Operating Instructions Janfire Pellet boiler Integral Typ 25

Transcription

1 _ EN_ver4 Janfire (45)

2 Due to the continuous development in methods, design and manufacture, the contents of this document may change at any time and without prior notice. Janfire do not accept any responsibility for errors or damage of any kind that be attributed to this publication. This pellet boiler is approved for the operation of an open or closed circuit hot water heating system with a permissible operating pressure of up to 3 bars and a maximum flow line temperature of 95 C. It is not permitted to operate the pellet boiler without a return flow booster. The operation of the return flow booster is to be monitored. A 4-way mixing valve is sufficient as a return flow booster on systems with a buffer tank. The boilers supplied by Janfire are stationary units that comply with the WEEE Directive. The electrical and electronic components contained in the boilers do not fall within the remit of this directive and will therefore not be taken back by Janfire. Please take these components to the recycling depot. We do not assume any liability for any malfunctions resulting from the use of non-genuine Janfire Components. This particularly applies to control units, external materials handling equipment and fuel pipes from other manufacturers. We also do not assume any liability for operational difficulties resulting from inadequate hydraulic and/or exhaust gas systems. We reserve the right to make technical changes. Permissible fuel It is only permitted to operate this pellet boiler with fuels that comply with the Federal Emission Control Ordinance (wood pellets manufactured from natural wood). Permissible pellets have a diameter of 6mm or 10mm. The pellets must comply with the EN-Plus standard or the PVA standard (Austrian Pellet Association). The fine fraction (proportion of pellets with a length of less than 10mm) is not permitted to exceed 8% in the pellet hopper. The volume density must be less than 0.75kg/l. Other fuels, in particular pellets that contain recycled materials, may not be used. The specified cleaning interval applies to pellets that comply with the EN-Plus standard. For reasons of operational safety and environmental protection the use of fuels other than pellets that comply with the EN-Plus or EN Class A1 standards is not permissible _ EN_ver4 Janfire (45)

3 Contents 1.1 General Conventions Safety Instructions for Installation and Service CE declaration Chimney Connection Technical Data Boiler Maintenance Ash Removal and Sweeping Sweeping Handle Emptying the Ashtray Boiler Control Panel Boiler Buttons and Controls Setting of Operating Temperature Start the Pellet Burner Stop the Pellet Burner from the boiler Start the Circulation Pump Stop the Circulation Pump Operational Description Modulated power regulation Gliding boiler temperature in function of outdoor temperature Burner Maintenance Menu System Target temperature Volume Adjustment Energy Value Choice of Effect Value Starting the Burner Starting the Burner after the Installation Stopping the Burner Pellets Filling Cleaning the Burner Cleaning the Dosage Auger Trouble-Shooting Red warning light shine -The Burner has stopped Yellow Control Lamp; Burner Running To low Effect from the Burner The Burner Display is of Fuses Adjusting the Capacity Sensor Electrical Connection Plan _ EN_ver4 Janfire (45)

4 1 Safety Information 1.1 General The safety information is based on a risk analysis that has been undertaken in accordance with the directions in relevant EU directives in order to meet the European CE marking standards. In practice, the pellet boiler does not convey any risks during operation. Read through the safety information before you carry out any maintenance on the boiler. Always follow the safety instructions when you carry out maintenance work. Follow the safety instructions on the warning labels! Installation, operation, service and other procedures must only be carried out by trained and qualified personnel and in accordance with applicable standards. Note Always follow these instructions during maintenance of the boiler. Note For reasons of personal and operational safety: Use only spare parts that are manufactured and approved by Janfire AB. 1.2 Conventions The following conventions are used in these instructions: DANGER! The text DANGER! is used when there is a risk of personal injury or death. WARNING! The text WARNING! is used when there is a risk of damage to the product, the equipment, the control panel etc. CAUTION! The text CAUTION! is used when there is a risk of system failure, interruption to operation, disruption etc. The above warning texts are used in a hierarchical order. The text DANGER! also includes the possibility of the occurrence of incidents that are represented by WARNING! or CAUTION! _ EN_ver4 Janfire (45)

5 1.3 Safety Instructions for Installation and Service All electrical installation and servicing must be carried out by qualified personnel in accordance with applicable standards and regulations. All heating, ventilation and sanitation installation and servicing must be carried out by qualified personnel in accordance with applicable standards and regulations. All sweeping must be carried out by qualified personnel in accordance with applicable standards and regulations. DANGER High Voltage inside this equipment DANGER Risk of burns Note The free space around the Janfire pellet boiler should be in accordance with BBR-94 (SWE) and local regulations (council planning department). The boiler room should meet the requirements of the fire authorities. Contact a qualified local chimney sweeping contractor. The boiler is equipped with a safety cut-out that prevents operation of the burner with the door open. 1.4 CE declaration If the unit is used in combinations other than those tested, then Janfire AB can not guarantee conformity with the EU directive. Please consult your heating installer about the precise system set-up. 1.5 Chimney Connection The exhaust gas duct to the chimney should be as short as possible, without any bends and installed at a slight incline. The connection to the chimney should have an aerodynamic design that curves upward. The connector joining the furnace and the chimney must comply with EN :2004 and have the required identification marking (CE). In accordance with EN :2004 non-insulated _ EN_ver4 Janfire (45)

6 connectors must be kept at least 40 cm away from combustible components. We recommend the use of insulated connectors. Calculated chimney diameters that are smaller than the flue gas connections of the boiler are not permissible. See technical data. Please note: Please note that the low exhaust temperatures occurring during prolonged operation may mean that it is necessary to fit a moisture-resistant chimney. Before connecting the pellet boiler to an existing chimney, subject it to a chimney calculation or obtain a chimney report. Before commencing with the installation it is essential to obtain the approval of your local master chimney sweeper. An insufficient draft or a dirty flue gas system will be detected by the burner via the temperature sensors. The display unit of the burner control unit will then display the fault message flue draft insufficient. Should this occur, the control lamp will switch to yellow and thereby show that the burner is in emergency operation mode. The display unit will then alternately show the above fault message and the fault message reduced output. If the problem cannot be handled by reducing the output of the burner and dangerous temperatures occur at the sensors, the burner will be switched off once the upper temperature limit is Chimney connection The exhaust gas duct to the chimney should be as short as possible, without any bends and installed at a slight incline. The connection to the chimney should have an aerodynamic design that curves upward. The connector joining the furnace and the chimney must comply with EN :2004 and have the required identification marking (CE). In accordance with EN :2004 noninsulated connectors must be kept at least 40 cm away from combustible components. We recommend the use of insulated connectors _ EN_ver4 Janfire (45)

7 2 Technical Data Janfire Integral typ 25 Pellet Boiler Power Load Stand by power Measurement accuracy of water temperature sensor Minimum return water temperature Output 230 V AC ± 10 %, 50 Hz 3 VA 2 W C ± 1 C 55 C 23 kw Boiler class according EN Relay output Fuse Water volume Waterside resistance 10/20K Maximum operation pressure Ash/fire box Weight Boiler Type Flue connection Convection part 5 A 250 V AC 6.3 A T 180 litres 25,3/14,1 mbar 3 bar 100 litres 280 kg Not Condensing under pressure controlled Backwards Ø 145 mm Vertical tubes Operation thermostat Adjustable intervals up to 15 C Flue gas thermometer Use of Sweeping Shunt/Mixing Valve Hot water Control panel Safety cut-out Required Draft in furnace Exhaust temperature nominal/min load Exhaust mass flue nominal/min load Combustion period Fuel Noise emission Option Automatic controlled Mounted together with hot water flange OBS Option High efficiency heat exchange coil Ø 22 mm L=11m, OBS Option Digital display with surface mounted switches Mounted on the top of the door 10 Pascal 145/73 C 0,013/0,05 kg/sec Cleaning manual after use of 6 tonnes pellets Wood Pellets EN Plus size Ø 6-12 mm 61 db _ EN_ver4 Janfire (45)

8 Accessories A Automatic sweeping Periodic controlled Placed on the left side. B Automatic ash outflow Placed on the left or the right side. C D E Location for Electric heater Boiler Operator Panel Burner Operator Panel Option up to 9 kw A D C E B Figure 1 Automatic sweeping and ash outflow _ EN_ver4 Janfire (45)

9 Figure 2 Janfire Pellet Boiler dimensions General _ EN_ver4 Janfire (45)

10 The Janfire pellet boiler is designed to burn wood pellets in a safe, easy-to-use and environmentally friendly way. The boiler has ten vertical tubes which effectively cool down the flue gases and through thermal convection raise the temperature of the water. The tubes are also equipped with retarders. The boiler is equipped with a large door. The door has a prepared hole suitable for installation of the burner. When the door is opened the burner remains on the door. This makes it very easy to clean the combustion chamber and burner. The door is also equipped with a safety cut-out which stops the burner when the door is opened. Recommended boiler temperature: Winter: 85 C +/- 3 C Summer: 83 C +/- 3 C Note Pellet quality EN Class A1 is recommended _ EN_ver4 Janfire (45)

11 Inbuilt Exhaust fan House, Fan Option Water mixer valve with drive Hatch for access to the tubes Operator panel Soot sweeping mechanism Domestic Hot Water Coil, Option Location for Electric Coil, Option Pellets Burner Ash bottom auger screw Bottom auger Drive Figure 3 Overview _ EN_ver4 Janfire (45)

12 3 Boiler Maintenance During normal use (6-8 tonnes per year) of pellets of EN class A1 the maximum interval for cleaning the boiler is months. 3.1 Ash Removal and Sweeping 1. Stop the burner, see burner instructions. 2. Wait for approximately 30 minutes until all the pellets are no longer glowing. 3. Open the door of the combustion chamber. Remove the baffle plate (see Figures) DANGER Risk of burns Note The boiler and burner can still be hot. 4. Clean out the ash. The Janfire ash can makes the job easier. 5. Open the upper hatch (see Figure 3 Overview) above the tubes and take out the spirals _ EN_ver4 Janfire (45)

13 6. Use the sweeping brush to clean the ten tubes. 7. Reassemble the spirals and screw down the upper hatch. CAUTION Breakdown Note Do not forget to clean the boiler flue so that soot does not prevent the smoke from going out into the chimney. 3.2 Sweeping Handle Sweeping starts automatically and is controlled by the boiler thermostat and a timer. Sweeping frequency is set as standard 1 minute every hour. If the boiler is not equipped with automatic handle sweeping then you should manually use the sweeping handle (OBS Option) at least once a week. Pull the handle quickly 3-5 times on each occasion _ EN_ver4 Janfire (45)

14 3.3 Emptying the Ashtray After the burning of about 1.5 t of pellets (depends strongly on the quality of pellets used), the ash tray must be emptied. Wearing of protective gloves is recommended. Ensure the hot ashes are not put into a container that either contains combustible materials or that is combustible itself. 4 Boiler Control Panel Boiler The switch panel controls the boiler pump and the burner. During operation the following can be read on the display of the control panel: Water temperature Actual Temperature Figure 4 Control Panel Thermostat P2 P _ EN_ver4 Janfire (45)

15 P 3 Figure 5 Temperature limiter Figure 6 Ash timer 4.1 Buttons and Controls Button Push Info P1 P2 P3 Thermostat Ash timer Actual Start/Stop the pellet burner Start/top the circulation pump Temperature limiter Change set point of water temperature Setting for on time off time ash removal and tube sweeping Adjusted from factory. No need for adjustment _ EN_ver4 Janfire (45)

16 Button Push Info Temperature Setting of Operating Temperature Turn the thermostat knob to the desired temperature normaly between C If the boiler temperature is below the desired value, the burner will be allowed to start Start the Pellet Burner Push the P1 button in On possition, The burner will illuminate and start if the boiler thermostat is demanding heat Stop the Pellet Burner from the boiler. Push the P1 button to off possition. The Burner stops emmidiately Start the Circulation Pump Push the ON button P2 and the the pump will start Stop the Circulation Pump Push the OFF button P _ EN_ver4 Janfire (45)

17 Figure 7 Dimension drawing NH-burner _ EN_ver4 Janfire (45)

18 5 Operational Description 5.1 General operation description An external auger feeds pellets from an pellet store via flexible drope tube and in to a receptacle in the burner (internal storage). An internal dosage auger then feeds the pellets to a drop shaft where they fall freely into the combustion chamber; this eliminates the possibility of reverse combustion. A fan feeds the burner with primary and secondary air. On its way to the burning cup the air cools heat-exposed parts of the burner effectively warming up the incoming primary and secondary air. A specific amount of air is fed into the combustion cup for primary and secondary combustion. The ignition coil preheats the air for automatic ignition. The thermometer (flame guard) notes when the pellets have ignited. If ignition does not succeed then the burning cup is automatically cleaned and a new attempt is made. If ignition still does not successful then the burner is shut down. If the airflow is insufficient then the hot flu gases will rise in the drop shaft. The burner control will register this rise in temperature with an temperature sensor and the burner will compensate by reducing the effect, thus eliminating the risk for reverse combustion. When this takes place the control lamp changes colour to yellow to indicate that the system is running in backup level and Low chimney flow will appear on the display screen. If the temperature drops to normal levels the burner control will return to normal operation but will continue to illuminate the yellow light warning of draft problems in the boiler or chimney. If the temperature in the drop shaft still rises and reaches the highest limit, then the burner will shut down.. The control lamp will turn red and Overheated will appear on the display screen. The burner output can be set in the burner control operator menu and is determined by the desired level of heat required, set between 6kW and 25kW (factory settings and permissible min/max level can be adjusted by the installer) Burner output is adjusted in 1kW steps and is governed by the burner thermostat sensor. In addition an optional pilot operation will continue to maintain combustion until further heat is in demand. The pellet feed rate at a given output is automatically adjusted when the lambda sensor is installed. Otherwise the volume weight of the pellets is entered into the burner control in order to allow the burner to adjust the pellet feed rate. The volume weight is typically 675 g / litre with energy content of 4.8 kwh / kg. In order to secure power and combustion in use of pellets with another volume weight or energy, change value of the volume and energy and pellets. Optimal burner performance can also be controlled with the (optional) installation of temperature sensor PT100, allowing the burner to automatically modulate up or down in relation to the heat demand. Alternative to using the modulation function the burner will operate between min and max temperature settings, heating until the desired temperature has been reached at the boiler thermostat _ EN_ver4 Janfire (45)

19 High quality pellets produce high efficiency and effect. High quality pellets are solid wood pellets 6-10 mm with little sawdust. Moisture levels should be no higher than 12%, ash content no higher than 1% weight, and energy content should be about 4,7 and 5,0 kwh/kg. Make sure you see a content declaration for the pellets on delivery.. The burner has a patented moving grate in the bottom of the combustion cup which scrapes away soot and ash residue into the boilers firebox. This ensures the combustion grate holes are kept clean to maintain the burner performance. The burner automatically cleans itself according to a signal from the boilers thermostat or from pre-programmed intervals (use of pellet) Additionally the boiler tubes are swept clean according to the thermostate and the time period set in the boiler control. Thermo switch in the upper part of drop shaft breaks power to burner if the temperature there exceeds 70 C. Manual reset through breaking power to burner, wait until burner cools down and connect the power again. A micro switch prevents the burner from operating when detached from the boiler bulk head. Figure 8 Micro switch The moving grate of the combustion cup scrapes away slag and waste material, feeding it into the boilers firebox according to a signal from the boilers thermostat or from pre-programmed intervals (number of fillings) The moving grate in operational position The moving grate in cleaning position Figure 9 Moving grate _ EN_ver4 Janfire (45)

20 Support (Accessories) Engine gearbox external auger External auger Boiler Drop tube Capacity sensor Internal pellets storage Dosage auger Drop shaft Burning chamber Inlet Figure 10. Function description 5.2 Modulated power regulation Contact for temperature sensors In order to be able to use the modulation function a Pt100 sensor connection is provided on the side of the burner.. The aim of this function is to save on fuel consumption and enhance operational efficiency while reducing the number of cycles per hour. Janfire's intelligent control system monitors the heating system demand trends and modulates the boiler output accordingly. This makes for quick and smooth response at maximum output when the demand is high and progressively drops and settles on low output when the heat load is nearly fulfilled. temperature decreases in the boiler. Difference of objectives temperature is set at +7 C to the regulation should have a little larger area to work in. It is at this temperature field burner to work best in. If or when the temperature comes up for the higher limit (when the heat consumption is lower than the Burner's lowest power) breaking the operation and the burner goes into standby or maintenance _ EN_ver4 Janfire (45)

21 The burner will restart the combustion operation again when the lower temperature limit (3C lower than target temperature) has been reached. Boiler temperature hysteresis is 10C from maximum target temperature (-3 C to +7C from target) When using the mody modulation function please set the boiler operating temperature above the +7C maximum level. If the PT100 temperature sensor is not connected to the burners control unit then the control will revert to the boiler thermostat and the system will operate using the set permanent set output level. If there is no boiler thermostat then breaking the operation and alarm "ERROR " are available. 5.3 Gliding boiler temperature in function of outdoor temperature This function regulates the temperature in the boiler depending on outside temperature as follows: Warmer outdoors lower boiler temperature and vice versa. Colder outdoor temperature create higher boiler temperature. In this way boiler temperature is adapted to outdoor temperature fluctuations during the day and during season cycles. With an outside temperature sensor type Pt 100 linked to the burner, the temperature is regulated in the boiler as follows: +20 C or higher out C boiler temperature -20 C or less absent C boiler temperature For outdoor temperatures between the specified limits obtained a sliding boiler temperature target value so, for example, at 0 C is target 75 C. 73 C [ ] In the above example: current boiler temperature calculated target temperature (gliding target value) temperature thermostat switched on at the current target temperature (this is 3 C for target value) temperature of the thermostat off at the current target temperature (7 C above target value) The outdoor temperature average value is calculated by measuring the outdoor temperature over 5 minute intervals. This is compared with the the previous value and once considered the boiler temperature is adjusted. Boiler temperature target value is adjusted 1C per interval whether is is measured greater tolerance than 1C. When the estimated target temperature approaching 90 C, the temperature limit for the thermostat off is adjusted to a maximum of 92 C. It is only +2 C above at 90 C although it is set to +7 C above target temperature thus the control system ensures optimal performance and protects the boiler from overheating. Identical level of control features exist for the low level limit which is restricted to 55C _ EN_ver4 Janfire (45)

22 6 Burner Maintenance Thanks to a new patented technique the Janfire NH Pellets burner has the least need of maintenance of all pellets burners on the market. The burner can run for 6 months at a time without maintenance (applicable for burners mounted on Janfire boilers). When mounted on an existing boiler the ash handling varies depending on the size of the boilers ash container. CAUTION Breakdown For optimal and safe operation it is important that all adjustments of the burner s operational parameters are correct. We recommend that you sign a service agreement with your retailer. NOTE Regularly check that the gasket around the burner is not damaged _ EN_ver4 Janfire (45)

23 6.1 Menu System A B C D E Figure 11 Menu system Janfire NH Control panel A B C D E Control lamp: Green = Normal, Yellow = Warning, Red = Error Start/Stop A press will stop all activities in the burner (complete), a new press and the burner is continuing where it left off. Reduce value Increase value Scroll menu (quick press). Save/confirm value (press for three seconds) Adjustment of the contrast in the display is made with the "+" and "-" buttons. The change can be made only when the display shows the status and operation information. By pressing and hold down the "+" button to be increased and by "-" reduced the contrast. In order to save the new setting, press and hold the "menu" button for a few second, until the confirmation appears: "saving in mind." NOTE: When not pressing any buttons for 1 minutes, display light tones down and is lit again through pressing some off buttons NOTE: When not pressing any buttons for 5 minutes, the status mode will automatically appear in the display. Menu System for the Janfire NH One press on the on/off button stops all activities in the burner. Press again and it continues where it left off _ EN_ver4 Janfire (45)

24 On start up status will be shown in the display. When not pressing any buttons for 5 minutes, the status mode will appear in the display automatically. Every press of the menu button scrolls through the menu list below. Adjustments are done using the - and + buttons and must be saved by pressing the menu button for 3 seconds ( save to memory appears on the display ). Status: This shows the present status information; it can show errors or running status etc. Boiler temperature 73 C < > Shown only on modulating regulation is elected at boiler temperature over 40 C. (In the example: 73 - the current temp, 75 target value; 72 - thermostats switched on, 82 off the thermostat). Target value amended by + / - and saved. Pellets use: Displays pellet consumption: total and changeable. Reset by pressing and holding down the "menu" button until the value is reset. Choose effect level: Here you can choose what effect you want to use. Any amendment must be saved. Ash scraping: Ash scrape every 18 kg (x, xxxkg). Here is determined how much the pellets should be consumed before the automatic ash scraping performed. As an aside, displayed up-to-date pellets consumption after last cleaning Volume settings: The correct level can be supplied by your pellets supplier or by weighing. Energy level: Your pellets supplier can supply the correct level. Automatic start with start-up: Choose if the burner should automatically start when the power is turn on. This function should always be on if the burner can start after a power cut. Running down: Is used when you wish to remove the ash from the boiler. Running down function runs in three sequences, begin cooling, burning cup scraping and then combustion stop. Pressing the menu button for more than 3 seconds activates this.. NOTE This function is shown only when the burner is running. Manuell feeding: Press and hold down the + button and the dosage auger will run until the button is released. NOTE This function is shown only when the burner is stopped. Manual external auger: Press and hold down the + button and the dosage auger will run until the button is released or when the level meter in the filling tube is effected. NOTE This function is shown only when the burner is stopped _ EN_ver4 Janfire (45)

25 6.2 Target temperature Boiler temperature appears only if modulating control is activated, and boiler temperature is over 40 C. 73 C < > In the above example: current boiler temperature target temperature (preferred boiler temperature target value) temperature thermostat switched on (this is 3 C below target value) temperature switched the thermostat off (this is the 7 C above target value) To change target temperature Scroll through the menu until you come to "boiler temperature" and change "-" and the "+" and save by pressing the "menu" of three seconds. Note that in the amendment of the desired boiler temperature limits to the thermostat and off (socalled hysteresis - in the example +7 C / -3 C) is included. Other limits and hysteresis can be set by the installer. 6.3 Pellets counter We show pellet consumption in kg: total and reset to zero. Reset by pressing and holding down the "menu" button until the value is reset. 6.4 Volume Adjustment Volume weight: XXX g/l _ EN_ver4 Janfire (45)

26 To achieve the best combustion and least exhaust a correct level for the volume weight of the pellets is needed. The correct level can be supplied by your pellets supplier or by weighing. 675 g/l is the standard level, which is the average weight per liter pellets. When adjusting the levels the dosage time is also changed (normally 1 sec.) to compensate for and discrepancies and to ensure good combustion. To change: Scroll in the menu until you come to volume weight xxx g/l and change with - and +. To save the new level by pressing and holding down the menu button for 3 seconds. Weighing: Fill a 1-liter container with pellets and weight it on a scale. Take away the containers weight. 6.5 Energy Value To achieve the best combustion and least exhaust a correct energy value for the pellets is needed. Your pellets supplier can supply the correct level. 4,80 kwh/kg is the standard level, which is the average energy per kilogram pellets. To change: Scroll in the menu until you come to volume weight xxx g/l and change with - and +. To save the new level by pressing and holding down the menu button for 3 seconds. 6.6 Choice of Effect Value Press and scroll through the menu button until you come to Choose effect level xx kw By pressing + or - buttons you can choose increase or decrease the power between the effect levels. To save the new level; press and hold down the menu button for 3 seconds. The effect can be selected between 6 and 15 kw. This is the standard setting. Limits for min and max power levels can be changed between 3 and 23 kw. This is carried out by the installation engineer and in consultation with the customer depending on the need for heating, boiler type, size of the chimney etc. 6.7 Starting the Burner 1. Place the burner into the boiler and lock it in place on both sides WARNING Product damage _ EN_ver4 Janfire (45)

27 NOTE The burner should be fitted securely so that no embers or smoke are released. A non-airtight connection can lead to a worse combustion and function. 2. Check that there are sufficient pellets in the external storage. The pellets level should not be lower than the external augers inlet. 3. Check that the power cables between the burner and boiler and between the boiler and the external auger are connected. Control that the drop tube between the external motor and the burner is secure. 4. Switch on main power. NOTE The main power switch is usually located on the wall next to the boiler or by the entrance to the boiler room. 5. Switch on the power to the burner (the switch is on the boiler) and the boiler will start automatically at the 12 kw effect level (Auto start at restart) 6. The change to the desired effect: Scroll the menu button until you come to Choose effect xx kw. Change the value be pressing the + and - buttons. Save the new level by pressing and holding down the menu button for 3 seconds, Saved to memory will appear on the display screen. OBS! The next time the burner is started, it will run in the last saved power level 7. To achieve a good combustion with low exhaust the values of the pellets volume weight and energy value has to be correct. The correct level can be supplied by your pellets supplier or by weighing. To change; scroll the menu button and change the value be pressing the + and - buttons. Save the new value by pressing and holding down the menu button for 3 seconds If the boilers thermostat is on, then the internal storage is filled (approx. 2 min.) if the pellets level is below the sensor. The burning cut is then cleaned. The start sequence then begins. Pellets are feed in, the ignition spiral warms up and the fan starts. The start sequence is pre-programmed to deliver a fast ignition and exhaust levels as low as possible. The start-up runs for about 10 minutes after which the chosen effect level begins. 6.8 Starting the Burner after the Installation NOTE It is important that when starting up for the first time that the internal storage and the dosage auger are full with pellets. 1. Switch on the power to the burner. After 2 minutes the external screw starts. The feeding stops after 2 minutes. If the internal storage is not filled within 2 minutes press the ON/OFF button and the auger will continue to feed. Continue this process until the correct level is reached. When the internal storage is full a sensor stops the external auger. The external auger can be used manually: Scroll the menu until you come to manual external auger, then press and hold the + button to start the motor. Fill until the burners internal storage is full. The motor will stop when the + button is released or when the internal storage sensor is activated. Since the automatic system will normally Auto start at restart and will try _ EN_ver4 Janfire (45)

28 to continue press the ON/OFF button to stop the burner. Stopped manually will appear on the display screen. Manual pellets feeding is only possible when the system is off 2. Since the internal storage has been filled the internal feeding auger must also be filled. This can be done manually by scrolling the menu button until you come to Manual feeding, then press and hold the + button to start the motor, let it run until pellets start to fall into the burning cup. The motor will stop when the + button is released. 3. Press the ON/OFF button to start the burner Keep Alive (kindling) burning is automatically selected from the thermostat stand by time is less than 1 hour (the standard setting). In Keep alive goes burner in a sharply lowered power (0.6 kw), which is burning up and running and enable quick power increase after thermostats switched on. At first OF on the thermostat after the start is not used maintenance. OF time (shorter or longer than 1 hour) determines whether the next OF maintenance should be used or not. 6.9 Stopping the Burner The burner can be stopped in the following ways: NOTE Shut Down in the user menu is recommended stop if not the stop caused by danger. Shut down in the menu when it is time to remove the ash the burner should be cooled and scraped. This function is only activated when the burner is running by scrolling though the menu until you comes to Shut down. Press and hold down the Menu button for 3 seconds to activate. Control that the fan has stopped and that the scraping is complete. This can take up to 10 minutes depending on the programme chosen. Manually stopped will appear on the display screen and the control lamp will turn red. Switch off the main power if you wish the burner to remain shut down. This will ensure that the burner will not start accidentally at a power failure. Press the ON/OFF button to stop the burner Stopped manually will appear on the display screen. All of the burner s functions will stop. This is standby. Pressing the ON/OFF button again restarts the burner at the point when it was stopped. (It can continue in standby mode or cool down, scrap clean and begin a new start up depending on how long it was turned off). Switch off the main power if you wish the burner to remain shut down. NOTE Use the ON/OFF button for stop only in emergency situation and let the burner remain in the boiler until it cool down. This to avoid injuries and overheating of the burner _ EN_ver4 Janfire (45)

29 NOTE Do not switch off the main power until the fan has stopped. NOTE Always switch off the power at the mains when the burner is to be off for a longer period or when servicing the burner. The main power switch is usually located on the wall next to the boiler or by the entrance to the boiler room _ EN_ver4 Janfire (45)

30 6.10 Pellets Filling The external auger can only feed the pellets to the burner if the external storage level is above the external augers inlet. NOTE Add pellets to the external storage when needed. DANGER Rotating parts NOTE Do not touch the dosage auger or the external augers in- or outlet when the external motor is connected Cleaning the Burner 1. Stop the burner according to the instructions in chapter Wait for 30 minutes until all glowing pellets has burnt out. 3. Disconnect the burner and roll it away from the boiler. DANGER Risk of burns NOTE The burner and the burning chamber can still be hot. 4. Lift the plate out with a pair of insulated pliers or wear protective gloves _ EN_ver4 Janfire (45)

31 5. Clean the plate and the burning chamber carefully. Use a vacuum cleaner together with the Janfire ash container (accessory). 6. Pour about 0.5 dl water on the scraper and burner cup. Water dissolves hard slag on the scraper. Let it dissolve for a few minutes and then wipe with a cloth. CAUTION Breakdown NOTE The plate s surface must rest tight on the burning chamber surface. All dirt between the surfaces must be removed. 7. Remove ash from the boiler. Open all doors to reach all convection areas and flue gas pipes. The Janfire ash container makes this procedure easier. NOTE Do not forget to clean around the smoke pipe so that no ash prevents the smoke to reach the chimney. Put the plate back in place _ EN_ver4 Janfire (45)

32 6.12 Cleaning the Dosage Auger 1. Switch off the power to the burner. NOTE The main power switch is usually located on the wall next to the boiler or by the entrance to the boiler room. 2. Remove the lid from the drop shaft and clean the dosage auger with a screwdriver. Use a hammer (if necessary) to remove stuck pellets. DANGER Rotating parts NOTE Do not touch the dosage auger or the external augers in- or outlet when the external motor is operational. 3. Switch on the main power. 4. Press the on/off button to stop the burner. 5. Start feeding away pellets remainders by pressing the menu button until you reach Manuel feeding in the menu and press the + button to start the motor. Continue feeding until you see good quality pellets in the auger _ EN_ver4 Janfire (45)

33 7 Trouble-Shooting 7.1 Display status texts JANFIRE AB Version 3.02 UK Startup underway Try 1 3 min Running 12,00kW Waiting Maintenance mm:ss Defaults sets Release buttons Saving in memory Heating up Step 1 mm:ss Manual stop Waiting. Shutdown activated Now shut down waiting Wait! Cooling down burner Waiting for pellets! Limit. run Start text at power up, shows program version Shows that burner lightning up, and time elapsed Run mode, actual power level Burner has shut down, waiting for thermostat Shows time elapsed in maintenance mode Default values have successfully being set Setting is being saved Transition to run mode from maintenance, a manual stop or after power failure. When burner is stopped with on/off button Burner is shut down via function in User menu, ash scraper will be activated when burner cooled down. Burner is shut down. Cooling burner bowl to reach limit in service menu 48 Filling up internal pellets storage Running with reduced power, poor chimney flow _ EN_ver4 Janfire (45)

34 ERROR MESSAGES PROBLEM A warning. Is shown when something is wrong and burner is taking actions to compensate this.. ERROR An alarm message. Burner is stopped due to an error that burner could not compensate for.!!! Problem!!! Ashscraper!!! ERROR!!! Ashscraper!!! Problem!!! Startsequence!!! Probblem!!! Fan stopped!!! ERROR!!! Fan stopped!!!problem!!! Flameguard trip.!!! Problem!!! Low chimney flow!! Problem!!! Service needed!!! ERROR!!! Not cooled down!!! ERROR!!! External feed Maximum time elapsed for ash scraper. Scrape cycle finished successfully on new attempt Ash scraper did not success scrape cycle despite several attempts Flame guard did not activate in time, new start attempt. Warning is reset after successful start. Tachometer can t sense fan rotation. Any other activity will be stopped until fan runs properly. Warning will be reset when fan starts No rotation signal from fan despite several restart tries. Flameguard tripped during run mode, low temperatures I burner bowl. One start attempt will be made. Temperature to high in drop shaft, service menu 49 Burner power level will be reduced until temperature decreases. Warning has to be acknowledged by pressing on/off twice (Stop and start). Pellets consumption has passed setting in service menu 59 Call your Janfire installer for accurate service. Cooling did not succeed within 20 minutes Internal pellets storage not filled within time period!!! ERROR!!! Drop shaft temperature exceeds maximum level _ EN_ver4 Janfire (45)

35 Overheated!!! ERROR!!! "Electronics Fault"!!! ERROR!!! Temp. senor Indicated an error in the outgoing electricity supply to extern auger, internal auger or heating coil. Indicated an error in the Temperature sensors (burner bowl or drop shaft sensors) has an unstable value. 7.2 Red warning light shine -The Burner has stopped Event Probable cause Action The green lamp on the control panel has gone out and the burner has no voltage. The fuse has blown. Reset the fuse (see chapter5). The burner will start automatically. Should the fuse blow again contact your Janfire retailer or a service technician. The control lamp shows red!!! ERROR!!! hot burner The feeding of the external auger has stopped. The control lamp shows red!!! ERROR!!! External The safety thermostat for the boiler has been turned off. Insufficient low-pressure caused by over heated burner. The external storage is empty. The drop tube is stuck with pellets. The level of the capacity sensor has been altered. The drop tube between the external augers outlet and the burner s inlet has come loose. Strange objects in the auger (gravel, cloth etc) which prevents the auger from rotating. Reset the safety thermostat (see the operating instructions for the boiler) Check the draught. Turn off the main switch Clean the boiler and flue pipes according to instructions. Inspect and clean the chimney. Fill the external storage with pellets. Adjust the capacity sensor Mount the drop tube and start the burner according to instructions. Knock carefully on the auger with a rubber/plastic hammer while you run the motor manually until the object comes loose and the auger rotates correctly again. Should this not work the auger may have to be dismounted. Contact your Janfire retailer _ EN_ver4 Janfire (45)

36 Event Probable cause Action Hollowing or crater in the external pellets storage. Level the pellets in the external storage. Control lamp turns red!!! ERROR!!! burner disconnected Ash scraper is stuck!!! ERROR!!! ash scraper The pellets get stuck in the tube and does not reach the burner. The tube between the external auger and the burner is to loose or the tube angle is insufficient. The burner has been disconnected from the boiler Faulty circuit breaker or incorrectly adjusted circuit breaker. The ash in the burning chamber sinters to hard slag. Insufficient pellet quality. Check if the pellets are stuck at the external augers outlet. Clean if necessary. Stretch the tube, increase the angle of the tube. Connect the burner to the boiler. Press ON/OFF to start. Adjust or replace. Contact your Janfire retailer for assistance. Remove the slag from the burning chamber. Lower the amount of feedings for ash scraping. Press ON/OFF to start Ash scrape is stuck Ignition is not working. Pellets may be stuck between the scraper and the burning chamber Remove pieces of pellets from the burning chamber. Press ON/OFF to start If this problem occurs again contact your Janfire retailer. NOTE: Do not switch the scraper to lose it, with the hammer or the like. In this way, damage to the gearbox occur The ash sintered in burner cup to a tough cookie. Pellets of poor quality. Remove the slag from burner cup Reduce the number of kg before ach cleaning. Press "on / off" to start Black deposits of tar and carbon on the scraper do it difficult to scrape clean. The cause of incorrect set pellets volume with poor combustion as a result. Scrape clean scraper manually with a knife, chisel or the like. Weigh pellet and set the correct value for volume weight. If the error repeats itself contact the dealer for a control of combustion. Dark grey slag on scraper caused by high temperatures in burner cup.. Pour about 0.5 dl water on the scraper and burner cup. Water dissolves hard coatings on the scraper. Let it ache for a few minutes and then wipe with a cloth. Start the burner. The ignition is not working. Unburned pellets have wedges itself between the scraper and burner cup Remove stuck pellet from burner cup. Press the "ON / OFF 'to start If the error repeats itself, contact the service technician _ EN_ver4 Janfire (45)

37 Event Probable cause Action Ash scrape position switch is badly adjusted or broken. Ash scrape runs back and forth without activating position switch. Call your service technicians to fix the error. Flame guard has been activated: The control lamp turns red.!!! ERROR!!! Ignition Ignition has not occurred or a faulty ignition coil. Bad quality pellet. The level of pellet in the burning chamber is to low. Check that pellets are fed to the dosage auger before the start. Contact your Janfire retailer or a service technician to replace the ignition coil. Change to better quality pellet. Insufficient low-pressure in the boiler can cause disturbance in augers due to tar (sticky) This will make the dosage auger stop. Strange objects in the pellets or damp pellets causing the dosage auger to stop. The fan is not correctly adjusted. Check values for the boilers low-pressure. (carried out by Janfire retailer or a service technician). Remove the damp pellets or the strange object. Contact your Janfire retailer or a service technician. The control lamp turns red!!! ERROR!!! Fan The display shows "Electronic Fault The control lamp turns red!! ERROR!! Temp Sensor The display shows!!! ERROR!!! Bad thermostat The fan is faulty. Mechanical obstacle that prevents the fan from operating. The software has detected an irregular condition. Temperature sensors (burner bowl or drop shaft sensors) has an unstable value. Control box receives reading from boiler sensor outside accepted range (0 120 C ). Contact your Janfire retailer or a service technician. 1.) Turn system OFF at main system s switch. Turn back on after 10 seconds. If error still persists, go to the following steps. 2.) Check connection to external auger. 3.) Check the fuse to heating coil 4.) If fault continues, Contact your Janfire retailer or a service technician. 1.) Turn system OFF at main switch. Turn back on after 10 seconds. If error still persists, Contact your Janfire retailer or a service technician. 1.) Check boiler sensor connections. 2.) If error still persists, Contact your Janfire retailer or a service technician _ EN_ver4 Janfire (45)

38 Event Probable cause Action If display completely blank/no read-out Tripped manual reset high limit or low water cut-off; bad fuse or. incorrect boiler sensor value. 1.) Check fuses. 2.) Check if main switch is in ON position 3.) Check if burner connector is plugged in. in system (See boiler manual). If 4.) Check if error light on low-water cutoff is on. If so, press reset and top off water problem persists, call MESys trained service technician. 5.) Check manual reset high limit. Press button. If burner operates, wait and check. If problem persists, Contact your Janfire retailer or a service technician. 6.) PT100 sensor for boiler water sensing may be defective. Contact your Janfire retailer or a service technician _ EN_ver4 Janfire (45)

39 7.3 Yellow Control Lamp; Burner Running Event Probable cause Action Control lamp turns yellow The burner still running. The display shows: reduced effect or running Insufficient draught or ash or soot between the boiler and smoke pipe or foreign objects in the chimney that prevents the smoke from getting out. The lamp indicates that the burner is trying to compensate (reduced effect in the display) or has tried to compensate insufficient draught by reducing the effect. The lamp will remain yellow until the burner has been restarted to indicate that there has been a problem with insufficient draught. Turn off the main switch. Clean the boiler and the flue pipes according to instructions. Inspect and clean the chimney. If necessary check the draught _ EN_ver4 Janfire (45)

40 7.4 To low Effect from the Burner Event Probable cause Action The burner does not create enough effect. The choosen level of effect is to low. Insufficient pellets quality. Increase the level of effect (see chapter 0). Contact your pellets distributor and demand a quality declaration. Adjust the volume (see chapter 0). To high or to low low-pressure in the boiler. The adjusted values for the boiler or the burner are not correct. Check by holding a match in front of a small opening on the boiler (for instance open a door slightly). The flame shall lean towards the boiler but not burn out. Contact your Janfire retailer or a service technician if you are uncertain. Check the protocol from the installation and contact your Janfire retailer or a service technician The feed auger bearing runs sluggish Contact your Janfire retailer or a service technician _ EN_ver4 Janfire (45)

41 7.5 The Burner Display is of Event Probable cause Action Display and indicator diodes Flashing No activity in the burner. Overheating safety thermal contact has tripped. Burning overheat. Cut the power to the burner. If the burner is still hot, let it cool first and turn on the power again. If the burner is already cold, wait for about min and turn on the power. If the display does not come on, break the power again and wait a few minutes and try again. Display and indicator diodes has gone off completely. No activity in the burner. If no actions from the row above delivers results- Broken electronics Contact your dealer or Janfire service technician. Display and diodes has gone off completely. The Diode on the level sensor is still lighting. The burner run normal The display is broken or the wiring between the controlunit and the display is broken. Contact your dealer or Janfire service technician _ EN_ver4 Janfire (45)

42 7.5 Fuses If the automatic fuse has blown the red button comes out. The fuse is reset by pressing the red button. 6A Automatic fuse. 6,3 A (5x20 mm) fast (F) blow fuse protects the ignition heating coil. Figure 11 Fuses _ EN_ver4 Janfire (45)

43 7.6 Adjusting the Capacity Sensor The capacity sensor on the burner is pre-set. The setting may alter during transportation or after some time (two weeks) during operation and will have to be adjusted. 1. Stop the burner. The main switch must be left on so that the burner has voltage. 2. Remove the drop tube from the burner s inlet. 3. Check the diode with your finger. The sensor should be lit at a distance of 8-9 mm (see figure below). 4. Use a small screwdriver to remove the protective plug. Turn the adjustable screw until you get the correct distance (8-9 mm). Anti-clockwise means less sensitivity, i.e. reacting at a shorter distance. Clockwise means higher sensitivity, i.e. reacting at a longer distance. 8-9mm Protective plug Diode Figure 1 Capacity sensor Adjustable screw NOTE The adjustable screw is very sensitive, only a few degrees are necessary. Do not screw to tight. 5. Mount the drop tube _ EN_ver4 Janfire (45)