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User manual Pelletherm V.2 M00

1. ccceccccccesseeeeeeeees 20 5 Hot water boiler installation and starting procedures 23 5 1 Basic fuel requirements cccccccccccccsssecceeceeseeceeeaeeeceeeaeeeees 23 5 2 Starting hot water pellet boiler of series Pelletherm v2 procedure Seige oa EEE ew IE EEA PEE AA E E R E E S ae EN E aaa ae 24 5 2 1 Interface control board of hot water pellet boiler of series Peet S cecesee te cts cate isa E 25 D262 Hot water boiler power supply cccccccccssescceeeeeeeeees 26 5 2 3 Hot water boiler very first start cc ccccccccessescceeeeeeeees 26 5 2 4 Main parameters for boiler operation ccccccceeeees 27 5 2 9 Adjustment process of the boiler according to the thermal load of the building consumer 0000nnn000onnnnsooennnsseennssseernssseersssseersssseerssse 31 p 3 52 5 2 6 Changing the working parameters of the process control modules srona E E AE 34 S2 Nominal operation mode of the boiler cceeececeeee 37 5 3 Adjustment of the thermal capacity of the boiler 0 000 0 0000 38 5 3 1 Decreasing the thermal capacity of the boiler 38 5 02 Increasing the thermal capacity of the boiler 39 5 4 Stopping the operation of hot water pellet boiler 000 000 00 39 5 5 Turning OFF the DOM er gees ssosthancapeseaantsavienctideaaiaoiwsa
2. NOTES 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 The producer reserves the right to change the specification and or the design adjustment of the unit without prior notice The table above contains factory default values for the parameters of the settings of the process control module which lead to optimal unit adjustment The described parameters T4 and T6 are most frequently changed they define the thermal capacity of the unit and its operating regime The following table contains main parameters which are utilized to control the functionality of the boiler Any changes of the parameter s values should be done in case that the meaning and the influence of a changed parameter is preliminary known In case that a parameter s value should be changed it is recommended to be done by trained authorized technician only p 28 52 Parameter Comment Recommended value Dimension Pelletherm Pelletherm Period of time for conducting initial doze of fuel to the 300 seconds burner Maximal period of time until stable combustion process is seconds achieved Pellet s feeding time seconds during this period pellets are minutes fed to the burner 020 determines the heat capacit
3. e Ifa 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 e It is not recommended to operate the hot water boiler at thermal capacity lower than the minimal thermal load as such regimes are not optimal and thus have low efficiency of the unit p 37 52 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 1s 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 wi
4. 0 2 Supply return flow ne A T a Hydraulic losses biai saadan the circulating 295 5 O4 water at nominal thermal capacity Power supply a E LI N PE 50Hz 230V Electrical capacity VA 120 250 at ignition process Electric protection IP20 Table 2 2 Dimensions and technical data for hot water pellet boiler of series Pelletherm v2 p 10 52 Parameter Dimension Value Pellet s characteristic size Recommended fuel net calorific value low MJ kg heating value kWh kg Wood pellet class ENplus A1 ENelue a2 ENplus B Ash content See Table 2 4 and Table 2 5 Moisture content Max 8 10 Table 2 3 Recommended solid fuel properties wood pellets SB 06 lt A 51 0 DU gt 97 0 1 0 lt A lt 2 0 1 0 lt A lt 2 0 Df 20 lt 4 lt 30 2 0 lt A lt 3 0 A gt 3 0 Table 2 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in boiler s producer company where A ash contents dry basis DU mechanical durability p 11 52 The European wood pellets standard EN 14961 2 2010 defines wood pellets certificate ENplus for pellets utilized in boilers and appliances for domestic heating systems The certificate EN B is applied for pellets utilized in industrial boilers In principal the ENplus standard defines two quali
5. Utilize the POWER switch positioned on the control board of the boiler to turn off the power supply of the unit p 3 14 2 3 Cooling down the boiler After the boiler is switched off it should be cooled down it is necessary to wait until the temperature of the circulating water is moderate and the heat exchanging surfaces are cooled down to safe levels and the ash cleaning procedure could start 2 4 Cleaning the ash of the heat exchanger surfaces Before the ash cleaning it is necessary to open the top cover of the heat exchanger body Unscrew the fixing nuts and remove the flue gas duct lid Figure 2 2 The top cover of the heat exchanger is lifted up The fixing nuts should be unscrewed and flue gases duct lid should be removed p 4 14 Figure 2 3 The flue gases duct lid is detached the ash residue is clearly seen on the boiler s heat exchanger surfaces Utilize appropriate tool to clean to grate the ash and char deposition off the internal surfaces of the boiler s body ATTENTION the practice shows that the ash grating is connected with intensive release of fly ash thus it is highly recommended to wear air breathing protective mask as well as appropriate clothing in order to minimize any lung issues and cloth staining p 5 14 Figure 2 5 Brushing the ash layer of the heat exchanger surfaces The next step of the cleaning procedure is to clean the ash deposits on the third par
6. Before cleaning the utility must be turned off and cooled down It is obligatory to use safety guards ia Pull the handle up and turn it left right Open left front door with several repeats Remove and clean the ash tray Remove burner head top cover and perform cleaning Remove lower fire grate and clean air inlet holes Install fire grate and cover back Clean the heat exchanger wall by scrapping them with the tool Unscrew both feather nuts Open the lid Remove heat exchanger front cover by pulling it forward Clean the ash residues Install the lid back Cleaning with the handle has to be performed on every refilling with pellets Cleaning the burner s fire grate has to be performed at least once per week or more often depending on fuel quality information by the fuel manufacturer Cleaning the heat exchanger walls has to be performed twice during the heating season or more often depending on fuel quality information by the fuel manufacturer Cleaning burner s head from ash residues has to be performed at least once per month but no longer than two months Cleaning set
7. These flaps are factory set and in principal need no adjustment Inflow and outflow connections to from the heating system of the supply and return circulating water are internal threads positioned in the rear side of the heat exchanger Draining connection is internal thread diameter G2 and is positioned on the lower part of rear side of the heat exchanger An appropriate drainage valve should be connected p 13 52 e Flue gases exit duct 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 ensuring low heat losses to the ambient environment e Outer decorative covers are carbon steel plates color painted details Figure 3 1 External view of hot water pellet boiler of series Pelletherm v2 The unit is designed and assembled in two main modules the heat exchanger the left one and the fuel hopper module the right one These modules are easily detachable and could be assembled onsite 1f necessary The producer reserves the right to make changes of the design of the hot water boiler of series Pelletherm v2 without obligations to inform the clients for that process p 14 52 Fuel hopper in Control board Fuel proportioner Fuel transport auger Burner s ash cleaning system
8. in Table 5 1 and if necessary use the parameters described in Table 5 2 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 called 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 described in Table 5 2 During the automatic ash cleaning interval a temporal decrease of the thermal capacity of the boiler is observed
9. in case of emergency situation boiler overheating the emergency thermostat is activated appropriate text is displayed on the control module s display 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 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 module by turning OFF the main POWER switch and then back ON in order to operate the boiler in normal operation mode p 40 52 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 pen
10. Difficult ignition fuel Boiler s emergency overheating Operation faults and their repairing Cause Insufficient heat capacity Low set point temperature of the boiler s operating thermostat Low set point temperature of the remote room thermostat 1f connected High set point temperature of the boiler s operating thermostat High set point temperature of the remote room thermostat aft connected START signal is not present Low quality fuel Absence of heat consumption or incorrect adjustment of the parameters of the boiler or poor Method for repairing Adjustment of operating parameters is required this should be performed by authorized technician It is necessary to increase the set point of the boiler s operating thermostat up to 90 C It is necessary to increase the set point of the room thermostat It 1s necessary to decrease the set point of the boiler s operating thermostat it is recommended to keep it above 60 C It 1s necessary to decrease the set point of the room thermostat It is necessary to check the status of the operation signal of any of the following room thermostat START switch boiler s operating thermostat It is necessary to replace the fuel most probably due to its high moisture content which could be above the required value for nominal operation of the boiler It is necessary to check the correct operation process of the hea
11. above considering the boiler s model 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 operation of hot water pellet boiler Stopping the operation of the boiler should be performed by turning OFF the 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 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 deposited on the metal surfaces ash 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 p 39 52 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 ch
12. and swing the lever in both direction several times which actually will activate the semi mechanized cleaning system of the boiler The total ash cleaning procedure should be performed once per month advisably but not more that two months period of hot water boiler s operation The period between ash cleaning of the boiler should be clarified at practice as it depends mainly on the fuel quality 2 Hot water boiler ash cleaning procedure ATTENTION it is strongly recommended to have self protection utilize gloves protection glassed and appropriate clothing as the risk of injuries is high at high temperatures of the surfaces in the combustion chamber of the unit The following sections will describe the cleaning ash cleaning procedures in details p 2 14 Figure 2 1 Working gloves and working apron provided for easy and safe cleaning process of the ash residue 2 1 How to stop the operation mode of the hot water boiler The nominal operation of the boiler should be stopped by switching off the START signal by switching off the START STOP switch positioned on the control board of the boiler in principal one could turn the boiler off by adjusting set point of the operating thermostat of the boiler to the minimum position and should wait until the fuel which is burning in the burner will be entirely combusted and the heat exchanger is cooled down to safe levels of the temperature 2 2 Switch off the boiler
13. approximately 5 kg e Manually driven 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 e Semi automatic ash deposited on the surfaces of the heat exchanger pipes cleaning system e Automatic fuel feeding auger system Unit s advantages The hot water boiler is designed to utilize solid biomass fuel making it environmentally friendly CO neutral and does not contribute to the global warming process result of fossil fuel utilization The specific price of the heat energy delivered by solid biomass utilization is less dependent on the world fuel market trends and practically the heat energy price is competitive to the conventional energy sources The boiler is automatic and the thermal comfort achieved is close to that originating from exploitation of 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 The unit is equipped with automatic fuel ignition system and another one for burner s grate ash cleaning The design of the heat exchanger is optimized and realizes three way flue gas duct thus allowing intensive heat exchange rate and high efficiency of the boiler above 90 and reduced fly ash e
14. 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 except 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 1s cooled to the ambient p 23 52 temperature This precautions are induced due to prevent rising of thermal stress of the steel boiler s body and its damage leakage 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 1s 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 of series Pelletherm v2 procedure Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manu
15. 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 p 38 52 5 3 2 Increasing the thermal capacity of 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 Jn case 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 the tables
16. of the heating installation and the warranty card is filled with the required information p 18 52 The recommended principal hydraulic scheme for connecting the hot water pellet boiler of series Pelletherm v2 to the heating system is snow on the following figure 4 6 22 ae f 16 9 10 L E l li Fi if EF j i i i Fi f i j j i Fi i j l f f i i f j i i e i Fi Fi i Cold tap Ra j fr f water al i j i oy E l gt i i OPC j f H 7 To heating 1 a I system Domestic hot E e syy y P water Yooo E A ma a From heating system gt mm a l a oe i J Fie i KA i i i i i i i l l 1 k i 2 z dh Las fa0 eui h7 a Figure 4 2 Recommender principal hydraulic scheme for connecting the hot water pellet boiler of series Pelletherm v2 to the heating system equipped with mixing valve and heat accumulator 12 Water filter oo Pelletherm v2 13 ThermovalveTV 14 Retumvalve _ _ 3 15 Contact thermostat l6 o 4 Circulating pump 1 o 6 Automatic circulating water Control valve charger 18 Drainage valve 8 Controlvalve ss 22 Automatic air separator 9 Three way mixing valve Table 4 1 Designation of the elements indexed on figure 4 2 12 13 14 15 16 17 18 p 19 52 NOTE According to EN 303 5 the heat accumulator is obligatory mo
17. of the operating process of the boiler it is possible to get risks as follows o Cauterization risks caused by high temperatures as a result of the combustion process in the combustion chamber and or direct access 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 o 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 uncontrolled 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 duct is not fully tightened and gas leaks are possible p 42 52 5 8 ba Operation fault Low temperatures in the heat supplied rooms High temperatures in the heat supplied rooms The boiler active but combustion process 1S no
18. 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 p 26 52 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 the pellet hopper 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 COMMENTS o At the period of fuel ignition an electrical heater is activated The heater will be deactivated when the flue gas temperature reaches certain level sensed by flue gas thermostat mounted on the exhaust duct of the boiler During 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 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 other
19. 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 of series Pelletherm v2 should be connected to heating system supplied with OPENED or CLOSED expansion vessel In case the heating system is equipped with closed expansion vessel then the system should be equipped with over pressure safety valve which opens at pressure exceeding the operating one of the hot water boiler 0 25 MPa and this overpressure safety valve should be certified according to PED 97 23 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 appl
20. 2 Pr Ta eee NG el ek B 7 CHI ek ie AT as Ni r 7 pes ES AS A SS I S XENI pk c Figure 3 2 Partly sectioned view of hot water pellet boiler of series Pelletherm v2 front view peut External fuel delivery orifice Figure 3 3 External view of hot water pellet boiler of series Pelletherm v2 top view p 15 52 Tertiary pass of flue gasses ee EEEE ii TEE YN nu m mm lt a MEE Specialized pellet burner equipped with ash cleaning mechanism E eih jes Figure 3 4 Cross section view of hot water pellet boile v2 The flue gasses duct and streamlines are visualized as well Tertiary pass of flue gasses Secondary pass of flue gasses Primary pass of flue gasses Specialized pellet burner equipped with ash cleaning mechanism Ash container Figure 3 5 Cross section view of hot water pellet boiler of series Pelletherm 45v2 The flue gasses duct and streamlines are visualized as well p 16 52 4 Installation process Norms and recommendations Basic requirements for installation of hot water pellet boiler of series Pelletherm v2 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 1s not allowed The hot
21. O T W boiler thermostat H O T R room thermostat T FL thermostat flue gas Ll 220V N KM1 250 W Ignition LE re SN ae TN Oe Cy an ACTUATOR p 48 52 210 POWER SUPPLY UNIT 24 V St PROCESS CONTROL QI Q2 Q3 STEP PS 1AC 24DC 0 5 PHOENIX CONTACT Actuator potentiometer J Q6 Q7 D OD D T ews TTT 5 3j Door 25 33 D r 1 LA2 L A ae JA an ae 24V St Actuator Flue gas fan N 2 L1 1 5 24 V St Capacitve 14 sensor D 6 24vV St 1 Q8 D External pellet transport option Figure 6 2 Electrical scheme of the control board of hot water pellet boiler of series Pelletherm v2 ANNEX 1 Hot water pellet boiler of series Pelletherm v2 end user maintenance procedures Contents p l General Principals arenen ieee 2 2 Hot water boiler ash cleaning procedure ccccccccceseeeecceeeeeaeeeees 2 2 1 How to stop the operation mode of the hot water boiler 3 2 2 Switch off the boiler 000oooeeeeneseeneseessssrssrerersesssseserseeressssseesereeeees 3 2 3 Cooling down the boiler 000 0000eeeeeeesssseeenesssseeerssssseserrsssssrreressssese 4 2 4 Cleaning the ash of the heat exchanger surfaces 000 4 2 5 Attachment and assembly of the elements detached at the ash leanine POCO CIE Gis as cic pass
22. USER MANUAL of hot water pellet boiler of series Pelletherm v2 http www greenecotherm eu Producer ZMM Haskovo Plc Address Bulgaria Haskovo 6300 Saedinenie 67 blvd Phone 359 800 15 145 Fax 359 38 603070 e mail ereenecotherm erato bg home page www greenecotherm eu Thank You for buying hot water pellet boiler of series Pelletherm v2 This manual will help You to use and maintain the unit properly The boiler s producer company requires the installer technicians which will perform the installation maintenance and service procedures of the boilers of series Pelletherm v2 to be trained and certified by the producer NOTE in the following document is used the designation Pelletherm v2 which includes all the models of the hot water pellet boilers Pelletherm 30v2 and Pelletherm 45 v2 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 FAILURES OF THE UNIT COULD BE EXPECTED OR EVEN FATAL CONSEQUENCES FOR WHICH THE PRODUCER COMPANY DOES NOT TAKE RESPONSIBILITY CONTENTS page 1 Hot water pellet boiler of series Pelletherm v2 description properties and ADVANAGES 0 0 eee cccccsssecceccaeseecceeeeesecceesaeeeecee
23. al 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 personal 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 e The door of the fuel hopper section of the boiler is equipped with a safety switch and in case the door is opened then the motor of the fuel transport auger will be powered off for safety reasons this door should be kept closed p 24 52 5 2 1 Interface control board of hot water pellet boiler of series Pelletherm v2 Alarm indicator emergency overheating Process control module Alarm indicator process malfunction Thermo mano
24. anger Notice that the lid is tightened in order to prevent and flue gases leakage or ambient air both in and out of the flue gas duct Figure 2 9 The lid of the secondary ash deposition zone is detached and the ash layer should be cleaned away p 9 14 Figure 2 10 Cleaning of the ash in the secondary deposition zone of the heat exchanger right beneath the pipes of the heat exchanger EXPLANATION it is recommended to position the ash hopper in a position which will allow easy collecting of the ash residue The next step is to clean the ash and char residue deposited in the burner ATTENTION before lifting up the cover of the burner it is necessary to make a safety check 1 e to verify that the temperature of the burner s details is low enough to handle and continue with the manipulations It is strongly recommended to get measures self protection a ae p N E E e Figure 2 11 Lift of the burner s arc lid p 10 14 EXPLANATION the lid of the burner is freely mounted and no fixing items are used It is positioned by special locking pins fixed to the lower part of the burner in its front side Figure 2 12 Ash and char cleaning procedure of the material laid on the burner s grate Figure 2 13 Brushing and cleaning the ash residue and any other char remaining on the burner s grate p 11 14 After the burner s grate has been thoroughly cleaned it is necessary to clean the ash benea
25. anging 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 parameters 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 Emergency 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 the informative text on the control module s display 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
26. at rece tacts ees 14 3 Recommendations and requirements ccccccccessseeccceeeeeeseeeeeeeeaes 14 http www greenecotherm eu ANNEX I Hot water pellet boiler of series Pelletherm v2 end user maintenance procedures Document edition 16 11 2011 12 59 1 General principals The fuel of the hot water pellet boiler of series Pelletherm v2 is wood pellets or any other verified and described in the user manual of the boiler and the residual of the combustion process is mineral ash The quantity of the ash depends on the fuel mineral mass content 1 e fuel s quality The practice shows that main part of the ash residue is collected in the ash hopper of the boiler however ash is deposited on the heat exchanging surfaces as well and other surfaces that are in direct contact with the flue gases the burner the flue gas fan etc The ash residue quantity collected in the main ash hopper positioned in the combustion chamber should be cleared periodically considering the operating mode of the boiler as well as the fuel quality The practice shows that according to the ash in that hopper should be cleaned thrown away periodically between one and five days the fuel should cover the requirements depicted in the user manual of the boiler It is advisable to clean the convective part of the heat exchanger by utilizing the applied the specialized lever it should be plugged in the profiled orifice
27. authorized technician It is necessary to perform adjustment of the operating parameters and the air flow rate the adjustment should be performed by authorized technician It is necessary to contact the service company and help of a authorized technician 1s required It is necessary to clean thoroughly the heat exchanger surfaces of the boiler It is necessary to perform adjustment of set point temperature which controls the circulating pump of the heating system It is recommended to adjust the thermostat set point to minimum of 65 C It is necessary to clean thoroughly the flue gas fan ants casing It is necessary to perform adjustment and tightening of the combustion chamber s door as well as any other lids eventually change the heat resistant ropes this p 45 52 gas duct should be performed by authorized technician only 13 The fuel transport The door of the The door s safety switch is active mechanism is not fuel hopper this door should be closed functioning section 1s opened The door of the The fuel transport mechanism fuel hopper should be checked this should be section 1s closed performed by authorized technician but the fuel only transport auger 1s not functioning Other failures not It is necessary to consult authorized described above technician and eventually service maintenance should be performed Table 5 4 Description of operation faults of the hot wat
28. cessinacaaneoneiencnedee 40 Emergency boiler Stop s s csciavisssccdciesaviactbcaseasennciaseiecdcadeesvietsstaverecsoesiee 40 5 6 Showing and teaching the end user about the maintenance and ACTUSLIMENE PROCCOULCS iss cease ee eee cece ees 4 5 7 Safety and unexpected risks 0 0 0 0 ccccecccccceeeseeecceeaeeeeceeeaaeeeeees 41 5 8 Operation faults and their repairing cc cccceeeeeececeeeeeeeeees 43 5 9 Hot water boiler warranty form completion cccccccceeeee 46 5 10 Actions after the unit is not in exploitation anymore 46 6 Electrical scheme of automatic pellet boiler of series Pelletherm v2 QUALITY CERTIFICATE 2 WARRANTY FORM ecesna a carte ene E T 50 WARRANTY CONDITIONS herccsscccnineoeuni cni an N N 5 WARRANTY SERVICE PROCEDURES LIST 0000000 ee 52 p 4 52 1 Hot water pellet boiler of series Pelletherm v2 description properties and advantages Pelletherm v2 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 consume
29. cting 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 grate 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 and conditions 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 1 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 Additionally the air duct is equipped with flaps for individual adjustment of the primary and secondary air flow rate
30. dule of a heating system equipped with solid fuel hot water boiler The dimensioning of the heat accumulator tank is described in the above mentioned standard The boiler producer could assist in appropriate designing of that module as well 4 1 Hot water pellet boiler connection methodology 4 1 1 Connecting to the chimney After the boiler has been positioned and leveled utilizing the leveling screws installed in the lower corners of the heat exchanger as well as the fuel hopper module the unit should be connected to an appropriately sized and designed chimney 4 1 2 Connecting to the heating system After the flue gas duct of the boiler is connected to a chimney the boiler should be connected to the heating system utilize appropriately sized fitting according to the preliminary prepared project p 20 52 f j 150 F 111 170 5 g Li i ce F 111 z ah ig G1 1 2 G 1f2 Figure 4 3 Back side view of heat exchanger connections of hot water pellet boiler Pelletherm 30 v2 p 21 52 G1 1 2 109 6 1258 13 8 G1 1 2 Figure 4 4 Back side view of heat exchanger connections of hot water pellet boiler Pelletherm 45 v2 p 22 52 5 Hot water boiler installation and starting procedures ATTENTION The unit should be installed adjusted and verified ONLY by trained and authorized staff 5 1 Basic fuel requirements e The fuel pellet shaped should be dry The uni
31. e hot water boiler Pelletherm 45 v2 p 33 52 5 2 6 Changing the working parameters of 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 in case it is necessary 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 displayed parameters are allowed to be changed p 34 52 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 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 4 Press button arrow RIGHT 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 d
32. er boiler of series Pelletherm v2 causes and methods for repairing 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 treated 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 p 46 52 6 Electrical scheme of automatic pellet boiler of series Pelletherm v2 Figure 6 1 and Figure 6 2 show electrical scheme of hot water pellet boiler of series Pelletherm v2 220 V Motors transformer thermostats PCB 12 14 V Pw 3 12 14V Pw 4 Figure 6 1 Electrical scheme for connecting the automatic pellet boiler of series Pelletherm v2 to the main power supply p 47 52 LA 12 1 P00 1 100 240 0 14K 0 25W 24 V St green Il input flame sensor 3 Start I6 back fire in auger option I8 pellet level capacitive sensor IB Actuator Potentiometer T A alarm thermostat H
33. erheating 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 boiler should be connected to the chimney according to the installation s project This duct should be sealed and verified that there is no flue gases leakage e The boiler should be connected to the heating system the system as well as the water jacket of the heat exchanger should be filled with circulating liquid free of air the control modules valves pumps motor valves etc should be checked for functionality as well 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 to transport fuel material by the pellet 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 5 235 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 if needed If the START switch is OFF then the boiler goes into stand by mode and waits
34. etration 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 ensure 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 5 7 Safety and unexpected risks Risks could arise at the exploitation of the boiler The hot water pellet boiler of series Pelletherm v2 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 of series Pelletherm v2 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 p 41 52 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
35. iances safety Part 1 General requirements p 17 52 Appliance positioning in order to achieve comfortable maintenance O O 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 to guarantee easy access at servicing of the flue gas fan of the unit Minimal distance of 500mm above of the unit and any ceiling 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 as well as fuel hopper charging Figure 4 1 Positioning of hot water pellet boiler of series Pelletherm v2 the minimal distances between the unit and any walls obstacles of the boiler s room are shown 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
36. ion 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 Lanbicntalt Ratio Heat an T6 a on Te Pee a ae pee See 10 30 080 160 240 _ os 25 060 120 180 _ o 2 030 60 Table 5 3 Appropriate adjustments of heat capacity parameters T4 and T6 according to the thermal load of the boiler Pelletherm 30 v2 where T room Mean value of the temperature in the heated rooms C T ambient air Mean value of the ambient temperature C p 31 52 AT Tyoom Tambient air temperature gradient C Taniera Ratio Heat T6 EE oe o ETA ee eee 10 25 9 l Table 5 4 Appropriate EEEN of heat ON parameters T4 and T6 according to the thermal load of the boiler Pelletherm 45 v2 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 as follows e for Pelletherm 30v2 0 30 66 33 T4 e fo
37. isplay of the process control module will show a question CONFIRM CHANGES Press buttons arrow DOWN 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 Jf 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 s
38. ituation reset the operation module The reset process of the unit 1s 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 mechanism is required The automatic cleaning procedure 1s performed regularly in a predefined period of time parameter T9 time period for automatic cleaning procedure e The user should choose the menu item PARAMETER This submenu does not require password entry However the access to the service submenu items are password protected and are eligible by service technicians only O000 6C Figure 5 4 Front view of the operation module of the control board of the pellet boiler p 35 52 For example if the user tried to get into other submenu like MONITORING then the controller will expect password entry as described on the following figure PASSWORD CLEAR 0 5 0000 5 maximal number of trials for password entry Figure 5 5 Example display which shows the status of the submenu entry protection SHIFT OK EXIT The way to exit such a menu is displayed press simultaneously the buttons SHIFT and OK The way to exit from the displayed submenu is to pre
39. le 2 4 e ENplus the European standard for wood pellets is shown in Table 2 5 Vawe Pelletherm Pelletherm Model of the hot water boiler as Nominal thermal capacity Thermal capacity operation range een a 7 Utilized solid fuel e Wood pellets e Pre dried cherry nuts e Other dried nuts ENplus ENplus B producer classification methodology caer om o Te nominal thermal capacity Fresh air flow rate required for effective combustion process and boiler operation mh 42 50 63 75 Mass flow rate of the exhaust gases ee agen ae me rate the unit is PAE in a pean heating D A E E a Flue gases temperature at nominal C 110 120 140 150 thermal capacity The quantity depends on Solid fuel residue aT the ash contents in the raw fuel as well as operating conditions Table 2 1 Thermal and technical data for hot water pellet boiler of series Pelletherm v2 utilizing wood pellets p 9 52 Parameter Dimension Value Pelletherm Pelletherm Weight 460 575 Wair jacket capaci a 95 o Fuel hopper capaciy dw pa kg 100kgwood pellets __ eee 1375 x 1380 Class according to EN303 5 according to EN 303 5 Operating overpressure of the MPa 0 25 circulating water Heating system expansion vessel Opened or closed up to type 0 25MPa Factory tested overpressure Recommended circulating water temperature Minimal recommended return water temperature Draught B 0 1
40. ler or the appliance producer s assistance 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 and efficient boiler s operation 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 fuel mass flow rate measurement The fuel 1s 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 Myereis 6 8 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 penters 0 00188 kg s o The net calorific value of the pellets is considered given by the fuel producer other source etc Hyenes 17 2 MJ kg 17200 kJ kg The practice shows that in some cases it is more convenient to utilize another dimension of the calorific value kWh The wood pellets have low calorific value of FH pe
41. ll 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 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 Jn 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 5 3 1 Decreasing the thermal capacity of the boiler It is realized by decreasing the value
42. meter Operating thermostat START switch Main POWER supply Emergency thermostat switch Figure 5 1 Interface control board equipped with control and operating devices of hot water pellet boiler of series Pelletherm v2 Interface control board devices description e Main POWER switch switches ON and OFF the main power supply of the boiler e Operating thermostat 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 p 25 52 e Thermo manometer indicates the operating temperature of the circulating water in the heat exchanger jacket of the boiler well as water overpressure 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 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 ov
43. missions to the chimney Automatic unit operation Hot water boiler could be connected to programmable room thermostat weekly programmable which guarantees maximal thermal comfort and economical fuel consumption 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 ENplus EN 14961 2 2010 ONORM M7135 DIN 51731 u DINPlus High efficiency Low pollutant contents in the flue gases The unit is applicable for domestic hot water heating purposes Automatic fuel feeding system transported from the built in daily hopper to the burner 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 Simplified maintenance and service procedures Minimized running costs p 7 52 p 8 52 Hot water boiler of series Pelletherm v2 technical data e Thermal and technical data for hot water pellet boiler of series Pelletherm v2 utilizing wood pellets are given in Table 2 1 e Dimensions and technical data for hot water pellet boiler of series Pelletherm v2 are given in Table 2 2 e Recommended solid fuel properties wood pellets are given in Table 2 3 e Pellets classification considering their physical properties based on fuel proximate analysis are shown in Tab
44. pliance 3 Recommendations and requirements It is highly recommended to perform the above described procedure of ash deposition cleaning as it will ensure high efficiency and reliability of the boiler It is recommended to ash clean the unit on a period of a month of operation but it is necessary to clean the ash on operation period of no more than two months considering the operating mode of the boiler as well as the ash content of the raw fuel ATTENTION e After each cleaning procedure the boiler should be checked out the correct attachment of the element the air tightness of the lids and the boiler s functionality e At the end of the heating season it is necessary to perform thorough ash cleaning of the boiler because the mineral ash acts as corrosive reagent and reduces the reliability of the boiler It is recommended to take away of the fuel hopper any pellets of other fuel if utilized as the pellets could absorb moisture from the ambient air and cause clogging of the fuel transport auger issues with the ignition etc The above depicted ash cleaning procedure is OBLIGATORY In case that the ash cleaning and boiler s maintenance procedures are not followed it is possible to decrease the efficiency and performance reliability of the boiler even operation failure could be achieved for example clogging of the ash cleaning mechanism flue gas fan blockage etc p 14 14 Instruction for cleaning pellet boiler
45. r The hot water pellet boiler of series Pelletherm v2 includes hot water boiler 1 sp ash tray l sp foot screws for installation and leveling 8 sp pair of working gloves Isp working apron l sp instruction manual I sp annex of the instruction manual I sp The unit could utilize following types of fuel e Wood pellets having diameter 6 up to 14 mm categorized in the range of A AB B BC C CD E EF according to the methodology developed for pellets properties estimation in boiler s producer 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 utilization need testing and approval by boiler s producer company laboratory p 5 52 p 6 52 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 100 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
46. r Pelletherm 45v2 0 26 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 8mm diameter wood pellets than these values should be considered as basis for appropriate adjustment of the boiler However one should check the values of other operating parameters for example TI or T9 p 32 52 Pellet s feeding time seconds BONO Ea 21 000 1 0900 0 9900 19 000 0 8900 17 000 0 7900 13 000 0 5900 11 000 aa 0 3900 9 000 0 2900 ao 0 1900 5 000 0 0900 9 00 18 00 24 00 30 00 9 00 18 00 24 00 30 00 Heat capacity of the boiler kW Figure 5 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 hot water boiler Pelletherm 30 v2 Pellet s feeding time seconds Ratio T4 T6 19 000 0 8900 17 000 0 7900 0 6900 15 000 0 5900 13 000 0 4900 11 000 0 3900 aad 0 2900 7 000 0 1900 5 000 0 0900 13 50 27 00 36 00 45 00 13 50 27 00 36 00 45 00 Heat capacity of the boiler kW Figure 5 3 Graphics of the T4 parameter and power ratio pellet s feeding time T4 and ratio T4 T6 values according to the heat capacity of th
47. saeeeeesssaaeeeees 5 The unit could utilize following types of fuel ce eeeccceeeeeee eens 5 The unit is equipped WIthe cc cccccccsseecceeceeeeeceeeaeeeeceesaeeeeeeeseeeeeeeeeeas 6 The unit is supplied with gases esscesnsnaricctcoiniuseeariedaasacniande nade aeuteieetwincae 6 2 Hot water boiler of series Pelletherm v2 technical data 8 Table 2 1 Thermal and technical data for hot water pellet boiler of series Pelletherm v2 utilizing wood pellets ccessssesssseeesseeeeeeeeeceeeeeeeeees 9 Table 2 2 Dimensions and technical data for hot water pellet boiler of series POED GaN 2 rE EE E EE S 10 Table 2 3 Recommended solid fuel properties wood pellets 1 Table 2 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in boiler s producer COMPANY cccceeceesssssseessssseeeeeeeececeeeeeees 1 Table 2 5 ENplus European standard for wood pellets ccceeeees 12 3 Description of hot water pellet boiler of series Pelletherm v2 13 4 Installation process 0000onnnsooennnsseenossseerossseerossseerssssserosssserssseeeenss 17 4 1 Hot water pellet boiler connection methodology 06 20 4 1 1 Connecting to the chimney ccccceccccceceeeeeeeeeeeeeeaeeees 20 4 1 2 Connecting to the heating System
48. ss the left arrow button lt 44 EXPLANATION in case that the above described procedure 1s not followed accidently the user could make up to 5 trials for password entry After the user has made the above mentioned number of password entry trials the display will state as depicted on the following figure PASSWORD CLEAR ERROR 5 5 gt gt gt 30 MINUTES Figure 5 6 Information shows on the control module s display at reaching the password entry trials limit The above shown information indicates that password entry limit has been reached The user should wait a period of 30 minutes at switched ON the power supply of the hot water boiler until this protection times 1s reset After passing the reset period 30 minutes one should press the SHIFT and the OK simultaneously the press the left arrow button lt 4 button follow the procedure described above After passing the 30 minutes protection period the control module protective timer set to 0 and one operate with the module EXPLANATION The user can operate within the submenu PRAMETER ONLY p 36 52 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
49. t of the flue gases duct of the boiler p 6 14 any Figure 2 6 Cleaning the ash deposits off the heat exchanger surfaces as well as off the ash cleaning mechanism The ash should be thoroughly cleaned off the metal parts of the cleaning mechanism and the heat exchanger as well p 7 14 EXPLANATION the ash particles laid on the horizontal surface of the heat exchanger at the flue gas pipes side could be cleared by a specialized vacuum cleaner or it could be swept down through the pipes to the surfaces underneath the ash will be cleaned from the surfaces underneath Detailed description will be shows in the next sections The next step of the cleaning procedure is to clean the internal surfaces of the pipes of the heat exchanger this is done by manual movement of the pipe s ash cleaning mechanism Ash cleaning lever used to clean the ash residue off the pipe s heat exchanger surfaces Figure 2 7 Attachment of the heat exchanger pipes ash cleaning actuating lever The next step is to detach the front face panel of the heat exchanger in order to get access to the lid of the second ash deposition zone of the boiler the area right above the burner and below the pipes p 8 14 Figure 2 8 Detaching the front panel of the heat exchanger The next step is to unscrew the fixing nuts of the lid which closes the secondary ash deposition zone of the three way flue gas duct of the heat exch
50. t 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 It is recommended to store the 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
51. tes 4 77 kWh kg which is equal to 17 2 MJ kg o The thermal efficiency is determined stated by the producer at nominal thermal capacity Ypoiter 93 Y0 0 93 o The thermal capacity of the boiler is calculated as follows Psie Note H penes 1 peters 0 93 17200 0 00188 30 2kW In case that the calorific value of the fuel is known in dimension kWh kg then the calculation is as follows l z a ll boiler i dD sie PI sis 0 93 4 17 j 6 8 30 2 kW p 30 52 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 D220 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 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 operat
52. th the grate EXPLANATION the burner s grate is detached by lifting and alongside pulling action It is possible to have difficulties when detaching the grate due to the deposited ash and eventually any thermal deformation of the details It is necessary to take care at the grate removal procedure and to keep the ash grating element not damaged it is not necessary to apply excessive force in order to remove away the grate Ash grating element moved forward backward by special mechanism Figure 2 14 Detaching the grate of the specialized burner p 12 14 Figure 2 15 Cleaning the ash residue fallen beneath the grate of the burner The next steps is to take away the ash hopper placed on the bottom of the combustion chamber to deposit away the ash residue in special fire protected container The cooled down ash could be utilized as soil fertilizer Figure 2 16 Tacking the ash hopper out of the combustion chamber p 13 14 2 5 Attachment and assembly of the elements detached at the ash cleaning procedure The attachment procedure should be done in reverse sequence of the steps depicted in the previous sections of the manual ATTENTION it is necessary to ensure air tightness if the lids of the flue gases duct of the boiler these are the lid of the ash deposition secondary zone as well as the top lid covering the flue gases duct of the heat exchanger in order to ensure high reliability and efficiency of the ap
53. ting installation and eventually appropriate adjustment of the operating parameters of the boiler and or control valves of the p 43 52 No fuel ignition operation of the heating installation Absence of fuel in the hopper Absence of fuel in the burner Fuel is present in the burner but it s not ignited or it is fully incinerated and the combustion process has extinguished 1 e not present Abnormal operation or malfunctioning of the flue gas thermostat this should be by authorized 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 installation performed oo 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 1s necessary to increase the value of the initial fuel mass parameter T1 the adjustment should be performed by authorized technician In case that the electrical heater is out of order or not operating then it should be replaced with appropriate working one In case that the heater is
54. ty classes Al n A2 The class Al is highly restricted considering the ash content The class A2 the limit of the ash content of the wood pellets is higher up to 1 5 For industrial boilers the certificate EN B is applicable which defines fewer restrictions on the pellets quality Parameter Diameter Length Bulk density Low calorific value Moisture content Dust Mechanical durability Ash content Ash melting point temperature Cl S N Cu Cr AS Cd Hg Pb Ni Zn Dimension mm mm kg m MJ kg ENplus Al ENplus A2 6 1 6 1 3 15 lt L lt 40 3 15 lt L lt 40 gt 600 gt 600 gt 16 5 gt 16 5 lt 10 lt 10 lt 1 lt 3 gt 97 5 295 lt 0 7 lt 1 5 gt 1200 gt 1100 lt 0 02 lt 0 03 lt 0 05 lt 0 05 lt 0 3 lt 0 5 lt 10 lt 10 lt 10 lt 10 lt 1 lt 1 lt 0 5 lt 0 5 lt 0 1 lt 0 1 lt 10 lt 10 lt 10 lt 10 lt 100 lt 100 1 not more that 1 of the wood pellets should be with length of 40 mm the maximal pellet length is 45 mm 2 determined on dry mass 3 the particles are lt 3 15 mm fine particles before fuel delivery 4 in case the test measurements are performed with Lignotester than the limit value is gt 97 7 m wW Table 2 5 ENplus European standard for wood pellets p 12 52 3 Description of hot water pellet boiler of series Pelletherm v2 The heat exchanger of the boiler complies with the a
55. wise 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 value Pelletherm Pelletherm 30v2 45v2 Pellet s feeding time during this period pellets seconds are fed to the burner Pellet s not feeding time fuel is not transported to seconds the burner Table 5 1 Main parameters description which define heat capacity of the unit ATTENTION The producer guarantees effective and reliable operation of the boiler ONLY when its running conditions are in its corresponding operating p 27 52 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 For_ Pelletherm 30v2 ae 0 30 lt ta lt an 1 00 where one 0 30 20 T6 20 20 defines the lower thermal capacity of the boiler corresponding to about 9kW and the ratio 1 00 defines the nominal thermal capacity of the unit For_ Pelletherm 45v2 a 0 26 lt is lt pee 0 85 where 2 0 26 20 T6 20 20 defines the lower thermal capacity of the boiler corresponding to about 13 5kW and the ratio defines the nominal thermal capacity of the unit
56. working then it is necessary to increase the time for ignition of the initial mass of the fuel parameter T2 the adjustment should be performed by authorized technician The flue gas thermostat should be adjusted or replaced in case it is out of order The flame looks Low quality Fuel replacement is recommended p 44 52 10 11 12 opaque and smoke is observed at the exit of the chimney of in Presence unburned fuel the ash tray Alarm absence of ash cleaning High temperature of the flue gases 1f flue gas thermometer IS mounted Water vapor condensates on the surfaces of the combustion chamber Flue gases are emitted out in the boiler s room after certain period of exploitation Inappropriate operating parameters adjustment Ineffective fuel combustion process A problem in ash cleaning module The heat exchanging surfaces of the boiler are deposited with ash presenting heat resistive layer thus decreasing the heat exchanging intensity Low temperature of the inlet water flow The flue gas fan is clogged or even blocked by fly ash deposits Incomplete tightness of the combustion door chamber s or and other flue pellets most probably the moisture content is higher than required It is necessary to perform adjustment of the operating parameters of the unit and achieve efficient combustion process the adjustment should be performed by
57. y of the unit Period of time for fuel combustion after STOP 30m 00 s signal has been set Pellet s not feeding time fuel 5 is not transported to the ue burner determines the eee all heat capacity of the unit T7 Period of time for initial fuel seconde doze combustion seconds Period of time between two cleaning procedures tA 00 02 hours ATTENTION change the tB 04 00 h m minutes value of the period only tB seconds pellet hopper Period of time for fuel combustion before burner S 400 acai ash cleaning mechanism actuation Period of time which generates false hysteresis of the level of the fuel in the Ignition attempts counter C 1 EXPLANATION at C 4 the boiler makes 3 three ignition attempts count Table 5 2 Description of the control parameters which define nominal operating mode of the hot water boiler of series Pelletherm v2 p 29 52 NOTES e In principal the fuel s ash content does not change its low calorific value However the combustion process is greatly influenced by the presence of mineral mass 1 e ash but requires specially designed burner in order to achieve efficient and reliable operation The above mentioned requires appropriate testing and verification of the fuel s applicability as energy source for the hot water pellet boiler of series Pelletherm v2 before making nominal exploitation of the unit Consult the requirement for fuel of the boi

User manual Pelletherm V.2 M00

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