PV1000agri pellet burner

Transcription

1 PV1000agri pellet burner User manual POOLELI - DRAFT

2 PV1000agri pellet burner p 1/ 50 Description Main components 1 Contents 2 Description Main components Specifications Installation Prerequisites Burner Water sprinkler External auger Pellet storage Electrical connections Commissioning Operation and maintenance User interface Starting and stopping Statuses and parameters Cleaning Replacing components Optional components GSM Modem Flue gas fan Common problems and solutions Annex A ameters Annex B Burner status change logic Annex C Controller board description... 49

3 PV1000agri pellet burner p 2/ 50 Description Main components Tables Table 1 PV1000agri connectors ( * optional extras) Table 2 Info menu description Table 3 Summary of burner statuses Table 4 List of tests in TESTING status Table 5 Cleaning parameters Table 6 Loading parameters Table 7 Ignition parameters Table 8 Pre-burn parameters Table 9 Heat-up parameters Table 10 Power levels Table 11 Hold flame parameters Table 12 End burn parameters Table 13 End blow parameters... 37

4 PV1000agri pellet burner p 3/ 50 Description Main components 2 Description PV1000Agri is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. Due to the unique design of the burning chamber you can use industrial pellets to fuel the burner. You cannot use any other form of fuel to run this burner. The construction of the burner allows it to be used with different boilers: liquid fuel, solid fuel and universal boilers. The burner is connected to the boiler using a connection plate. The burner is equipped with a safety thermostat, a melting hose, temperature sensor, sprinkler system (optional) and auxiliary battery for protection against back-burning.

5 PV1000agri pellet burner p 4/ 50 Description Main components 2.1 Main components

6 PV1000agri pellet burner p 5/ 50 Description Main components No Name Description 1 Burning chamber The part of the burner that is inside the boiler and where pellets are burnt. 2 Burner body The part of the burner that is outside the boiler. 3 User interface Screen, navigation buttons and indication lights. For more information, please see chapter Control box Contains inverters, fuses, relays, main controller board etc. 5 Water sprinkler Sprinkler system will spray water to extinguish the fire in case of back burning. The sprinkler system is only activated when the temperature of inner auger rises dangerously high. 6 Grate cleaning motor Linear motor moves the grates in burning chamber and pushes ash out from burning chamber. This cleaning cycle is made periodically. The interval between cleaning cycles can be managed by parameter 48. In each cleaning cycle, the linear motor pulls grates back then pushes the grates completely out and then pulls the grates on the half way. The linear motor has 75mm stroke and end switches for stop. Linear motor current limit can be set by parameter 47. There is also fuse F10 installed on the controller board (board version BBB v2.1) 7 Igniter Igniter s purpose is to ignite loaded fuel making the burning process start. Igniter is installed on the burner together with igniter holding pipe. PV1000agri has total four igniters. 8 Brick temperature sensor A sensor to adjust burner start up speed according to temperature rise. Brick temperature rise speed must be controlled to extend its lifetime. 9 Cleaning hatch Hatch below burning chamber to ease the removal of ash under grates. 10 Grates support frame Holds moving and stationary grates in correct position. 11 Grates Cast iron grates form fire bed and distribute combustion air through holes in grates. Some of the grates are moving to periodically clean the burning chamber. 12 Fire bricks Heat resistant bricks that cover the burning chamber. Bricks are necessary for proper airflow and combustion. 13 Flame sensor Photocell s purpose is to recognize flame in the burning chamber. 14 Level sensor Optical fuel level sensors recognize the fuel level in the vertical pipe. Fuel is recognized when pellets pass the optical beam between sensors. 15 Combustion air fans Primary fan delivers main burning air needed for gasification of the fuel. Primary air is also used to burn the gasified fuel (charcoal) and to ignite the pellets together with igniters. Left primary Right - Secondary Secondary fan blows air through burning chamber back-wall and holds burning quality and optimal flue gas content. If oxygen sensor (optional) is used the secondary fan speed is regulated by oxygen level in flue gases. Both fans rotation speed is measured by sensor, installed near the impeller axle. The sensor is reading magnetic field changes caused by magnet installed on the impeller axle. 16 Controller board Controller board controls the burner s burning process, by calculating fuel amount also feeder and auger work during burning process. Depending on the input signals from the sensors, controller makes necessary changes to the output states to maximize burning efficiency. Controller has a single control board. 17 GSM modem (optional) 18 Internal feeder motors A GSM modem enables burner to send SMS messages with various information of burner s operating states (errors). GSM modem is located in controller unit. More information in chapter 5.1 Internal feeders are used to deliver correct amount of fuel into burning chamber. Delivered fuel amount is regulated by periodical work of feeder gear motors. 24V DC motors are supplied from backup battery to empty feeder tubes in case of power failure. 19 Battery When there is no power from the main power supply then the burner is operating on battery power. PV1000 uses two 12V 3,4 Ah batteries. Because the battery is a safety element, the

7 PV1000agri pellet burner p 6/ 50 Description Specifications 20 Internal feeder screw 21 Pressure sensor connection burner checks batteries condition and does not start the next working cycle if the batteries voltage is too low. Hollow spiral connected to feeder motor to transport pellets into burning chamber. Screw is not tightened to motor, but has small slack. It lowers the mechanical stress and expands gearmotor lifetime. Metal tube to connect pressure sensor input. Pressure sensor measures draught in burning chamber and enables the controller to regulate flue gas fan speed. 2.2 Specifications ameter Unit PV1000agri L total length mm 1300 L1 burner body length mm 630 L2 burning chamber length mm 690 H total height mm 620 H1 burner chamber height mm 550 W total width mm 710 W1 burner housing width mm 620 Mass kg 290 Supply voltage VAC 0 Power max W 620 Power at standby W 7 Noise db 58 Emission class 1-5 Operating temperature C o Nominal heat input kw 1000

8 PV1000agri pellet burner p 7/ 50 Description Specifications Figure 1 Dimensions Figure 2 Dimensions

9 PV1000agri pellet burner p 8/ 50 Description Specifications Figure 3 Dimensions

10 PV1000agri pellet burner p 9/ 50 Installation Prerequisites 3 Installation 3.1 Prerequisites In order to install the burner, the boiler must meet to the following requirements: Recommended to use three pass boilers. The construction of the boiler must make it possible to open the door of the boiler with the burner connected and removing ash from the furnace. If the door of the boiler is too narrow for opening it with the burner, then extra hinges must be installed. If there is not sufficient (less than 5Pa) negative pressure in the furnace, a draught fan should be installed for the exhaust gases. The boiler must be positioned in a way that there is enough space for cleaning the burner, the boiler, the smoke pipe and removing the ash. The burning chamber must not touch the bottom of the boilers furnace (min 10cm distance needed). The boiler room where the burner is installed must fulfill all rules and recommendations given by local authorities. Boiler room must provide constant air supply of 1500 m³ per hour (ca cm2 air inlet opening). In order to install the burner to the boiler door, there must be mounting holes as shown below. D hole for burning chamber neck D1 flange bolt ring diameter D2bolt holes a bolt hole offset angle Unit PV 1000 mm 400 mm 490 mm 6x13 deg 30 deg angle between bolt holes 60 Figure 4 Boiler door mounting hole Note: If the burner is installed to the boiler, the door or the installation flange s thickness should be 8-14mm.

11 PV1000agri pellet burner p 10/ 50 Installation Burner 3.2 Burner Mount the burning chamber on the inner side of the boiler door. Figure 5 Use 6 M12x60mm bolts, spacers and distance nuts respective to the bolts Figure 6

12 PV1000agri pellet burner p 11/ 50 Installation Burner Install the insulation rope between the burning chamber and the boiler door. The rope must be installed near the outer perimeter of the burning chambers back wall. Figure 7 Grate holders installation Install the burning chambers bottom panel (15x15mm insulation rope must be inserted to the slot in the panel) with 6 M8x16mm bolts. Install the burning chambers front panel (heat shield), use M8x16mm bolts. Figure 8

13 PV1000agri pellet burner p 12/ 50 Installation Burner Connect the static grate holders with the side stone holders separately and install them together into the burning chamber as a frame. Fix them with M8x16mm bolts to the burning chamber. Figure 9 Connect the moving grate holders with M6x12mm bolts. Figure 10

14 PV1000agri pellet burner p 13/ 50 Installation Burner Install the burning chambers front brick holders, use M8x16mm bolts. Figure 11

15 PV1000agri pellet burner p 14/ 50 Installation Burner Release the igniter tube screws and while inside the holders pull the tubes out about half of the total length. Move the air separator to its correct position (according to the boiler door thickness) and fix it with screws. Figure 12

16 PV1000agri pellet burner p 15/ 50 Installation Burner Install the ceramic sealing strips on the boiler door. Fix them temporarily in position with any ordinary cellophane tape (scotch). Cut away the excessive sealing on the perimeter of the air chamber. Figure 13 Mount the burner body on the boiler door, using 4 M12x70mm bolts and respective washers. Figure 14

17 PV1000agri pellet burner p 16/ 50 Installation Burner Push the igniter tubes through the burning chambers back wall and fix them in position with M4 screws. Figure 15 Connect the linear actuator with the moving grate holder. Use 27x2,5mm pipe (length 240mm), M8x45mm bolt for the burning chamber side and a M6x25 socket set screw (DIN914 45H) on the actuator side. Figure 16

18 PV1000agri pellet burner p 17/ 50 Installation Burner Push the stone temperature sensor through the hole in the burner body and the pipe on the burning chambers back wall, isolate it from the air flow (accessible from the burning chamber side) with ceramic sealing to prevent cold air from tampering with the measurements. Figure 17 Install the 8 lower position grates with 5mm holes. Install the 8 higher position grates with 7mm holes. Figure 18

19 PV1000agri pellet burner p 18/ 50 Installation Burner Install the ceramic paper on the back wall of the burning chamber. Install the back wall stones on the burning chambers back wall. ATTENTION!: Care must be taken not to damage the temperature sensor! Figure 19 Push the stone temperature sensor into the opening in the back wall stone. Install the upper grate holder and 2 upper grates. Fix the holder with M10 wing nuts Figure 20

20 PV1000agri pellet burner p 19/ 50 Installation Water sprinkler Install the 6 side bricks. Install the 6 arc-stones. ATTENTION!: The arc-stones are numbered, they must be installed as pairs! Figure Water sprinkler Water sprinkler is main safety element against back burning. It is strongly recommended to install sprinkler system. In Figure 22, water supply line and pressure switch is used. Pressure switch allows starting the burner only if water supply is present. If no water is available on installation site, reservoir can be filled manually. In this case, pressure switch is not connected to safety circuit as there is no pressure in water system. In case of back burning, sprinklers will open and extinguish fire in feeder tubes. Flow control valve limits the amount of water flowing into burner after the reservoir is emptied. The burning chamber must be cleaned from wet ash and pellets before turning the burner back on again.

21 PV1000agri pellet burner p 20/ 50 Installation External auger Figure 22 Sprinkler installation 3.4 External auger The external auger transports pellets from the pellet container to the burner. The burner controls the work of the auger. The auger is connected to the burner with a special hose ( 80), which is made from easily melting material that acts as a safety measure against back-burning. PV1000Agri pellet burner s fuel consumption at full power is about kg of pellets per hour ( 3,3-3,7 kg per minute ). External auger s productivity must be at least 270kg of pellets per hour. The auger can be fixed to the storage or a ceiling depending on the conditions at the installation site. Requirements for auger installation: The raising angle of the auger must not exceed 45 The end of the exit tube of the auger and the input of the burner must not be aligned. The recommended minimal horizontal distance is 20cm.

22 PV1000agri pellet burner p 21/ 50 Installation Pellet storage The distance between the input of the burner and the exit tube of the auger must be at least 60cm vertically recommended distance is cm. Hose between auger and burner must be tight, otherwise pellets will block the auger. Falling angle must me between 65 and 85. Figure 23 External auger installation 3.5 Pellet storage Pellets must be stored in a dry and ventilated room that is separated from the boiler room. A purpose built silo is recommended. All safety regulation must be taken into consideration according to the local laws. It is recommended to wear a respirator when handling pellets. Refilling must be carried out before the storage runs empty. 3.6 Electrical connections Table 1 PV1000agri connectors Nr. Name Color, type Signals X11 Power, thermostat black F/ brown F 230V 3A, 230V X12 Main Power supply black F 3x380V 16A X13 Safety circuit white M 230V X14 Pellet auger 1 black M 3x380V 0,55kW 1,6A X15 Ash augers white M 230V 90W X15* Pellet auger 2 black M 3x380V 0,55kW 1,6A X16 Secondary fan white M 3x230V 0,18kW 1,4A X17 Ignitors black M 2x500W 2,2A X21 Fluegas fan white M 3x230V max 1,5kW X21* Fluegas inverter brown M V, 24V DC X22 Modbus Brown M 24V DC X23 Pt100/4..20mA sensors Green M 24V DC X24* Level sensors Brown M 24V DC X25* by request X26 Primary fan white M 3x230V 0,18kW 1,4A X27 Ignitors black M 2x500W 2,2A

23 PV1000agri pellet burner p 22/ 50 Installation Electrical connections * optional extras Figure 24 Connector markings Burner is designed to work at 230V. Boiler should be equipped with thermostat or external switch between plug X11 pin T1 and T2 for turning on/off the pellet burner. Internal feeder is equipped with motor thermal protection, which prevents motor from overheating. As soon as the nominal trip temperature (TNF) of the sensor set point is exceeded, the relay detects this variation and the output relay cuts off the power to the motor. Burner can be equipped with optional lambda sensor. It provides efficient control for optimal performance concentrating emissions and burning efficiency. Lambda sensor output range has linear relationship with following points: 0 % O² % O² - 20 ma ma

24 PV1000agri pellet burner p 23/ 50 Installation Electrical connections

25 PV1000agri pellet burner p 24/ 50 Installation Electrical connections

26 PV1000agri pellet burner p 25/ 50 Installation Electrical connections

27 PV1000agri pellet burner p 26/ 50 Installation Commissioning 3.7 Commissioning Prior to the initial start-up of the burner make sure that: The burner is connected to the boiler The boiler thermostat is installed and is functioning properly The feeding auger of the burner is installed and connected to the burner The smoke duct is connected to the chimney, the dampers for smoke gases are open and there is sufficient draught. When the burner is operating, the negative pressure inside the furnace must stay between 5-20 Pa Sprinkler system is connected and pressure switch connected to safety circuit (chapter 3.3). Phase and neutral wires in power cable are connected properly....

28 PV1000agri pellet burner p 27/ 50 Operation and maintenance User interface 4 Operation and maintenance 4.1 User interface The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log etc. Yellow light (2) shows the presence of flame in burning chamber. Or if blinking, the burner is out of normal operation. Status can be seen on log screen. Green light (3) indicates if there is fuel in the burner. Navigation buttons enable to move in menus and make changes in parameters setup. Burner on/off switch (4) can be used any time to turn on or off the burner. Using this switch, the burner will make all necessary action to safely stop or start the burning process. Figure 25 User interface 1 4x20 character display 2 Yellow LED, indicates if flame is detected in burning chamber 3 Green LED, indicates if pellets are present in internal feeder 4 Burner on/off switch with power indication light. 5 Burner operation light, showing if the boiler thermostat sends a signal to the burner. 6 Fault light 7 - GSM modem antenna

29 PV1000agri pellet burner p 28/ 50 Operation and maintenance User interface Figure 26 Main menu structure Status info screen displays last events (burner states) and their duration. The duration is in form mm:ss ( m in the middle) or hh:mm ( h in the middle). For example Igniting 01m25 means the burner ignition state lasted 1minute and 25 seconds. Last row of the log shows current state. To reach the last row, press the down button, until you reach the current state. The duration of current state updates every second or minute. Info menu Info menu is useful to troubleshoot various problems. It gives access to some input signals and internal parameters. Use up and down arrows to scroll through info menu.

30 PV1000agri pellet burner p 29/ 50 Operation and maintenance Starting and stopping Note: Comma, is used as decimal separator. Table 2 Info menu description Screen text Pwr 00/550 kw Tstn=181 0 C T1= C Fan=10/13±2 14/15 Δp=-0,2/-15Pa Total=10 kg Count=12,1 kg 180/254 U=25V68 I=0.0A Ver=2.02c 19/12/12 Description Current and maximum power. Max power can be changed from main menu. Tstn fire brick temperature, T1 - PT 10 primary fan actual speed, 13 primary fan setpoint speed. Actual speed is controlled to match setpoint speed. ±2 - Base air value. Controller tries to keep speed setpoint + base air. In this case controller keeps speed 15rps. Speed unit is rps (revolutions per second). 14/15 same as above for secondary fan. Base air setting is same ±2 Burning chamber pressure value. -0,2 is current measured pressure and -15 is setpoint. Controller regulates flue gas fan speed to keep this pressure. Depends also on PAR60 value. Roughly the amount of pellets burnt. It is measured by counting internal feeder rotations. Number is reset by firmware upgrade Roughly the amount of pellets burnt, resettable by user. U - DC power voltage 25V68 means 25.68V. I Feeders and/or grate motor current Firmware version and date 4.2 Starting and stopping To turn on the burner, switch on boiler main switch. If burner displays Stopped, then go to STATUS menu and change parameter Burner from ON to OFF. The display shows Waiting. Now turn boiler thermostat to desired temperature. The burner will go to Loading-state. If this is the first run, external auger needs to fill up with pellets. It can take as long as 20minutes. 4.3 Statuses and parameters PV1000agri pellet burner operates in many different states, which are called Status. Current and previous statuses can be seen from user interface panel (chapter 4.1). Burner changes its status based on input signals from sensors and user. Below are given the statuses in order of typical working cycle. Table 3 Summary of burner statuses Status Waiting Testing Cleaning Loading Igniting Pre-burn Heat up Burning Hold flame End burn Short description Waiting signal from boiler thermostat Thermostat is switched on, testing battery, fans, feeder, level sensors, draft Ash removing from burning chamber Loading pellets with auger into burner and by feeder into burning chamber Igniter is turned on, pellets igniting Flame is recognized, small amount of pellets is added by feeder Burning chamber Ceramic is heated up Normal burning operation Thermostat is switched off, small flame is held alive Thermostat is switched off, feeder is cleaned up

31 PV1000agri pellet burner p 30/ 50 Operation and maintenance Statuses and parameters End Blow Waiting Pellet coals in burning chamber is burned, flame has disappeared Wait signal from boiler thermostat Waiting In this status, the burner is waiting signal from boiler thermostat. There is no limit time for waiting status. Only internal feeder is working periodically at Waiting time ½ rotations after every 2 minutes. When signal comes from the thermostat, burner will go to Testing. Testing At Testing time, burner integrity and important device functioning is checked. Table 4 List of tests in TESTING status Test name nr. Value Unit Test conditions Battery voltage - 22 V Battery loading is turned OFF and feeder is turned ON - voltage must be greater than 12V Feeder current A Feeder is turned ON feeder current must be smaller than 46 Draft Pa All fans are turned on. Draft must be under 62 Primary fan 4 38 rot Fan must rotate faster than 35rot = 38 (4) - 3 Secondary fan 4 38 rot Fan must rotate faster than 35rot = 38 (4) - 3 Cleaning In Cleaning cycle, the linear actuator moves the grates and pushes out from burning chamber the ash and residues. The cleaning cycle has been divided into 3 steps: 1. Grates are pulled fully in to actuator end limit. 2. Grates are pushed fully out to actuator end limit. 3. Grates are pulled in, actuator works 4 seconds. Table 5 Cleaning parameters name nr. Value Unit Test conditions Cleaning cycle interval Actuator max. current min Burning time between Cleaning cycles. If 0 then cleaning is turned off. If burned longer then 2x 48 then forced cleaning is made A Actuator maximum current level. If greater, then actuator is stopped and cleaning cycle is started

32 PV1000agri pellet burner p 31/ 50 Operation and maintenance Statuses and parameters again. Actuator min. current A If smaller, then actuator is stopped and running direction can be changed. Max. move time - 58 sec Maximum time to move actuator to one direction. Max. cleaning time sec Maximum Cleaning cycle time Loading In the Loading cycle, pellet auger is turned on. When pellet level in the burner reaches to level sensors, internal feeder is started. Feeder loads correct amount of fuel into burning chamber needed for ignition. Loaded fuel amount is measured by counting internal feeder rotations. Loading cycle is ended when feeder is made correct amount of rotations, fixed in parameter nr.24 (loading feed rot.) Table 6 Loading parameters Default ameter name Nr. value Unit Comment 24 Loading feed rot Feeder rotations neede to load pellets into burning chamber. Depends from burner model. 25 Loading 2 feed 5 rot Feeder rotations for second loading. - Max loading time 5 min Maximum regular loading time - First loading time 20 min Maximum loading time after manual start. after manual start - Auger start 3 sec Auger Start delay if no fuel in burner - Auger stop 3 sec Auger Stop delay if fuel in burner - Feeder start 1 sec Feeder Start delay if fuel in burner - Feeder stop 4 rot Feeder rotations made without fuel level before stopped At the Loading time, external auger holds permanent fuel level in the feeder tube. Depending of the level sensor signal, the auger is turned ON or OFF. Internal feeder work is also depending on fuel level sensor signal. Maximum loading time is limited by 20 minutes after manual (first) start because extra time for external auger filling is needed. In next loadings, maximum time is limited by 5 minutes. If maximum loading time is exceeded and silo selection on burner is used, the pellet delivery will be switched on other auger. In single pellet delivery system No pellets error will occur.

33 PV1000agri pellet burner p 32/ 50 Operation and maintenance Statuses and parameters Igniting In ignition cycle the igniter is heated up and fan blows hot air thru pellets in burning chamber. Hot air ignites pellets. Igniter is working periodically at ignition time to avoid overheating. Igniter is preheated already in the end of loading cycle. When internal auger has made 10 rotations (full load rotations* - 12) the igniter is turned on for preheating. If the igniter has been turned on more than 1 minute at loading time, the igniter is turned off. Table 7 Ignition parameters Default ameter name Nr. value Unit Comment rps Primary fan speed at ignition - Max ignition time 255 sek Maximum ignition time - First loading time 20 min Maximum loading time after manual start. after manual start - Auger start 3 sec Auger Start delay if no fuel in burner - Auger stop 3 sec Auger Stop delay if fuel in burner - Feeder start 1 sec Feeder Start delay if fuel in burner - Feeder stop 4 rot Feeder rotations made without fuel level before stopped Pre-burn The purpose of pre-burn status is to get correct burning and flame after ignition. There is minimum fuel amount added periodically at pre-burn time. Fans are working with same speed as at ignition. Table 8 Pre-burn parameters Default ameter name Nr. value Unit Comment 8 Fan@ignition 20 rps Primary fan speed at ignition and preburn 39 Fan 2 min 7 rps Secondary fan minimum speed. Used at Ignition, Preburn, Heat up, Hold flame and End blow time. 41 Preburn time 25 s Delay between pellet feedings at Preburn 42 Preburn cycles 6 x Number of pellet feeding cycles at Preburn - Preburn feed 1/2 rot Feeder turns at each feeding Heat up

34 PV1000agri pellet burner p 33/ 50 Operation and maintenance Statuses and parameters Heat up cycle is needed for slow heating of the burning chamber and to minimize thermal stress in ceramic stones. Heat up mode is selected from main menu between ON, OFF or AUTO. Table 9 Heat-up parameters Default ameter name Nr. value Unit Comment 70 Heat up time 20 min Maximum cycle time 71 Heat up power kw Depends from burner model 72 Heat up temperature 500 C Ceramic stone minimum temperature When Heat up is mode is ON - burner will leave from Heat up cycle after heat up time is exceeded (stone temp. is not measured) When Heat up is mode is AUTO - burner will leave from Heat up cycle after heat up time is exceeded or stone temp. is higher than setpoint (PAR72) Burning This is main operation status in burner operation. Burner can operate on 11 different fixed power levels. There are 6 main power levels, which can be selected and adjusted. Virtual power levels (between main levels) are for smoother operation they can't be adjusted or selected. For every power level, the primary fan speed is fixed in parameters and secondary fan speed in parameters The fan speed for virtual levels is calculated as average from previous and next main level speed. Table 10 Power levels Power Level Power by burner model (kw) Air parameters level type PV350 PV500 PV700 PV1000 Primary Secondary 1 main virtual main virtual main virtual main virtual

35 PV1000agri pellet burner p 34/ 50 Operation and maintenance Statuses and parameters 9 main virtual main Power level 17 Selected power Figure 27 Burning at fixed power Burning time min Power level can be selected in main menu. Power level selection for burning time can be automatic or fixed on some main level. When power level is fixed, the power is slowly raised to selected level and will be there until boiler thermostat is switched off. In Automatic Power mode (POWER = AUTO in main menu), the operation power is selected automatically depending of burning cycle length. Power level Thermostat ON Operation power Burning OFF Testing Loading Igniting End burn Pre-burn End Blow Waiting Max power (par 14) New operation power 15 Burning Time(min) Figure 28 Burning when power selection = AUTO

36 PV1000agri pellet burner p 35/ 50 Operation and maintenance Statuses and parameters Slow down In Slow down mode, the burner power is reduced step-by-step to 1 level after boiler thermostat is switched OFF. This mode can be used only is systems with high and stable power demand. Using Slow down mode in systems with low thermal inertia or unstable power demand, there will be risk of system overheating. The Slow down mode is recommended to use together with Hold flame. Slow down mode can be switched ON or OFF from main menu. Power level 18 Burning Slow down Thermostat ON Operation power 17 Burning Thermostat OFF Burn end OR Hold flame Slow down Status/time Figure 29 Slow down mode Hold Flame Hold flame mode purpose is to avoid burner start-up procedures every time when burner is switched on from boiler thermostat. In Hold flame mode, minimum fuel and air amount is delivered into burning chamber. Hold flame mode can be switched from burner main menu to ON, OFF or AUTO. When Hold flame is selected as AUTO then burner will turn the mode on or off depending of Waiting time: If Waiting (time between End blow and thermostat ON) is shorter then 11, then Hold flame mode is switched on. If Hold flame is longer than 12, hold flame mode is turned off Hold flame is also used as intermediate state before cleaning or after Slow down Table 11 Hold flame parameters Nr. ameter name Default value Unit Comment

37 PV1000agri pellet burner p 36/ 50 Operation and maintenance Statuses and parameters 8 flame 10 rps Primary fan speed at hold flame 39 Fan 2 min 7 rps Secondary fan minimum speed. Used at Ignition, Preburn, Heat up, Hold flame and End blow time. 11 Hold flame ON 15 min Short Waiting limit. 12 Hold flame OFF 60 min Maximum time in Hold flame End burn The End burn cycle is needed to stop the burner. All pellets inside the burning chamber and feeder tubes are burned. Pellet feeding frequency and fan rotation speed (power level) is same as in Burning status. If burner goes to End burn from other states (example Hold Flame ), first power level is selected. Burner works in End burn until feeder tube is empty - feeder has made as many turns as selected in 26. End burn is used in case of some errors. Table 12 End burn parameters Default ameter name Nr. value Unit Comment 26 End burn feed rot Feeder rotations neede to clean feeder pipe. Depends from burner model. - Minimum feed 20 rot If less rotations maid and boiler thermostat is switched ON then back to Burning End blow The End blow cycle is needed to finish unburned pellet coals in the burning chamber. Burner will wait the flame disappearing in burning chamber. In 27 is fixed the time, how long the fans continue to blow after flame disappearing. Table 13 End blow parameters Default ameter name Nr. value Unit Comment 9 blow 20 rps Fan speed at End blow 39 Fan 2 min 7 rps Secondary fan minimum speed. Used at Ignition, Preburn, Heat up, Hold flame and End blow time. 27 End blow time 2 min Time to blow air after flame is disappeared - Max. End blow time 15 min Maximum time when flame must disappear in End Blow

38 PV1000agri pellet burner p 37/ 50 Operation and maintenance Cleaning External auger control 4.4 Cleaning Pellet burner requires systematic maintenance. The maintenance period depends on the quality of the pellets and heating intensity. To clean the burner: 1. Turn off the burner by turning the thermostat to Let the burner cool down for at least 1 hour. 3. Open the boiler's door to gain access to the burning chamber 4. Remove the grates and clean them from any residues. Make sure all holes on the grates are clean. 5. Remove the bottom panel to gain access under the grate movers to clean the ash from the burning camber. 6. Reattach the bottom panel. 7. Clean the boiler. The frequency of cleaning the boiler depends on the type of the boiler and heating intensity. For more information about cleaning the boiler, please see boiler's user manual. 8. Put back the grates. 9. Close the boiler's door to finish the maintenance and turn the thermostat to desired temperature. The connection between the boiler and chimney must be completely airtight. There mustn't be any extra draught in the smoke draft of the boiler. All cleaning and maintenance openings must be closed with covers. 4.5 Replacing components Step by step, how to replace igniter etc

39 PV1000agri pellet burner p 38/ 50 Operation and maintenance Replacing components...

40 PV1000agri pellet burner p 39/ 50 Optional components GSM Modem 5 Optional components 5.1 GSM Modem Modem enables users to receive burner error messages via SMS. Boiler room must have GSM coverage in order to use the modem. Preconfiguring SIM card Before inserting the SIM card to burner, SIM card must be preconfigure. That can be done by inserting the SIM card to a mobile phone and making following actions: Figure 30 Modem SIM card must the activated by the mobile operator SIM card pin code must be turned off Mobile operator s messaging center number must be correct In SIM card s phonebook, there must be only the numbers, where the messages from the burner will be sent. The number of receiving contacts is limited to 5. Insertion and removal of the SIM card The terminal has a built-in toggle spring (Push-Push) SIM holder, accessible through a slot in the panel at the antenna side of the housing. Do not insert or remove the SIM when the product is in power saving mode. To insert and remove the SIM, a plastic strip of the same width of the SIM and appropriate length of ca mm shall be prepared as a tool. The figure printed on the panel shows the position of the cut edge and the direction, how Figure 31 SIM card insertion the SIM shall be inserted.

41 PV1000agri pellet burner p 40/ 50 Optional components Temperature sensor Insert the SIM and push it with the tool slightly inside until the spring snaps in. Removing the tool, the SIM shall remain inside the GT863-PY. For removing the SIM, push the tool slightly inside until the spring is released so that it pushes the SIM outside when the tool is retracted. Burner s GSM modem menu can be accessed in the PARAMETERS menu, parameter no. 52 LED indicators The GT863-PY Terminal has 2 LED indicators, one for Power, one for Status. Power LED When on, the green Power LED indicates that the supply voltage is arriving at the GSM Engine inside the GT863-PY Terminal. Status LED: Indication of network service availability. The red Status LED is connected internally to the STAT_LED output of the module by an inverting circuit. In addition to the status information obtainable via AT commands, this LED shows information on the network service availability and Call status. Status LED indications LED status Device Status permanently on a call is active fast interrupt sequence Net search / Not registered / turning off (period 0,5s, Ton 1s) slow interrupt sequence Registered full service (period 0,3s, Ton 3s) permanently off device off 5.2 Temperature sensor Temperature sensor can be resistive PT100 type or ma output type. In 5.3 Flue gas fan Schematics, instructions for set up.

42 PV1000agri pellet burner p 41/ 50 Common problems and solutions 6 Common problems and solutions Problem description Possible cause and solution

43 PV1000agri pellet burner p 42/ 50 Annex A ameters 7 Annex A ameters Nr ameter name Unit Burner model Default Min. Max. Description 1 1 rps PV PV PV PV rps PV PV PV PV rps PV PV PV PV rps PV PV PV PV rps PV PV PV PV rps PV PV PV PV FAN START % Initial speed for prim., sec. and flue gas fan to start. 0=100%, 255=0% 8 FAN IGNITION rps FAN BURN END rps FAN HOLD FLAME rps HOLD FLAME min ON HOLD FLAME min MAX MIN POWER kw PV /150/200/250/300/350 PV /240/320/400/480/560 PV /300/400/500/600/700 PV /400/550/700/850/1000 MAX POWER kw PV /150/200/250/300/350 PV /240/320/400/480/560 PV /300/400/500/600/700 PV /400/550/700/850/1000 POWER UP min POWER DOWN min

44 PV1000agri pellet burner p 43/ 50 Annex A ameters UP CYCLE min DOWN CYCLE min PELLET NORMAL g/n PV PV PV PV PELLET LIGHT g/n PV PV PV PV PELLET HEAVY g/n PV PV PV PV LOADING FEED rot PV PV PV PV LOADING 2 rot FEED BURN END FEED rot PV PV PV PV END BLOW TIME min FAN 2 ON AUTO ON/OFF/AUTO AUTO for normal operation FAN 1 rps PV PV PV PV FAN 3 rps PV PV PV PV FAN 5 rps PV PV PV PV FAN 7 rps PV PV PV PV FAN 9 rps PV

45 PV1000agri pellet burner p 44/ 50 Annex A ameters 35 PV PV PV FAN 11 rps PV PV PV PV FAN 2 BASE % FAN 2 MIN rps PHOTOCELL LEVEL % Photocell sensitivity 100% = infinity flame PRE-BURN TIME s PRE-BURN x CYCLE FEED CURRENT A PV350 3,0 1,0 9,9 Feeder max. Current. PV500 6,0 1,0 9,9 PV700 6,0 1,0 9,9 PV1000 6,0 1,0 9,9 GRATE CURRENT A 2,0 0,2 6,0 Grates actuator max. Current CLEANING min Cleaning cycle delay. CYCLE ERROR RELAY ON ON/OFF Error relay action at error: ON-contact closed at error (NO), OFF-contacts opened at error (NC) SMS COUNT x TEMP TYPE Temp. Sensor action type: 0-no sensor, 1- overheat sensor, 2-temp. holding sensor TEMP LEVEL C Temp. Holding setpoint TEMP HYST C Temp. Holding hysteresis BASE FREQUENCY Hz Power grid frequency (for triac operated fans) FLUEGAS TYPE Flue gas fan/ underpressure control type: 0 - no-fan, no-control, 1 - no-fan but controlled underpressure, 2 - inverter, 3-230V triac DRAFT SET -Pa Draft setpoint DRAFT ERROR +Pa Draft error level DRAFT BASE % Draft sensor calibration value HEAT UP TIME min Max. Time for HEAT UP cycle.

46 PV1000agri pellet burner p 45/ 50 Annex A ameters HEAT UP POWER kw PV Power at HEAT UP PV PV PV1M HEAT UP TEMP C Stone temperature to reach at HEAT UP TEMP BASE C BURNER TYPE PV350 PV350/PV500/PV700/PV1M

47 PV1000agri pellet burner p 46/ 50 Annex B Burner status change logic 8 Annex B Burner status change logic Status Next Status Change conditions Waiting Testing Signal from boiler thermostat Testing Loading All tests are done successfully Battery error Fan error Level error Battery voltage is too low Fan does not reach 40* rps at pre-burn The level sensor recognizes pellets in the feeder Loading Ignition Loading (22* rot.) made by feeder No pellets Burn end Maximum loading time (5 or 20 min.**) is reached Flame detected and unknown start conditions Loading 2 Ignition Previous state was ignition and rotations (3* rot.) made by feeder Pre-burn Previous state was hold flame and rotations (3* rot.) made by feeder Ignition Pre-burn Flame recognized Loading 2 Ignition error Max ignition time (255* sec) is reached and load 2 is not done Max ignition time (255* sec) is reached and load 2 is done Pre-burn Burning Pre-burn cycles (3*x40*sec.) is done and continuous flame is recognized more than 10 seconds Loading 2 No flame Pre-burn cycles is done and flame is NOT recognized and load 2 is NOT done Pre-burn cycles is done and flame is NOT recognized and load 2 is done Burning Burn end NO Signal from boiler thermostat (hold flame is NOT allowed) Hold flame Burn end Burn end -> End blow ->Level error Burn end -> End blow ->No pellets No flame NO Signal from boiler thermostat (hold flame is allowed) Maximum burning time (4 hours) is reached Fuel level is continuously detected in time of 8 feeder rotations Fuel level is not detected in 4 min. No Flame more than 2 minutes Hold flame Loading 2 Signal from boiler thermostat Burn end Max keep flame time (1 hour) is reached

48 PV1000agri pellet burner p 47/ 50 Annex B Burner status change logic Burn end End blow Burn end (15*rot. + 10rot.) plus time 30sec. is reached Burning Signal from boiler Thermostat, feeder made less than 8 rot and previous state was BURN End Blow Waiting No Flame 1 min. and RUN command is active Stopped No flame Level error No pellets No Flame 1 min. and RUN command is NOT active Max cleaning time (5 min.) is reached No Flame 1 min. and error is set From: Burn-> Burn end-> End blow- >Level error No Flame 1 min. and error is set From: Burn-> Burn end\-> End blow- >No pellets No Power Wait Power exist and RUN command is active Stopped Burning Power exist and RUN command is NOT active Any other Waiting RUN command is activated If Burned before No Power and less than 15 min in No Power

49 PV1000agri pellet burner p 48/ 50 Annex C Controller board description 9 Annex C Controller board description Fuses F4=6A, F10=2A

50 PV1000agri pellet burner p 49/ 50 Annex C Controller board description Connector LoPr FANx-1 FANx-2 FANx-3 MOD1-1 MOD1-2 MOD1-3 MOD1-4 Description Boiler pressure sensor connection. Must be connected to tube on left feeder tube. Prim/sec fan speed sensor +5V power Prim/sec fan speed sensor GND Prim/sec fan speed sensor digital input Modem interface +5V output, fused through F9 Modem interface Rx input Modem interface Tx output Modem interface GND TMP1-1 Temperature sensor power +5V TMP1-2 Temperature sensor GND TMP1-3 Temperature sensor signal 0 2.5VDC RSV-1 RSV-2 TRS-1 TRS-2 Level sensor receiver diode cathode Level sensor receiver diode anode Level sensor transmitter LED anode Level sensor transmitter LED cathode X VDC power output, fused through F1 X1-2 Open collector output, max 200mA, 30VDC X1-3 Open collector output, max 200mA, 30VDC X1-4 Open collector output, max 200mA, 30VDC X1-5 Open collector output, max 200mA, 30VDC X1-6 Open collector output, max 200mA, 30VDC X1-7 Open collector output, max 200mA, 30VDC X1-8 Open collector output, max 200mA, 30VDC X1-9 Open collector output, max 200mA, 30VDC X1-10 Open collector output, max 200mA, 30VDC X2-1 GND X VDC power output, fused through F3 X VDC power output, fused through F2 X2-4 GND X3-1 + Thermocouple input (fire brick temperature sensor) X3-2 - Thermocouple input (GND) X3-3 1 st feeder motor black wire X3-4 1 st and 2 nd feeder motors red wire (+27VDC power output) X3-5 2 nd feeder motor black wire X3-6 Battery positive terminal X3-7 GND X VDC Power supply input X4-1 Connects to X4-2 through K1 X4-2 AC supply N X4-3 AC supply L X4-4 Boiler thermostat (AC voltage)

51 PV1000agri pellet burner p 50/ 50 Annex C Controller board description X5-1 Grate cleaning motor position feedback X5-2 GND X5-3 not connected X5-4 Grate cleaning motor X5-5 Grate cleaning motor X5-6 not connected X6-1 DC input X6-2 DC input X6-3 DC input X6-4 DC input X7-1 MODBUS signal A X7-2 MODBUS signal B X7-3 MODBUS GND X8-1 DAC 0 10V output X8-2 DAC 0 10V output X8-3 DAC 0 10V output X8-4 DAC 0 10V output X VDC power output, fused through F5 X8-6 PT100/mA/2.56V input. JP1 & JP2 selects function X8-7 PT100/mA input, JP3 & JP4 selects function X8-8 DC input X8-9 Flame sensor input X8-10 Flame sensor input Figure 32 DC input circuit