hot water pellet boiler of series “MARIO”
Contents
1. 39 52k Interface control board of hot water pellet boiler of series MARIO a E E E AET OAIE 40 5 2 2 Hot water boiler of series MARIO power supply 4 5 2 3 System very first Sart sscaccesseceashowsiiavenisseassausicarenreiiaroemeiesieneis 41 5 2 4 Operating parameters of the boiler cceeeeeeeeeees 42 3 25 Operating parameters for adjustment of the pellet burner of series ERATO GEF orinn nee nr TOR tartar mn Rn en NOR por eee 42 5 2 6 Nominal operating mode of the system cccccee 44 5 3 Control of the thermal capacity of the system c eee 44 5 3 1 Decreasing the thermal capacity of the system 45 3 3 2 Increasing the thermal capacity of the system 45 5 4 Adjustment of the combustion process cccccceseeeccceeeeeeeeees 45 5 5 Stopping the operation of the System cc cceccccccccceeeeeeeeeeeeees 45 5 6 Turning OFF the System 0 0 0 ccc cccccccccesseeccceeeseeccceeeeeecceeeas 46 p 4 60 Emergency stop of the System cccccccsseccccceseecceeeeeeecceeaaeeeees 46 5 7 Showing and teaching the end user about the maintenance and adjustment procedures sssccasentecernespnocetaessincernineraestsdinounseaicenoingaumioiaedieses 47 5 8 Safety and unexpected risks ccc cccceeseccccceeeeeeeeeccceeeeaeeeees 49 5 9 Operation faults and thei2. ERATO GP20 right side burner attachment is shown p 21 60 Top cover of the boiler Flue gases exit duct Tertiary pass of the flue gases in the boiler Secondary pass of the flue gases in the boiler First pass of the flue gases in the boiler Convective duct ash removal lid Combustion chamber of the boiler Combustion chamber door a i i i i i re ia i i cep a mi Ash container HAYA avi Figure 3 7 Cross section of hot water pellet boiler of series MARIO the flue gasses pathway is schematically shown the main elements of the heat exchanger are pointed right side burner attachment is shown p 22 60 4 Installation process of the system 4 1 Special features and requirements for assembly and installation of automatic pellet burner of series ERATO GP20 and hot water pellet boiler of series MARIO The automatic pellet burner of series ERATO GP20 is attached and mounted on the heat exchanger of hot water pellet boiler of series MARIO The design of the heat exchanger of hot water boiler of series MARIO allow only either left or right side installation of the burner through an attachment flange so the choice of the position of the pellet burner should be performed at the heating system project development The installation of the burner should achieve reliable insulation between the burner and the boiler so to preve
3. Installation of the flue gases duct lid The flue gases duct lid should be positioned by supporting it s side to the specially welded supporting elements on the heat exchanger and supporting the other lid s side on the heat exchanger vertical wall EXPLANATION this lid directs the flue gases from the secondary flue gases duct to the tertiary one in case of alarm modes for example at high pressure in the combustion chamber due to fuel explosions this lid open due to pressure difference and thus allow damage prevention and pressure pulse reduction ATTENTION this lid 1s thermally loaded that s why it is symmetric It is recommended to turn over this lid periodically for example to turn it upside down on a period of two to three week operation of the boiler p 29 60 The directing lid is put aside on the upper surface of the heat exchanger before being installed Figure 4 6 The flue gases lid is put aside and the flue gases exit duct of the boiler is seen Flue gases lid is correctly positioned Flue gases lid hanger for easy handling Flue gases lid lower support welded on the heat exchanger Figure 4 7 The directing lid correct position 1s shown p 30 60 4 4 7 Installation verification of the horizontal combustion lids and the combustion chamber cover Figure 4 8 Positioning the cover elements of the hot water boiler of series MARIO 4 4 8 Install the heat exchanger s convec
4. Arrangement of the modules of the pellet burner side view e Preliminary information for the fuel hopper The fuel hopper is the reservoir for the fuel of the pellet package which ensures conditions for compact fuel storage of the required fuel needed for nominal operation of the system for appropriate period of time and optimal operating conditions of the pellet transport auger as well as the main unit of the burner In case that the pellet hopper is designed onsite then it s construction must allow easy and unobstructed fuel gravity driven transport of the wood pellets to the fuel extraction orifice of the hopper The design of the hopper should consider easy fuel charging easy access for wood fine particles cleaning and mainly appropriate capacity for prolonged and reliable pellet system operation ERATO company 1s a producer of an prefabricated pellet hopper which 1s designed to be assembled onsite The hopper is produced from zinc coated steel plates The capacity of the main module of the pellet hopper is 250kg one or two no more than two additional sections could be attached and the overall fuel capacity will be 450kg and 650kg respectively p 13 60 Figure 2 4 Main module of the prefabricated metal pellet hopper the figure shows the main module with wood pellets capacity of 250kg p 14 60 3 Technical data for the system consisting of hot water pellet boiler of series MARIO and a pellet burner of s
5. ERATO GP20 at nominal thermal capacity and nominal operating conditions will be in the range of 86 90 depending the individual variation of each system this is achieved through combustion process adjustment by utilizing gas analyzer measurement performed by trained technician 4 3 Installation and attachment of the modules of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 Install the hot water pellet boiler following the requirements and instructions described below 4 3 1 Basic requirements for installation of hot water pellet boiler of series MARIO p 24 60 The room dedicated to mount the system should be supplied with fresh air supply duct necessary for optimal combustion process as well as room ventilation Installation of the system in inhabitable premises including dwelling corridors is not allowed The hot water boiler should be connected to the heating system by authorized technicians only Installation and service procedures of solid fuel hot water boiler as well as the pellet burner should be performed by authorized qualified and certified technician ONLY The hot water pellet boiler of series MARIO should be connected ONLY to heating system supplied with OPENED expansion vessel Both the entire heating system and the hot water boiler should be totally filled with circulating fluid water and air free before op
6. factory set electrical bridge Yellow lt a Remove the bridge and een connect the room thermostat to this connector brown Be black Be yeaa The colors of the wiring is valid for flue gas fan produced by EBM PAPST Connector Figure 6 1 Principal electrical scheme of the control board of the pellet boiler of series MARIO EXPLANATION the principal electrical scheme of the automatic pellet burner of series ERATO GP20 is shown in its user manual p 56 60
7. necessary to perform adjustment of set point temperature which controls the circulating pump of the heating system It 1s recommended to adjust the thermostat set point to minimum of 65 C are The gaskets of the lids the It 1s necessary to check p 53 60 emitted out in the boiler s room after certain period of exploitation Pellet burner combustion combustion chamber gasket eventually the gasket between the pellet burner and the boiler are out of order and need replacement Overheating of the pellet burner the their and tget tightened gaskets or replacement this procedure should be performed by authorized technician It is necessary to change the operating parameters of the pellet burner or eventually replace it It is necessary to consult authorized technician and eventually service maintenance should be performed chamber s thermal deformation Other failures not described above Table 5 1 Description of operation faults of the system consisting of hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 causes and methods for repairing 5 10 Pellet system 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 FORMS of the hot wate
8. pellet burner of series ERATO GP20 utilizing wood pellets 0 1 0 2 The next figures show the dimensions and the design of the modules of the system p 17 60 p 18 60 Figure 3 1 Front side view of the hot water pellet boiler of series MARIO the overall as well as the attachment dimensions are shown front side view Figure 3 2 Side view of the boiler of series MARIO the overall as well as the attachment dimensions are shown burner flange side view H Figure 3 3 Front view of the system the overall dimensions are shown hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 left side burner attachment is shown Figure 3 4 Top view of the system the overall as well as the attachment dimensions are shown hot water pellet boiler of series MARIO and a pellet burner of series Ww ERATO GP20 left side burner attachment is shown p 19 60 100 Figure 3 5 Back side view of the system the overall as well as the attachment dimensions are shown hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 right side burner attachment is shown p 20 60 Front top lid of the combustion chamber Combustion chamber s door cover Figure 3 6 Isometric view of the system hot water pellet boiler of series MARIO and a pellet burner of series
9. running costs p 7 60 2 Description of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 The system consists of e Hot water pellet boiler of series MARIO e Automatic pellet burner of series ERATO GP20 2 1 Description of the heat exchanger of hot water pellet boiler of series MARIO The hot water pellet boiler is steel plate welded construction which is applied as heating unit for domestic heating systems which could be realized as driven by natural convection of the circulating water or systems equipped with circulating pump The hot water boiler is a module of the automatic heating system designed for automatic wood pellets utilization and domestic hot water heating The ash deposits cleaning 1s performed by special tool grating the ash off the heat exchanging surfaces collecting the mineral mass and other residues in the ahs container and waste depositing it into specially designed ash container The combustion process realized by the pellet burner along with the combustion chamber of the hot water boiler is optimized and sustains the high efficiency of the system However the overall performance of the system hot water pellet boiler of series MARIO and the pellet burner of series ERATO GP20 depends on the chimney s draught In principal the draught of the chimney depends on its condition 1 e its height as well its te
10. two ceramic plates in the combustion chamber OLMEDO oona aA E T E E NTA N 28 p 3 60 4 4 5 Install the secondary ash lid at the bottom of the convective part OF UNS WOUSI astecscegabaoriscauec tance a ie banaue a a an a 29 4 4 6 Installation of the flue gases duct lid oo eeeseeeeeeeeeeees 29 4 4 7 Installation verification of the horizontal combustion lids and the COMDUSH ONC HaImMDel COV Classe cos a EE E EEE OET 31 4 4 8 Install the heat exchanger s convective duct lid eee 31 4 4 9 Install the boiler s heat exchanger combustion chamber lid 32 4 4 10 Connect the pellet burner of series ERATO GP20 to the hot water boiler of senes MARIO 4 0 ccccspccecncuan tesvacdese ade sedasteneetsiancncanueetactedagdentncabads 33 4 4 11 Installation of the pellet transport auger cc ceeeececcccceeeeeeeees 34 4 4 12 Pellet transport auger fuel charging cccccccceseeeecccceeeeeeeees 34 4 4 13 Connect the control box of the boiler to the power supply 34 4 4 14 Pinal View OL ING SY StCIM saeia ni ENIN 35 4 4 15 Recommended principal hydraulic scheme for the hot water PeO DOUCE renen a T ee 36 5 System starting procedures ccccccceccsstseeessesssssseeeeeeeeeeeeeeeees 38 Si Basic fuelreg iremeitS eocsnye n ea r E TE 38 5 2 Starting up the system consisting of hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20
11. 0 and hot water pellet boiler of series MARIO oii oda srisisveee cin eatnasees wontiebaaedeusaniateetes tanieri tinia iae 23 4 2 Requirements for installation of system hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 23 4 3 Installation and attachment of the modules of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 osc ctse cactus cohaivaiccciadbe leases ueeesgunieadannsaieiielaiameaueuctiabe 24 4 3 1 Basic requirements for installation of hot water pellet boiler OP series MARIO eenean AREE ERN SaS 24 4 3 2 Installation of the system 000oeeeeesseeneesseeesssereresssrrrssserrssse 25 4 3 3 Installation of the hot water pellet boiler of series MARIO considering it s easy maintenance and servicing cccccccceeseeeceeeeeeees 25 4 3 4 Boiler s positioning according to the requirements for attachment to the electric power supply circuit 0 cece ccceeeeceeee eee ee 26 4 4 Procedure for installation of the modules of the system 26 4 4 1 Connecting to the chimney ccccccccccceeeeecceeeeeeeeeeeeeees 26 4 4 2 Connecting to the heating System cccceecccceeeseeeeeeeees 26 4 4 3 Installation of the automatic pellet burner of series ERATO GEER E E cers cane noes ae pete meee 2 4 4 4 Installation of the
12. User manual of hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 http www erato bg Producer ERATO Product Ltd Address Bulgaria Haskovo 6300 blv Saedinenie 67 Telephone 359 38 603050 359 38 603052 Fax 359 38 603054 product erato bg home page http www erato bg product Thank You for buying the system consisting of hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 This manual will help You to use and maintain the units properly This document is intended to be used as additional information for the service team which will install and adjust the system as well as maintenance information which will help the end user The producer requires the service staff which will perform the above mentioned procedures to get training course at the producer s training center and get certified as well ATTENTION e Jn interest of your personal security it is obligatory to read thoroughly and carefully this instruction manual before proceeding with any actions with the system mounting connecting etc its elements In case that requirements depicted in this manual are not satisfied failures of any element of the system could be expected or even fatal consequences for which the system s producer does not take responsibility e Jn interest of your personal security it is obligatory t
13. be filled in the appropriate documents of the boiler as well as the pellet burner where the required data fields should be filled in this is obligatory p 37 60 5 System starting procedures ATTENTION the system consisting of hot water pellet boiler of series MARIO and an automatic pellet burner of series ERATO Gp20 should be installed and commissioned by trained authorized and certified company only 5 1 Basic fuel requirements e The fuel pellet shaped should be dry The unit producer recommends that the fuel should be stored in dry and well ventilated rooms e Itis strongly forbidden to store the fuel in close region of the system both the boiler and the burner the minimal safety distance between the fuel and the appliance is 400 mm e The system 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 system 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 o
14. bute to the global warming process result of fossil fuel utilization e The specific price of the heat energy delivered by solid biomass utilization is less dependent on the world fuel market trends and practically the heat energy price is competitive to the conventional energy sources e The system consisting of pellet boiler of series MARIO and a pellet burner of series ERATO GP20 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 it applicable in heating systems equipped with programmable room thermostat e Automatic operation of the system easy adjustment of the thermal capacity of the burner utilizing the burner s potentiometer the operation of the system could be controlled by programmable room thermostat thus achieving high levels of thermal comfort and fuel consumption economy e The burner utilizes solid biomass fuel in shape of pellets wood pellets dried nuts cherry nuts for example for additional information see the burner s user manual e High efficiency e Low pollutant contents in the flue gases e Compact design allowing simplified installation procedure and easy maintenance at servicing as well as ash deposits cleaning e The system could be utilized to heat up domestic hot water e Simplified maintenance and service procedures e Minimized
15. cedure after the system has been switched off and the burner is cooled down to ambient temperature level it 1s necessary to open the door of the boiler s combustion chamber take away the grate of the burner clean the ash residue put the burner s grate back then close the door and switch on the START and start the system EXPLANATION the door of the pellet boiler s combustion chamber is Closed by a handle It is recommended not to apply high force at the closing process in order to protect the door s gasket heat resistant rope and to ensure combustion chamber s tightness The opening of the door is performed by turning the handle clockwise the handle s lever should be lifted upwards Figure 5 2 Scrapping the ash residue off the walls of the pellet boiler of series MARIO heat exchanger Figure 5 3 Taking the ash tray out of the combustion chamber and cleaning the ash Open the combustion chamber s door and take out the ash tray positioned on the bottom of the boiler the ash residue is collected there Pour the ash residue in heat resistant container or any appropriate container put the ash tray back on its position close the door check the position and tightness of the upper lid on the heat exchanger as well 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 perf
16. combustion process and boiler operation eT Averaged wood pellets consumption rate the boiler is kg h operating in a popular heating system Thermal e at 86 90 90 86 90 90 nominal e Air excess ratio a L5 1 7 Flue gasses temperature at 180 200 nominal thermal capacity Solid fuel residue The quantity depends on the ash contents in the raw fuel as well as operating conditions Table 3 1 Thermal and technical data for the system hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 utilizing wood pellets p 16 60 Parameter_ Dimension Value Hot water pellet boiler model w MARIO 25 MARIO 30 Pellet burner model ERATO ERATO GP20 25 GP20 Weight of the boiler kg 180 190 Weight of the system Vs 222 2 Boiler s water jacket capacity Overall W width dimension of D depth it 770 770 the system according to EN 303 5 circulating water Heating system expansion bey P opened vessel type Factory tested overpressure Recommended circulating C water temperature in the boiler a i C water temperature in the boiler Minimal recommended return hP Supply return G flow Sonina Flue gases duct 149 Power supply a LI N PE 50Hz 230V Electrical capacity lt 100 1100 at ignition Electric protection IP20 Table 3 2 Dimensions and technical data for the system hot water pellet boiler of series MARIO and
17. d be above the required value for nominal operation of the burner It is necessary to check the correct operation process of the heating installation and eventually appropriate adjustment of the Operating parameters of the pellet burner and or control valves of the installation this should be performed by authorized technician p 51 60 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 system 1s thus restarted No fuel ignition Absence of fuel in the The fuel hopper should be hopper charged Absence of fuel in the It is possible to manually restart the operation process of the burner Check if the ignition process needs to be elongated the adjustment should be performed by authorized technician only Fuel is present in the In case that the electrical burner but it s not ignited heater 1s out of order or or it is fully incinerated not operating then it and the combustion should be renewed In case process has extinguished that the heater is working then it is necessary to increase the time for ignition of the initial mass of the fuel the adjustment should be performed by authori
18. e 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 p 39 60 5 2 1 Interface control board of hot water pellet boiler of series MARIO Alarm thermostat START indicator Alarm signal boiler s overheating PUWEH Pr aA ity a i gn ee 0 se i EON a AIR h er y DOWER switch START switch Operating thermostat Fuse Thermo manometer Figure 5 1 Interface control board equipped with control and operating devices of hot water pellet boiler of series MARIO Interface control board devices description e Main POWER switch switches ON and OFF the main power supply of the hot water pellet boiler of series MARIO and the pellet burner of series ERATO GP20 e Operating thermostat assigns the set point of circulating water temperature in the boiler The pellet burner of series ERATO GP20 i e the system will run until this set point is reached and will supply heat energy to the heating system e Emergency thermostat protects the hot water boiler of series MARIO from exceeding emergency temperature levels and overheating This thermostat is factory preset to switch off the power supply of the pellet burner of series ERATO GP20 at water temperature in the boiler above 95 C factory set e START switch sends START STOP signa
19. edures of the burner as well as the pellet hopper COMMENTS the requirements for the installation of the fuel transport auger are given in the user manual of the automatic pellet burner of series ERATO GP20 o The minimal distance between the opposite side on the pellet burner s one of the boiler and a wall should be 500 mm in order to ensure easy access to the heat exchanger and to allow easy cleaning of the deposited ash The minimal distance between the top side of the boiler and a wall ceiling should be 600 mm in order to ensure easy access for the cleaning and maintenance procedures of the heat exchanger for example for ash cleaning O o The minimal distance between the hot water boiler of series MARIO and the pellet hopper should be 1000mm in order to p 25 60 ensure fire safe operating conditions and prevent and alarm modes 4 3 4 Boiler s positioning according to the requirements for attachment to the electric power supply circuit The system should be positioned and should allow easy access to the power supply plug box 230V 50Hz 4 4 Procedure for installation of the modules of the system After the hot water boiler of series MARIO has been positioned it should be connected to the heating system as well as to the chimney considering the appropriate requirements In order to ensure safe and reliable operation of the boiler it should be horizontally leveled which will allow easy air re
20. er 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 p 47 60 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 p 48 60 system The pellet auger takes out the fuel from the hoper and transport the fuel to the main module of the pellet burner Ash cleaning procedure it is recommended periodically at least once per every 72 hours of system s operation to stop the pellet burner by switching off the START switch of the control board of the boiler wait until the system cools down at least 30 minutes and clean the ash residue of the heat exchanger of the hot water pellet boiler of series MARIO by manually scrapping and brushing the ash Take away the ash residue collected in the ash tray of the boiler if necessary Covering this requirement will ensure effective heat exchanging process and will sustain optimal operating conditions of the boiler Switch the boiler ON by turning on the START switch and the systems will start if there is signal for operation 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 pellet burner grate ash cleaning pro
21. erating the boiler Maintenance procedures of the modules of the system should be performed by trained adult persons which have read the user manual of the unit 4 3 2 Installation of the system Installation procedure of the system hot water boiler of series MARIO and the pellet burner of series ERATO GP20 requires development of 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 e Local requirements for attachment to the chimney Local requirements for fire prevention requirements To the power circuit EN 60335 1 1997 Household and similar electrical appliances safety Part 1 General requirements 4 3 3 Installation of the hot water pellet boiler of series MARIO considering it s easy maintenance and servicing o The minimal space in front of the boiler for cleaning maintenance etc should be 1000 mm o The minimal distance allowed between the back side of the boiler and a wall should be 400 mm o The minimal distance from the boiler s side where the pellet burner of series ERATO GP20 will be attached and a wall should be 500 mm in order to allow easy maintenance and servicing proc
22. erformed by trained authorized technician only e The producer reserves the right to make any changes of the factory settings of the burner without any obligations to inform the end users e The adjustment of the thermal capacity of the system hot water pellet boiler if series MARIO and pellet burner of series ERATO GP20 could be realized by determination of the fuel flow rate i e to measure the mass of the pellets transported for defined period of time considering the calocific value of the fuel and the thermal efficiency of the system Detailed description of such procedure could be found in the user manual of the pellet burner e During the nominal operation mode of the burner alarm or abnormal situations could rise 1 e unsuccessful fuel ignition to run out of pellets etc The pellet burner will go into alarm mode and will indicate its status through appropriate indication of its LEDs In case of such situation the burner should be restarted this is performed by swithching off the power supply and then back on only after the alarm mode issue has been clarified and removed 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 p 43 60 mineral mass 1 e ash but requires specially designed burner in order to achieve efficient and reliable operation The above mentioned requires appropriate testin
23. eries ERATO GP20 e Thermal and technical data for the system hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 utilizing wood pellets are given in Table 3 1 e Dimensions and technical data for the system hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 utilizing wood pellets are given in Table 3 2 e Properties of the recommended fuel which could be utilized on the pellet system are described in the user manual of the automatic pellet burner of series ERATO GP20 e Classification of the wood pellets according to their proximate analysis is shown are described in the user manual of the automatic pellet burner of series ERATO GP20 EXPLANATION the hot water pellet boiler of series MARIO is produced in two versions left side flanged for the attachment of the pellet burner and right side flanged looking in front of the boiler p 15 60 ____ Parameter Dimension Value Hot water pellet boiler MARIO 25 MARIO 30 model Pellet burner model ERATO ERATO ores BER AE Nominal thermal capacity WwW DG Thermal capacity operation Ow 75_25 a range Utilized fuel e Wood pellets e Pre dried cherry nuts Other dried nuts Utilized pellets complying ERATO classification A AB B methodology Wood pellets fuel consumption rate at nominal kg h 7 2 thermal capacity for effective
24. g and verification of the fuel s applicability as energy source for the pellet burner of series ERATO GP20 before making nominal exploitation of the unit Consult the requirement for fuel of the burner or the appliance producer s assistance 5 2 6 Nominal operating mode of the system After the initial start up of the automatic pellet burner of series ERATO GP20 i e the fuel is successfully ignited and the boiler has reached its nominal thermal conditions the circulating water and the entire heating system are in steady state thermal conditions 1 e they are tempered which takes time it could be considered that the system is in nominal operation mode The adjustment of the operating both the boiler s as well as the pellet burner s parameters should be performed Detailed description of the pellet burner adjustment is given in its user manual At nominal operation of the system the commissioning of the burner s and boiler s operation should be performed following the governing local requirements NOTES e The temperature of the return flow of the circulating water of a heating system is recommended to be above 60 C because of possibility to achieve condensation of the water vapor on the internal surfaces of the boiler e tis recommended to operate the boiler s thermal capacity in the range described in Table 3 1 In case that lower thermal capacity are needed this modes are much less efficient and
25. he control board of the pellet boiler The system 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 burner goes or stays into stand by mode and waits until new command arise In case of power supply break down the burner will go into the same state of the unit before the interruption The START signal for the pellet burner is given by the operating thermostat of the boiler in case that room thermostat is installed then this thermostat should set START mode as well ATTENTION e Jt is possible to observe flue gases emission out of the boiler at starting up the system especially in case that the chimney does not have appropriate draught for example lack of chimney s height or the chimney s flue duct is clogged The above mentioned gases could be released through the door gasket or the upper section of p 41 60 the boiler where the flue gases lids are positioned check and verify their position It is recommended to check the condition of the chimney as well The same process could be observed during the transition periods during spring and autumn when the natural draught of the chimney is not covering the loses in the flue duct of the system due to the high levels of the ambient temperature e t is possible due to incorrect adjustment of the initial doze of the fuel to observe smoke e
26. heat accumulator is recommended to be attached to the system see 4 4 15 in order to ensure reliable and efficient operation of the system e At the initial start up of the pellet boiler of series MARIO intensive water vapor condensation could be observed This 1s a single process and does not influence the performance of the system neither causing any operating issues 5 3 Control of the thermal capacity of the system p 44 60 The control of the thermal capacity of the system is performed by adjustment of the thermal capacity of the pellet burner of series ERATO GP20 For detailed information about this process please refer to the user manual of the pellet burner ATTENTION Jn case of change of the fuel type for example changing the pellets category supplier size etc it should be followed by adjustment of the thermal capacity parameters and the operating mode of the burner 5 3 1 Decreasing the thermal capacity of the system It is realized by turning the thermal capacity potentiometer on the control board of the pellet burner anticlockwise For more information refer to the pellet burner user manual ATTENTION do NOT decrease the thermal capacity of the burner below the minimal one for the system as such operating modes strongly decrease the thermal efficiency of system and lead to its low reliability 5 3 2 Increasing the thermal capacity of the system It is realized by turning the thermal ca
27. ice of the boiler the next step is to tighten the attachment nuts in order to ensure air tight assembly between the heat exchanger and the burner s attachment flange p 27 60 Figure 4 3 USide view of the pellet burner of series ERATO GP20 installed on the boiler s heat exchanger 4 4 4 Installation of the two ceramic plates in the combustion chamber of the boiler Install of the two ceramic plates in the combustion chamber of the boiler they will direct and flue gases and will allow efficient combustion process these plates are packed and positioned in the at ash tray at the transport of the boiler Figure 4 4 The ceramic elements are installed in the combustion chamber of the hot water boiler of series MARIO they are positioned on specially welded supporting plates p 28 60 4 4 5 Install the secondary ash lid at the bottom of the convective part of the boiler ane J Ash lid Figure 4 5 The ash lid which covers the orifice for ash cleaning between the secondary and tertiary flue gases duct of the heat exchanger 1s positioned EXPLANATION the correct installation of the ash lid is strongly required as its correct position allows proper and efficient operation of the boiler That why after the boiler has been positioned and leveled the position of the ash lid should be checked and verified as well as each ash cleaning of the internal surfaces of the heat exchanger 4 4 6
28. l to the process control module of the pellet burner of series ERATO Gp20 which controls its operation e Thermo manometer indicates the operating temperature of the circulating water in the heat exchanger jacket of the boiler well as water overpressure p 40 60 e Alarm indicator emergency boiler overheating indicates emergency overheating state of the boiler due to activation of the emergency thermostat of the boiler In case of activation cool down the unit and check and repair the reason for the emergency situation finally reset the emergency thermostat e START indicator indicator lamp light up at presence of operating signal for the pellet burner of series ERATO GP20 e Fuse main electrical power fuse of the boiler 5 2 2 Hot water boiler of series MARIO power supply e The unit should be connected to the main power supply according to the safety rules and appropriate norms The system includes a power supply cable use this to connect the boiler 5 2 3 System very first start The pellet hopper which is not an element of the system pellet boiler of series MARIO and pellet burner of series ERATO GP20 should be filled with pellets in order transport material by the pellet feeding auger to the burner Read the user manual of the pellet burner of series ERATO GP20 first The system is switched on by the main POWER supply switch placed on t
29. left or right side the burner is a separate and independent module of the system The pellet burner of series ERATO GP20 is separate module which could be installed on already existing hot boilers and thus to perform fuel switch 1 e to change the energy source from fossil fuel like coal wood logs LPG etc to biomass based densified fuel wood pellets making the boiler s operation automatic The wood pellets allow easy automation of the combustion process as well as high efficiency at energy utilization The wood pellets are solid biomass fuel and as they are utilized solid residue mineral ash will remain in the combustion chamber as well as on any other flue gas duct surfaces However the quantity of the ash residue is less that the ash of any solid fuel due to the low ash content of the fuel The specific price of the heat energy produced at wood pellets utilization is concurrent compared to the price of the energy achieved from any other fuels and energy sources The process performance of p 10 60 the automatic pellet burner of series ERATO GP20 corresponds to the process control performed by any automatic burner utilizing fossil fuel for example gas oil heavy oil etc The operation process includes automatic start up and ignition nominal operation and control of the high efficient combustion process are controlled by the control board of the burner These properties of the burner allow to achie
30. lieving of the circulating water 4 4 1 Connecting to the chimney After the boiler has been positioned and leveled it should be connected to the chimney following the requirements for efficient and reliable operation of the system Figure 4 1 Backside view of the boiler of series MARIO 4 4 2 Connecting to the heating system p 26 60 The boiler of series MARIO should connected to the heating system by appropriate fittings and other control elements it should be performed following the prepared project 4 4 3 Installation of the automatic pellet burner of series ERATO GP20 EXPLANATION at the installation of the automatic pellet burner of series ERATO GP20 it is necessary to follow strictly the requirements depicted in the burner s user manual Use the applied mineral wool insulation gasket applied to the pellet burner Please take care to prevent any gasket damages as the burner is attached to the flange of the boiler this gasket both reduces the ambient air penetration into the combustion chamber as well as plays role of thermal insulation and thus reduces the heat flow rate back to the burner s main module Orifice for the pellet burner Screws to attach the pellet burner of series ERATO GP20 to the boiler Figure 4 2 Side view of the orifice and the flange for attaching the pellet burner to the hot water boiler After the pellet burner has been mounted in the orif
31. ll 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 up the system consisting of hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manual e Any intervention in the working process of the system which could lead to unit s failure and or dangerous and health threatening situations are strongly prohibited e The system 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 system 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 1s not described there e Any adjustments of thermal capacity higher than the nominal thermal load of the modules 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 Pleas
32. llowing figure B8 24 23 3 4 4 5 6 22 22 7 16 9 10 i 1 i Fi Ea i a m ims i l i i l fi i i i Tap water la i OPENED i Dmi i F fexpansion Fi li Pe j F f j i i E i li eee fF ty To the heating gt T A yO 7 if A system Domestic hot AT j Fo ra _ i j 1 1 From the heating system f i i a i Tap water H i r E of Ss L Eoen poeta lpia i 4 i i i i ij l i i i i 4 Y Drain l 2 ja das jio a4 13 11 12 AB age 17 E Figure 4 14 Recommended principal hydraulic scheme for connecting the hot water pellet boiler of series MARIO to a heating system equipped with OPENED expansion vessel obligatory mixing valve and a heat accumulator Index _ Designation 4 Returnvalve Heat accumulator 6 Control valve 8 Controlvalve _ 9 Three way mixing valve 17 Automatic circulating water charger Safety valve Table 4 1 Description of the elements indexed on figure 4 14 p 36 60 EXPLANATION According to EN 303 5 the heat accumulator tank is obligatory module of a local heating system operating with solid fuel hot water boiler The heat accumulator capacity calculation is made according to the above mentioned norm as well as heat accumulator methodology developed by ERATO ATTENTION The finalization of the system installation and performing the commissioning tests should
33. mperature and ash deposition other factors which influence the draught The heat exchanger of the hot water pellet boiler of series MARIO complies with the acting requirements for such kind of units defined in operating norm EN 303 5 2000 Heating boilers for solid fuels hand and automatically fired nominal heat output up to 300 kW Terminology requirements testing and marking p 8 60 Figure 2 1 Front view of the hot water pellet burner of series MARIO The hot water boiler consists of the following elements modules e The main part of the hot water boiler is the heat exchanger which has side orifice for pellet burner installation The heat exchanger 1s produced in two versions left sided the pellet burner will be installed on its left side looking in front of the boiler and right sided the burner will be installed in the orifice of the heat exchanger made in its right side again looking in front of the boiler e The heat exchanger is steel plate welded construction In the front section of the heat exchanger is formed a combustion chamber and underneath is positioned the ash container The heat exchanger is relatively compact construction and is designed as so called three way heat exchanger the flue gasses duct 1s realized as three passes one This design allows intensive heat exchange ratio and relatively small overall dimensions of the system e Ceramic elemen
34. nt flue gases extraction out of the boiler s combustion chamber out to the ambient environment either ambient air penetration to the combustion chamber The burner s attachment and installation procedures should follow the requirements depicted below e easy access for ash cleaning procedure of the burner s grate e reliable and safe operation of the burner and system s modules e possibility for adjustment and service procedures of the systems hot water boiler of series MARIO and the pellet burner of series ERATO GP20 for burner s operation adjustment for fuel transport auger service procedures and maintenance for loading the fuel hoper and maintenance etc 4 2 Requirements for installation of system hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 Preliminary notes the achieved thermal capacity of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 depends on e The thermal capacity of the pellet burner i e its thermal capacity adjustment e The ash deposition on the heat exchanging surfaces of the boiler e The condition of the gasket between the burner and the heat exchanger as well as the combustion chamber s door gasket rope e Chimney s draught p 23 60 The efficiency of the system hot water pellet boiler of series MARIO and automatic pellet burner of series
35. ntil 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 pellet burner by turning off the boiler s the main POWER switch and then back on in order to operate the system in normal state e in case that the pellet burner of series ERATO GP20 has reached alarm mode it will stop and go into alarm mode which is indicated with the LEDs on its control board Please refer the pellet burner s user manual for description of the alarm mode and take preventive actions e in case that the alarm mode is neither described in this documemnt or the pellet burner s user manual then it is strongly recommenced to contact the system s servicing company in order to resolve the issue and start the nominal operation of the system 5 7 Showing and teaching the end user about the maintenance and adjustment procedures It is necessary to read thoroughly this user manual as well as the user manual of the pellet burner of series ERATO GP20 as well as the basic properties of the modules of the system It is necessary to know the operation process of the boiler as well as the burner 1 e starting running switching off cleaning the ash etc 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 ord
36. o read thoroughly and carefully instruction manual of the pellet burner of series ERATO GP20 before proceeding with any actions with the burner mounting connecting etc In case that requirements depicted in its manual are not satisfied failures of the pellet burner could be expected or even fatal consequences for which the burner s producer does not take responsibility USER MANUAL of hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 Document version 13 12 2010 10 30 p 2 60 CONTENTS 1 Main properties and advantages of the system consisting of hot water pellet boiler of series MARIO and pellet burner of series ERATO 74 cL eee ee ee eee ere eee 6 2 Description of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 0 eee 8 2 1 Description of the heat exchanger of hot water pellet boiler of series SMA al 0 ager renee E E R 8 2 2 Description of the pellet burner of series ERATO GP20 10 3 Technical data for the system consisting of hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 15 4 Installation process of the System cccccccccesssecccceceeeseeeceeeeaneeees 23 4 1 Special features and requirements for assembly and installation of automatic pellet burner of series ERATO GP2
37. ormance of the unit 5 8 Safety and unexpected risks Risks could arise at the exploitation of the system The modules of the system hot water pellet boiler of series MARIO and automatic pellet burner of series ERATO GP20 are designed and produced 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 MARIO is operating incorrectly e Automatic pellet burner of series ERATO GP20 is operating incorrectly e The system is installed by unauthorized unqualified personal e The safety instructions described in this manual are not followed and fulfilled p 49 60 e The safety instructions described in the user manual of the pellet burner of series ERATO GP20 are not followed and fulfilled Unexpected risks The modules of the system pellet boiler of series MARIO and pellet burner of series ERATO GP20 are designed and produced according to the requirements of the operating EU safety norms However in spite of that possible risks are considered as a result of the operating process of the modules it is possible to arise 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
38. p e automatic pellet burner of series ERATO GP20 1 sp e ash tray I1 sp e bottom cap for the cleaning section between the secondary and tertiary flue gases duct 1 sp e ceramic elements 2 sp flap l sp door holder I sp cleaning set rake 1 sp hook 1 sp electrical connectors for room thermostat I sp for flue gas fan l sp power supply cable I sp e nut and washer M10 2 sp e instruction manual I sp The automatic pellet burner of series ERATO GP20 which is an element of the system could utilize following types of fuel Wood pellets having diameter 6 8 mm categorized in the range of A AB B according to the methodology developed for pellets properties estimation in ERATO company or class ENplus Al according to EN 14961 2 2010 Pre dried nuts cherries for example e Fuel mixture pellets and nuts for example mixture ratio could be 50 50 p 6 60 Other solid biomass based pellets but confirmation for these fuels utilization need testing and approval by ERATO company laboratory The system consists of e Hot water pellet boiler of series MARIO a steel plate heat exchanger equipped with control board e Automatic pellet burner of series ERATO GP20 System advantages e The system is designed to utilize solid biomass fuel making it environmentally friendly CO neutral and does not contri
39. pacity potentiometer on the control board of the pellet burner clockwise For more information refer to the pellet burner user manual ATTENTION do NOT increase the thermal capacity of the burner above the nominal one for the system as such operating modes strongly increase the thermal loads of some of the components of the system which could lead to alarm situations and eventually thermal deformations of parts of the combustion chamber of the pellet burner the reliability of the system is decreased as well 5 4 Adjustment of the combustion process The adjustment of the combustion process of the pellet burner is described in details in the pellet burner s user manual The combustion process adjustment should cover the requirements for the flue gases parameters of norm EN 303 5 as well as the requirements for nominal safe and reliable operation of the system 5 5 Stopping the operation of the system p 45 60 Stopping the operation of the system should be performed by turning OFF the START switch mounted on the interface panel of the hot water boiler of series MARIO Respectively the starting process will be invoked by turning START switch in ON position In case that the system 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 as well as the combustion chamber s walls of the pellet burne
40. 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 Electrical shock risks at indirect contact The pellet boiler and the pellet burner are connected to the power circuit and their 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 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 5 9 Operation faults and their repairing In case of system failure it is necessary to clarify the issues and find appropriate solution Some of the operating faults are described in the pellet burner s ERATO GP20 user manual and appropriate solution is proposed This document contains additional information which will be helpful both for the end user as well as the technicians Operation fault Method for repairing Low temperature
41. r EXPLANATION the stopping operation mode of the pellet burner of series ERATO GP20 is described in details in the burner s user manual ATTENTION Jn case that the system will not operate for a long period of time then the hot water boiler s 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 systems main modules heat exchanger of the boiler as well as the burner It is obligatory to perform service procedures and preventive observations of the systems by trained service personal only as well as thorough cleaning at the end of each heating season Completing these requirements will ensure long exploitation duration of the system and its high efficiency and reliability 5 6 Turning OFF the system The system i e pellet boiler of series MARIO and pellet burner of series ERATO GP20 is turned off by changing the START switch of the boiler into OFF position this is the recommended method for turning the system off During the working process in OFF state the control board of the pellet burner performs so called controlled turning off procedure in which the operating fan is working and certain operating system parameters are controlled After the boiler has cooled down to ambient temperature the system should be switched off by turning off the boile
42. r s main POWER switch It 1s recommended to clean the deposited ash thoroughly of the heat exchanging surfaces of the boiler e Emergency stop of the system In operating process of the system emergency situations could arise and the component i e the boiler and the pellet burner will go into alarm failure mode Some situations are detected by the safety units and the process control board and the systems 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 board indicates alarm mode through its LEDs Please refer to the pellet burner user manual as well as this document before taking any p 46 60 actions After the cause of the alarm situation 1s clarified take adequate actions for bringing back the system into normal operating conditions and restart the burner by switching OFF and back into ON state by turning the main POWER switch of the pellet boiler of series MARIO ATTENTION e in case of emergency situation boiler overheating the emergency thermostat is activated and the alarm 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 u
43. r pellet boiler of series MARIO and the one for the pellet burner of series ERATO GP20 COMMENT the automatic pellet burner of series ERATO GP20 has its own warranty form which should be fulfilled as well 5 11 Actions after the modules of the system are not in exploitation anymore After the lifetime period of the modules of the system have been completed then they should be treated properly in order to preserve environment contamination The units should be dismounted and disassembled p 94 60 by environmentally safe methods This requirement is most commonly completed by appropriate components recycling considering separate waste disposal and utilization methods p 55 60 6 Electrical scheme of hot water pellet boiler of series MARIO Figure 6 1 shows the principal electrical scheme of the control board of the pellet boiler of series MARIO BOILER Boiler s operating ae thermostat b Connector 7 Room thermostat E go B e lt lt Brown Alarm i E FSI boiler A DEARI E ieee Cable of Brown e T or 3 th llet L 220 7 T lt Black e pelle Phase 2 S 2 T Alarm boiler burner OS eee ao aes e ae i Gray or PA START amp Z blue E Yellow PE A _ Gray or Yellow green oe 35 a blue L OPTION 9 Ea z Flue gas fan ATTENTION the room i thermostat connector should lt blue be plugged in It has
44. r repairing 0000000ooeeenennsssssssreeereees 50 5 10 Pellet system warranty form completion ccccccccccccceeeeeeeees 54 5 11 Actions after the modules of the system are not in exploitation AnS TIME Goo sansa sts sccnseseess casa encesun EER 54 Electrical scheme of hot water pellet boiler of series MARIO 56 QUALITY CERTIFICATE ise scrceraissaacasliceaevutacedevsiavetaisterntesdsazeuaacaeceesaiets 57 WARRANTY CONDITIONS 0 000000 ccc cccccccccccssesseseeeeccceeeeeaaaaeeseeeeeeeees 58 WARRANTY SERVICE PROCEDURES LIST en 60 p 5 60 1 Main properties and advantages of the system consisting of hot water pellet boiler of series MARIO and pellet burner of series ERATO GP20 The hot water pellet boiler of series MARIO 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 described in the user manual of the pellet burner of series ERATO GP20 the resulting heat energy from thermo chemical conversion i e combustion process 1s transmitted to the circulation water in its water jacket and the heat energy is transported to the heating system consumer The system of the hot water pellet boiler of series MARIO includes e hot water boiler l s
45. s Insufficient thermal Adjustment of operating p 50 60 the supplied rooms High temperatures in the supplied rooms The _ boiler active but combustion process Difficult ignition Boiler s emergency overheating heat 1S no fuel heat capacity Low set point temperature of the boiler s operating thermostat Low set point temperature of the remote room thermostat if connected High set point temperature of the boiler s operating thermostat High set point temperature of the remote room thermostat if connected START signal is not present Low quality fuel Absence of heat consumption or incorrect adjustment of the parameters of the boiler or poor operation of the heating installation parameters of the burner 1s required check the burner s user manual 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 is necessary to decrease the set point of the boiler s operating thermostat it is recommended to keep it above 60 C It is necessary to decrease the set point of the room thermostat It is necessary to check the status of the operation signal of the pellet burner check the room thermostat START switch boiler s operating thermostat It is necessary to replace the fuel most probably due to its high moisture content which coul
46. s status e Transport auger connector which realizes power supply to the electric motor of the auger e Interface panel which is equipped with light indicators and thermal capacity control gauge p 11 60 e Transparent window though which the operation of the control board could be checked without removing the cover and any interventions e Electrically driven external for the main unit fuel transport auger which extracts the solid fuel from the bunker and delivers pellets to the main unit according to the operating mode of the burner The transport auger consists of electric gear motor a transport pipe with one end in the fuel hopper and the other end is side opened and delivers fuel to the main unit though a aperture e Flexible hose which is made of specific semitransparent thermal resistant material in case of combustion process it does not emit toxic substances and does not sustain combustion process which connects the transport auger and the main module COMMENTS Actual and detailed information for the technical information of the automatic pellet burner of series ERATO GP20 is described in its user manual Figure 2 2 External isometric view of automatic pellet burner of series ERATO GP20 The main modules of the pellet burner and their arrangement are shown of the following figure p 12 60 Fuel transport auger from the bunker to the main unit Flexible pipe Figure 2 3
47. t side then switch on the power supply of the pellet boiler of series MARIO ERATO company reserves the right to make any changes of the design and factory setting of the burner as well as the hot water boiler without obligation to inform about that the end users 4 4 13 Connect the control box of the boiler to the power supply Use the applied connectors connect the power supply cable to the boiler then connect it to the main power supply chain The connection should be performed by authorized technician only EXPLANATIONS e The producer reserves the right to make changes of the desing of the modules of the system without noticing the end user e At initial start up of the pellet burner as well as when the contents of the pellet hoper is consumed the auger must be filled up with fuel This fuel charging process is described in the automatic pellet burner s user p 34 60 manual This operation should be explained and demonstrated on the end user by trained service technician 4 4 14 Final view of the system Figure 4 13 Final view of the system hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 p 35 60 4 4 15 Recommended principal hydraulic scheme for the hot water pellet boiler Recommended principal hydraulic scheme for connecting the hot water pellet boiler of series MARIO to a heating system equipped with OPENED expansion vessel is shown on the fo
48. tive duct lid EXPLANATION this lid has thermal insulation protection plate produced from stainless steel Figure 4 9 The convective part lid is put at the place of its position p 31 60 4 4 9 Install the boiler s heat exchanger combustion chamber lid EXPLANATION this lid has thermal insulation protection plate intended to operate at high temperature levels of the flue gases in the combustion chamber of the boiler Figure 4 10 The combustion chamber lid 1s put at its position Figure 4 11 Both flue gases directing lids are positioned on their place of the hot water boiler s heat exchanger ATTENTION these flue gases directing lids are not one and the same do not change their position p 32 60 4 4 10 Connect the pellet burner of series ERATO GP20 to the hot water boiler of series MARIO Connect the automatic pellet burner to the boiler by plugging burner s connector to the boiler female connector On the back side of the hot water boiler are installed electrical connectors these connectors are for the power supply of the boiler for connecting the pellet burner for connecting a room thermostat for connecting a flue gas fan this fan is an option 1 e it is not a module of the system ATTENTION these electrical connectors are equipped with an element which prevents involuntarily detachment of the connectors do not force them use appropriate tool in order to unplug Fl
49. ts installed in the combustion chamber which provide optimal conditions for the combustion process and efficient fuel utilization p 9 60 e Ash tray is positioned on the bottom of the combustion chamber It collects the ash residue and allows easy de ashing of the boiler s heat exchanging surfaces e Inlet and outlet orifices of the inflow and outflow circulating water positioned on the back side of the boiler and are connections with female internal thread of size G12 though which the boiler is connected with the heating system e Drainage orifice is an connection with female internal thread of size G2 which should be equipped with drainage valve e Flue gas orifice is positioned in the upper part of the back side of the boiler the chimney should be connected to that flue pipe e Steel plate heat exchanger its lid and doors are insulated with mineral wood which ensures low heat loses rates to the surroundings e Control board equipped with operating thermostat controlling the operating mode of the pellet burner alarm thermostat which protects the boiler of overheating thermo manometer gauge central POWER switch and a START switch e External decorative plates produced from carbon steel color painted 2 2 Description of the pellet burner of series ERATO GP20 The automatic pellet burner of series ERATO GP20 is mounted horizontally on either on the boilers of series MARIO
50. ue gases fan connector EXPANATION the flue gas fan is an option it s not part of the system Figure 4 12 Back side view of the boiler the electrical connectors are labeled p 33 60 4 4 11 Installation of the pellet transport auger The process of pellet transport auger is described in the pellet burner s user manual At the installation of the pellet transport auger the requirements which are described in details in the automatic pellet burner of series ERATO GP20 user manual should be followed EXPLANATION The angle between the axis of the auger and horizontal plane of inclination of the transport auger influences on its productivity i e on the fuel flow rate achieved at the local conditions on the systems installation That s why at variation of the auger s inclination the burner could require adjustment of its operation mode The burner s adjustment ts done by trained authorized technician only 4 4 12 Pellet transport auger fuel charging The transport auger of the pellet burner of series ERATO GP20 is initially empty no fuel inside it s pipe The power supply plug should be connected to power supply thus the motor of the auger will operate constantly Charge the pellet hopper and wait until the pellets start to drop out of the exit orifice of the auger then unplug the power supply of the auger and connect it to the female plug of the pellet burner positioned on burner s righ
51. ve high levels of thermal comfort which is known from the popular fossil fuel based burners but the fuel is biomass based product with its advantages attractive price and ecologically oriented e Description of the construction of automatic pellet burner of series ERATO GP20 The automatic pellet burner of series ERATO GP20 is compact module based construction consisting of the following elements modules e The basis part of the pellet burner is the main unit which consists of e Combustion chamber which forms combustion domain and optimal environment for solid biomass combustion 1s designed of high quality stainless steel e Grate of the combustion chamber which could be easily detached and reveals access for ash removal e Air duct which uniformly distributes the airflow and ensures safe cooling of the elements of the burner e Electric heater which heats and ignites the fuel The heater 1s positioned beneath the inclined plate of the grate in the combustion chamber e Air supply fan equipped with Hall sensor for rotation speed monitoring e Photosensor which monitors the intensity presence of the combustion process installed aside of the combustion chamber for easy access and cleaning e Alarm thermo probe which stops and blocks burner operation in case of back fire process in the fuel delivery pipe e Control board which monitors and controls the operation of the burner and indicates it
52. xtraction out of the boiler due to uptightness of the gaskets of the hot water boiler In case of this situation it is necessary to make adjustment of the operating parameters of the burner this procedure is performed by authorized trained and certified technician only EXPLANATIONS e In ignition mode the electric heater is activated i e switched on this heater is mounted under the inclined plate in the combustion chamber of the burner This electric element heat up the fuel until the pellets are ignited and combustion process is stabilized The photo sensor of the burner senses the presence of light from the flame Additional information about the ignition process is described in the pellet burner s user manual e The automatic pellet burner of series ERATO GP20 operates by predefined algorithm which is implemented through specialized control board of the burner The adjustment of the operating parameters of the control board of the burner is performed by authorized trained and certified technician only 5 2 4 Operating parameters of the boiler The operating mode of the hot water boiler of series MARIO is defined directly by setting its operating thermostat set point However one should consider that the inflow circulating water temperature influences the operating mode of the system reflecting on its reliability and efficiency ATTENTION The producer guaranties effective and reliable operation of the s
53. xygen from the atmosphere though the free surface The increased oxygen content in the water threatens the metal of the unit as well the pipes Through the free surface of the expansion vessel water evaporation is observed as well Considering these appropriate water should be added through the expansion vessel it must cover the requirements of norm BDS 15207 81 During the heating season regular checking of circulating water level in the expansion vessel should be performed by the end user The water content in the circulating system should be kept constant If additional water is required then precautions should be taken not to add air in the heating system as well The water utilized for filling purposes of the heating system should be decontaminated and air free and is not dedicated for any other purposes but as a circulating fluid only Any heating system drainage is inadmissible 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 p 38 60 In case that additional water is required the filling process should be performed carefully when the hot water boiler is cooled to the ambient temperature This precautions are induced due to prevent rising of thermal stress of the steel boiler s body and its damage leakage In case that the boiler as well as the heating installation wi
54. ystem hot water pellet boiler of series MARIO and a pellet burner of series ERATO GP20 only when the operating mode is in the range of the parameters described in Table 3 2 of this user manual 5235 Operating parameters for adjustment of the pellet burner of series ERATO GP20 p 42 60 In the user manual of the pellet burner ERATO GP20 are given the adjustable parameters of the burner which determine the operating mode of the burner as well as the burner s thermal capacity The user accessible parameters the P2 parameter the fuel etc should be explained to the end user by the installer thus giving opportunity to control the burner according to the client s heat demands and comfort requirements EXPLANATION t is recommended to make any changes of the operating parameters of the burner ONLY when the influence of this parameters on the overall performance of the burner s operation are know in advance It is recommended to make any changes of the operating parameters by trained technician COMMENTS e Inthe user manual of the automatic pellet burner of series ERATO GP20 are shown the operating parameters which define the thermal capacity of the boiler as well as the adjustment procedure e The user manual of the pellet burner contains information about the default values the adjustment and the influence of the operating parameters of the unit their variation and adjustment should be p
55. zed technician only p 52 60 Flue The flame looks opaque and smoke is observed at the exit of the chimney Presence of unburned fuel in the ash tray of the boiler High temperature of the flue gases if flue thermometer mounted gas 1S Water vapor condensates on the surfaces of the heat exchanger gases Abnormal operation malfunctioning of burner s photocell or the Low quality pellets Inappropriate operating parameters adjustment of the pellet burner Ineffective fuel combustion process 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 burner s photocell should be checked or replaced see the pellet burner s user manual Fuel replacement is recommended most probably the moisture content is higher than required It is necessary to perform adjustment of the Operating parameters of the pellet burner and achieve efficient combustion process the adjustment should be performed by authorized technician It is necessary to perform adjustment of the Operating parameters of the burner _ the adjustment should be performed by authorized technician It is necessary to clean thoroughly the heat exchanger surfaces of the hot water pellet boiler of series MARIO Check the adjustment of the heating system It 1s
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