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Instruction for installation and operation

1. according to OENORM M7133 O ee Dry calibrated wood chips consumption rate G30 W10 A2 at kg h 7 4 nominal thermal capacity Fresh air flow rate required for kg h 53 64 effective combustion process and 5 boiler operation m h 44 53 Mass flow rate of the exhaust gases g s 19 8 Averaged dry wood chips consumption kesh 52 rate in a heating system Thermal efficiency at nominal capacity 92 5 Air excess ratio A 1 6 1 7 Flue gases temperature at nominal oC 160 170 thermal capacity The quantity depends on the Solid fuel residue ash on a Resa conditions Table 2 1 Thermal and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO at operation utilizing main fuel dry calibrated wood chips p 9 53 Parameter Dimension Value Model of the hot water boiler Pelletherm 30v2 BIO Nominal thermal capacity kW 30 Thermal capacity operation range kW 9 30 Secondary fuel e Wood pellets e Dry cherry nuts e Other dried nuts Utilized wood pellets complying ENplus ENplus Al Enplus A2 ENplus B Utilized pellets complying with boiler s producer classification methodology A AB B BC C CD D DE Wood pellet ti te at ood pellets consumption rate a igh 6 9 nominal thermal capacity Fresh air flow rate required for kg h 50 60 effective combustion process and m h 42 50 boiler operation Mass flow rate of the
2. 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 display 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 p 38 53 8 Press the green button Menu OK once more time and the process control module will exit the PARAMETER mode and will display the nominal operation process of the boiler control NOTE f any accidental change of a parameter has been made at t
3. COMMENTS 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 again The boiler is operating controlled by predefined algorithm loaded in the process control module The program itself is protected against unauthorized intrusion by a password The user can change some unlocked and unprotected parameters The meaning of any available parameter should be clear before any intervention and changes otherwise the operating results are hardly predictable and malfunction could be caused 5 2 4 Main parameters for boiler operation The following table contains parameters which define boiler s heat capacity Para Description Recommended value Dimension meter Pelletherm 30v2 BIO Wood chips feeding time T4 during this period fuel 21 0 seconds is fed to the burner T6 Wood chips combustion time fuel is not transported to the burner 16 0 seconds Table 5 1 Description of the operating parameters which define the thermal capacity of the aut
4. Electric protection IP20 Table 2 3 Dimensions and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO Parameters of the recommended main fuel dry calibrated wood chips for the hot water boilers of series Pelletherm 30v2 BIO are given in the following table p 11 53 Parameter Symbol Dimension Value ae chips particles main fraction P ou 20 Moisture content M W lt 10 Ash content A lt 1 5 Bulk density BD kg m 200 Recommended main fuel low LHV MJ kg gt 16 0 calorific value LHV kWh kg gt 4 4 Wood chips properties according to EN 14962 1 P16A M10 A3 BD200 Wood chips properties according to OENORM M7133 G30 M10 A2 Table 2 4 Recommended primary fuel properties dry calibrated wood chips The wood chips quality clacification is based on the fuel properties estimation as described in the table above In practice the fuel net calorific value depends on the fuel moisture content and is only slightly dependent on the fuel ash content The following table contain parametric data for the wood chips net calorific value as function of the moisture content and a second parameters its ash content Symbols A ash content dry base W moisture content of the raw fuel LHV fuel low heating value MJ kg kWh kg W
5. 13 Thermovalve TV 2 Safety valve 14 Return valve 3 Hot water boiler 15 Contact thermostat 4 Return valve 16 Heat accumulator 5 Circulating pump 1 17 Automatic circulating water 6 Control valve charger 7 Expansion vessel 18 Drainage valve 8 Control valve 22 Automatic air separator 9 Three way mixing valve 23 Safety valve 10 Circulating pump 2 24 Return valve 11 Control valve Table 4 1 Designation of the elements indexed on figure 4 2 4 1 Automatic hot water 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 automatic hot water boiler of series Pelletherm 30v2 BIO should be connected to the heating system utilize appropriately sized fitting according to the preliminary prepared project p 24 53 G1 1 2 842 5 1377 120 G1 1 2 G 1 2 Murypa 4 3 Back side view of heat exchanger connections of the automatic hot water boiler Pelletherm 30v2 BIO p 25 53 5 Hot water boiler installation and starting procedures ATTENTION The unit should be installed adjusted and verified ONLY by trained and authorized staff
6. Figure 3 3 External view of automatic hot water boiler of series Pelletherm 30v2 BIO top view p 19 53 Tertiary pass of flue gasses Secondary pass of flue gasses Primary pass of flue gasses Specialized pellet burner equipped with ash cleaning mechanism Figure 3 4 Cross section view of automatic hot water boiler of series Pelletherm 30 v2 BIO The flue gasses duct and streamlines are visualized as well p 20 53 4 Installation process Norms and recommendations Basic requirements for installation of automatic hot water boiler of series Pelletherm 30v2 BIO The room dedicated to mount the boiler should be supplied with fresh air supply duct necessary for optimal combustion process as well as room ventilation Installation of the unit in inhabitable premises including dwelling corridors is not allowed The hot water boiler should be connected to the heating system by authorized personal only Installation and service procedures of solid fuel hot water boilers should be performed by authorized qualified and certified personal ONLY The automatic hot water boiler of series Pelletherm 30v2 BIO 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 opera
7. located on the control panel of the equipment Is it also recommended that the equipment to be cleaned of the deposited ash It is forbidden to stop the boiler through the POWER switch at work 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 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 thermost
8. 10 W 20 W 30 AS LHV AS LHV Ad LHV MJ kg kWh kg MJ kg kWh kg MJ kg kWh kg 1 0 16 17 4 49 1 0 14 10 3 91 1 0 12 05 3 34 2 0 15 98 4 44 2 0 13 94 3 87 2 0 11 90 3 30 3 0 15 80 4 39 3 0 13 78 3 83 3 0 11 75 3 26 40 15 60 4 34 4 0 13 60 3 78 40 11 60 3 23 5 0 15 42 4 28 5 0 13 44 3 74 5 0 11 46 3 18 6 0 15 23 4 24 6 0 13 28 3 69 6 0 11 32 3 15 7 0 15 04 4 18 7 0 13 10 3 64 7 0 11 18 3 10 8 0 14 87 4 13 8 0 12 95 3 60 8 0 11 03 3 07 Table 2 5 Net calorific value of wood chips at different moisture content and different ash content p 12 53 LHV kWh kg Hf TOES oe a foo oo fo Ad Figure 2 1 Wood chips net calorific value as function of the moisture and ash content The following tables contain wood chips classification based on their characteristics according to the standard EN 14961 2010 Symbol Main fraction Fine fraction Coarse fraction maximal lt 3 15mm wood particles length mm Dimensions P16A 3 15 lt P lt 16mm lt 12 lt 3 gt 16 and all lt 31 5mm P16B 3 15 lt P lt 16mm lt 12 lt 3 gt 45 and all lt 120 mm lt 6 gt 63mm and max as 8 lt P lt 45 mm lt 8 3 5 gt 100mm all lt 120mm lt 6 gt 63mm and max PASE S SES4S mm S8 3 5 100mm all lt 350mm P63 8 lt P lt 63 mm lt 6 lt 6 gt 100 mm all
9. 4 Installation PEOCESS oo scieutstostrarsaoserutecomenverumenantstebbcareincnnsehekestinnt distant stersies 21 4 1 Automatic hot water boiler connection methodology 24 4 1 1 Connecting to the chimney cccccccccssseeceeesesteeeeeseeeees 24 4 1 2 Connecting to the heating system cccccccccsesseceeeeeeees 24 5 Hot water boiler installation and starting procedure 26 5 1 Basic fuel requirements 0 0 cccccccesscececsessececeesesseeeeeeeesseaeeeeees 26 5 2 Starting the automatic hot water boiler of series Pelletherm 30v2 BIO procedure 0 00000eeoooeeensssseseossssrrosssesersssseseessssereesssseressseseessssereesesse 27 5 2 1 Interface control board of automatic hot water boiler of series Pelletherm 30V2 BIO oonnoeeesseesssseesseressseesseressseesseressserssereessersssrees 28 p 3 53 5 2 2 Hot water boiler power supply ccccesssseceeeesseeeeeees 29 5 2 3 Hot water boiler very first start 0 00 cc ccccccceceesteeeeeeees 29 5 2 4 Main parameters for boiler operation cceccceeees 30 5 2 5 Adjustment process of the automatic hot boiler of series Pelletherm 30v2 BIO according to the thermal load of the building consumer cesta eaca trance aie Neen arene 35 5 2 6 Changing the working parameters of the process control module Siecle Clie a eee ae ae 38 5 2 7 Hot water b
10. 5 1 Basic fuel requirements e In order to achieve complete combustion of the utilized fuel it is required to use fuel which complies with fuel requirements described in the tables referring the main fuel dry calibrated wood chips and the secondary fuel as well The unit producer recommends that the fuel should be stored in dry and well ventilated rooms e It is strongly forbidden to store the fuel in close region of the boiler the minimal safety distance between the fuel and the appliance is 400 mm e The unit producer recommends an optimal distance between the boiler and the fuel container to be at least 1000mm 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
11. are not followed and fulfilled Unexpected risks The unit is designed and produced according to the requirements of the operating EU safety norms However in spite of that possible risks are considered as a result of the operating process of the boiler it is possible to get risks as follows 5 8 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 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 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 l
12. 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 26 53 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 will not be in exploitation for a long period then in order to prevent local water freezing and damages it is advisable to perform total drainage of the circulating water Please take into account that the presence of liquid in the heating system as well in the boiler will p
13. 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 The air flow rate decrease is performed by closing the air flow rate control flap installed on the air fan entrance section while the air flow rate increase is performed by opening the above mentioned flap Also the user Should pay attention especially when the fuel type changes for example switching from main fuel dry calibrated wood chips to secondary fuel wood pellets because the above two fuel types have different net calorific value It is highly recommended to perform the boiler s thermal capacity by authorized trained technician using gas analyziser e Incase of change of heat capacity parameters T4 and T6 it should be determined the ratio T4 T6 in order to verify that this ratio is in the range of the limits described in Table 5 1 5 2 5 3 or 5 4 for the appropriate fuel type 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 again pay attention to comply with the ratio requirements for the type of fuel main fuel or secondary one e It is recommended to change the value of one of the thermal capacity parameters T4 5 4 Stopping the operation of automatic hot water boiler Stopping the operation
14. lt 350mm P100 16 lt P lt 100 mm lt 4 lt 6 gt 200 mm all lt 350mm Table 2 6 Wood chips classification according to their granulometric content according to standard EN 14961 2010 p 13 53 Parameter Symbol Value M10 lt 10 M15 lt 15 M20 lt 20 M25 lt 25 Moisture MO ZD content Mee S35 M40 lt 40 M45 lt 45 M50 lt 50 M55 lt 55 M55 gt 55 max value must be specified AO 5 lt 0 5 AO 7 lt 0 7 A1 0 lt 1 0 Al 5 lt 15 A2 0 lt 2 0 Ash content A30 lt 30 A5 0 lt 5 0 A7 0 lt 7 0 A10 0 lt 10 0 A10 0 gt 10 0 max value must be specified Table 2 7 Wood chips classification according to their proximate analysis according to standard EN 14961 2010 Parameters of the recommended secondary fuel wood pellets for the hot water boiler of series Pelletherm 30v2 BIO are given in the following table Parameter Dimension Value Pellets diameter mm 6 14 Recommended net calorific value MJ kg gt 17 2 kWh kg gt 4 7 ENplus A1 ENplus A2 Wood pellets class according to ENplus Enplus B Pellet category according to unit A AB B BC C CD E producer methodology os EF Ash content See Tables 2 9 and 2 10 Moisture Max 8 10 Table 2 8 Parameters of the recommended secondary fuel wood pellets p 14 53 Wood pellets cl
15. notification and its repairing The warranty period of the unit is 24 months The warranty of the unit is valid when the original invoice document and the original warranty form are presented only p 53 53
16. 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 p 43 53 ATTENTION In 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 Completing these requirements will ensure long exploitation time of the boiler and its high efficiency and reliability 5 5 Turning OFF the boiler ATTENTION The shutdown of the equipment is done by returning the switch START in position OFF This is the recommended way of shutdown as is done etc controlled shutdown during which the relevant fans work and the emergency signals by the boiler s controller are monitored After cooling the boiler must be switched off using the switch POWER
17. only SHIFT O00 06Cc Figure 5 4 Front view of the hot water boiler main control module p 39 53 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 press the left arrow button lt 4 EXPLANATION in case that the above described procedure is 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 urypa 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 is reset After passing the reset period 30 minutes one should press the SHIFT and the OK simultaneously the press the left arrow button l
18. safety reasons this door should be kept closed p 27 53 5 2 1 Interface control board of automatic hot water boiler of series Pelletherm 30v2 BIO Alarm indicator emergency overheating Process control module Alarm indicator process malfunction Thermo manometer Operating thermostat START switch Emergency thermostat Main POWER supply switch Figure 5 1 Interface control board equipped with control and operating devices of automatic hot water boiler of series Pelletherm 30v2 BIO 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 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 p 28 53 Process control module a programmable unit that contr
19. to connect heat accumulator to the heating system which will ensure high efficiency economical and reliable operation of the boiler itself and the entire heating system in general e During the very first time of operation the boiler it is possible to observe water vapor condensation on the heat exchanging surfaces of the unit Practically this is one time process and will not affect the performance of the unit neither any problems will arise as well ATTENTION The air flow rate is crucial for optimal operation of the combustion process organized in the burner and the boiler overall operation effectiveness when the air flow rate is less than the optimal one then this insufficiency will result in incomplete combustion of the fuel as the supplied oxygen is less than required When the air flow rate is higher than optimal the result will be unsatisfying as well because the excessive air will lead to low temperatures in volume for controlled combustion and will result in incomplete combustion of the fuel s volatile gases released by the combustion process That s 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 simul
20. 0v2 BIO is steel plate hot water boiler which uses solid fuel in shape of wood chips as primary fuel and wood pellets as secondary replacement fuel The boiler is designed to be connected to local hot water heating systems as well as heating up domestic hot water The boiler uses dry calibrated wood chips or wood pellets and other solid biomass as replacement fuel The generated heat energy is transferred to the circulating hot water and is transferred to the local heating system The unit utilizes the following types of fuel Primary fuel e dry calibrated wood chips which have the following parameters of the main fraction P 20 and its moisture content is W lt 10 0 and its ash content is A lt 2 0 The fuel should cover the requirements of standard OENORM M7133 G30 W10 class Al or A2 for the ash content According to the European standard for solid biomass fuels EN 14961 1 2010 Annex 2 P16 M10 AO 7 or A1 5 BD200 e Secondary fuel e wood pellets with characteristic size diameter 6 8 upto 14 mm class ENplus Al ENplus A2 and ENplus B according to standard ENplus or having the category A AB B BC C CD E EF according to methodology developed and applied by the unit producer company e dried nuts from cherries etc e mixture of dry calibrated wood chips wood pellets and other for example in ratio 50 50 e other _ biomass in_pellet_shape but its utilization should be confirmed by the unit producer test
21. 6 1 6 1 Length mm 9 81528409 Sse Leche Bulk density kg m gt 600 gt 600 Low calorific value MJ kg gt 16 5 gt 16 5 Moisture content lt 10 lt 10 Dust at z Mechanical durability gt 97 5 SIGN a Ash content lt 0 7 lt 1 5 Ash melting point temperature IC gt 1200 gt 1100 Cl lt 0 02 lt 0 03 S lt 0 05 lt 0 05 N lt 0 3 lt 0 5 Cu mg kg lt 10 lt 10 Cr mg kg lt 10 lt 10 As mg kg lt 1 lt 1 Cd mg kg lt 0 5 lt 0 5 Hg mg kg lt 0 1 lt 0 1 Pb mg kg lt 10 lt 10 Ni mg kg lt 10 lt 10 Zn mg kg 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 w Table 2 10 ENplus European standard for wood pellets p 16 53 3 Description of the automatic hot water boiler of series Pelletherm 30v2 BIO The heat exchanger of the boiler complies with the acting requirements for such kind of units defined in operating norm EN 303 5 2000 Heating boilers for solid fuels hand and automatically fired nominal heat output up to 300 kW Terminology requirements testing and marking The unit consists of Main part of the unit is heat exchanger In the combustio
22. Automatic burner s ash removal system Semi automatic ash deposited on the surfaces of the heat exchanger pipes cleaning system 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 emissions 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 variety of solid biom
23. Graphics of the T4 parameter and power ratio fuel feeding time T4 and ratio T4 T6 values according to the thermal capacity of the automatic hot water boiler Pelletherm 30 v2 BIO at utilizing main fuel dry calibrated wood chips Fuel feeding time seconds Ratio T4 T6 9 00 18 00 24 00 30 00 24 00 Birune 3 Graphics of the p water boiler thermal capac kW ia Hie T4 and ratio T4 T6 values according to the thermal capacity of the automatic hot water boiler Pelletherm 30 v2 BIO at utilizing secondary fuel wood pellets p 37 53 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 of series Pelletherm 30v2 BIO 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 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 VF or UP A and choose the item PARAMETER
24. USER MANUAL for installation and operation of automatic hot water boiler utilizing dry calibrated wood chips of series Pelletherm 30v2 BIO http www greenecotherm eu Producer _ZMM Haskovo Plc Address Bulgaria Haskovo 6300 Saedinenie 67 blvd 7 ns aooo a eea i oo EOE TI 7777 nn Thank You for buying our product The boiler s producer company requires the installer technicians which will perform the installation maintenance and service procedures of the boilers of series Pelletherm 30v2 BIO to be trained and certified by the producer NOTE in the following document is used the designation Pelletherm 30v2 BIO which refers to the hot water boiler Pelletherm 30v2 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 USER MANUAL for installation and operation of automatic hot water boiler utilizing dry calibrated wood chips of series Pelletherm 30v2 BIO Edition 29 10 2012 15 49 CONTENTS page 1 Hot water boiler of series Pelletherm 30v2 BIO description Properties and advantages ccccecccccccessececes
25. ass fuel dry calibrated wood chips as primary fuel or as replacement fuel wood pellets dried cherry nuts etc which have ash content above the requirements of the standards ENplus EN 14961 2 2010 ONORM M7135 DIN 51731 n DINPlus High efficiency Low pollutant contents in the flue gases The unit is applicable for domestic hot water heating purposes DHW Automatic fuel feeding system transported from the built in daily hopper The control operating module can operate the function of additional external fuel feeding system which delivers fuel to the built in fuel hopper from external one The external fuel hopper could be filled with the primary fuel the dried calibrated wood chips or it can be another container for the replacement fuel for example filled with wood pellets Simplified maintenance and service procedures Minimized running costs The boiler s design allows easy detachment and attachment of its main modules considering the logistic issues as well as final positioning of the unit in the boiler s room p 7 53 p 8 53 Hot water boiler of series Pelletherm 30v2 BIO technical data Thermal and technical data of the automatic hot water boiler of series Pelletherm 30v2 BIO at operation with main fuel dry calibrated wood chips_are given in Table 2 1 Thermal and technical data of the automatic hot water boiler of series Pelletherm 30v2 BIO at operation with secondary f
26. assification according to their proximate analysis properties are given in the following table Pellets category A DU A A lt 0 6 DU 97 0 AB A lt 0 6 DU lt 97 0 B 0 6 lt A lt 1 0 DU 2 97 0 BC 0 6 lt A lt 1 0 DU lt 97 0 C 1 0 lt A lt 2 0 DU 2 97 0 CD 1 0 lt A lt 2 0 DU lt 97 0 D 2 0 lt A lt 3 0 DU gt 97 0 DE 2 0 lt A lt 3 0 DU lt 97 0 E A gt 3 0 DU gt 97 0 EF A gt 3 0 DU lt 97 0 Table 2 9 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 15 53 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 m boilers In principal the ENplus standard defines two quality classes Al u 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 Dimension ENplus Al ENplus A2 Diameter mm
27. at should be manually reset by unscrewing its preventive cap and its p 44 53 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 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 operating 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 Boiler s fuel hopper charging ropupoto ce u3cnumBa B OyHKepa Ha KOTEJA Cle KOTO TpxAOBa Ja Ce 3ATBOPH Karnaka Ha TO3H OyHKep 3a a ce OrpaHHYH HaBJIM3aHeTO Ha HeOpraHu3upaH BE3AYX pes TO3H MOMYJI oT kotea B ciy4av 4e B CHCTeMaTa e MOHTHPaH BBHIMeH WHeK 3a 3apexaHe Ha OyHKepa C TOpuBO TO TOraBa B bHIUIHHAT OYHKep OT KOHTO TO3H INHeK OTHEMA TOPHBOTO TpAOBa a bye 3apeyeH TpAOBa a be 3allbIHeH IWIHeKa C ropHBO HM ga ce MpoBepu pa orara Ha CHCTeMaTa 3a ABTOMATHYHO 3apexaHe C rOpHBO e External main fuel
28. automatic hot water boiler of series Pelletherm 30v2 p 52 53 WARRANTY CONDITIONS The producer guarantees correct and reliable operation of the unit ONLY when installation and maintenance requirements are completed The warranty period of the boiler starts from date when the warranty form is filled and stamped by the authorized organization THE WARRANTY OF THE UNIT IS NOT VALID in case one of the following is fulfilled e Unit damages caused by incorrect handling transport and or loading unloading which are not organized by the producer e Failures caused by natural disasters Earth quakes fires floods etc e Unsatisfied installation maintenance and service requirements which are described in this manual and its annex e Repairing of any failure of the unit performed by unauthorized technicians or the end user e Any changes in the design of the boiler e Incorrect heating system project design and implementation e Failures caused by factors for which the producer could not be blamed and or has no control over them e Any malfunctions or damages which are not caused by the operation of the boiler itself but result in unit damages and its functionality Every warranty service operation should be noticed in its warranty service procedures list The warranty period of the unit is interrupted by the period during which the unit is warranty serviced by authorized technicians the period between failure
29. d diameter G2 and is positioned on the lower part of rear side of the heat exchanger An appropriate drainage valve should be attached p 17 53 e Flue gases exit duct its external diameter is 150mm 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 Side view of the automatic hot water boiler of series Pelletherm 30v2 BIO The unit is designed and assembled in two main modules the heat exchanger the left one and the fuel hopper module the right one consisting of fuel hopper specialized burner fuel transport auger and control module These modules are easily detachable and could be assembled onsite if necessary The producer reserves the right to make changes of the design of the hot water boiler of series Pelletherm 30v2 BIO without obligations to inform the clients for that process p 18 53 Fuel hopper Control board Fuel proportioner Fuel transport auger Burner s ash cleaning system a Figure 3 2 Partly sectioned view of automatic hot water boiler of series Pelletherm 30v2 BIO front view External fuel delivery orifice
30. e content which could be requirements above the required value for nominal operation of the boiler it is recommended to consult the unit maintenance company Boiler s Absence of heat It is necessary to check the emergency consumption or correct operation process of the overheating incorrect adjustment heating installation and of the parameters of eventually appropriate the boiler or poor adjustment of the operating operation of the heating installation parameters of the boiler and or control valves of the installation this should be performed by authorized technician After the p 47 53 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 6 No fuel ignition Absence of fuel in the hopper The fuel hopper should be charged The boiler s operation should be restarted Absence of fuel in the burner It is possible to manually restart the operation process of the boiler This way the ignition process could be elongated If this approach results in stable ignition then it is necessary to increase the value of the initial fuel mass parameter T1 described
31. e 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 operation process of the boiler requires regular adjustment of the heat capacity parameters of the unit EXPLANATION the data shown in the following table are calculated on the assumption that the mean temperature level in the heat supplied rooms of the p 35 53 building is Tyoom 20 C If any other value is the case than refer the temperature gradient instead NOTE the value of the operating parameters T4 is determined based on the assumption that the value of the operating parameter T6 is preserved constant Tambient AT Ratio T4 T6 T4 Thermal T6 air capacity seconds seconds C C Main Wood Main Wood kW Main Wood fuel pellets fuel pellets fuel pellets 15 35 1 312 0 206 21 0 3 3 30 0 10 30 1 050 0 165 16 8 2 7 24 0 16 0 16 0 5 25 0 787 0 124 12 6 2 0 18 0 0 20 0 250 0 050 4 0 0 8 9 0 Table 5 5 Appropriate adjustments of thermal capacity parameters T4 and T6 according to the thermal load of the hot water boiler of series Pell
32. eaks are possible Operation faults and their repairing No Operation fault Cause Method for repairing p 46 53 Low temperatures in the heat supplied rooms Insufficient heat Adjustment of operating capacity parameters is required this Should be performed by authorized technician Low set point It is necessary to increase the set temperature of the point of the boiler s operating boiler s operating thermostat up to 90 C thermostat Low set point It is necessary to increase the set temperature of the point of the room thermostat remote room thermostat if connected High High set point It is necessary to decrease the temperatures in temperature of the set point of the boiler s operating the heat supplied boiler s operating thermostat it is recommended to rooms thermostat keep it above 60 C High set point It is necessary to decrease the temperature of the set point of the room thermostat remote room thermostat if connected The boiler is START signal is It is necessary to check the status active but no not present of the operation signal of any of combustion the following room thermostat process START switch boiler s operating thermostat Difficult fuel Low quality fuel or It is necessary to replace the fuel ignition its properties does most probably due to its high not comply with the moistur
33. etherm 30 v2 BIO where Tyoom Mean value of the temperature in the heated rooms C Tambient air Mean value of the ambient temperature C AT Troom Tambient air temperature gradient C 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 Pelletherm_30v2 BIO 0 25 am utilizing main fuel dry calibrated wood chips and 005 at utilizing the secondary fuel wood pellets COMMENT The above defined values of the heat capacity parameters are given for fuel which complies with the fuel requirements defined in the technical data table of the boiler In case the fuel differs from the one described in the technical data table for example its moisture content dimension of the chipped particles etc the operation parameters should be changed but the requirements for reliable and safe unit operation must be fulfilled However one p 36 53 should check if the values of some of the other main operating parameters need adjustment for example TI or T9 Fuel feeding time seconds Ratio T4 T6 1 4900 1 2900 1 0900 0 8900 0 6900 0 4900 0 2900 0 0900 24 00 9 00 18 00 24 00 30 00 Hot water boiler thermal capacity kW Figure 5 2
34. exhaust gases g s 18 6 Averaged wood pellets consumption rate the unit is operating in a popular heating kg h 4 5 system Thermal efficiency at nominal capacity 92 5 Air excess ratio A 1 6 1 7 F lue gases temperature at nominal oC 160 170 thermal capacity The quantity depends on the ash contents in the raw fuel Solid fuel residue ash avwell axoperanie conditions Table 2 2 Thermal and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO at operation utilizing secondary fuel wood pellets p 10 53 Parameter Dimension Value Model of the hot water boiler Pelletherm 30v2 BIO Weight kg 465 Water jacket capacity dm 95 dm 152 Fuel hopper capacity i Se foe Kood 100 kg wood pellets Overall dimension of the unit WxDxH mm 1515 x 850 x 1375 Class according to EN 303 5 3 Operating overpressure of the circulating MPa 0 25 water Heating system expansion vessel type Opened or closed up to l 0 25MPa Factory tested overpressure MPa 0 4 Recommended circulating water oC 80 temperature Minimal recommended return water oC 60 temperature Draught hPa 0 1 0 2 Connections Supply return flow G 1 Drainage G y Flue gases duct Hm 150 Hydraulic losses of the circulating water hPa 2 95 at nominal thermal capacity Power supply L1 N PE 50Hz 230V Electrical capacity VA 120 250 at ignition process
35. he exit of this process a summary question will be displayed CONFIRM CHANGES choose the answer NO and any changes will be canceled 9 Following the algorithm described above one can change any available parameter of the process control module and can vary the setting and the performance of the boiler NOTES e During the operating process of the boiler it is possible to arise an alarm situation for example unsuccessful ignition process fuel supply interruption etc A short description of the alarm status is written on the display of the process control module After removing the cause of the alarm situation reset the operation module The reset process of the unit is performed by switching OFF the main power supply switch and turning it back into ON position e At nominal operation process a manual ash residue removing process in the burner could be invoked by pressing the button arrow LEFT lt 4 This option is dedicated for testing the performance of the cleaning module ONLY and should NOT be activated unless testing the cleaning mechanism is required The automatic cleaning procedure is 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
36. he combustion process is greatly influenced by the presence of mineral mass i 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 automatic hot water boiler of series Pelletherm 30v2 BIO before making nominal exploitation of the unit Consult the requirement for fuel of the boiler or request the appliance producer s assistance e The fuel moisture content significantly influences the fuel net calorific value In practice the fuel moisture content in the secondary fuel wood pellets is changed in narrow range between 6 up to 10 which actually guarantees its stable and reliable properties However the moisture content of the main fuel the wood chips varies and depends on the production process their transportation method as well as the storage conditions The practice shows that in case the wood chips moisture content is increased the overall efficiency of the heating unit is decreased this also leads to increased pollutant emissions released with the exhaust gases e The producer reserves the right to change the adjustment of the unit control module operating parameters without prior notice e The tables above contains factory default values for the parameters of the settings of the process control module which lead to optimal unit adjustment and efficient bo
37. hopper charging the hopper for dry calibrated wood chips the fuel particles should be poured in the hopper after that the fuel should be smoothly spread in order to optimally utilize the hopper capacity The external fuel transport auger which extracts the fuel from this hopper and transports the chips to the boiler s hopper should also be filled with chips the entire fuel storage and automatic transport system should be carefully checked 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 5 7 Safety and unexpected risks Risks could arise at the exploitation of the boiler p 45 53 The automatic hot water boiler of series Pelletherm 30v2 BIO 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 The automatic hot water boiler of series Pelletherm 30v2 BIO is operating incorrectly e The unit is installed by unauthorized unqualified personal e The safety instructions described in this manual
38. iler 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 considering the fuel type main fuel dry calibrated wood chips or secondary fuel _wood pellets e The values of the main operating parameters T4 and T6 are due to change according to the type of the utilized fuel In case the fuel type has been changed the user should verify change the values of the above mentioned parameters considering the type of the new fuel Not complying the operating parameter adjustment could result in boiler s alarm operating mode which also decreases its lifetime and overall reliability e The automatic hot water boiler of series Pelletherm 30v2 BIO thermal capacity adjustment could be realized by weighting the fuel consumption rate the mass of the fuel transported to the specialized burner for predefined period of time the fuel net calorific value and the boiler s overall efficiency should be considered as well The following section describes the method p 34 53 o Weight the fuel consumption rate for one hour Myood chips 7 33 kg h Calculate the instant fuel consumption rate as follows the instant fuel rate is divided by 3600 1 hour 3600 seconds and the result is Mood chips 0 002036 kg s o Consider the fuel net calorific value Ayooa chips 16 17 MJ kg 16000 kJ kg The practice shows that in some cases it i
39. imal 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 600mm 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 400 1000 L S Figure 4 1 Positioning of automatic hot water boiler of series Pelletherm 30v2 BIO the minimal distances between the unit and any walls obstacles of the boiler s room are shown p 22 53 Positioning the main fuel hopper dry calibrated wood chips this hopper should be installed or build onsite and should allow easy access as well as easy fuel charging The fuel hopper design should consider the requirements for the installation of the external fuel transport auger the inclination angle of the lower hopper surfaces in order to allow free fuel flow to the extraction section a revision orifice for easy cleaning the fine fraction residues etc The design and installation of the fuel hopper should be performed by specialized trained company which have experience with the installation of such type of systems e The hot water boiler should be positioned in the boiler s room according to the requirements for attaching electrical appliances to
40. in Table 5 3 and Table 5 4 the change of that parameters is recommended to be made by authorized technician considering the type of the fuel the adjustment should be performed by authorized technician Fuel is present in the burner but it s not ignited or it is fully incinerated and the combustion process has extinguished i e not present In case that the electrical heater is out of order or not operating then it should be replaced with appropriate working one In case that the heater is working then it is necessary to increase the time for ignition of the initial mass of the fuel parameter T2 described in Table 5 3 or Table 5 4 the adjustment should be performed by authorized technician p 48 53 Abnormal operation or malfunctioning of The flue gas thermostat should be adjusted or replaced in case it the flue gas is out of order thermostat 7 The flame looks Low quality fuel or Fuel replacement is opaque and the fuel does not recommended most probably the smoke is comply with the moisture content is higher than observed at the requirements required exit of the Inappropriate It is necessary to perform chimney operating parameters adjustment of the operating adjustment parameters of the unit and achieve efficient combustion process the adjustment should be performed by authorized technician 8 Presence of Ineffect
41. ing laboratory The hot water boiler of series Pelletherm 30v2 BIO includes e hot water boiler Isp e ashtray l sp e foot screws for installation and leveling 8 sp e pair of working gloves Isp e working apron l sp e instruction manual l sp e annex of the instruction manual I sp p 5 53 The unit is equipped with p 6 53 Steel plates welded heat exchanger for heating up the circuit water Flue gas fan Fresh air supplying fan Burner s ash removal mechanism removes the ash residuum out of the burner s grate Daily fuel hopper with capacity of 150dm which allows storage of about 30kg dry calibrated wood chips the primary fuel or about a 100 kg of wood pellets as replacement fuel However the described data are tentative because the real fuel hopper capacity depends on the fuel bulk density which depend on the fuel particle overall dimensions both the wood chips and the wood pellets as well as the moisture content 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 Ash residue container with capacity of approximately 5 kg 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 Automatic fuel ignition system
42. ive fuel t is necessary to perform unburned fuel in combustion process adjustment of the operating the ash tray parameters and the air flow rate the adjustment should be performed by authorized technician 9 Alarm absence A problem in ash It is necessary to contact the of ash cleaning cleaning module service company and help of a authorized technician is required 10 High temperature The heat exchanging It is necessary to clean of the flue gases surfaces of the boiler thoroughly the heat exchanger Gf flue gas are deposited with surfaces of the boiler thermometer is ash presenting heat mounted resistive layer thus decreasing the heat exchanging intensity 11 Water vapor Low temperature of It is necessary to perform condensates on the inlet water flow adjustment of set point the surfaces of the temperature which controls the combustion circulating pump of the heating chamber system It is recommended to adjust the thermostat set point to minimum of 65 C 12 Flue gases are The flue gas fan is It is necessary to clean emitted out in the clogged or even thoroughly the flue gas fan and boiler s room blocked by fly ash its casing this should be done after certain deposits by authorized technician period of Incomplete tightness It is necessary to perform p 49 53 exploitation of the combustion chamber s door or and other flue gas duct adjustment a
43. n 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 Specialized stainless steel burner horizontally mounted in the combustion chamber of the heat exchanger Ash container positioned in the lower part of the combustion chamber below the burner Fuel hopper is mounted aside of the boiler s heat exchanger Beneath the hopper is mounted a fuel auger separator which also acts as fuel proportioner followed by horizontal transport auger The fuel proportioner prevent the so called back fire process i e ignition of the fuel in the hopper by the hot flue gases in the auger duct in case of abnormal situations Fresh air fan is mounted on the air duct of the burner The fan is equipped with position adjustable air flow rate control flap Additionally the air duct is equipped with two separate flaps for individual adjustment of the primary and secondary air flow rate 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 of size G1 2 positioned in the rear side of the heat exchanger Draining connection is internal threa
44. nd tightening of the combustion chamber s door as well as any other lids eventually change the heat resistant ropes this should be performed by authorized technician only 13 The fuel transport mechanism is not functioning The door of the fuel hopper section is opened The door s safety switch is active this door should be closed The door of the fuel hopper section is closed but the fuel transport auger is not functioning The fuel transport mechanism should be checked this should be performed by authorized technician only 14 Other failures not described above It is necessary to consult authorized technician and eventually service maintenance should be performed Ta6sanya 5 5 Description of operation faults of the hot water boiler of series Pelletherm 30v2 BIO 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 Thi
45. oiler nominal operation mode 6065 41 5 3 Adjustment of the thermal capacity of the boiler 0 42 5 3 1 Decreasing the thermal capacity of the boiler 42 5 3 2 Increasing the thermal capacity of the boiler 43 5 4 Stopping the operation of automatic hot water boiler 43 5 5 Turning OFF the bonericsiccccinncucc aiaticaieaitedtccicn ehiaavd 44 O Emergency boiler stop cccccccsssccesssssscecesessnececesssneeecesssaeeees 44 5 6 Showing and teaching the end user about the maintenance and adjustment procedures cccecccccccessscececsessecececeesneceeeesssneeececeesneeeeeeees 45 5 7 Safety and unexpected risks 0 ccccccecccceeesececeeececeeseeeeeseeeesenaees 45 5 8 Operation faults and their repairing cc eeeecccceeeesteeeeeees 46 5 9 Hot water boiler warranty form completion cccceseees 50 5 10 Actions after the unit is not in exploitation anymore 50 6 Electrical scheme of automatic hot water boiler of series Pelletherm OY 2 BIO anced aca ea dics E E cde tee daetadeu tad acales easticlietetecestuclayen O E 51 WARRANTY CONDITIONS 0000 0 ccecccccssecsssceceneceeseeceseeeesaeceeeeeeseceeaeeensees 53 p 4 53 1 Hot water boiler of series Pelletherm 30v2 BIO description properties and advantages Pelletherm 3
46. ols the functions of unit according to predefined program firmware Alarm indicator process malfunction indicates any abnormal state of the boiler for details check the information written on the process control module s display Alarm indicator emergency overheating indicates emergency overheating state of the boiler due to activation of the emergency thermostat of the boiler In case of activation cool down the unit and check and repair the reason for the emergency situation finally reset the emergency thermostat 5 2 2 Hot water boiler power supply 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 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 The unit should be connected to the main power supply according to the safety rules and appropriate norms The main fuel hopper should be filled with dry calibrated wood chips the boiler s fuel transport auger should be filled with fuel as well in order to allow uninterruptable and reliable unit operation The boiler s fuel hopper should be filled in order to allow the boiler s fuel transport auger to supply the fuel to the burne
47. omatic hot water boiler of series Pelletherm 30v2 BIO at nominal thermal capacity utilizing main fuel dry calibrated wood chips p 30 53 ATTENTION The producer guarantees effective and reliable operation of the boiler ONLY when its running conditions are in its corresponding operating range That s why if any parameter is changed it s value should be checked and verified to lie in the appropriate limits Special care should be taken to fulfill the following requirements the ratio of the described periods T4 and T6 T4 T6 should be in the following range when utilizing main fuel dry calibrated wood chips e Pelletherm 30v2 BIO Ta 0 25 lt a lt an 1 31 where ae 0 25 16 T6 16 16 defines the lower thermal capacity of the boiler corresponding to about 9kW while the ratio 1 31 defines the nominal thermal capacity of the boiler operating on dry calibrated wood chips Para Description Recommended value Dimension meter Pelletherm 30v2 BIO Wood pellets feeding time during this aA period fuel is fed to the ia secondi burner Wood pellets T6 combustion time fuel is 16 0 PREA not transported to the burner Table 5 2 Description of the operating parameters which define the thermal capacity of the automatic hot water boiler of series Pelletherm 30v2 BIO at nominal thermal capacity utilizing secondary fuel wood pellets ATTENTION The producer guarantee
48. on meter Pelletherm 30v2 BIO Period of time for conducting initial i doze of dry wood chips to the burner ka seconds T2 Maximal period of time until stable 900 ae combustion process is achieved Dry wood chips feeding time during this period the fuel is fed to the burner ca determines the heat capacity of the oa peCOnEN unit Period of time for fuel combustion after minutes ia STOP signal has been set eens seconds Wood chips not feeding time fuel is not T6 transported to the burner determines 16 0 seconds the heat capacity of the unit T7 Period of time for initial fuel doze 100 eanas combustion Period of time between two cleaning _ T9 procedures ATTENTION change the nee bes tB 02 00 h m minutes value of the period only tB Period of time which generates false TB hysteresis of the level of the fuel in the 60 seconds fuel hopper Period of time for fuel combustion TC before burner s ash cleaning mechanism 400 seconds actuation Ignition attempts counter C 1 C EXPLANATION at C 4 the boiler 4 count makes 3 three ignition attempts Table 5 3 Description of the control parameters which define nominal operating mode of the hot water boiler of series Pelletherm 30v2 BIO utilizing main fuel dry calibrated wood chips p 32 53 Para meter Description Recommended value Pelletherm 30v2 BIO Dimension TI Period of time for conducting initial doze of
49. r s grate It is recommended to keep the fuel hopper s lid closed in order to minimize the uncontrolled air flow through this module of the unit NOTE at the boiler s very first start as well as in case the fuel in the hopper has been totally consumed the fuel transport auger is emptied and need to be refilled which takes time In order to allow refilling of the fuel transport auger the boiler s operation should be restarted until the fuel reaches the entrance section of the burner s grate 5 2 3 Hot water boiler very first start The unit is switched on by the main POWER supply switch placed on the control board The unit gets activation signal by switching ON the START and goes into automatic operating mode it goes through ignition mode if needed If the START switch is OFF then the boiler goes into stand by mode and waits until new command arise In case of p 29 53 power supply break down the boiler will go into the same state of the unit before the interruption ATTENTION During the operation of the boiler when the door of the combustion chamber is opened it is possible to observe smoke leakage through the transport auger tract as well as the fuel 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
50. revent oxidation process of the metal surfaces corrosion and system failures 5 2 Starting the automatic hot water boiler of series Pelletherm 30v2 BIO procedure Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manual e Any intervention in the working process of the unit which could lead to unit s failure and or dangerous and health threatening situations are strongly prohibited e The unit should be checked by the maintenance staff or any trained 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 unit 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 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
51. s requirement is most commonly completed by appropriate components recycling considering separate waste disposal and utilization methods p 50 53 6 Electrical scheme of automatic hot water boiler of series Pelletherm 30v2 BIO Figure 6 1 and Figure 6 2 show electrical scheme of the automatic hot water boiler of series Pelletherm 30v2 BIO Motors transformer thermostats PCB N 12 14 V Pw 3 12 14V Pw 4 Figure 6 1 Electrical scheme for connecting the automatic hot water boiler of series Pelletherm 30v2 BIO to the main power supply p 51 53 Il input flame sensor 13 Start 16 back fire in auger option I8 pellet level capacitive sensor Power supply IB Actuator Potentiometer POWER N 2 SUPPLY UNIT PHOENIX CONTACT T T A alarm thermostat H O 24 V S 24V L T W boiler pies H 0 t CERMANY ee T R room thermostat T FL thermostat flue gas Capacitve sensor Actuator potentiometer 7 Feed Bt a PROCESS 220V N CONTROL Alarm Overheat N 1 KM1 2 3 L11 1 250 W N 220Vac Ignition LA 12 1 P00 1 100240 9 ACTUATOR 14K 0 25W o 24V St 24V Alain 24V St 24V St F biaa A E ignition Feed External pellet 24 V St green Air fanl Actuator Flue gas transport option amp 2 lt lt _ fan N Figure 6 2 Electrical scheme of the control board of the
52. s effective and reliable operation of the boiler ONLY when its running conditions are in its corresponding operating range That s why if any parameter is changed it s value should be checked and verified to lie in the appropriate limits Special care should be taken to fulfill the following requirements the ratio of the described periods T4 and T6 T4 T6 should be in the following range when utilizing secondary fuel wood pellets e Pelletherm 30v2 BIO oS 0 05 lt Er 0 206 where La 0 05 16 T6 16 16 defines the lower thermal capacity of the boiler corresponding to about 9kW while the ratio 0 206 defines the nominal thermal capacity of the boiler operating on wood pellets p 31 53 NOTE 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 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 Para Description Recommended value Dimensi
53. s more convenient to utilize another dimension of the calorific value kWh The wood chips complying with the automatic hot water boiler of series Pelletherm 30v2 BIO requirements have calorific value of about 4 49 kWh kg which is equal to 16 17 MJ kg o The thermal efficiency is considered stated by the producer at nominal thermal capacity Npoiter 92 5 Fo 0 925 o The thermal capacity of the boiler is calculated as follows use the boiler s efficiency the fuel calorific value in kJ kg and the instant fuel consumption rate then calculate Psie Moter H pood chips M wood chins 0 925 16170 0 002036 30 45kW In case that the calorific value of the fuel is known in dimension kWh kg then the calculation is as follows P 0 925 4 49 7 33 30 44 kW x l Ky boiler Mooiter H wood_ chips m wood _chips o Any other thermal capacity of the boiler is calculated following the described procedure above for example if the fuel has different calorific value or the required thermal capacity is lower than the nominal one The producer reserves the right to make changes of the setting of the process control module without obligations to inform the clients for that process 5 2 5 Adjustment process of the automatic hot boiler of series Pelletherm 30v2 BIO according to the thermal load of the building consumer It is recommended to make appropriate adjustments of the process control modul
54. sessececessesnececesseaeeeesseeeeeeeeseeaes 5 The unit utilizes the following types of fuel 0 cece ccceessneeeeeeeeeees 5 The unit is equipped with xc ane aene arate 6 The unit is supplied with oo ccc ccccesseececeesseeeeeesssseaeeeceesseaeeeeeeeaees 6 2 Hot water boiler of series Pelletherm 30v2 BIO technical data 8 Table 2 1 Thermal and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO at operation utilizing main fuel dry calibrated wood chips ensia va otuial AAEE EE NEEE AEE A ENEE 9 Table 2 2 Thermal and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO at operation utilizing secondary fuel wood pellets A E E E N A E E ines eudareetead 10 Table 2 4 R ded pri y fuel i dr librated d able 2 4 Recommended primary fuel properties y calibrated woo hi 12 C APIK E E E S T em ctCoamna use amaana Nudes Table 2 8 Parameters of the recommended secondary fuel wood pellets 14 Table 2 9 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in boiler s producer company sssesessssssesssessresersseresresseessressees 15 Table 2 10 ENplus European standard for wood pellets eeeeeeeeeees 16 3 Description of the automatic hot water boiler of series Pelletherm OVD BIO a a o ese sence aE ea a ERE E E E aS 17
55. t 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 40 53 5 2 7 Hot water boiler nominal operation mode After successful ignition of the fuel and when the operating temperature of circulating water is stable it could be assumed that the hot water heating boiler is in nominal thermal load This mode should be utilized in order to make adjustments of the operating parameters of the unit The parameters described in Table 5 1 and Table 5 2 and if necessary use the parameters described in Table 5 3 and Table 5 4 will define the thermal capacity 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 capacity 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 b
56. taneous 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 fuel feeding time at nominal thermal capacity and T6 fuel combustion period i e period of time when fuel is not fed to the burner which will determine the thermal capacity of the boiler according to the utilized type of fuel main fuel dry calibrated wood chips and secondary fuel wood pellets ATTENTION In case of change of the fuel type for example switching from main fuel to secondary fuel 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 of parameter T4 which will result in decreasing the fuel flow rate fuel consumption The same result p 42 53 decreasing the thermal capacity is achieved by increasing the value of parameter T6 The air flow rate should be decreased proportionally 5 3 2 Increasing the thermal capacity of 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 ATTENTION e Adjustment of the thermal
57. the power circuit the unit should be positioned in a way that will provide easy access to the power supply plug 230V 50Hz ATTENTION the installation process of the boiler is finalized by performing so called hot tests procedure of the heating installation and the warranty card is filled with the required information The recommended principal hydraulic scheme for connecting the automatic hot water boiler of series Pelletherm 30v2 BIO to the heating system is snow on the following figure 8 2423 3 l oF l E i Coldtap ha 1 water Domestic hot water pp SSsssces a From heating system f X l i i i 2 iz fa bs ao eua j7 8 Figure 4 2 Recommender principal hydraulic scheme for connecting the automatic hot water boiler of series Pelletherm 30v2 BIO to the heating system equipped with mixing valve and heat accumulator PENNA Se ee p 23 53 NOTE According to standard EN 303 5 the heat accumulator is obligatory module 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 Index Designation Index Designation 1 Hot water boiler of series 12 Water filter Pelletherm 30v2 BIO
58. ting 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 appliances safety Part 1 General requirements p 21 53 e Appliance positioning in order to achieve comfortable maintenance 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 as well as the other modules installed in this section of the boiler Min
59. uel wood pellets are given in Table 2 2 Dimensions and technical data for automatic hot water boiler of series Pelletherm 30v2 BIO are given in Table 2 3 Recommended primary fuel properties dry calibrated wood chips_ are given in Table 2 4 Net calorific value of wood chips at different moisture content and different ash content are given in Table 2 5 Classification of wood chips considering its granulometric composition according to standard EN 14961 2010 are given in Table 2 6 Wood pellets classification considering their physical properties according to standard EN 14961 2010 are given in Table 2 7 Recommended replacement fuel properties wood pellets are given in Table 2 8 Wood pellets classification considering their physical properties based on the fuel proximate analysis and categorized according to unit producer methodology is given in Table 2 9 ENplus the European standard for wood pellets is shown in Table 2 10 Parameter Dimension Value Model of the hot water boiler Pelletherm 30v2 BIO Nominal thermal capacity kW 30 Thermal capacity operation range kW 9 30 Main fuel Dry calibrated wood chips having the following characteristics dimension P 20 mm moisture W lt 7 0 ash content A lt 2 0 Characteristics of the woof chips according to EN 14962 1 P1I6A M10 A3 BD200 Characteristics of the wood chips
60. urner 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 3 and Table 5 4 for the appropriate type of fuel During the automatic ash cleaning interval a temporal decrease of the thermal capacity of the boiler is observed e Jfa 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 41 53 e In case that continuous operation in low thermal load regimes are required then it is recommended
61. wood pellets to the burner 150 seconds T2 Maximal period of time until stable combustion process is achieved 900 seconds T4 Wood pellets feeding time during this period the fuel is fed to the burner determines the heat capacity of the unit 3 3 seconds T5 Period of time for fuel combustion after STOP signal has been set 30m 00 s minutes seconds T6 Wood pellets not feeding time fuel is not transported to the burner determines the heat capacity of the unit 16 0 seconds T7 Period of time for initial fuel doze combustion 100 seconds T9 Period of time between two cleaning procedures ATTENTION change the value of the period only tB tA 00 02 tB 02 00 h m hours minutes TB Period of time which generates false hysteresis of the level of the fuel in the fuel hopper 60 seconds TC Period of time for fuel combustion before burner s ash cleaning mechanism actuation 400 seconds Ignition attempts counter C 1 EXPLANATION at C 4 the boiler makes 3 three ignition attempts count Table 5 4 Description of the control parameters which define nominal operating mode of the hot water boiler of series Pelletherm 30v2 BIO utilizing secondary fuel wood pellets p 33 53 NOTES e In principal the fuel s ash content does not change its low calorific value However t

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