Service Settings. EASY PFA Universal Biomass Heating System Controller. Technical Documentation

Transcription

1 Service Settings EASY PFA Universal Biomass Heating System Controller Technical Documentation

2 Safety Precautions Caution! Schock Hazard! Risk of electrical schock which may cause serious injuries or death. Please disconnect the mains before servicing this equipment. Caution! Hot Surfaces! The boiler assembly and/or the temperature sensors may be extremely hot which may cause serious burns. Turn off the equipment then wait at least one hour before servicing. Caution! Moving Parts! Watch your hands while servicing the moving parts such as auger assembly which may cause serious injuries. Caution! This device is intended to be professionally installed. Incorrect installation and/or operating parameters may cause dangerous conditions.

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4 Service Menu Service Settings Service Menu Map

5 Machine Settings This section adjusts the machine specific data which has already adjusted by Factory. Setting Unit Min. Max. Description Machine Type None HA HW Selects the main function of the control panel. HA: Hot Air furnace HW: Hot Water boiler Min. Power kw 1 < Max Power Max. Power kw > Min. Power Describes the minimum operational power of the burner. This value is machine specific and should not be changed before consulting the manufacturer. 99 Describes the maximum operational power of the burner. This value is machine specific and should not be changed before consulting the manufacturer. Efficiency % - 99 Describes the heat transfer ratio of the air furnace/boiler body. This value is machine specific and should not be changed before consulting the manufacturer. Feed Rate gr.min Describes the feeding capacity of the auger screw. See Feed Rate Calibration for further information. Clean Period h 4 18 Describes the maximum duration of heating cycle. After the clean period timer has been expired, software will stop the combustion and start over. Audible and/or visible warning message may appear on the display. Room Thermostat Function None LP STOP Selects the main function of room thermostat. LP (Low Power): Forces the burner to operate at lowest power if there is no heat demand. This function is recommended fora ir furnaces in order to save electricity consumption and fast start-up in case of instant heat demand. STOP: Flame outs the burner. This function is recommended for boilers. Room Thermostat Type None NO NC Control panel is compatible with all types of mechanical and electronic room thermostats. NO: Normally Opened type room thermostat NC: Normally Closed type room thermostat. Warning: Room thermostat input is DRY-CONTACT type. Do not energize the

6 input by mains. Feed Rate Calibration Software uses the Feed Rate value in order to calculate the dosage of the fuel. If you use standard DIN+ pellets, the Factory calibration will be enough. However the density of the pellets might be different. To initiate a Feed Rate calibration, a sensitive weigh scale and a stopwatch are required. Calibration Steps: Stop the boiler/air furnace and wait for cool down. Place a small container in the burner and make sure that all pellets delivered by the auger screw will captured by the container. Go to Service->I/O Test Turn on the auger screw by setting AUG = 1. Start the stopwatch at the same time. Let the auger screw run for 3 minutes. Stop the auger screw by setting AUG = 0. Scale the container. Divide the weight by 3 and set the Feed Rate with this value. Combustion Settings Setting Unit Min. Max. Description Fuel energy kwh.kg Describes the fuel energy. Refer to the pellet manufacturer s datasheet for more information. Some manufacturers describe the fuel energy in kcal.kg -1 If it is so, multiply the value by in order to convert to kwh.kg -1 Modulator None - - Control panel has three power regulation settings. PID: Proportional-Integral-Derivative Control (see Understanding PID for more information) Mod1..Mod5: Fixed output modes 5Step: 5 level modulation Modulation Window C - 10 See How does Modulation work for more information Hysterezis C - - See How does Modulation work for more information Feed Period Sec Time Base for auger screw. See Understanding Fuel Dosage for more information Exhaust Limit C - - Adjusts the maximum allowable emission temperature. If the chimney gas temperature exceeds this value, software will reduce the output power in order to prevent heat loss through the chimney.

7 Mod1 Mod5 kw See How does Modulation work for more information. Fan1 Fan5 none See How does Modulation work for more information. PID Settings Submenu See Understanding PID for more information Ventilation1 Ventilation5 none Adjusts the ventilation fan speed for air furnaces. Forced Air Cleaning none OFF ON See Forced Air Cleaning for more information. Understanding Fuel Dosage Software performs several calculations in order to deliver right amount of pellets to the burner. DC=(RP FP)/(FE FR 60 EF) Where DC: Auger screw duty cycle in seconds RP: Rated Power in kilowatts FP: Feed Period in seconds FE: Fuel Energy in kwh/kgs FR: Feed rate in gr/mins EF: Heat Exchanger Transfer Coefficient

8 How does Modulation work? Software adjusts the output power in order to maintain the boiler temperature constant. A brief information about modulation and settings in the modulation. Setpoint: Desired temperature Hysterezis: Maximum allowable overshoot of the desired temperature Modulation Window or Modulation Delta: The output power will be modulated by PID algorithm if the actual temperature is in between Setpoint-Mod.Window Setpoint. If the actual temperature is les then Setpoint-Mod.Window, the boiler will operate at maximum power. Understanding PID The PID control scheme is named after its three correcting terms, whose sum constitutes the manipulated variable (MV). The proportional, integral, and derivative terms are summed to calculate the output of the PID controller. Defining output, the final form of the PID algorithm is: as the controller where : Proportional gain, a tuning parameter : Integral gain, a tuning parameter : Derivative gain, a tuning parameter : Error : Time or instantaneous time (the present) : Variable of integration; takes on values from time 0 to the present.

9 Forced Air Cleaning Forced air cleaning helps burner to keep clean during the heating cycle by interrupting the fuel supply and blowing excess air to the burner. Applied for Waiting Time Minutes Air blasting time Seconds 0..20% of output F.A. Wait1 Observe the F.A.Clean1 Observe the % of output F.A. Wait2 combustion and F.A.Clean2 combustion and % of output F.A. Wait3 change the value F.A.Clean3 change the value % of output F.A. Wait4 if necessary F.A.Clean4 if necessary % of output F.A. Wait5 F.A.Clean5 Timing diagram: Wait Clean Wait Clean Primary fan speed and auger Auger OFF screw controlled by software Fan to MAX Ignition Settings Setting Unit Min. Max. Description Feed Time Sec - - Adjustes the initial fuel feed before ignition Timeout Min - - Adjustes the timeout for ignition. If boiler fails to ignite within Timeout a warning message will appear on the display. Fan Speed None - - Basic fan speed for ignition cycle Burn. Detect Delta C - - Temperature difference to detect flame in Burn-in Time Min - - Time delay after flame detection to routine operation Burn-in Fan Speed None - - Fan speed during the burn in time Burn-out time Sec - - Time delay to consume all pellets in the burner before shutdown Burn-out temp C - - Temperature threshold to detect flame out.

10 Flow Chart of the Ignition Cycle Pump Settings Setting Unit Min. Max. Description Startup Temp C - - Adjustes the startup threshold for pump Hysterezis C - - Adjustes the hysterezis for fump operation. Startup Temp. Hysterezis Temp. Pump Starts Pump Stops Boiler Temp.

11 I/O Test Warning! This menu is only for testing the outputs of the boiler for a short time. Leaving the boiler in Test Devices menu may cause dangerous conditions. IGN Igniter (1: ON) IN0 Not implemented PUMP Pump IN1 Limit Thermostat (1: Triggered) AUGER Auger Screw IN2 Room Thermostat (1: ON) * (1: Triggered) FAN1 Ventilation IN3 Pressure Switch Fan (0..255) (0: Triggered) FAN2 Combustion Fan (0..255) IN4 Back Burning Thermostat (0: Triggered) T1 Monitors the primary NTC sensor T2 Monitors the AUX NTC sensor TC Monitors the Chimney temperature TB Monitors the electronic board temperature * Auger motor is electrically connected to pressure switch and limit thermostat. If any of those triggered the motor will not work. Pressure switch is not available in all machines. Outputs Connector pin diagram 6.2 Sensor Connector pin diagram

12 Factory Defaults This option restores all the adjustments to Factory defaults

13 Notes: