Recommended solid fuel properties wood pellets Pellet s category A DU A A 0 6 DU gt 97 096 AB A 0 6 DU lt 97 0 B 0 6 A lt 1 0 DU gt 97 096 BC 0 6 lt A 1 096 DU 97 096 C 1 0 A lt 2 096 DU gt 97 096 CD 1 0 lt 2 0 DU lt 97 0 D 2 0 A lt 3 0 DU gt 97 0 DE 2 0 A lt 3 0 DU 97 096 E A gt 3 096 DU gt 97 0 gt 3 096 DU lt 97 0 Table 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in ERATO company where ash contents dry basis DU mechanical durability Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 10 38 3 Description of hot water pellet boiler ERATO Pelletherm 25 automatic The heat exchanger of the boiler complies with the acting requirements for such kind of units defined in operating norm EN 303 5 2000 Heating boilers for solid fuels hand and automatically fired nominal heat output up to 300 kW Terminology requirements testing and marking The unit consists of Main part of the unit is heat exchanger In the combustion chamber of this exchanger is mounted specialized gra
7. ERATO Pelletherm 25 automatic user manual version December 2008 p 24 38 e It is not recommended to operate the hot water boiler at thermal capacity lower than 60 of its nominal thermal load as such regimes are not optimal and thus have low efficiency of the unit e In case that continuous operation in low thermal load regimes are required then it is recommended to connect heat accumulator to the heating system which will ensure high efficiency economical and reliable operation of the boiler itself and the entire heating system in general e During the very first time of operation the boiler it is possible to observe water vapor condensation on the heat exchanging surfaces of the unit Practically this is one time process and will not affect the performance of the unit neither any problems will arise as well ATTENTION The air flow rate is crucial for optimal operation of the combustion process organized in the burner and the boiler overall operation effectiveness when the air flow rate is less than the optimal one then this insufficiency will result in incomplete combustion of the fuel as the supplied oxygen is less than required When the air flow rate is higher than optimal the result will be unsatisfying as well because the excessive air will lead to low temperatures in volume for controlled combustion and will result in incomplete combustion of the fuel s volatile gases released by the combustion process That s
8. by unscrewing its preventive cap and its stem should be pressed until the thermostat switches back on a click sound is heard in this process screw the cap back After the boiler is checked and the cause for overheating is determined and repaired restart the control operation Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 27 38 module by turning off the main POWER switch and then back on in order to operate the boiler in normal state 5 6 Showing and teaching the end user about the maintenance and adjustment procedures It is necessary to show and teach the end user the maintenance procedures for operating the boiler efficiently and keep its reliability in high degree order Also the installer should demonstrate and teach the end user how to change the operative parameters of the control module of the boiler in order to operate the unit in different modes and heat capacities according to the local heat consumption e Fuel hopper charging the fuel is poured out in the hopper of the boiler and the hopper s cap should be closed in order to prevent uncontrolled air penetration to the burner through this section e Ash cleaning procedure it is recommended to clean periodically the ash residue at least once per day the convective heat exchanger part of the unit by manually swinging the cleaning lever for semiautomatic ash cleaning process Covering this requirement will e
9. initial mass of the fuel parameter 2 the adjustment should be performed by authorized technician Abnormal The flue gas thermostat should be operation or adjusted or replaced in case it is out malfunctioning of of order the flue gas thermostat The flame looks Low quality pellets Fuel replacement is recommended opaque and smoke is most probably the moisture content is higher than required Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 31 38 observed at the Inappropriate It is necessary to perform exit of the operating adjustment of the operating chimney parameters parameters of the unit and achieve adjustment efficient combustion process the adjustment should be performed by authorized technician 8 Presence of Ineffective fuel It is necessary to perform unburned fuel in combustion adjustment of the operating the ash tray process parameters and the air flow rate the adjustment should be performed by authorized technician 9 Alarm absence A problem in ash It is necessary to contact the service of ash cleaning cleaning module company and help of a authorized technician is required 10 High temperature The heat It is necessary to clean thoroughly of the flue gases exchanging the heat exchanger surfaces of the f flue gas surfaces of the boiler thermometer is boiler are mo
10. pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 11 38 e Flue gases exit duct external diameter 150 mm is positioned in the upper rear side of the heat exchanger after the flue gases fan concerning the flue gases track utilized for forced flue gases extraction e Boiler s heat exchanger is covered with decorative covers isolated with mineral wool plates The front side of the heat exchanger is equipped with decorative door as well e Outer decorative covers are carbon steel plates color painted details Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 12 38 4 Installation process Norms and recommendations Basic requirements for installation of hot water pellet boiler ERATO Pelletherm 25 automatic The room dedicated to mount the boiler should be supplied with fresh air supply duct necessary for optimal combustion process as well as room ventilation Installation of the unit in inhabitable premises including dwelling corridors is not allowed The hot water boiler should be connected to the heating system by authorized personal only Installation and service procedures of solid fuel hot water boilers should be performed by authorized qualified and certified personal ONLY The hot water pellet boiler ERATO Pelletherm 25 automatic should be connected ONLY to heating system supplied with OPENED expansion vessel
11. the boiler It is realized by increasing the value of parameter T4 which will result in increasing the fuel flow rate fuel consumption The same result increasing the thermal capacity is achieved by decreasing the value of parameter T6 The air flow rate should be increased proportionally Comment n case of changing the thermal capacity of the boiler it is recommended to adjust the air flow rate as well by adjusting the position of plate controlling the air flow rate Decreasing the air flow rate is performed by closing the flap mounted at the entrance of the air fan respectively the increase of the air flow rate is realized by opening that flap ATTENTION e Adjustment of the thermal capacity parameters should be performed by trained personal end user in order to achieve high efficient combustion process and optimal utilization of the fuel energy It is recommended to adjust the boiler by authorized personal using gas analyzer e Incase of change of heat capacity parameters T4 and T6 it should be determined the ratio T4 T6 in order to verify that this ratio is in the range of the limits described in Table 6 In case that the ratio T4 T6 exceeds the operating interval one of the parameters T4 or T6 should be changed in order to comply the requirements and the ratio is in the operating range 5 4 Stopping the hot water boiler Stopping the operation of the boiler should be performed by turning OFF the
12. the very first starting period of the unit it takes time to fill the auger volume with fuel According to the settings of the unit the first ignition may Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 18 38 fail If this is the case please restart the unit by switching OFF and ON by the main POWER switch and check the ignition process gain e The boiler is operating controlled by predefined algorithm loaded in the process control module The program itself is protected against unauthorized intrusion by a password The user can change some unlocked and unprotected parameters The meaning of any available parameter should be clear before any intervention and changes otherwise the operating results are hardly predictable and malfunction could be caused 5 2 4 Main parameters for boiler operation The following table contains parameters which define boiler s heat capacity Parameter Comment Recommended Dimension value Pellet s feeding time during this period pellets are feeded 4 heat to the burner determines seconds the heat capacity of the unit Pellet s not feeding time fuel is T6 not transported to the burner 20 AA determines the heat capacity of the unit Table 5 Main parameters description which define heat capacity of the unit ATTENTION The producer guarantees effective and reliable operation of the boiler ONLY when
13. why it is recommended to use specialized device gas analyzer in order to adjust the operating parameters of the control module and to optimize the boiler s performance thus achieving high efficiency and economical operation of the unit 5 3 Adjustment of the thermal capacity of the boiler The adjustment of the thermal capacity of the boiler is performed by simultaneous adjustment of the fuel flow rate and the air flow rate supplied by a fan to the burner The adjustment of the fuel flow rate is controlled by so called thermal capacity parameters T4 pellet s feeding time at nominal thermal capacity and T6 pellet s combustion period i e period of time when fuel is not fed to the burner which will determine the thermal capacity of the boiler ATTENTION case of change of the fuel type for example changing the pellets category it should be followed by adjustment of the thermal capacity parameters and the operating mode of the boiler Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 25 38 5 3 1 Decreasing the thermal capacity of the boiler It is realized by decreasing the value of parameter T4 which will result in decreasing the fuel flow rate fuel consumption The same result decreasing the thermal capacity is achieved by increasing the value of parameter T6 The air flow rate should be decreased proportionally 5 3 2 Increasing the thermal capacity of
14. Both the entire heating system and the boiler should be totally filled with circulating fluid water and air free before operating the boiler Maintenance procedures of the boiler should be performed by trained adult persons which have read the user manual of the unit Installation procedure of the boiler requires engineering project for the heating system prepared according to the acting local norms and recommendations as follows To the heating system EN 303 5 2000 Heating boilers Part 5 Heating boilers for solid fuels hand and automatically fired nominal heat output of up to 300 kW Terminology requirements testing and marking To the chimney Fire prevention requirements To the power circuit EN 60335 1 1997 Household and similar electrical appliances safety Part 1 General requirements Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 13 38 e Appliance positioning in order to achieve comfortable maintenance Minimal distance of 1000mm in front of the unit and any wall should be provided Minimal distance of 400mm from the rear wall of the unit and any wall should be provided Minimal distance of 500mm from the right hand side of the unit and any wall should be provided in order to guarantee easy access to the fuel transporting auger Minimal distance of 300mm from the left hand side of the unit and any wall should be provided in order
15. ERATO company laboratory The unit is equipped with e Steel plates welded heat exchanger for heating up the circuit water e Flue gas fan e Fresh air supplying fan e Burner s ash removal mechanism removes the ash residuum out of the burner s grate e Daily fuel hopper with capacity of about 135 kg e Programmable operating module which controls the functions of the unit and is adjustable to the specific need of a heating system as well as the properties of the fuel e Ash residue container with capacity of approximately 6 8 kg e Manually driven lever for activation of the semi automatic ash cleaning system this system cleans the ash deposited on the internal surface of the pipes of boiler s convective section The unit is supplied with e Automatic fuel ignition system e Automatic burner s ash removal system Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 5 38 e Semi automatic cleaning system of the ash deposited on the surfaces of the heat exchanger pipes e Automatic fuel feeding auger system Unit s advantages e The hot water boiler is designed to utilize solid biomass fuel making it environmentally friendly neutral and does not contribute to the global warming process result of fossil fuel utilization e The specific price of the heat energy delivered by solid biomass utilization is less dependent on the world fuel market trends
16. Hot water pellet boiler ERATO Pelletherm 25 automatic USER MANUAL http www erato bg Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 1 38 Thank You for buying hot water pellet boiler ERATO Pelletherm 25 automatic This manual will help You to use and maintain the unit properly According to Bulgarian government decree MC Ne 187 21 09 2000 the unit should be treated as high risk equipment and the end user should report it to the regional technical supervision register ATTENTION IN INTEREST OF YOUR PERSONAL SECURITY IT IS OBLIGATORY TO READ THOROUGHLY AND CAREFULLY THIS INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY ACTIONS WITH THE BOILER MOUNTING CONNECTING ETC IN CASE THAT REQUIREMENTS DEPICTED IN THIS MANUAL ARE NOT SATISFIED FAILURE OF THE UNIT COULD BE EXPECTED OR EVEN FATAL CONSEQUENCES FOR WHICH ERATO COMPANY DOES NOT TAKE RESPONSIBILITY Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 2 38 Contents page 1 Hot water pellet boiler ERATO Pelletherm 25 automatic description and advantages 5 The unit could utilize following types of fuel 5 The unit is equipped with sse 5 The unit is supplied with do odorata dede feed eeu tastes 5 2 ERATO Pelletherm 25 automatic hot wate
17. It 1s recommended the storage of fuel in room next to that where the boiler is installed e At the installation procedure of the unit as well as the fuel storage one fire prevention recommendation should be considered It is also recommended to install a fire extinguisher in a safe and easy accessible place In principle heating systems which are hydraulically opened to the atmosphere allow direct contact between the circulating fluid in most cases it is water and the air During the heating season the water content in the expansion vessel absorbs oxygen from the atmosphere though the free surface The increased oxygen content in the water threatens the metal of the unit as well the pipes Through the free surface of the expansion vessel water evaporation is observed as well Considering these appropriate water should be added through the expansion vessel it must cover the requirements of norm BDS 15207 81 During the heating season regular checking of circulating water level in the expansion vessel should be performed by the end user The water content in the circulating system should be kept constant If additional water is required then precautions should be taken not to add air in the heating system as well The water utilized for filling purposes of the heating system should be decontaminated and air free and is not dedicated for any other purposes but as a circulating fluid only Any heating system drainage is inadmissible ex
18. It is necessary to increase the set temperature of the point of the boiler s operating boiler s operating thermostat up to 90 C thermostat Low set point It is necessary to increase the set temperature of the point of the room thermostat remote room thermostat f connected 2 High High set point It is necessary to decrease the set temperatures in temperature of the point of the boiler s operating the heat supplied boiler s operating thermostat it is recommended to rooms thermostat keep it above 60 C High set point It is necessary to decrease the set temperature of the point of the room thermostat remote room thermostat f connected 3 The boiler is Operate It is necessary to check the status of active but no command is not operation signal of any of the combustion present following room thermostat process START switch boiler s operating thermostat 4 Difficult fuel Low quality fuel It is necessary to replace the fuel ignition most probably due to its high moisture content which could above the required value for nominal operation of the boiler 5 Boiler s Absence of It is necessary to check the correct emergency demand for boiler operation process of the heating overheating operation or installation and eventually incorrect appropriate adjustment of the adjustment of the operating parameters of the boiler parameters of the and or control valves of the bo
19. START switch mounted on the interface panel of the unit Respectively the starting process will be invoked by turning START switch in ON position In case that the boiler will not operate for a relatively short period of time than it is recommended to clean the ash deposited on the easy accessed heating surfaces of the heat exchanger Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 26 38 ATTENTION Jn case that the boiler will not operate for a long period of time then the heat exchanger should be thoroughly cleaned from the deposited ash The ash layer acts corrosively on the carbon steel surfaces which will lead to a decrease of the lifetime of the boiler s main modules heat exchanger as well as the burner It is obligatory to perform service procedures and preventive observations of the unit by trained service personal only as well as thorough cleaning at the end of the heating season Completing these requirements will ensure long exploitation duration of the boiler and its high efficiency and reliability 5 5 Turning OFF the boiler The hot water boiler is turned off by changing the START switch into OFF position this is the recommended method for turning the boiler off During the working process in OFF state the control module of the boiler performs so called controlled turning off procedure in which the operating fans are working and certain operating boiler par
20. ameters are controlled After the boiler has cooled down to ambient temperature the boiler should be switched off by turning off the main POWER switch It is recommended to clean the deposited ash thoroughly of the heat exchanging surfaces of the boiler e Accidental boiler stop In operating process of the boiler emergency situations could arise and the boiler will go into alarm failure mode Some situations are detected by the process control module and it will go into automatic preventive regimes in order to protect the boiler and the heating system These regimes are operated by appropriate automatic preventive measures as well as the control module display shows a short informative text describing the cause of the alarm state and the alarm lamp is indicating the state of the boiler Please refer this text before taking any actions After the cause of the alarm situation is clarified take adequate actions for bringing back the boiler into normal operating conditions and restart the boiler by switching it OFF and back into ON state by turning the main POWER switch ATTENTION in case of emergency situation boiler overheating the emergency thermostat is activated appropriate text is displayed as well as indicator lamp is lit In this case the boiler should be cooled down and the reason for such excessive process should be investigated and preventive measures should be performed The emergency thermostat should be manually reset
21. and practically the heat energy price is competitive to the conventional energy sources e The boiler is automatic and the thermal comfort achieved is close to that originating from fully automatic boilers for example liquid or gas fuel as well as electric boiler which makes is applicable in heating systems equipped with programmable room thermostat e The unit is equipped with automatic fuel ignition system and another one for burner s ash cleaning e Automatic unit operation Hot water boiler could be connected to programmable room thermostat weekly programmable which guarantees maximal thermal comfort and economical fuel consumption e The unit utilizes solid biomass fuel in shape of pellets wood pellets dried nuts cherry nuts for example which have ash contents higher that the limits defined in following norms ONORM M7135 DIN 51731 u DINPlus e High efficiency e Low pollutant contents in the flue gases e The unit is applicable for domestic hot water heating purposes e Automatic fuel feeding system transported from the built in daily hopper to the burner e The control operating module can operate the function of additional external fuel feeding system which deliver fuel to the built in fuel hopper from external one e Simplified maintenance and service procedures e Minimized running costs Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 6 38
22. asl re eeu eere vera denn 35 WARRANTY ERR ER 36 WARRANTY SERVICE PROCEDURES LIST 37 Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 4 38 1 Hot water pellet boiler ERATO Pelletherm 25 automatic description properties and advantages ERATO Pelletherm 25 automatic is steel plate hot water pellet boiler which uses solid biomass fuel in shape of pellets The boiler is designed to be connected to local hot water heating systems as well as heating up domestic hot water The boiler uses wood pellets as well as other type shape of biomass the resulting heat energy from thermo chemical conversion i e combustion process is transmitted to the circulation water in its water jacket and the heat energy is transported to the heating system consumer The unit could utilize following types of fuel e Wood pellets having diameter 6 and 8 mm categorized in the range of A AB B BC C CD E EF according to the methodology developed for pellets properties estimation in ERATO company e Pre dried nuts cherries for example e Fuel mixture pellets and nuts for example mixture ratio could be 50 50 e Pellets produced of any other solid biomass for example olive husk residue e Other solid biomass based pellets but confirmation for these fuels need testing and approval by
23. ccess to the front door of the combustion chamber at manual cleaning processes of the surfaces of the burner and or combustion chamber or ash residue cleaning accumulated in the ash tray or any unburned fuel material smoldering in the ash tray e Electrical shock risks at indirect contact The boiler is connected to the power circuit and its operating modules are separated in specialized electric control box equipped with required protective and short circuit preventive devices It is obligatory to perform boiler ground connection by authorized personal technician e Fingers injuring risks at opening closing the doors caps of the boiler at maintenance and cleaning process of the unit It is recommended to use appropriate individual resources for self protection e Suffocation risks due to flue gas emissions in the boiler s room in case when the chimney draught is insufficient in case that the convective part of the boiler is clogged or in case that the flue gas tract is not fully tightened and gas leaks are possible Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 29 38 5 8 Operation faults and their repairing No Operation fault Cause Method for repairing 1 Low temperatures Insufficient heat Adjustment of operating parameters in the heat capacity is required this should be supplied rooms performed by authorized technician Low set point
24. cept when repairing modules sections of the system Practical experience shows that water level checkup should be performed regularly in a period of 14 days in order to sustain quasi constant water content In case that additional water is required the filling process should be performed carefully when the hot water boiler is cooled to the ambient temperature This precautions are induced due to prevent rising of thermal stress of the steel boiler s body and its damage leakage Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 15 38 In case that the boiler as well as the heating installation will not be in exploitation for a long period then in order to prevent local water freezing and damages it is advisable to perform total drainage of the circulating water Please take into account that the presence of liquid in the heating system as well in the boiler will prevent oxidation process of the metal surfaces corrosion and system failures 5 2 Starting hot water pellet boiler ERATO Pelletherm 25 automatic procedure Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manual e Any intervention in the working process of the unit which could lead to unit s failure and or dangerous and health threatening situations are strongly prohibited e The unit should be checked by the maintenance staff or any trained persona
25. d hot test check the entire heating system according to the acting norms for an operating heating system for example check for any circulating water leakages NOTES e During the nominal thermal load of the boiler regular cleaning process is activated and the ash residue remained on the grate of the burner is removed away and is deposited in the ash container positioned on the bottom of the combustion chamber It should be noted that before the ash removal process the fuel delivery to the burner is paused while the air fan is working thus ensuring conditions for utilization of the char remained on the grate of the burner A decrease of the thermal capacity of the boiler could be noticed however Comment the period of ash removal of the grate plate of the burner is defined by the value of parameter T9 which is not described in Table 5 During the automatic ash cleaning interval a temporal decrease of the thermal capacity of the boiler is observed e circulating pump is installed in order to transport the heat energy of the boiler to the consumers it is recommended to control the inflow temperature to the boiler to be above 60 C In case of low inflow temperature level condensation of water vapor could be observed on the internal heat exchanging surfaces please consider that water vapor is one of the final products of the combustion process and always persist in the flue gases of the boiler Hot water pellet boiler
26. d properly in order to preserve environment contamination The unit should be dismounted and disassembled by environmentally safe methods This requirement is most commonly completed by appropriate components recycling considering separate waste disposal and utilization methods Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 33 38 QUALITY CERTIFICATE Product Hot water pellet boiler ERATO Pelletherm 25 automatic Serial number Date of production h Operation test check Technical control Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 34 38 ERATO Product LTD Haskovo WARRANTY FORM Product _ Hot water pellet boiler ERATO Pelletherm 25 automatic Serial number Date of purchase Warranty period Vendor company Buyer signature Seller signature Initial operation date Service company technician signature and stamp Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 35 38 WARRANTY CONDITIONS The producer guarantees correct and reliable operation of the unit ONLY when installation and maintenance requirements are completed The warranty period of the boiler starts from date when the warranty form is filled and stamped by the authorized organization
27. fuel mass flow rate measurement The fuel is collected at the exit of the burner by switching the unit to normal operation mode for a measured period of time and thus the flow rate is calculated The appropriate adjustment shall be done through fuel mass flow rate determination considering the fuel net heating value as well as thermal efficiency of the boiler Here an example of thermal capacity determination is given o Average fuel mass flow rate is determined per hour Mpeiteis 6 0 kg h The instant mass flow rate is calculated as follows the average fuel mass flow rate value is divided by 3600 1 hour 3600 seconds and the result is m 0 00167 kg s o The net calorific value of the pellets is considered given by the fuel producer other source etc Hays 17 2 MJ kg 17200 kJ kg o The thermal efficiency is determined stated by the producer at nominal thermal capacity Nooiter 89 0 89 o The thermal capacity of the boiler is calculated as follows Tide E 1 boiler s H pones i TW pelles 0 89 i 17200 0 00167 25 654 KW o Any other thermal capacity of the boiler is calculated following the described procedure above for example if the fuel has different calorific value or the required thermal capacity is lower than the nominal one The producer reserves the right to make changes of the setting of the process control module without obligations to inform the clients for that process 5 2 5
28. iler or installation this should be operation of the performed by authorized Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 30 38 heating installation technician After the boiler is cooled down to ambient temperature and the reason for boiler overheating is serviced out the protective cap of the emergency overheating thermostat should be unscrewed its rod should be pressed until the thermostat is reset and it s cap should be screwed back The main POWER switch is turned OFF and back ON afterwards and the boiler is thus restarted No fuel ignition Absence of fuel in the hopper Absence of fuel in the burner The fuel hopper should be charged It is possible to manually restart the operation process of the boiler This way the ignition process could be elongated If this approach results in stable ignition then it is necessary to increase the value of the initial fuel mass parameter T1 the adjustment should be performed by authorized technician Fuel is present in the burner but it s not ignited or it is fully incinerated and the combustion process has extinguished i e not present In case that the hot air gun is out of order or not operating then it should be replaced with appropriate working one In case that the hot air gun is working then it is necessary to increase the time for ignition of the
29. its running conditions are in its corresponding operating range That s why if any parameter is changed it s value should be checked and verified to lie in the appropriate limits Special care should be taken to fulfill the following requirements the ratio of the described periods T4 and T6 T4 T6 should be in the following range lt 0420 lt lt 0 700 where 0 420 determines lower level of thermal capacity of the unit corresponding to about 15kW while the ratio 0 700 determines the nominal heat capacity of the boiler NOTES e The choice of these parameters could be preceded as well as followed by other parameters which are not described in the table above These parameters are dedicated to be varied by authorized trained service personal and their variation by the end user is not recommended Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 19 38 e The producer reserves the right to change the specification and or the design adjustment of the unit without prior notice e The table above contains factory default values for the parameters of the settings of the process control module which lead to optimal unit adjustment e The described parameters T4 and T6 are most frequently changed they define the thermal capacity of the unit and its operating regime e The adjustment of appropriate thermal capacity of the units could be realized through field
30. l regularly e The end user should not perform any interventions repairs etc of the unit In case that warning and failures arise check the failures table applied at the end of this manual and call the service support if the case is not described there e Any adjustments of thermal capacity higher than the nominal thermal load of the units are not allowed e The ash deposited in the combustion chamber of the boiler should be collected in fireproof containers and cooled down to ambient temperature The cooled ash should be disposed in appropriate waste containers Please take into account that the mineral ash result of wood biomass pellets could be considered as soil fertilizer and dispersed for agricultural purposes for example Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 16 38 5 2 1 Interface control board of hot water pellet boiler ERATO Pelletherm 25 automatic Alarm indicator 4 99 1 STARI Swen process malfuction Alarm indicator emergency overheating Process control module Operating thermostat Main POWER supply switch Emergency thermostat Figure 1 Interface control board equipped with control and operating devices of hot water pellet boiler ERATO Pelletherm 25 automatic Interface control board devices description e Main POWER switch switches ON and OFF the main power supply of the boiler e Operating therm
31. nsure effective heat exchanging process and will sustain optimal operating conditions of the boiler Detailed ash cleaning and maintenance procedures are described in ANNEX 1 of this manual ATTENTION regular cleaning of the ash residue deposited on the heat exchanging surfaces of the boiler will ensure long life reliable exploitation period economic and efficient performance of the unit S 7 Safety and unexpected risks Risks could arise at the exploitation of the boiler The hot water pellet boiler ERATO Pelletherm 25 automatic is designed according to the safety requirements of the operating European standards and norms However safety and unexpected risks could arise in situations like following e Hot water pellet boiler ERATO Pelletherm 25 automatic is operating incorrectly e The unit is installed by unauthorized unqualified personal e The safety instructions described in this manual are not followed and fulfilled Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 28 38 Unexpected risks The unit is designed and produced according to the requirements of the operating EU safety norms However in spite of that possible risks are considered as a result of the operating process of the boiler it is possible to arise risks as follows e Cauterization risks caused by high temperatures as a result of the combustion process in the combustion chamber and or direct a
32. ostat assigns the set point of circulating water in the boiler The boiler will run until this set point is reached and will supply heat energy to the heating system e Emergency thermostat protects the boiler from exceeding emergency temperature level and boiler overheating This thermostat is factory preset to switch off the unit at water temperature in the boiler above 95 C e START switch sends START STOP signal to the process control module which controls the operation of the boiler e Process control module a programmable unit that controls the functions of unit according to predefined program firmware Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 17 38 e Alarm indicator process malfunction indicates any abnormal state of the boiler for details check the information written on the process control module s display e Alarm indicator emergency overheating indicates emergency overheating state of the boiler due to activation of the emergency thermostat of the boiler In case of activation cool down the unit and check and repair the reason for the emergency situation finally reset the emergency thermostat 5 2 2 Hot water boiler power supply e The unit should be connected to the main power supply according to the safety rules and appropriate norms e The hopper should be filled with pellets in order transport material by the pelle
33. r boiler technical data 7 Table 1 Thermal and technical data for hot water pellet boiler ERATO Pelletherm 25 automatic using wood pellets esses 8 Table 2 Dimensions and technical data for hot water pellet boiler ERATO 25 rani 9 Table 3 Recommended solid fuel properties wood pellets 10 Table 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in 10 3 Description of hot water pellet boiler ERATO Pelletherm 25 ONIN ER 11 4 Installation process hh ot eter tut 13 5 Hot water boiler installation and starting procedures 15 5 1 Basic fuel requirements eio i Dei be ics Ea co va Rel ve Sahel 15 5 2 Starting hot water pellet boiler ERATO Pelletherm 25 automatic procedures seat Raa hae 16 5 2 1 Interface control board of hot water pellet boiler Pelletherm 25 automatic bu tea ente chili 17 5 2 2 Hot water boiler power supply 18 5 2 3 Hot water boiler very first 18 5 2 4 Main parameters for boiler operation
34. set process of the unit is performed by switching OFF the main power supply switch and turning it back into ON position e At nominal operation process a manual ash residue removing process in the burner could be invoked by pressing the button arrow LEFT lt 4 This option is dedicated for testing the performance of the cleaning module ONLY and should NOT be activated unless testing the cleaning Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 23 38 mechanism is required The automatic cleaning procedure is performed regularly in a predefined period of time parameter T9 time period for automatic cleaning procedure 5 2 7 Nominal operation mode of the boiler After successful ignition of the fuel and when the operating temperature of circulating water is stable it could be assumed that the hot water heating boiler is in nominal thermal load This mode should be utilized in order to make adjustments of the operating parameters of the unit The parameters described in Table 5 will define the thermal load of the boiler After setting the values of operating parameters of the units please check the position of the air flow rate adjustment flap of the air fan The air flow rate is crucial for optimal operation and high efficiency combustion process organized in the combustion chamber of the boiler The nominal thermal load of the units should be utilized in order to perform the so calle
35. t feeding auger to the burner It s recommended to set the pellet hoper lid closed in order to preserve uncontrolled air penetration to the combustion chamber through this tract 5 2 3 Hot water boiler very first start The unit is switched on by the main POWER supply switch placed on the control board The unit gets activation signal by switching ON the START and goes into automatic operating mode it goes through ignition mode 1f needed If the START switch is OFF then the boiler goes into stand by mode and waits until new command arise In case of power supply break down the boiler will go into the same state of the unit before the interruption ATTENTION During the operation of the boiler when the door of the combustion chamber is opened it is possible to observe smoke leakage through the transport auger tract as well as hot air gun entrance zone Because of these reasons the opening of that door is not recommended The same processes could be observed at the transition periods during spring and autumn seasons when the chimney s draught is reduced due to high ambient temperature COMMENT e At the period of fuel ignition by hot air gun is activated The gun has specific noise at functioning and should be not treated as malfunctioning sound The hot air gun will be deactivated when the flue gas temperature reaches certain level sensed by flue gas thermostat mounted on the exhaust duct of the boiler e During
36. te burner designed for horizontal fuel feeding The heat exchanger is welded construction of carbon steel plates and steel pipes The lower part of the exchanger is designed as combustion chamber The burner is mounted in this chamber as well as lining for efficient combustion process Linings mounted in the combustion chamber providing high intensive and efficient combustion process Stainless steel burner mounted in the combustion chamber of the heat exchanger Ash container positioned in the lower part of the combustion chamber below the burner Fuel hopper is mounted aside of the boiler s heat exchanger Beneath the hopper is mounted a fuel auger separator which also acts as fuel proportioner followed by horizontal transport auger The fuel proportioner prevent the so called back fire process i e ignition of the fuel in the hopper by the hot flue gases in the auger duct in case of abnormal situations Fresh air fan is mounted on the air duct of the burner The fan is equipped with position adjustable flap in order to set the air flow rate Inflow and outflow connections to from the heating system of the supply and return circulating water are internal thread diameter G172 positioned in the rear side of the heat exchanger Draining connection is internal thread diameter and is positioned on the lower part of rear side of the heat exchanger An appropriate drainage valve should be connected Hot water
37. ted rooms T ambient air Mean value of the ambient temperature C AT Tyoom Tambient air temperature gradient C The value of parameter T4 is determined according to the assumption that value of parameter T6 is conserved constant i e T6 20 seconds ATTENTION In case that the boiler is working for heating purposes of domestic hot water ONLY than the heat capacity of the unit should be considered the T4 T6 ratio limits 0 420 COMMENT The above defined values of the heat capacity parameters are given for certain fuel wood pellets with diameter d 8mm In case that the fuel type or its characteristic size is different than 6mm diameter wood pellets than these values should be considered as basis for appropriate adjustment of the boiler Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 21 38 Pellet s feeding time seconds Ratio T4 T6 16 000 0 7900 14 000 0 6900 12 000 0 5900 10 000 0 4900 8 000 0 3900 6 000 0 2900 4 000 0 1900 2 000 0 000 r 0 0900 7 t 15 00 18 33 21 67 25 00 15 00 18 38 21 67 25 00 Heat capacity of the boiler kW Figure 2 Graphics of the T4 parameter and power ratio pellet s feeding time T4 and ratio T4 T6 values according to the heat capacity of the boiler 5 2 6 Changing the working parameters of
38. the process control module Algorithm for changing the value of working parameters of the process control module of the boiler The following text describes algorithm for changing the values of any parameter of the process control unit It s recommended to change these parameters only when it is necessary The physical meaning of any parameter should be clarified as well as the influence of a parameter on the performance of the boiler The visualized parameters are allowed to be changed 1 Press the green button marked Menu OK on the interface panel of the process control unit A menu list will be displayed 2 Press buttons arrow DOWN V or UP A and choose the item PARAMETER 3 Press button arrow UP A until reaching the desired parameter T4 or T6 NOTE Do not try to change any other parameter unless the meaning and the influence on the performance of the unit is now known a priory Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 22 38 4 Press button arrow RIGHT gt and choose the field of the parameter value 5 Press button arrow DOWN or UP A and change the value of the parameter Note Holding the buttons pressed arrow DOWN Y or UP A after certain period will increase the increment of the change of the parameter s value 6 After the desired value is defined press the green button Menu OK 7 The display of the process control mod
39. to guarantee easy access to the semi automatic cleaning system lever Minimal distance of 500mm above of the unit and any wall should be provided in order to guarantee easy access to the fuel s hopper as well as enough room for cleaning purposes of the heat exchanger body e The hot water boiler should be positioned in the boiler s room according to the requirements for attaching electrical appliances to the power circuit the unit should be positioned in a way that will provide easy access to the power supply plug 230V 50Hz Attention the installation process of the boiler is finalized by performing so called hot tests procedure of the heating installation and the warranty card is filled with the required information Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 14 38 5 Hot water boiler installation and starting procedures Attention The unit should be installed adjusted and verified ONLY by trained staff authorized by ERATO company 5 1 Basic fuel requirements e The fuel pellet shaped should be dry The unit producer recommends that the fuel should be stored in dry and well ventilated rooms e It is strongly forbidden to store the fuel in close region of the boiler the minimal safety distance between the fuel and the appliance is 400 mm e The unit producer recommends an optimal distance between the boiler and the fuel container to be at least 1000mm
40. ule will show a question CONFIRM CHANGES Press buttons arrow DOWN W or UP A until selecting the desired answer Yes or Not Choose the answer Yes by pressing the green button Menu OK in order to confirm the change or answer Not in order to reject the change of the value of operating parameter IMPORTANT If the user is not confident in the necessity of the change of the value of any parameter or the value of a parameter is changed accidentally then it s recommended to choose the answer Not 8 Press the green button Menu OK once more time and the process control module will exit the PARAMETER mode and will display the nominal operation process of the boiler control NOTE f any accidental change of a parameter has been made at the exit of this process a summary question will be displayed CONFIRM CHANGES choose the answer NO and any changes will be canceled 9 Following the algorithm described above one can change any available parameter of the process control module and can vary the setting and the performance of the boiler NOTES e During the operating process of the boiler it is possible to arise an alarm situation for example unsuccessful ignition process fuel supply interruption etc A short description of the alarm status is written on the display of the process control module After removing the cause of the alarm situation reset the operation module The re
41. unted deposited with ash presenting heat resistive layer thus decreasing the heat exchanging intensity 11 Water vapor Low temperature It is necessary to perform condensates on of the inlet water adjustment of set point the surfaces of the flow temperature which controls the combustion circulating pump of the heating chamber system It is recommended to adjust the thermostat set point to minimum of 65 C 12 Flue gases The flue gas fan is It is necessary to clean thoroughly emitted out in clogged even the flue gas fan ants casing boiler s room blocked by fly ash after certain deposits period of exploitation 13 Other failures not It is necessary to consult authorized described above technician and eventually service maintenance should be performed Table 7 Description of operation faults of the boiler causes and methods for repairing Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 32 38 5 9 Hot water boiler warranty form completion The applied WARRANTY FORM should be completed by filling the required information in the appropriate fields The assigned field for signatures and stamp should be completed as well in order to VALIDATE the WARRANY FORM of the unit 5 10 Actions after the unit is not in exploitation anymore After the lifetime period of the unit has been completed then it should be treate
42. well as operating conditions Table 1 Thermal and technical data for hot water pellet boiler ERATO Pelletherm 25 automatic utilizing wood pellets Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 8 38 Parameter Dimension Value Weight kg 405 Water jacket capacity dm 120 Exhaust gases duct diameter mm 150 Fuel hopper capacity dm 200 kg 135 kg wood pellets Overall dimension of the unit WxDxH mm 1350x920x1450 Class according to EN 303 5 3 Operating overpressure of the circulating MPa 0 15 water Heating system expansion vessel type Opened Factory tested overpressure MPa 0 4 Recommended circulating water C 80 temperature Minimal recommended return water C 60 temperature Draught hPa 0 1 0 2 Supply return flow G 1 Connections Drainage G 75 Flue gases duct mm 150 Power supply IPEN 50Hz 230V Electrical capacity VA 120 1600 at ignition process Electric protection IP20 Table 2 Dimensions and technical data for hot water pellet boiler ERATO Pelletherm 25 automatic Hot water pellet boiler ERATO Pelletherm 25 automatic user manual version December 2008 p 9 38 Parameter Dimension Value Pellet s characteristic size mm 6 12 Recommended fuel net calorific value MJ kg gt 17 2 kWh kg 4 7 Wood pellets category A AB
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