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2. Status Next Status Change conditions WAITING TESTING Boiler s thermostat switches on TESTING CLEANING All tests are passed successfully BATTERY Battery voltage is less than 24V in burdened status ERROR FAN ERROR Fan does not reach 40 rps at PRE BURN LEVEL ERROR The level sensor recognizes pellets in the feeder CLEANING LOADING The grates are moved and ash is removed from burning chamber GRATE ERROR Grates are not moving as expected LOADING IGNITING Feeder makes loading rotations 40 rot min PAR24 NO PELLETS Maximum loading time b min normal or 20 min initial is reached END BURN Flame detected and unknown start conditions LOADING restarts LOADING 2 IGNITING Previous state was ignition and feeder made 3 rotations PRE BURN Previous state was hold flame and feeder made 3 rotations IGNITING PRE BURN Flame recognized LOADING 2 Max ignition time 255 sec is reached and load 2 is not done IGN ERROR Max ignition time 255 sec is reached and load 2 is done 292 22 DK9401B1 www pelltech eu PV700a PV1000a pellet burners 46 59 PRE BURN BURNING 3 pre burn cycles each 40 sec are done and continuous flame is recognized more than 10 seconds LOADING 2 Pre burn cycles are done and flame is NOT recognized and load 2 is NOT done NO FLAME Pre burn cycles are done and flame is NOT recognized and load 2 is done B
3. PERF ha e EUER 30 3 5 1 5 31 3 6 External boiler temperature i iiiaae 31 4 tet rr rro Rayon ou arredi eae veniae resto tu E ERR 32 4 1 Userinterface E 32 4 2 Starting and ees 33 4 3 PUG I EEUU 33 4 4 Statuses and paratmeters ciss cccsseseciccsnsceicacscacecdeasct sepe Lena da Dese 33 4 5 Output DOWSF levels xenon 40 4 6 Main menu and settings eiecti cete e Oc re bo edu E dante 40 242 52252 pelltech ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 3 59 4 7 doses ccd ERR RR ERR x FR ERR eR Rea DERART da vices 43 5 91 186 43 6 JB rrnerstat s change ri 45 7 gt Annex 1 Electrical diagrams iie 47 8 Annex2 Controller board 1 reete cadres itd eoe patent ever 50 9 3 Control unit asroriga enaner eraan o EE
4. WAITING Waiting when boiler s thermostat switches on TESTING Boiler s thermostat is switched on testing the battery fans feeder level sensors and draught in progress CLEANING Ash removing from burning chamber LOADING Loading pellets with external auger into burner and by feeder auger into burning chamber IGNITING Igniter is turned on pellets are ignited PRE BURN Flame is recognized small amount of pellets is added by feeder auger HEAT UP Burning chamber ceramic stones are heated up BURNING Normal burning operation HOLD FLAME Thermostat is switched off small flame is held alive END BURN Thermostat is switched off feeder is burned up END BLOW Pellet coals in burning chamber are burnt flame has disappeared WAITING Burner waits when boiler s thermostat switches on At WAITING status the burner waits when boiler s thermostat switches There is no time limit for WAITING status Only feeder auger is working periodically at WAITING status and makes rotations after every 2 minutes With this feeder augers spiral cleans feeder s tube from wastes When boilers thermostat switches on burner will go to TESTING At TESTING status burner s integrity and important device functioning are checked List of tests is given in Table 10 Table 10 List of tests in TESTING status Test name PARNo Value Unit Test conditions Battery voltage 22 V Battery loading is turned OFF and feeder i
5. 1 Pressure switch Flexible hose Sprinkler Sprinkler Figure 25 Water sprinkler installation 2 4 External auger p 24 59 Principal chart of water sprinkler installation is depicted in Figure 25 Water sprinkler is main safety element against back burning It is strongly recommended to install sprinkler system Pressure switch allows starting the burner only if water supply is present If no water is available on installation site reservoir can be filled manually In this case pressure switch is not connected to safety circuit as there is no pressure in water system In case of back burning sprinklers will open and fire is extinguished in feeder tubes Flow control valve limits the amount of water flowing into burner after the reservoir is emptied The burning chamber must be cleaned from wet ash and pellets before turning the burner back on again The external auger transports pellets from the pellet container to the burner The burner controls the work of the external auger The auger is connected to the burner with a special hose 2 76mm which is made from easily melting material polyurethane that acts as a safety measure against back burning PV1000a pellet burner s fuel consumption at full power is about 208 222 kg of pellets per hour 3 3 3 7 kg per minute External auger s productivity for PV700 PC1000 must be at least 270kg of pellets per hour The auger can be fixed to the storage or a ceilin
6. Table 20 Main menu Menu Menu para Description Default Options nr meter ENG settings 1 STATUS gt Submenu with status 2 INFO gt Burner s info 3 BURNER Burner s turning OFF ON OFF 4 HOLD FLAME Hold flame allowed OFF ON OFF AUTO 5 HEAT UP Slow heat up AUTO AUTO ON OFF 6 SLOW DOWN Slow cool down OFF ON OFF 5 PELLETS Fuel quality options NORM NORM LIGHT HEAVY 7 POWER Power level selection AUTO PV700 AUTO 200 300 400 500 600 700 PV1000 AUTO 250 400 550 700 850 1000 8 BASE AIR Fan speed change at 0 2 1 0 1 2 3 4 5 once for all power levels 9 SILO Container selection 1 1234 10 LANGUAGE Language options ENG Annex 5 List of languages 11 PARAMETERS Parameters menu Annex 4 List of parameters STATUS info screen displays last events burner states and their duration The duration is in form mm ss in the middle or hh mm h in the middle For example Igniting 01m25 means the burner ignition state lasted 1minute and 25 seconds Last row of the log shows current state To reach the last row press the down button until you reach the current state The duration of current state updates every second or minute INFO menu is useful to troubleshoot various problems It gives access to some input signals and internal parameters Use up and down arrows to scroll through info menu un Note Comma is used as decimal separator Table 21 Info me
7. www pelltech eu DK9401B1 pelltech PV700a PV1000a pellet burners Table 2 List of main components No Name Description 1 Burning The part of the burner that is inside the boiler and where pellets are burnt chamber 2 Burner body The part of the burner that is outside the boiler and where burner s control and pellets supply takes place 3 User interface Control board with screen navigation buttons and indication lights 4 Control unit Electrical and control panel what contains inverters fuses relays main controller board and other control devices 5 Water sprinkler Sprinkler system will spray water to extinguish the fire in feeder s tube in case of back burning The sprinkler system is activated only when the temperature of feeder auger rises dangerously high 6 Grate cleaning Linear motor moves the grates in burning chamber and pushes ash out from motor burning chamber This cleaning cycle is made periodically The interval between cleaning cycles can be controlled by PAR48 In each cleaning cycle the linear motor pulls grates back then pushes the grates completely out The linear motor has 75mm stroke and end switches for stop Linear motor current limit can be set by PAR47 Linear motor is protected by fuse F10 what is installed on the controller board board version BBB v2 1 7 Igniter Igniter s purpose is to ignite loaded fuel making the burning process sta
8. Eure 53 10 Annex 4 Table of parameters cere ret e ERR e ER 55 11 Annex 5 Table of la nguages ccccccccssssccceessececsesseeeceesseeecsessececsesaeeeesesaeeecsesaesecsesaeseesesaeeeeeeaeeeeeees 57 NY ALAIN M T m 58 22 pelitech 5 2 DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 4 59 Safety precautions Do not start the burner before it is connected to the boiler and the boiler is connected to the chimney It is recommended to wear a respirator while handling pellets The boiler room where the burner is installed must fulfil all rules and recommendations given by authorities All electrical connections must be done by trained professionals No flammable materials must be stored near the burner Warnings Changing the construction of the burner without written permission from the manufacturer is forbidden Use only spare parts provided or approved by the manufacturer in order to avoid any damage to the burner and dangers resulting from it Welding is allowed only after disconnecting the burner from electric supply The circuit board must be removed from the burner Do not open any boiler door while the burner is in operation Notice Manufacturer of burners has right to make changes in construction of burner and its firmware Burner corresponds to following directives and standards Directive 2004 108 EC Directive 2006 95 EC Directive 2001 95 EC Directiv
9. 59 secondary fan quality and optimal flue gas content To control the burning procedure oxygen sensor optional for fan s speed regulation is used Both fans rotation speed is measured by sensor installed near the impeller axle The sensor is reading magnetic field changes caused by magnet installed on the impeller axle 16 Controller board Controller board controls the burner s burning process by calculating fuel amount also feeder and auger work during burning process Depending on the input signals from the sensors controller makes necessary changes to the output states to maximize burning efficiency Controller has a single control board 17 GSM modem A GSM modem enables burner to send SMS messages with various information optional of burner s operating states errors GSM modem is located on control unit 18 Feeder auger Internal feeders are used to deliver correct amount of fuel into burning motors chamber Delivered fuel amount is regulated by periodical work of feeder gear motors 24V DC motors are supplied from backup battery to empty feeder tubes in case of power failure 19 Battery When there is no power from the main power supply then the burner is operating on battery power PV1000 uses two 12V 3 4 Ah batteries Because the battery is a safety element the burner checks batteries condition and does not start the next working cycle if the batteries voltage is too low 20 Interna
10. Annex 5 Menu PARAMETER gives overview of burner s default and minimum maximum settings The menu enables fine tuning of the burner what in general is not necessary Short description of burner s parameters is given in Annex 4 4 7 Regular maintenance Pellet burner requires systematic maintenance The maintenance period depends on the quality of the pellets and heating intensity The boiler must be cleaned weekly For more information about cleaning the boiler please see boiler s user manual The burner should be cleaned at least two times in a heating season To clean the burner 1 Turn off the burner by turning the boiler s thermostat to O 2 Letthe burner cool down for at least 1 hour 3 Open the boiler s door to gain access to the burning chamber 4 Remove the grates and clean them from any residues Before removing is recommendable to mark grates Make sure that all holes on the grates are clean 5 Remove the bottom panel to gain access under the grate movers to clean the ash from the burning camber 6 Reattach the bottom panel Place back the grates taking into account their marking Ensure that grates fit to holders 8 Close the boiler s door to finish the maintenance and turn the thermostat to desired temperature M The connection between the boiler and chimney must be completely airtight There mustn t be any extra draught in the smoke draft of the boiler All cleaning and maintenance openings must be closed with covers 5 Pr
11. DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 47 59 7 Annex 1 Electrical diagrams BI Black TETTE Br Brown 9 5 Bu Blue Gr Green Rd Red Wh White YL Yellow cr 4 ot BES RE 7 ay 285 lt 8 Figure 36 PV700 Electrical diagramm Pose DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 48 59 BI Black Br Brown Bu Blue Gr Green Wh White YL Yellow Figure 37 Principle diagram 3333 pelltech 225 P DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 49 59 HERR INVERTER F X2 I PWRSRC amp 5 BATIPWRSRC E 0102 BATTERY E 012 NrFEDER2 DCPWR B wTFEDER 2 BOILER THERMOSTAT 001 202 2284 2253 gt 1 Sec Air FAN PrimAir FAN MODEM PELLETS LEVEL Figure 38 Principle diagram pelltech DK9401B1 www pelltech eu PV1000a pellet burner 8 Annex 2 Controller board p 49 58 Fuse F4 6A 24VDC Power supply Fuse F10 2A Linear motor Figure 41 Controller board BBB v2 1 pelltech DK9401B1
12. Menu POWER determines caloric productivity of burner in kilowatts Power is calculated by reading the rotations of the feeder auger taking into account average caloric value of 1 kg of pellets It is possible to pre set particular 200 300 or else power level value or AUTO automatically selected value In AUTO status burner selects necessary power level depending on time what is needed to achieve pre set temperature Burner changes its capacity what is determined by parameters MIN POWER PAR13 and MAX POWER PAR14 If burner cannot achieve pre set temperature in certain time PAR15 it will raise its power automatically by one level and continues rising power up to reaching maximum level PAR14 or boiler has achieved pre set temperature If boiler achieves pre set temperature faster than set in PAR16 burner will work one power level lower in next cycle Power will be reduced as long as burner has reached minimal power level PAR13 Su pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 43 59 Menu BASE AIR increases or decreases speed of fan in all power levels by same number It is reasonable to use base air to balance different characters of particular heating systems For example if draught is very strong the fan can work at lower speed and thus reduce the draught SILO menu enables to burner to choose between four pellet containers Menu LANGUAGE enables user to select between 17 languages Table of languages is in
13. NO or NC selection values in PAR50 have to be changed PARSO value Description 1 Normaly open circuit NO Switches on when error appears Normaly closed circuit NC Switches off when error appears SWITCHED ON in IGNITING HEAT UP BURNING and HOLD FLAME statuses Not in use Not in use 32 Delitech ese DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 29 59 3 3 Flue gas fan The burner needs stable under pressure in burning chamber for its correct operation Simplest way to assure this is to use the flue gas fan between boiler and chimney With flue gas fan the burner can control and hold constant under pressure In order to control flue gas the PAR60 value has to be set to 2 ON Selected flue gas fan must provide transmission of the maximum flue gas amount and exceed the pressure provided by boiler ash cyclone and chimney The flue gas capacity for burned pellets can be calculated by simplified formula T oom V V Capacity range in m h P Burner max power in kW Tg Flue gas absolute temperature in K Troom Room absolute temperature in lambda Excess air ratio PV burners are designed to work at lambda values 1 2 1 5 for calculations choose value of 1 5 Flue gas fan must be installed between boiler and chimney If ash cyclone is used then flue gas fan must be installed between ash cyclone and chimney to avoid overpressure in cyclone and
14. PV700a PV1000a pellet burners p 30 59 3 4 Oxygen amount sensor Oxygen amount sensor oxygen sensor allows the burner to keep pre set oxygen level in flue gas what increases the efficiency of the burning process The oxygen sensor is connected to socket X23 as shown on Figure 31 If the sensor requires heater connection it can be connected between T6 and B5 PT100 oN mA PT100 27 2V e GND 2 1 Figure 31 Oxygen sensor connector Following instruction is applicable for firmware version 2 08 In order to implement oxygen sensor two parameters PAR66 and PAR67 in parameters menu have to be set up Table 6 PAR66 and PAR67 set up Parameter Description Unit Def Min Max PAR66 OXYGEN TYPE 0 no sensor 0 0 2 1 4 20mA 0 25 oxygen 2 4 20mA 0 20 oxygen PAR67 OXYGEN SET Oxygen level set point in flue gas 6 4 12 For oxygen amount sensor 0006 in parameters menu the PAR66 value has to be set to 1 Some third party oxygen amount sensors use 4 20mA output for 0 20 oxygen In this case value 2 must be selected If PAR66 is set to 0 no sensor secondary fan is driven by air table set in PAR31 PAR36 Secondary fan also switches back to air table if oxygen level reading is below 396 or over 1996 Oxygen sensor is located inside the burning chamber Oxygen level control starts 5min after b
15. burning min chamber PAR71 HEAT UO POWER Initial heat up power for burners with ceramic burning k chamber PAR72 HEAT UP TEMP Initial heat up temperature for burners with ceramic burning chamber PAR73 TEMP BASE TEMP BASE PAR99 BURNER TYPE Selecting model of burner Software of wrongly selected model works incorrectly gt PAR67 OXYGEN SET Oxygen level setpoint 11 Annex 5 Table of languages Language ENG English SPA Spanish EST Estonian FIN Finnish FRA France GER Germany GRE Greece HRV Croatian LIT Lithuanian LAT Latvian NED Dutch POR Portuguese RUS Russian SLO Slovenian SRB Serbian SVK Slovakian SWE Swedish 3388 pelltech 92 DK9401B1 www pelltech eu Warranty Warranty objects in this context are pellet burner PV700 or PV1000 and supplied auger Producer gives 2 years warranty from the date of sale for the PV 700 or PV 1000 burner and supplied auger Exception is ignition element igniter for this item warranty is 1 one year Warranty is valid when user had not made changes in the construction and setup of the burner Warranty does not cover defects caused by an accident misuse abuse improper installation or operation lack of reasonable care unauthorized medication loss of parts tampering attempted repair by a not authorized person mains errors or using poor quality fuel Warranty is valid only if the b
16. mm 76 76 H total height mm 598 621 H1 burning chamber height mm 451 545 W burner housing width mm 606 706 W1 burning chamber width mm 528 614 Required chimney diameter mm 300 350 Mass net bruto kg 150 185 230 280 Max amount of flue gases 1800 2500 Max fuel consumption kg h 150 213 Maximum nominal power kW 700 1000 Minimum power kW 200 250 Hold flame power kW 40 60 Noise level dB 58 58 Emission class EN 15279 5 5 Operating temperature 10 40 10 40 Supply voltage VAC 3x380 3x380 El power at ignition W 1100 2100 El power average W 370 480 El power at standby W 20 20 Main components of the burner and their locations are depicted in Figure 2 and described in Table 2 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 9 59 L 1306 1 1 4 po _ 1 706 1 1 3 8 5 E Y Y o o W1t 614 Lt 1306 1 _ S Y Y L1 624 12 682 Figure 1 Main measurements of PV1000 burner 335 ege DK9401B1 www pelltech eu p 10 59 PV700a PV1000a pellet burners re 4 zo Figure 2 Main components
17. p 7 59 Set of components o P 1 Burner with burning chamber 2 Bracket 2 pcs 3 Hose 76mm 8338 pelltech ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 8 59 1 General description PV700a and PV1000a are burners of wooden pellets sawdust granules that are intended to use in different boiler houses Only wooden pellets with 6 or 8mm diameter can be used to run burners You cannot use any other form of fuel but pellets to run the burner Unique design of burners burning chambers allows to burn also industrial pellets The construction of the burners allows them to be used with different boilers liquid fuel solid fuel and universal boilers The burner is connected to the boiler by using a connection plate The burner is equipped with a safety thermostat a melting hose temperature sensor sprinkler system with pressure switch and auxiliary battery for protection against back burning Main technical data are given in Table 1 and Figure 1 Table 1 Technical data of burner Parameter Unit PV700a PV1000a L total length mm 1190 1306 L1 housing length mm 592 624 L2 burning chamber length mm 590 682 D1feeder auger s tube diameter mm 80 80 Pellet inlet tube diameter
18. rps Fan speed at END BURN PAR39 FAN 2 MIN 7 Minimum speed of secondary fan Used at IGNITION PREBURN HEAT UP HOLD FLAME and END BLOW statuses PAR27 END BLOW TIME 2 min Time to blow air after flame is disappeared Max END BLOW 15 min Maximum time when flame must disappear at END time BLOW 4 5 Output power levels Burner has 6 pre set output power levels For every level the program calculates correct fuel amount what depends on fuel s calorific value and burner s internal feeder productivity The feeder productivity for normal light and heavy pellets can be changed from main menu For normal pellets it is 160 grams per rotation PAR21 Calculated amount of fuel is divided into periodic feeding cycles In every normal cycle internal feeder makes half rotation If the calculated time of cycle comes too short then the cycle length will doubled and fuel will loaded with full rotation of feeder For every power level there is different pre set fan rotation speed PAR1 PAR6 Burner chooses the output level between pre set min and max powers When burning time has been more than 15 minutes PAR15 next time burner takes one power level up when burning time has been less than 30 minutes PAR16 next time burner takes one power level down 4 6 Main menu and settings To enter to set up menu press OK To go back to main menu press lt button 32 926 DK9401B1 www pelltech eu
19. smoke leakage Burner setup Depending on burner s configuration weather inverter included or not the electrical connections may be different In case the frequency inverter has already been installed in factory to the burner the flue gas fan can be directly connected to the burner through connector Y8 Fan must be connected to burner with 3 wire cable 3 1 5 Internal inverter output is x 230 If flue gas fan motor is a three phase motor 3 x 230 380V then it has to be connected as triangle In case the burner has no inverter the external inverter for flue gas fan can be used Inverter must be selected according to fan motor s parameters and available power supply The inverter must be switched to sink logic negative common To connect the external inverter with burner there is connector Y7 with 3 output signals T1 burner DC common ground must be connected with external inverter input common S3 inverters run command must be connected with F forward pin on inverter input Burner will connect this pin to ground when fan must run B4 10V output for fan speed must be connected with inverter analogue input Inverter setup Inverter parameters are set up at factory for automatic control To test flue gas fan manually 1 Press Easy button on inverter 2 Press Dial button and change settings CNOd 0 FNOD 0 F174 0 29 o DK9401B1 www pelltech eu
20. 000a pellet burners p 18 59 Figure 12 Connect the moving grate holders with M6x12mm bolts Install the burning chamber s front brick holders use M8x16mm bolts Figure 13 3333 ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 19 59 Figure 14 Release the igniter tube screws and while inside the holders pull the tubes out about half of the total length Figure 15 Move the air separator to its correct position according to the boiler door thickness and fix it with screws 2252 elltech P DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 20 59 Figure 16 Install the ceramic sealing strips on the boiler door Fix them temporarily in position with any ordinary cellophane tape scotch Cut away the excessive sealing on the perimeter of the air chamber Figure 17 Mount the burner s housing on the boiler door using 4 M12x70mm bolts and respective washers Figure 18 Push the igniter tubes through the burning chambers back wall and fix them in position with M4 screws DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 21 59 Figure 19 Connect the linear motor with the moving grate holder Use 27x2 5mm pipe length 240mm M8x45mm bolt for the burning chamber side and a M6x25 socket set screw DIN914 45H on
21. 1 www pelltech eu PV700a PV1000a pellet burners p 38 59 level menu Power level selection for Selected power burning time can be automatic or fixed on some main level When power level is fixed the power is slowly raised to selected level and will be there until boiler thermostat Par 17 switches off Burning time p D o Power level can be selected in main 6 5 4 3 2 1 Figure 33 BURNING at fixed power In Automatic Power mode POWER set to AUTO in main menu the operation power is selected automatically depending of burning cycle length 9 Max power par 14 8 Thermostat ON New operation power a 6 5 Operation power 4 3 Testing mi Loading 2 Par 15 Par 15 igniting 1 End Par 17 Burning Waiting Burning T 222 30 30 Time min Figure 34 Burning procedure when power selection AUTO In SLOW DOWN mode the burner power is reduced step by step to 1 level after boiler thermostat is switched OFF This mode can be used only in systems with high and stable power demand Using Slow down mode in systems with low thermal inertia or unstable power demand there will be risk of system overheating SLOW DOWN mode is recommended to use together with HOLD FLAME 32 ege DK9401B1 www pelltech eu PV700a
22. 850 Secondary fan speed at 5 power level PV700 PV1000 PAR36 FAN 2 700 1000 Secondary fan speed at 6 power level PV700 PV1000 PAR38 FAN 2 BASE Changing amount of secondary fan base air with flue gas fan speed setting in all power levels PAR39 FAN 2 MIN Secondary fan minimal speed rps 4 PHOTOCELL LEVEL Flame sensor sensitivity Higher number means that 96 flame is recognized when less light PAR41 PRE BURN TIME Length of one PRE BURN cycle state sec PAR42 PRE BURN CYCLES Number of PRE BURN cycles Total length of PRE BURN cycles is length of one cycle times number of cycles PAR46 FEED CURRENT Preset feeder auger motors current Overcurrent protection threshold PAR47 GRATES CURRENT Grate motor overcurrent protection threshold PAR48 CLEANING CYCLE Pre set time between two cleaning cycles OZCLEANING in OFF 50 RELAY ERROR ERR output function selection C m 1 PAR52 SMS COUNT Selecting number of phones receiving alert SMS PAR53 TEMP TYPE Determines temperature sensor type plugged in TMP1 connector 54 TEMP LEVEL Set point value for temperature sensor plugged to TMP1 PAR55 TEMP HYST PAR54 maximum set point hysteresis lt 5 2 9 5 DK9401B1 www pelltech eu PV1000a pellet burner p56 58 BASE FREQUENCY Grid frequency Hz PAR66 OXYGEN TYPE Type of oxygene sensor O nosensor 1 4 20 0 25 2 4 20 0 20 PAR70 HEAT UP TIME Initial heat up time for burners with ceramic
23. Fan speed at 6 power level PV700 PV1000 r FAN START Fan speed at TESTING FAN IGNITING Fan speed at IGNITING and PRE BURN PAR7 PAR8 PAR9 FAN END BURN Fan speed at END BURN FAN HOLD FLAME Fan speed at HOLD FLAME If HOLD FLAME is set to ON in main menu then this min 15 5 30 15 5 function starts at any case If HOLD FLAME is set to AUTO in main menu then this function starts if time set with this parameter is shorter than 2 sequential WAITING times r r PAR10 r PAR11 HOLD FLAME ON Max time when burner holds flame HOLD FLAME function in main menu has to be set to AUTO or ON PAR12 HOLD FLAME OFF PAR13 MIN POWER Minimum power level up to what burner decreases 200 200 700 250 250 1000 output power Applies if POWER in main menu is in AUTO status only PAR14 MAX POWER Maximum power level up to what burner decreases 700 200 700 1000 250 1000 output power Applies if POWER in main menu is set to AUTO only Timeframe to burner to increase power to one level up i 120 15 5 120 if BURNING state lasts longer than set with this parameter Applies if POWER in main menu is set to AUTO only Timeframe to burner to decrease power to one level i 45 30 15 up if BURNING state lasts longer than set with this parameter Applies if POWER in main menu is set to AUTO only UP CYCLE Pace of increasing targeted power level part steps DOWN CYCLE Pace of decreasing targeted power level part steps PAR21 PELLETS NORMAL De
24. PV1000a pellet burners p 39 59 O0 a Thermostat ON 7 6 Thermostat OFF 5 mc Operation power 4 3 2 4 Burn SI OR dein flame Slow down Status time Figure 35 SLOW DOWN mode The purpose of HOLD FLAME mode is to avoid burner start up procedures i e TESTING CLEANING LOADING IGNITING etc every time when burner is switched on from boiler thermostat In HOLD FLAME mode minimum fuel and air amount are delivered to burning chamber HOLD FLAME mode can be switched on from burner main menu When HOLD FLAME is set to AUTO burner will turn the mode ON or OFF depending on WAITING time e f WAITING time between END BLOW and boiler thermostat switched on is shorter than set in PAR 11 then HOLD FLAME mode will be switched on e f HOLD FLAME time is longer than set in PAR12 HOLD FLAME mode is switched off HOLD FLAME is also used as intermediate state before CLEANING or after SLOW DOWN Table 17 HOLD FLAME parameters PAR Parameter name Default Unit Comment value PAR10 FAN HOLD FLAME 10 rps Primary fan speed at HOLD FLAME PAR39 FAN 2 MIN 7 rps Minimum speed of secondary fan Used at IGNITION PREBURN HEAT UP HOLD FLAME and END BLOW statuses PAR11 HOLD FLAME ON 15 min If two consecutive WAITING states have been shorter than 15 min HOLD FLAME will be activated PAR12 HOLD FLAME OFF 60 min Maxim
25. PV700a PV1000a pellet burners p 1 59 pelltech PV700a PV1000a pellet burners User manual DK9401B1 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 2 59 Contents Safety precaution Siste en D ILU ILL D REM 4 e aa H 4 E 4 580 qu ace Re vocero dnos 7 1 General description e tato 8 1 1 EVI C CS ee PEERS 12 1 2 13 MEE ELEC EE 13 2 1 Prerequisites to boiler and boiler 13 2 2 Burner installation teo 15 2 3 24 2 4 External USEF 24 2 5 Pellet StOLdB8 a dedii 25 2 6 Electrical COMMOCHIONS den 25 2 7 initial StartUp eai 27 3 Optional 27 31 85 ET 27 3 2 Em 28 3 3 FIUG BAS LER 29 3 4 Oxygen AMOUNT SENSOM ee E
26. URNING END BURN Boiler s thermostat is NOT switched on HOLD FLAME is NOT allowed HOLD FLAME Boiler s thermostat is NOT switched on HOLD FLAME is in AUTO mode END BURN Maximum continuous burning time 4 hours is reached BURN END gt Fuel level is continuously detected in time of 8 feeder auger rotations END BLOW gt LEVEL ERROR BURN END gt Fuel level is not detected in 4 min END BLOW gt NO PELLETS NO FLAME No Flame more than 2 minutes HOLD LOADING 2 Boiler thermostat is switched on FLAME END BURN Max KEEP FLAME time 1 hour is reached END BURN END BLOW Flame is not recognised in 1 min and boiler s thermostat is switched off BURNING Boiler thermostat is switched on feeder auger has made less than 8 rotations and previous state was BURNING END BLOW WAITING Burning end Feeder auger has made 15 10 rot and blowing time 60 sec is reached STOPPED Flame is not recognised in 1 min and burner is not switched on NO FLAME In Burning status flame misses more than 1 minute LEVEL ERROR In Burning status level of fuel in feeder s inlet doesn t decrease NO PELLETS No pellets recognised in feeder s inlet NO POWER WAITING Power exists and boiler s thermostat is switched off STOPPED Power exists and boiler s thermostat is not switched on BURNING If status before No Power was Burning and No Power didn t last more than 5 min Any other WAITING Boiler s thermostat is switched on 32
27. boiler and boiler room In order to install the burner the boiler must meet to the following requirements Itis recommended to use three pass boilers e The 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 mounted e lf there is not sufficient less than 5Pa negative pressure in the furnace a flue gas fan should be installed to improve the movement of the exhaust gases The boiler must be installed into boiler s room in a way that there is enough space for cleaning the burner the boiler the smoke pipe and removing the ash e The burning chamber must not touch the bottom of the boilers furnace min 10 cm distance needed pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 14 59 e The boiler room where the burner is installed must fulfill all rules and recommendations given by local authorities Boiler room must provide constant air supply of 1500 m per hour ca 1600 cm air inlet opening In order to mount the burner to the boiler door it must have mounting holes See Figure 3 Notice If the burner is installed to the boiler the door s or the installation flange s thickness should be 8 14mm Dimension Unit Value D hole for burning chamber neck m
28. burners p 13 59 e Firesafety water pressure control switch pressostat Enables to keep necessary water pressure in water reservoir and to ensure with that successful extinguishing procedure when needed Pressostat switch allows starting the burner only if water supply is present and pressure exists 1 2 Pellets Wooden pellets or saw dust granules are concentrated and homogenized wooden fuel Pellets are pressed with high temperature No extra materials are added pellets are held together by a natural ingredient found in wood lignin Pellets are neutral renewable fuel Its burning doesn t spoil CO balance in the atmosphere Not only premium but also the industrial pellets can be used in PV700 1000a Pellets must be stored in a dry and ventilated room Table 3 provides an overview of pellet properties and threshold values Table 3 Pellets overview Premium pellets Industrial pellets Raw material Sawdust cutter shavings stem wood Forest plantation and other virgin wood chemically untreated wood residues Calorific value 4700 5100 kWh ton ca 4700 kWh ton Volume weight ca 650 670 kg m 5675 kg Volume of 1 ton pellets 1 5 1 6 ca 1 5 m Diameter 6 10 mm 6 12 mm Length 3 5 x diameter ca 4mm Moisture content 8 10 96 ca 5 96 Ash content ca 0 596 ca 296 To replace 1000 light oil ca 2 tons or 3 m 2 tons or 3 m 2 Installation 2 1 Prerequisites to
29. c66 7 2 www pelltech eu PV1000a pellet burner p 50 58 Table 23 Controller board connectors Connector Description LoPr Boiler pressure sensor connection Must be connected to tube on left feeder tube FANx 1 Prim sec fan speed sensor 5V power FANx 2 Prim sec fan speed sensor GND FANx 3 Prim sec fan speed sensor digital input MOD1 1 Modem interface 5V output fused through F9 MOD1 2 Modem interface Rx input MOD1 3 Modem interface Tx output MOD1 4 Modem interface GND TMP1 1 Temperature sensor power 5V TMP1 2 Temperature sensor GND TMP1 3 Temperature sensor signal 0 2 5VDC RSV 1 Level sensor receiver diode cathode RSV 2 Level sensor receiver diode anode TRS 1 Level sensor transmitter LED anode TRS 2 Level sensor transmitter LED cathode X1 1 27VDC power output fused through F1 X1 2 Open collector output max 200mA 30VDC X1 3 Open collector output max 200mA 30VDC X1 4 Open collector output max 200mA 30VDC X1 5 Open collector output max 200mA 30VDC X1 6 Open collector output max 200mA 30VDC X1 7 Open collector output max 200mA 30VDC X1 8 Open collector output max 200mA 30VDC X1 9 Open collector output max 200mA 30VDC X1 10 Open collector output max 200mA 30VDC X2 1 GND X2 2 27VDC power output fused through F3 X2 3 27VDC power output fused
30. ceramic stones PAR72 HEAT UP 500 Ceramic stone minimum temperature TEMPERATURE When HEAT UP is in mode ON burner stops HEAT UP cycle after heat up time set in PAR7O is exceeded Temperature of stones is not measured directly When HEAT UP is in AUTO mode burner stops HEAT UP cycle after time set in 70 is exceeded or stone temperature is higher than set in PAR72 Temperature of stones is not measured directly BURNING is main action status in burner s every day s operation Burner can operate on 11 different fixed power levels There are 6 main power levels which can be selected and adjusted 5 virtual power levels between main power levels are for smoother operation they can t be adjusted or selected For every power level the primary fan speed is fixed in PAR1 PAR6 and secondary fan speed in PAR31 PAR36 The fan speed for virtual levels is calculated as average from previous and next main level speed Power levels are represented in Table 16 Table 16 Power levels Power Level type PV700 PV1000 Primary fan Secondary fan level 1 main 200 250 PAR 1 PAR 31 2 virtual 250 320 3 main 300 400 PAR 2 PAR 32 4 virtual 350 470 5 main 400 550 PAR 3 PAR 33 6 virtual 450 620 7 main 500 700 4 PAR 34 8 virtual 550 770 9 main 600 850 5 PAR 35 10 virtual 650 920 11 main 700 1000 6 PAR 36 pelleech DK9401B
31. circle 7 GSM modem antenna Table 8 User interface controls Button Push time Action OK 3s To enter to setup menu To confirm settings in parameter edit mode OK 535 To reset error resume normal operation To reset counter only in counter screen in INFO menu lt To move back in menu by one level 29220 DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 33 59 To cancel change in parameter edit mode lt gt 35 restart burner 4 2 Starting and stopping To turn on the burner e Turn on boiler main switch e f burner displays STOPPED then go to main menu and BURNER set from ON to OFF WAITING is displayed e Turn boiler s thermostat to requested temperature e Burner goes to TESTING state and then to LOADING state If this is the first run external auger needs to fill up with pellets It can take as long as 20minutes because external auger has to be filled with pellets To stop the burner e setin main menu BURNER from ON to OFF Now the burner will burn all pellets in burning chamber and turn safely to STOPPED mode STATUS menu displays the changes BURNING gt SLOW DOWN END BURN END BLOW WAITING gt STOPPED The stopping procedure may take up to 30 minutes Attention If necessary the boiler s thermostat can be turned on off from burner red switch with power indication light Figure 32 Caution Do not turn off mains power to term
32. connected to the chimney the dampers for smoke gases are open and there is sufficient draught When the burner is operating the negative pressure inside the furnace must stay between 5 20 Pa e Sprinkler system is connected and pressure switch connected to safety circuit chapter 2 3 e Phase L and neutral N wires in power cable are connected properly 3 Optional components 3 1 GSM modem PV700a and PV1000a burners are ready to send burner s error SMS messages up to 5 phone numbers When error occurs the modem will send list with history of errors and statuses before error If list is very long then so much information what has a room in message will be sent Average length of one message is 8 statuses or errors In order to send messages 7 modem has to be connected to burners control board s connector X2 See Figure below RS232 modem adapter cable has to be connected between modem s connector MOD1 and connector MOD1 what is located lower part of control board Figure 29 Modem connection Before inserting the SIM card to burner the following actions have to be done 1 SIM card must by activated by the mobile operator 2 PIN code request has to be switched out 3 4 In SIM card s phonebook must be only the numbers where to the messages from the burner Check by using mobile phone that it is possible to send SMS with this SIM card will be sent 23 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet b
33. d marking of sockets is described on Table 4 power d Figure 27 Connection of socket X11 DK9401B1 www pelltech eu PV700a PV1000a pellet burners Table 4 PV1000a connectors p 26 59 No Name Voltage amps X11 Control voltage boiler s 230VAC 3A thermostat X12 Main power supply 3x380VAC 20A X13 Safety circuit 230V X14 External auger 1 3x380V 0 55kW 1 6A X15 External auger 2 3x380V 0 55kW 1 6A X16 Primary fan 3x230V 0 18kW 0 37kW PV700 PV1000 X17 lgniters 2x500W 2x2 2A PV1000 X21 Flue gas fan 3x230V max 1 5kW X20 Flue gas inverter 0 10V 24V DC X22 Modbus 24V DC X23 Pt100 4 20mA sensors O and 24V DC boiler water X24 Level sensors silo1 and silo2 24V DC X25 Ash auger and scraper 230V 90W X26 Secondary fan 3x230V 0 18kW 0 37kW PV700 PV1000 X27 Igniters 2x500W 2 2A PV700 PV1000 X15 X14 X13 X12 X11 X16 Figure 28 Connectors markings Su DK9401B1 x25 X24 X23 Xn X26 www pelltech eu PV700a PV1000a pellet burners p 27 59 2 7 Initial start up Prior to the initial start up of the burner make sure that e The burner is connected to the boiler e The boiler thermostat is installed and is functioning properly e The feeding auger of the burner is installed and connected to the burner e The smoke duct is
34. ding to boiler manufacturer instructions 2 Connect the sensor to TMP1 connector on controller board 3 Choose 53 value sensor type according to Table 7 4 Set requested temperature PAR54 It should be lower than boiler thermostat temperature Otherwise the boiler thermostat would force the burner to turn off before reaching PAR54 value 5 Optionally PAR55 the hysteresis of requested temperature can be changed THM activates if PAR53 value is larger than 1 and BURNING status has lasted longer than set in PAR15 typically 30min The burner will change its output power according to current measured temperature and the rate of temperature change New power level is selected after every time interval specified in PAR17 Table 7 PAR53 values PAR53 Sensortype Temp min Temp max Function 0 No sensor 1 0 2 5V 0 0 5V 1252C 1 75 Burner s actual internal over temperature sensor Overheat value to be set PAR43 2 0 2 5V 0 0 5V 1252C 1 75V Boiler temperature control with external sensor After activating THM following row is displayed on INFO screen e g f 22 3 70 5 200 It means following 22 3 Actual measured temperature 70 Set point temperature PAR54 5 Set point hysteresis PAR55 Y Shows weather actual temperature is increasing or decreasing 200 Forecasted temperature in 10min Su pelltech DK9401B1 www pelltech eu PV700a PV1000a
35. draught too much ash in burner or in boiler or poor burning procedure Improve draught remove ash use only quality pellets Poor burning may be caused by big amount pellets feed heavy pellets or poor stream of the air Change PAR23 heavier oGeneral blackout Wait for end Restart burner e Burner internal temperature reached over set point as fixed in setup menu e Possibly back burning is happened oBad connection of temperature sensor Check and improve if needed olnsufficient entrance of fresh air into the boiler room Draught to wrong direction Ensure pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p45 59 availability of fresh air and improve draught GRATE ERROR Over current of grate movers motor has exceeded value set in PAR47 and over current protection has applied o Ash removing grate has jammed before reaching extreme point Remove reason Screen empty backlights on Screen empty no backlights e Motors power screw got dirty and stops rotation Clean the screw e Controller error or screen error o Replace respective component e The contrast of screen is poor Contrast can be adjusted with small screwdriver by turning the resistor CONTR on down edge of controller In one extreme the screen displays nothing and in other extreme screen is filled with black rectangles e No mains supply 6 Burner status change logic Table 22 Error me ssages in screen
36. e 2006 42 EC EN 15270 2008 EN 230 2005 EN 60370 2 5 2002 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p5 59 Pellet burner PV 700a No Year of production 2014 Electrical supply 230V Max heat input 20kw Emission class 5 Noice emission 52dB Power consumption at stand by 7W Manufacturer Pelltech OU Sara tee 3 Peetri Estonia Pellet burner PV 1000a No Year of production 2014 Electrical supply 230V Max heat input 1000kw Emission class 5 Noice emission 52dB C Power consumption at stand by 7W Manufacturer Pelltech OU Sara tee 3 Peetri Estonia DK9401B1 www pelltech eu PV700a PV1000a pellet burners p6 59 25252 99269 4 DECLARATION CONFORMITY We Pelltech OU T koja 1 11313 Tallinn Estonia www pelltech eu Declares under sole responsibility that the machinery described as Pellet burner Type 700 PV 1000 to which this certificate applies is in conformity with the standards or other applicable rules and regulations as mentioned below Conformity with the stipulations of EN 15270 2008 EN 230 2005 EN 60370 2 5 2002 Directive 2004 108 EC Directive 2006 95 EC Directive 2001 95 EC Directive 2006 42 EC Tallinn 10 06 2010 Aavo Isak CEO member of board 322 ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners
37. g 100 sec Maximum CLEANING cycle time At the LOADING cycle external auger is turned on When pellet level in the burner reaches to level sensors internal feeder is started Feeder auger loads necessary amount of fuel needed for ignition into burning chamber Amount of loaded fuel is measured by counting the rotations of feeder auger LOADING cycle is ended when feeder auger has made exact number of rotations pre set in PAR24 Table 12 Loading parameters PAR Parameter name Default value Unit Comment PAR24 LOADING FEED 35 40 rot Number of feeder auger rotations needed to load pellets into burning chamber Depends from burner model PAR25 LOADING 2 FEED 5 rot Number of feeder auger rotations for second loading Max loading time 5 min Maximum regular loading time First loading time 20 min Maximum loading time after manual start after manual start External auger start 3 sec Auger Start delay if no fuel in burner External auger stop 3 sec Auger Stop delay if fuel in burner Feeder auger start 1 sec Feeder Start delay if fuel in burner Feeder auger stop 4 rot Feeder rotations made without fuel level before stopped At the LOADING time external auger holds permanent fuel level in the feeder auger s tube Depending on the level sensor signal the external auger is turned on or off Feeder auger s work depends also on fuel leve
38. g depending on the conditions at the installation site Critical requirements for external auger installation e The raising angle of the auger must not exceed 45 e The end of the exit tube of the auger and the input of the burner must not be aligned The recommended minimal horizontal distance is ca 20cm e The distance between the input of the burner and the exit tube of the auger must be at least 60cm vertically recommended distance is 80 200cm e Hose between auger and burner must be tight otherwise pellets will block the auger Falling angle must me between 65 and 85 All critical requirements for installation of external auger are depicted in Figure 26 23 DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 25 59 20cm gt 60cm Figure 26 External auger installation 2 5 Pellet storage Pellets must be stored in a dry and ventilated room that is separated from the boiler room A tailor made storage silo is recommended All safety regulation must be taken into consideration according to the local laws It is recommended to wear a respirator when handling pellets Refilling must be carried out before the storage runs empty 2 6 Electrical connections Following connections must be done by the electrical installer 1 phase supply and boiler s thermostat to socket X11 See Figure 27 e 3 phase supply to socket X12 e External auger to socket X14 Names an
39. inate burning process Use the boilers thermostat for that In order to complete burning procedure safely let the burner to burn all fuel in burning chamber Never leave burner unattended when you had to stop boilers work turning boiler off from mains switch in any reason 4 3 Fuel refilling Fuel container silo has to be refilled before its runs out The fuel can be added any time to container silo If container runs out before refilling refill it and restart the burner The start up takes now longer about 20 minutes because external auger has to be filled with pellets like in initial start up Turn burner from BURNER menu ON Vice versa the LEVEL ERROR will be displayed because loading time is exceeded 44 Statuses and parameters PV700a PV 1000a pellet burner operates in many different states which are called Statuses and which are displayed in user interface in STATUS menu chapter 4 1 Burner changes its statuses based on input signals from sensors and user setup The working statuses of the burner in typical order of succession are given in Table 9 The duration of all actions are in form mm ss m in the middle or hh mm h in the middle For example IGNITING 01m25 means the burner ignition state lasted 1 minute and 25 second 32 ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 34 59 Table 9 Summary of burner statuses Status Short description
40. l feeder Hollow spiral connected to feeder motor to transport pellets into burning screw chamber Screw is not tightened to motor but has small slack It lowers the mechanical stress and expands gear motor lifetime 21 Pressuresensor Metal tube to connect pressure sensor input Pressure sensor measures connection draught in burning chamber and enables the controller to regulate flue gas fan speed 1 4 Safety devices The back burning is the biggest danger risk at burners working procedure Back burning appears when usual pressure or draught conditions have changed in boiler s combustion chamber There are several reasons for such changes In order to secure operational and fire safety the PV700a PV1000a burners are equipped with following safety devices Back up batteries Enable to finish safely burning procedure in normal conditions or during unexpected black out in mains supply Melting hose The external auger is connected to the burner with a special hose 76mm which is made from easily melting polyurethane material that interrupts when back burning takes place Such measurement avoids entrance of the flame from burner into external auger and pellets container Thermostatic sprinkler valve Enables to extinguish the fire in feeder s augers tube by spraying water into it when burner is overheated due to possible back burning or any other reason pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet
41. l sensor signal Maximum loading time is limited by 20 minutes after manual initial start up because extra time for external auger filling is needed In next loadings maximum time is limited by 5 minutes If maximum loading time is exceeded and silo selection on burner is used the pellet delivery will be switched to other external auger In single pellet container delivery system NO PELLETS error will occur u pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 36 59 At IGNITING cycle the igniter is heated up and fan blows hot air on pellets in burning chamber Hot air ignites pellets Igniter is working periodically at ignition time in order to avoid its overheating Igniter is pre heated already in the end of loading cycle When internal auger has made 10 rotations full number of load rotations is 12 the igniter is turned on for pre heating If the igniter has been turned on more than 1 minute at LOADING time then it will be turned off Table 13 IGNITING parameters and timing PARNo Parameter name Default Unit Comment value PAR8 FAN IGNITING 25 rps Primary fan speed at ignition Max ignition time 255 sec Maximum ignition time Time of first loading 20 min Maximum loading time after manual start Auger start 3 sec Auger Start delay if no fuel in burner Auger stop 3 sec Auger Stop delay if fuel in burner Feeder start 1 sec Feeder Start delay if fuel in b
42. m 400 201 flange bolt ring diameter mm 490 D2 bolt holes mm 6x 13 Bolt hole offset angle deg 30 Angle between bolt holes deg 60 Figure 3 Boiler door mounting opening Cutting contour of hole to be cut to boilers door in order to install PV1000 burner xt NX gt 8 ot 3 _ 500 _ 636 _ _ 720 Figure 4 Contour of cutting Su pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 15 59 Boiler s firebox depth L must be at least 2 5 V times longer than the length of burner s burning chamber Thus minimal length of the firebox L for PV700 has to be 1500 mm and for PV1000 1800mm The height of firebox must leave at least 100 mm space t H1 for ash below burning chamber Minimum dimensions L1 gt 700mm H 2650mm See Figure 5 Figure 5 Firebox depth Pellet burners need regular cleaning and therefore boiler construction must allow easy opening of boiler s door without removing the burner The minimum size of opening in boiler s door depends on the position of door hinges Figure 6 below illustrates the situation Point C is the critical point In order to keep door width minimum and boiler s door opening small a double hinge solution can be used As double hinges add another degree of moving freedom door must be fastened on both sides Slide out doors with guide rails is also an option Figure 6 Burner ha
43. nu description Screen text Pwr 150 700 kW Tstn 181 C T1 205 7 C Fan 27 28 2 12 13 Description actual and selected power Max power can be changed from main menu Tstn fire brick temperature and boiler s temperature 27 Primary fan s actual speed 28 Primary fan s set point speed Actual speed is controlled to match set point speed 2 Base air value Controller tries to keep speed set point base air In this case controller keeps speed 15rps Speed unit is rps rotations per second 12 13 same as above for secondary fan Base air setting is same 2 pelitech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p42 59 Ap 0 2 8Pa Measured under pressure value in bpoler 0 2 is actual pressure and 8 is set point Controller regulates flue gas fan speed to keep this pressure Depends also on 6 value Total 10 kg Roughly the amount of pellets burnt It is measured by counting internal feeder rotations Number is reset by firmware upgrade Count 12 1 kg 180 254 Roughly the amount of pellets burnt resettable by user U 25V68 0 0 U DC power voltage 25V68 means 25 68V Feeder s or grate s motor current Ver 2 08 19 12 12 Firmware version and date Menu BURNER enables to turn burner safely ON or OFF The main idea of HOLD FLAME function is to reduce permanent ON OFF cycles This function is useful if burner s working time is much l
44. oblems and solutions Message on Reason and solution screen BATTERY LOW e Battery voltage is less than 24V with load working feeder motor oWhen there was blackout then just wait when battery recharges itself oReplace battery IGN ERROR e No flame detected at ignition time olgniter is out of order or fuse is blown Usually fuse blows when igniter is broken or its body is in short circuit Replace fuse or igniter oFlame sensor is dirty or smelt Clean or replace sensor if needed Su pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 44 59 oAmount of pellets for igniting is too small If error is frequent increase amount of pellets PAR24 oTo turn burner on hold OK button down 3 seconds or change in BURNER menu OFF to ON LEVEL ERROR Feeder auger doesn t rotate oRemove plastic hose and check is there any foreign object or very long pellet jammed the feeder auger Remove obstacle e Level sensor is dirty or smelt Clean or replace sensor if needed e Poor draught dirty sensor Check sensor clean if needed Improve draught NO PELLETS e Max loading time is reached but level sensor hasn t detected enough fuel in feeder or in burning state during 4 minutes no pellets detected oNo pellets in container Check existence of pellets refill container oExternal auger is broken Check fuse and connection with burner Replace fuse or auger oFuel level sensor is broken or short In this case transparent tube has
45. onger than WAITING time For example 1 hour of working time and 10 minutes of waiting time In HOLD FLAME status the fan rotates slowly PAR10 and small quantities of fuel are added to burner Existence of flame is not checked Such status may last max one hour after what burner ends usual BURNING cycle and goes to WAITING If boiler s thermostat switches on before an hour burner goes to BURNING state HOLD FLAME is activated when it is set to AUTO and two WAITING times have been shorter than set value in PAR11 HOLD FLAME turns off if flame has been hold more than PAR12 value HEAT UP status enables slow heat up of fire bricks It reduces termal stress and prolongs their lifetime SLOW DOWN enables slow cooling down of fire bricks It reduces termal stress and prolongs their lifetime Menu PELLETS enables to select between 3 pre set fuel quality options Depending on fuel quality the mass of fuel could differ in same amount That s why the calorific value of same amount may differ By default burner calculates that one rotation pushes 80 grams pellets PAR21 to burning chamber If pellets density is smaller i e they are lighter then with one rotation less pellets will be delivered into burning chamber Such mistake has to be compensated by choosing LIGHT from PELLETS menu Now burner calculates that one rotation equals with 75 grams of pellets PAR31 and makes more rotations In general case there is no need to make change in PELLETS menu
46. ottom half of the warranty ticket is filled in and sent or brought to the office of Pelltech OU Sara tee 3 Peetri Rae vald 75312 Harjumaa ESTONIA Ph 372 677 5277 www pelletikeskus ee info pelltech ee Warranty ticket Burners model Product number Sales date Installation commissioning date Owners contacts Name Phone nr City village Street House Warranty ticket Burners model Product number Sales date Installation commissioning date Owners contacts Name Phone nr City village Street House PV700 or PV1000 PV700 or PV1000 Warranty is valid only if the bottom half of the warranty ticket is filled in and sent or brought to the office of Pelltech OU Sara tee 3 Peetri Rae vald 75312 Harjumaa ESTONIA Ph 372 677 5277 www pelletikeskus ee info pelltech ee
47. pellet burners p 32 59 4 Operation and service 4 1 User interface The burner is controlled via user interface on the front panel 3 row LCD screen 1 displays main menu submenus event log and statuses Yellow light 2 shows the existence of flame in burning chamber If it blinks the burner is out of normal operation Green light 3 indicates existence of pellets in the burner Burner on off switch 4 can be used any time to turn the burner safely on or off Operation light 5 indicates weather the boiler thermostat is turned on or off Fault light 6 is connected to safety circle and indicates its being in order Up and down A V buttons enable to move in menus Left and right gt lt buttons enable to control the burner and change parameters To get back to main menu lt button is used It acts like an escape button Right gt button enables to change values in selected parameter To enter to setup menu or to confirm changes of values OK button is used OK and buttons have different functions depending on context See Table 8 2 3 Figure 32 User interface 1 4x20 character display 2 Yellow LED indicates if flame is detected in burning chamber 3 Green LED indicates if pellets are present in internal feeder 4 Burner on off switch with power indication light 5 Burner operation light showing if the boiler thermostat sends a signal to the burner 6 Fault light of safety
48. rt Igniter is installed on the burner together with igniter holding pipe PV700 has 2 igniters and PV1000 4 igniters 8 Brick A sensor to adjust bricks heat up speed according to temperature rise Brick temperature temperature rise speed control helps to reduce thermal stress of bricks and sensor prolong their lifetime 9 Cleaning hatch Hatch below burning chamber to ease the removal of ash under the grates 10 Grates support Holds moving and stationary grates in correct position frame 11 Grates Burning of pellets takes place on the cast iron grates Air needed for burning is blown to burning chamber via holes with different size Burner has moving and fixated grates Moving grates move periodically to clean the burning chamber 12 Fire bricks Burning chamber is surrounded with heat resistant from up and sides Bricks are necessary for proper airflow and combustion 13 Flame sensor Photocell s purpose is to recognize flame in the burning chamber 14 Level sensor Optical fuel level sensors recognize the fuel level in the vertical pipe Fuel is recognized when pellets pass the optical beam between sensors 15 Combustion air fans Left primary Primary fan blows main burning air needed for ignition burning and gasification of the fuel Right Secondary fan blows air through burning chamber back wall and holds burning 32 DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 12
49. rtol unit Su pelltech DK9401B1 www pelltech eu PV1000a pellet burner p 53 58 Table 24 Names of components on Figure 40 Abr Description INV1 Secondary fan s inverter INV2 27V Primary fan s inverter Flue gas fan optional K1 Main power supply 3 pole contactor a i A INV3 K3 External auger 1 3 pole contactor K4 External auger 2 3 pole contactor MF3 External auger 1 3 pole motor protector 4 External auger 2 3 pole motor protector K5 Igniters contactor GND GND K6 Battery on off contactor K7 Ash auger contactor K8 Fault circuit QF1 Igniters 1 pole thermo magnetic protector switch QF2 INV3 L1 1 pole thermo magnetic protector switch Figure 43 DC input circuit QF3 INV2 L1 1 pole thermo magnetic protector switch QF4 INV1 L1 1 pole thermo magnetic protector switch T1 Power supply 230VAC 27 2VDC F6 Battery s fuse 6A F20 Ash auger s motor fuse 3A F21 Ash scraper s motor fuse0 25A F22 Control voltage X11 fuse1 A F23 Cooling fan s motor fuse 1A pelltech 05060 o DK9401B1 www pelltech eu PV1000a pellet burner p54 58 10 Annex 4 Table of parameters Firmware version 2 08 22 11 13 mmm KHEN i PV700a PV1000a PAR Name PAR1 PAR2 PAR3 PAR4 PAR5 PAR6 FAN 700 1000
50. s to Double hinges reach off from boiler 2 2 Burner installation Burners are delivered to customer in fully put together Before mounting the burner to boiler it has to be disassembled i e bricks have to be removed and burning chamber separated from burner and air box Mount the burning chamber on the inner side of the boiler door Figure 7 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 16 59 Use 6 M12x60mm bolts spacers and distance nuts respective to the bolts Figure 8 Install the insulation rope between the burning chamber and the boiler door The rope must be installed near the outer perimeter of the burning chambers back wall Figure 9 2e 5 pelltech ege DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 17 59 Figure 10 Grate holders installation Install the burning chambers bottom panel 15x15mm insulation rope must be inserted to the slot in the panel with 6 M8x16mm bolts Install the burning chambers front panel heat shield use M8x16mm bolts Figure 11 Connect the static grate holders with the side stone holders separately and install them together into the burning chamber as a frame Fix them with M8x16mm bolts to the burning chamber Su pelltech DK9401B1 www pelltech eu PV700a PV1
51. s turned ON voltage must be greater than 24V Feeder current PAR 46 3 6 A Feeder auger is turned ON feeder current must be smaller than PAR 46 Draught PAR62 10 Pa All fans are turned on Draft must be under PAR 62 Primary fan PAR4 38 rot Fan must rotate faster than 35rot 38 3 Secondary fan PAR4 38 rot Fan must rotate faster than 35rot 38 PAR4 3 At CLEANING cycle the linear actuator moves the grates and pushes out from burning chamber the ash and residues The cleaning cycle has been divided into 3 steps 1 Grates are pulled fully in to actuator end limit 2 Grates are pushed fully out to actuator end limit 3 Grates are moved to middle position 22 DK9401B1 www pelltech eu PV700a PV1000a pellet burners Table 11 CLEANING parameters PAR name PAR No Value Unit Test conditions time CLEANING CYCLE PAR48 0 250 min BURNING time between two CLEANING cycles If set to then CLEANING is turned off If BURNING has been longer than 2x PAR48 set then extraordinary cleaning will made GRATES CURRENT PAR47 0 2 6 A Linear motors maximum current level If greater then motor is stopped and cleaning cycle is started again Linear motor s 0 1 A If current is smaller then motor is stopped and min current running direction can be changed Max move time 58 sec Maximum time to move actuator to one direction Max cleanin
52. termines how many grams of pellets feeder auger g rot 160 120 250 160 120 transports to burning chamber with one full rotation when PELLET NORM ie normal weight pellets are selected w wl Y aj wl al al ojl gt aj 8 aj oj PAR15 POWER UP PAR16 POWER DOWN A 17 18 DK9401B1 www pelltech eu PV1000a pellet burner p55 58 PAR22 PELLETS LIGHT Determines how many grams of pellets feeder auger transports to burning chamber with one full rotation when PELLET LIGHT ie lighter than normal weight pellets are selected PAR23 PELLETS HEAVY Determines how many grams of pellets feeder auger transports to burning chamber with one full rotation when PELLET HEAVY ie heavier than normal weight pellets are selected PAR24 LOADING FEED Number of feeder auger rotations in LOADING state PAR25 LOADING 2 FEED Number of feeder auger rotations in LOADING2 state PAR26 END BURN FEED Number of feeder auger rotations in END BURN state PAR27 END BLOW TIME Fan s END BLOW time after flame has disappeared PAR30 FAN2 Secondary fan On OFF control not used in PV5Ob PAR31 FAN 2 200 250 Secondary fan speed at 1 power level PV700 PV1000 PAR32 FAN 2 300 400 Secondary fan speed at 2 power level PV700 PV1000 PAR33 FAN 2 400 550 Secondary fan speed at 3 power level PV700 PV1000 PAR34 FAN 2 500 700 Secondary fan speed at 4 power level PV700 PV1000 PAR35 FAN 2 600
53. the linear motor side Figure 20 Push the stone temperature sensor through the hole in the burner body and the pipe on the burning chambers back wall isolate it from the air flow accessible from the burning chamber side with ceramic sealing to prevent cold air from tampering with the measurements 2252 elltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 22 59 Figure 21 Install the 2 lower position grates Install the 8 middle position grates with 5mm holes Install the 8 higher position grates with 7mm holes Figure 22 Install the ceramic seal on the back wall of the burning chamber Install the back wall stones on the burning chambers back wall Caution Be careful not to damage the temperature sensor Push the stone temperature sensor into the opening in the back wall stone Su pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 23 59 Figure 23 Install the upper grate holder and 2 upper grates Fix the holder with M10 wing nuts Figure 24 Install the 6 side bricks Install the 6 arc stones Notice The arc stones are numbered they must be installed as pairs Su pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners 2 3 Water sprinkler Water line Flow control valve Reservoir 6 8L To safety circuit Quick connect
54. through F2 X2 4 GND X3 1 Thermocouple input fire brick temperature sensor X3 2 Thermocouple input GND u pelltech DK9401B1 www pelltech eu PV1000a pellet burner p 51 58 X3 3 1 feeder motor black wire X3 4 1 and 2 feeder motors red wire 27VDC power output X3 5 27 feeder motor black wire X3 6 Battery positive terminal X3 7 GND X3 8 27VDC Power supply input X4 1 Connects to X4 2 through K1 X4 2 AC supply N X4 3 AC supply L X4 4 Boiler thermostat AC voltage X5 1 Grate cleaning motor position feedback X5 2 GND X5 3 not connected X5 4 Grate cleaning motor X5 5 Grate cleaning motor X5 6 not connected X6 1 DC input X6 2 DC input X6 3 DC input X6 4 DC input X7 1 MODBUS signal A X7 2 MODBUS signal B X7 3 MODBUS GND X8 1 DAC 0 10V output X8 2 DAC 0 10V output X8 3 DAC 0 10V output X8 4 DAC 0 10V output X8 5 27VDC power output fused through F5 X8 6 PT100 mA 2 56V input JP1 amp JP2 selects function X8 7 PT100 mA input amp JP4 selects function X8 8 DC input X8 9 Flame sensor input X8 10 Flame sensor input 5 pelltech DK9401B1 www pelltech eu PV1000a pellet burner p 52 58 9 Annex 3 Control unit E UN mc INV2 2 V ieee Figure 42 PV1000 cont
55. to be filled with pellets Replace sensor oToo much sawdust in container and external auger can t reach the pellets Remove sawdust NO FLAME e Flame is disappeared at pre burning time or at burning time oFuel level sensor is dirty or broken Check sensor clean or replace if needed oFlame sensor is dirty or smelt Clean or replace sensor e Appears in screen for some seconds when turning on the burner olf messa t di front panel FEEDER e Feeder auger has not ma 8 seconds at its running time ERROR oFeeder auger motor s rotation sensor is too far from magnet Check sensor s placement It has to be located maximally on magnet and not far than 2 3 mm Sensor has not to touch rotating parts of motor oFeeder motor s reducer may be broken if motor makes noise Replace both e Feeder auger motor current has reached its limit and over current protection applied oFeeder auger may be blocked or jammed by foreign object Remove obstacle FAN ERROR e Fan has not reached enough speed at testing time Fan motor s rotation sensor is too far from magnet Check sensor s placement It has to be located maximally on magnet and not far than 2 3 mm Sensor has not to touch rotating parts of motor oFan doesn t rotate Bearings too dusty or fuse blown Clean bearings or replace fan oFuse has blown Replace fuse NO POWER e The mains supply doesn t reach controller oBack burning and safety thermostat have turned mains off Possible reasons are poor
56. um time when burner holds flame The END BURN cycle helps securely to stop burning procedure in burning chamber of burner All pellets inside the burning chamber and feeder tubes will be burnt Amounts of pellets delivered and fan rotation speed power level are same as in BURNING status If burner goes to END BURN from other states e g HOLD FLAME the first power level is selected Burner works in END BURN until feeder tube is empty feeder has made as many rotations as selected in PAR26 END BURN can be used in case of some 5 pelltech DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 40 59 occurred errors e g If pellets have run out and NO PELLETS is displayed the burner stops safely normal BURNING cycle Table 18 End burn parameters PAR Parameter name Default Unit Comment value PAR26 END BURN FEED 50 80 rot Feeder auger rotations to clean up feeder s pipe Minimum feed 20 rot If less rotation are made and boiler thermostat is switched on then burner goes back to BURNING state The END BLOW cycle is needed to burn finally all unburned pellet coals in the burning chamber Burner will wait for flame disappearing in burning chamber In PAR27 is fixed the end blow time i e the time how long the fans continue to blow after flame s disappearing Table 19 END BLOW parameters Parameter name Default Unit Comment value PAR9 FAN END BURN 20
57. urner Feeder stop 4 rot Feeder rotations made without fuel level before stopped The purpose of PRE BURN status is to create stabile flame and assure effective pellets burning procedure after ignition Minimum fuel amount is added periodically at pre burn time Fans are working with same speed as at IGNITION Feeder auger makes gt rotations at every 25 sec up to 6 rotations achieved See Table 14 Table 14 PRE BURN parameters PARNo Parameter name Default Unit Comment value PAR8 FAN IGNITING 20 rps Primary fan speed at IGNITING and PRE BURN PAR39 FAN2MIN 7 rps Secondary fan s minimum speed Used at IGNITING PRE BURN HEAT UP HOLD FLAME and END BLOW statuses 41 PRE BURN TIME 25 5 Length of one PRE BURN cycle PAR42 PRE BURN CYCLES 6 X Number of PRE BURN cycles Pre burn feed 1 2 rot Number of feeder auger s rotations at each PRE BURN cycle HEAT UP cycle is needed to slow down too fast heating up of the burning chamber s ceramic stones in order to minimize their thermal stress and thus prolong their lifetime sssss 926 DK9401B1 www pelltech eu N PV700a PV1000a pellet burners p 37 5 Table 15 HEAT UP parameters value PAR No Parameter name Default Unit Comment PAR70 HEAT UP TIME 20 min Initial heat up time of ceramic stones PAR71 HEAT UP POWER 30 70 kW Initial heat up power of
58. urner enters into BURNING status It can take about 10min for oxygen level to stabilize Oxygen level can be seen in INFO menu next to pressure reading The value on the screen must be divided by 10 to get the real value For example O2 113 means oxygen level value 11 3 32 92 DK9401B1 www pelltech eu PV700a PV1000a pellet burners p 31 59 3 5 Ash removal system The burner can control external ash removal auger and scraper motors via X25 connector During burner s cleaning cycle the X25 connector is powered and ash removal and scraper motors can be switched on via X25 connector s L1 and L2 3 6 External boiler temperature sensor External temperature sensor enables the burner to maintain constant boiler s water temperature For that external temperature sensor has to be installed to relevant place on boiler existing burner s temperature sensor to be disconnected from TMP1 connector on controller s board and external sensor to be connected to connector TMP1 In parameters menu PAR53 value has to be chosen 2 When temperature holding status is activated then burner will change its capacity according to water temperature and speed of temperature changing Burner starts to change its capacity when BURNING status has lasted longer than set in PAR15 Capacity is changed after time set in PAR17 Following actions must be done to enable temperature hold mode THM 1 Mount external temperature sensor to boiler accor
59. urners p 28 59 To insert the SIM card the modem has to be disconnected from supply mains To insert the card push it into a slot as long as its spring clicks and fixes the card See Figure 30 To remove card push it in as long as spring clicks and pushes it out In order to activate SMS sending in burners menu PAR52 has to be changed Value shows for how many numbers the message will be sent 0 means no messages to be sent 2 means that messages will be sent to 2 first recipients in SIM card in order of phone card connector number insertion Figure 30 SIM card insertion Modem has two indicators Green one shows that modem is turned on Red one shows modem status Modem s statuses are described in Table 5 Table 5 Modem statuses LED indicator Modem status Permanently on Sending message on going call Fast interrupt sequence period 0 5 s Ton 1s Net search Not registered Turning off Slow interrupt sequence period 0 3s Ton 3 sec Registered full service Permanently off Device is turned off 3 2 Error output PV700 PV1000 burner has built in error output what gives 230 VAC tension NO to 7 pole socket s S3 connector or interrupts it NC if burner delivers any error message from elven FLAME ERROR BATTERY EMPTY IGN ERROR etc Device motor modem etc to 5A 0230VAC can be connected to circuit PARSO defines weather error output is closed or open during error appearance Depending on

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