PV 100b and PV180b pellet burners

PV 100b and PV180b pellet burners User manual

PV100b / PV180b pellet burner page 2/ 40 Table of contents Safety... 4 Warnings... 4 Notice... 4 Set of components... 6 1 Description... 7 1.1 Principal function... 9 1.2 Safety devices... 10 1.3 Pellets... 11 2 Installation... 11 2.1 Requirements for boiler and boiler room... 11 2.2 Burner installation... 13 2.3 External auger... 16 2.4 Electrical connections... 17 2.5 Initial start-up... 18 3 Optional components... 18 3.1 GSM modem... 18 3.2 Error output... 20 3.3 Flue gas fan control... 20 3.4 External boiler temperature sensor (TMP1)... 21 4 Operation and service... 22 4.1 User interface... 22 4.2 Starting and stopping... 23 4.3 Refilling fuel... 23 4.4 Status description... 23 4.5 Output power levels... 25 4.6 Main menu and settings... 25 4.7 Regular maintenance... 27 4.8 Replacing the components... 27 4.8.1 4.8.2 4.8.3 4.8.4 Replacing igniter... 27 Resetting safety thermostat... 28 Replacing fuses... 28 Replacing fuel level sensors... 29

PV100b / PV180b pellet burner page 3/ 40 4.8.5 Replacing flame sensor... 29 4.8.6 Replacing battery... 29 5 Status change logics... 30 6 Status durations... 31 7 Error messages and solutions... 32 8 Annex 1 Electrical diagrams... 34 9 Annex 2 Table of parameters... 36 10 Annex 3 Table of languages... 39 Warranty... 35 Manufacturer of pellet burners PV100b and PV180b: Pelltech OÜ Manufacturers address: Sära tee 3, Peetri, Rae vald, 75312 Harjumaa ESTONIA Name of product: Pellet burners 100b and PV180b Ph.. + 372 677 5277 info@pelltech.ee

PV100b / PV180b pellet burner page 4/ 40 Safety Do not start the burner before it is connected to the boiler and the boiler is connected to the chimney. When the burner is connected to the main power supply the burner casing must always be mounted Always make sure that the burner is unplugged from the main power supply before performing any cleaning or maintenance. Keep children away and do not touch the equipment during operation. Make sure that no flammable or liquid materials are stored in the boiler room or vicinity of the boiler. It is recommended to wear a respirator while handling pellets. The boiler room where the burner is installed must fulfil all rules and recommendations in accordance with local codes and regulations. All electrical installation, plumbing, chimney sweeping and service work shall be done by certified and qualified personnel in accordance with local codes and regulations. Warnings Changing the construction of the burner without written permission from the manufacturer is forbidden. Use only spare parts provided or approved by the manufacturer in order to avoid any damage to the burner and dangers resulting from it. Welding is allowed only after disconnecting the burner from electric supply. The circuit board must be removed from the burner. Do not never open boiler door while the burner is in operation. Notice Manufacturer of burners has right to make changes in burners constructions and its firmware. Present user manual is original user manual for PV20a and PV 30a pellet burners. Burner corresponds to following directives and standards: EN 15270 2008 EN 61000-6-2 EN 230 2005 EN 61000-6-3 EN 60335-1 EN 55014-1 EN 60335-2-102 2004/108/EC EN 60730-1 2006/95/EC EN 60730-2-5 2001/91/EC EN 61000-6-1 2006/42/EC

PV100b / PV180b pellet burner page 5/ 40 Pellet burner PV 100b Electrical supply 230V Max heat output 100kW Emission class 5 Noice emission 58dB Power consumption at stand-by 7 W Manufacturer: Pelltech OÜ Sära 3, Peetri, Harjumaa ESTONIA No Pellet burner PV 180b Electrical supply 230V Max heat output 180kW Emission class 5 Noice emission 58dB Power consumption at stand-by 7 W Manufacturer: Pelltech OÜ Sära 3, Peetri, Harjumaa ESTONIA No

PV100b / PV180b pellet burner page 6/ 40 Set of components Set of components includes: 1. Lower burning grate 8. Fixating flange 2. Upper burning grate 9. Plug 3. Arc fire brick 2 pc 10. Bracket 2 pc 4. End fire brick 1 or 2 11. Casket strip 5. Side fire brick 2 pc 12. Ceramic seal 6. Side fire brick 2 pc 13. External auger s fixing chain 7. Burner 14. Hose 3 4 14 5 1 2 6 7 13 8 9 10 11 12

PV100b / PV180b pellet burner page 7/ 40 1 Description PV100b and PV180b are pellet (sawdust granules) burners for heating of the industrial and public buildings. Both burners share similar construction but differ by burning chamber size and maximal capacity. PV 100b/180b unique construction enables them to be used with many oil, solid fuel and universal boilers. Only pellets with diameter 6..8 mm can be used to run the burner. The burner is mounted to boiler with standard oil burner 130mm flange. The burner is protected against back-burning with backup battery, temperature sensor and melting hose. Main measurements of the burner are shown on Figure 1and Table 1. Table 1 Main measurements Parameter Unit PV100a PV180a L total length mm 750 750 L1 housing length mm 295 295 L2 burning chamber length mm 330 330 D burning chamber width mm 230 310 D1 burning chamber neck diameter mm 129 129 D2 internal feeder diameter mm 76 76 H total height mm 285 285 H1 housing height mm 220 220 W total width mm 300 300 W1 housing width mm 275 275 Mass kg 38 44 Nominal power kw 100 180 Minimum power kw 40 80 Noise level db 58 58 Emission class (EN 15279) 5 5 Operating temperature o C 0-60 0-60 Supply voltage VAC 220-240 220-240 El power at ignition W 570 620 El power, average W 50-80 60-120 El power at standby W 7 7 Figure 1 Main measurements

PV100b / PV180b pellet burner page 8/ 40 The main components are depicted on Figure 2 and Table 2. 1 2 3 4 5 6 7 22 21 19 20 8 14 15 16 17 18 9 9 10 11 12 13 Figure 2 Burner main components

PV100b / PV180b pellet burner page 9/ 40 Table 2 Descriptions of main components Name Description 1. Arc fire bricks To cover the top of burning chamber. 2. Side fire bricks To cover the sides of burning chamber. 3. Burning chamber Place of gasification and burning of pellets. 4. Fuel level sensor Optical sensor, which signal starts external auger. Sensor consists of sender receiver pair. 5. Fan Blows burning air into burning chamber according to burner s actual power. 6. Controller board Controls the functioning of the burner. 7. Backup battery Enables to complete the burning procedure if mains supply lost. It is a safety measure against back-burning and takes approx. 30min. 8. User interface screen 2-row LCD screen to move in menus, set up and change parameter values. 9. User interface buttons Enable to navigate in burner menus and change parameter values. 10. Grate s linear motor Moves middle burning grate to remove ash from burning chamber. 11. Feeder motor Rotates internal feed screw. The feeder is connected to feeder motor with little slack in order to avoid the auger getting stuck. 12. Transformer Supplies power to controller, internal sensors and motors. 13. Safety thermostat Cuts main power from grid and external auger if temperature rises over set limit inside the burner. It is a safety measure against back-burning. 14. Connecting nut Connects burning chamber to burner body. 15. Igniter connection hole Round hole, where from is possible to fix/ unroll with screwdriver igniter s fixing bolt. 16. Flame sensor Optical sensor (photocell) to detect flame in burning chamber. 17. Igniter Electrical heating element to heat air and ignite pellets. 18. Internal feeder Transports pellets to the burning chamber. The feeder is connected to feeder motor with little slack. It prolongs motor and feeder lifetime. Do not over tighten the feeder connection. 19. Upper grate Permanently fixed cast iron grate. 20. Lower grate Periodically moving cast iron grate. Removes the ash from burning chamber. 21. Chamber s housing Metallic housing of burning chamber. 22. Connectors To connect mains power, boiler thermostat, external auger and optional flue gas fan. 1.1 Principal function The PV100b and PV 180b burners are meant to be installed in a boiler and fuelled with wood pellets. The external auger transports the pellets from a pellet container to the burner. The controller board contains a microprocessor system that tests main safety components, monitors and regulates the burning procedure, starts and stops the burner automatically according to the boiler temperature. A warm air element (electrical igniter) ignites the pellets. The start procedure is designed to create a quick and smoke free ignition.

PV100b / PV180b pellet burner page 10/ 40 The burner starts burning when the boiler temperature cools down and boilers thermostat switches on. Burner runs until the pre-set maximum boiler temperature (switch-off temperature) has been reached. After that burner stops safely burning procedure and goes to waiting (stand by) status. Main supply interruptions (blackouts) are taken care of by the control system. After a main supply interruption burner stops safely burning and goes to stopped status. When a blackout occurs, the burner ends safely burning process. If there is a safety risk, the burner switches off. 1.2 Safety devices The burner has following safety devices against back-burning and other dangerous situations. 1. Melting hose Figure 18 2. Temperature sensor Figure 2 behind the fan 3. Controller Figure 2 pos 6 4. Back-up battery Figure 2 pos 7 5. Safety thermostat Figure 2 pos 13 1.Melting hose To avoid the reaching of fire during back-burning to external auger, a melting hose is put between external auger and pellet burner. The hose will melt when air temperature inside reaches 100 o C. 2.Temperature sensor A temperature sensor is mounted on burners input tube. If the burner is not regularly cleaned, part of burning gases start to move through fuel line. The sensor detects temperature rise in fuel line and shuts down the burner. This safety device is not meant to replace regular cleaning by the user. 3.Controller Software supervision made by controller monitors continuously all inputs and outputs and shuts down the operation of burner in case of abnormal condition occurs. Controller has watchdog timer to reset the controller in case program lock up. It also has a brown-out detection and reset circuit to reset the controller when power supply voltage falls below threshold. Burner makes self-testing after applying power by measuring: - Existence of feeder auger motor current (motor is turned on for a moment) - Existence of speed signal from fan (fan is turned on for a moment) - Voltage level on backup battery is > 12V when loaded with feeder auger motor or displays last error state. To ensure there are no explosive gases inside the boiler, the fan is ran for short duration before loading/ignition starts. 4.Backup battery If mains supply is lost, the burner runs on backup battery power and feeder auger transports pellets from feeder s tube to the burning chamber for final burning. Fan rotation and all other functionalities are stopped. Burning ends with help of natural draught. Battery voltage is checked at startup and continuously monitored during the operation.

PV100b / PV180b pellet burner page 11/ 40 5.Safety thermostat In case back-burning has reached into feeder auger, safety thermostat cuts mains power off and feeder auger is unloaded by using battery power. Thermostat acts at 65 o C and must be reset manually. 1.3 Pellets Wood pellets or saw dust granules are concentrated and homogenized wooden fuel made from stem wood and chemically untreated residues from the wood industry by intrusion. No extra materials are added, pellets are held together by a natural ingredient found in wood lignin. Pellets are neutral, renewable fuel. Its burning doesn t spoil CO 2 balance in the atmosphere. Only wood pellets e.g. ENplus-A1, ENplus-A2 and EN-B (EN14961-2) can be used to run PV100/180 burners. Pellets must be stored in a dry and ventilated room. Some key data for wood pellets are given in Table 3. Table 3 Key data for wood pellets Raw material Sawdust, cutter shavings and stem wood Calorific value 4700-5100 kwh/ton Bulk density ca 650-670 kg/m 3 Volume of 1 ton 1.5-1.6 m 3 Diameter 6-8 mm Length 3-5 x diameter Fines content (<3,2 mm) < 1% Moisture content 8-10 % Ash content < 3% Ash fusion > 1100 o C To replace 1000 l light oil ca 2 tons or 3 m 3 2 Installation 2.1 Requirements for boiler and boiler room In order to install the burner, following requirements must be met: Boiler door must have 130 mm opening. Boiler door thickness must be below 90 mm. Boiler door construction must allow easy access to burning chamber. If the door is too narrow, double hinges can be used. If draught in boiler room is insufficient (for normal working under pressure 5-20 Pa is needed), additional flue gas fan must be installed. Boiler room must conform to fire safety regulations. Boiler has to be installed the way than there were enough space to clean boiler and remove ash. Pellet burners need regular cleaning and therefore boiler construction must allow easy opening of boiler s door without removing the burner. The minimum size of opening in boiler s door depends on the position of door hinges. Figure 3 below illustrates the situation. Point C is critical point. In order to keep door width minimum and boiler s opening small, a double hinge solution

PV100b / PV180b pellet burner page 12/ 40 can be used. As double hinges add another degree of moving-freedom, door must be fastened on both sides. Slide-out doors with guide rails is also an option. Figure 3 Burner has to come off of from boiler Double hinges Boiler firebox depth L (Figure 4) must be at least 2..2,5 times longer than the burner s burning chamber. The minimal length of the firebox L has to be 700..800 mm. The height of firebox must leave at least 100 mm (H1) for ash below burning chamber. Minimum dimensions: L1 380mm; H 450mm. Figure 4 Firebox measurements Flange mounting holes The burner is fixed to boilers door with supplied mounting flange. Bolt hole dimensions D1 and D2 are valid only if the supplied flange is used Table 4. Table 4 Flange mounting holes Dimension Unit Value D hole for burning chamber neck mm 130 D1 flange bolt hole circle mm 170..210 D2 flange bolt holes mm 13

PV100b / PV180b pellet burner page 13/ 40 2.2 Burner installation Following tools are needed to install the burner: Spanner no 19 for connecting the mounting flange to boiler Spanner no 13 for connecting the burning chamber to burner body Crosshead screwdriver for fixing the burners cover 6 mm hex key for fixing the burner to flange Remove fire bricks from burning chamber. Remove burning grates. Figure 5 Figure 6 Remove grate holder bolts. Remove red cover to gain access to connecting nut. Figure 7 Figure 8

PV100b / PV180b pellet burner page 14/ 40 Remove the connecting nut fixing housing with burning chamber. Pull burning chamber apart from the burners housing. Figure 9 Figure 10 Mount the flange to boiler door. To do that firstly the flange has to be fixed to outer side of boilers door. Then put ceramic seal to the burning chamber s neck and push then chamber thru boilers door from inner side. Figure 11 Ensure that burning chamber is positioned horizontally and fix chamber with two adaptive screws. Figure 12

PV100b / PV180b pellet burner page 15/ 40 Connect burner housing and burning chamber. Feeder auger s tube has to go thru opening in burning chambers back wall. Check that igniter has not got stuck behind the back wall and is visible from its opening. Figure 13 Tighten the nut fixing the halves of burner. Connect with two bolts the holder of the lower grate. Figure 14 Figure 15 Place burning grates. Lower grate goes to holder. Upper grate remains to lean on to up bended edge of back wall of the burning chamber with one edge. Other edge leans on lower grate. Figure 16

PV100b / PV180b pellet burner page 16/ 40 Place carefully back the fire bricks to burning chamber. Figure 17 2.3 External auger The external auger transports pellets from the pellet container to the burner. The auger is controlled by burner. The auger is connected to the burner with a special hose, which is made from easily melting polyurethane material that interrupts when back-burning takes place. The auger can be fixed to the storage or to room s ceiling depending on the conditions at the installation site. As the hose is the safety element it has to be installed like described below: 1. Hang the auger to the ceiling in the way that requirements have been filled. Figure 18 2. Place hose between auger and burner. Fix hose from both sides with metallic brackets. 3. Connect auger motor s cable with burner. Make sure that: 1. The vertical distance between the input tube of the burner and the output tube of the auger has to be 40 70cm. 2. The horizontal distance between augers output and burners input has to be 10-20 cm (augers rising angle 30 o..45 o ) It ensures, that during back burning the flame smelts the hose and fire can t reach by auger into container. 3. The rising angle in relation with ground has not been bigger than 45. Vice versa auger cannot transport enough pellets. 4. Hose between auger and burner must be strait, otherwise pellets can block the tube. Falling angle must me between 50 and 85. Then can pellets fall freely into burner. 5. External augers cable is connected to burner. 6. External augers plug is firmly connected to burner s socket.

PV100b / PV180b pellet burner page 17/ 40 Figure 18 Installation external auger 2.4 Electrical connections The burner is equipped with a standard oil burner plug that has 7 contacts. There will be different connection schemes used for different boilers. Usually the burner is connected to the boiler with a 5- wire cable. It is also possible to connect with a 4-wire cable. See Figure 19. Connection of boiler s thermostat Tt is different in both cases. Make sure that plug has pushed entirely into socket. Halves are fixed with plastic stud. Burner s plug connections are depicted in Figure 20. Tt boiler thermostat 5 wire connection 4- wire connection Figure 19 Connection with 5 wire cable

PV100b / PV180b pellet burner page 18/ 40 Figure 20 Burners plug connections Attention! All electrical connections of the burner must be done by a qualified professional. 2.5 Initial start-up Before starting the burner first time, make sure that: The nut that connects burner body and burning chamber is securely tightened. The neck of burning chamber fits to burner s housing. Grates and firebricks are placed. Igniter is not get stuck behind burning chamber back wall and is visible from chamber. Boiler thermostat is installed and functioning properly. Boiler thermostat is set to lowest temperature. External auger is installed and connected to the burner according to Figure 18. The smoke duct is connected to the chimney, the dampers are open and there is sufficient draught. When the burner is operating, the draught inside the firebox must stay between 5-20 Pa. The air hatches are closed and all air goes thru burner. Electrical plugs of external auger and boiler are pushed completely into sockets. 3 Optional components 3.1 GSM modem Modem enables users to send burner error messages via SMS up to 5 phone numbers. Following products are needed to set up modem Figure 21: 1 Modem signal converter EP0005, connected between modem and UART plug 2 Modem EP0007 3 Modem power cable EP0001

PV100b / PV180b pellet burner page 19/ 40 X2-8 White (+) X2-4 Brown (-) UART GND Tx Rx +5V 1 2 3 Figure 21 Connecting the modem Power supply cable is connected to pins X2-8 and X2-4. Adaptor EP0005 is connected with modem and controllers UART- plug. Depending on the location of the modem, extension cables may be needed. Before inserting the SIM card to burner the following actions have to be done: 1. SIM card must by activated by the mobile operator 2. PIN code request has to be switched out. 3. Check by using mobile phone that it is possible to send SMS with this SIM card. 4. In SIM card s phonebook must contain only the numbers, where to the messages from the burner will be sent. To insert the SIM card the modem has to be disconnected from supply mains. To insert the card push it into a slot as long as it clicks. To remove card push it in as long as it clicks and spring pushes it out. Figure 22 SIM card insertion In order to activate SMS sending in burners menu PAR52 has to be changed. Value shows for how many numbers the message will be sent. 0 means no messages to be sent. 2 means that messages will be sent to 2 first recipients in SIM card.

PV100b / PV180b pellet burner page 20/ 40 Modem has two indicators. Green one shows that modem is turned on. Red one shows modem status. Modem s statuses are described in Table 5. Table 5 Modem statuses Red LED indicator Permanently on Fast interrupt sequence (period 0,5 s Ton 1s) Slow interrupt sequence (period 0,3s Ton 3 sec) Permanently off Modem status Sending message (on-going call) Net search/not registered/ Turning off Registered full service Device is turned off 3.2 Error output It is possible to connect to burner additional devices like pump, modem etc., what switches a device on or off when error occurs in burner. The error output is marked with ERR and is located in controllers upper part ( red arrow on Figure 23).It is allowed to switch up to 5A @230VAC device to circuit. PAR50 in burners parameters menu defines is the error circuit open or closed when error occurs. 1 means ON closed when error, and 2 means OFF open when error. Table 6 PAR50 values PAR50 value Description 1 Normally open circuit. Turns ON when error occurs. 2 Normally closed circuit. Turns OFF when error occurs. 3 Turns ON in IGNITING, HEAT UP, BURNING and HOLD FLAME statuses. 4 Not in use 5 Not in use Figure 23 ERR output location 3.3 Flue gas fan control Usage of flue gas fan improves work of heating system and optimises burning procedure. In order to activate flue gas fan, set PAR30 to value 1 (ON). In this case flue gas fan control is proceed by controllers internal air-table, where for every power level certain amount of combustion air is prescribed by parameters PAR31 36. These parameters are unit less and describe relative speed of

PV100b / PV180b pellet burner page 21/ 40 flue gas fan. Smaller number means lower speed and bigger number bigger speed. Speeds of all levels can be changed together by PAR38. Flue gas fan does not have any speed measuring and holding function. Therefore PAR 31 36 are to be set differently according to individuality of every boiler house. If select 2 in PAR30, the flue gas fan is switched OFF. Value 3 is not applicable in this burner. Value 4 in PAR30 allows controlling fan s speed with O 2 (λ) sensor and value 5 with underpressure sensor. In both cases flue gas fan follows pre-set oxygen level by PAR67 or pre-set draft by PAR61. PV100b/180b burners have built-in under-pressure sensor. Before implementing under-pressure control the sensor has to be calibrated. To do that go to INFO menu and check value of ΔP. It has to be close to 0 (-0,3 +0,3). If not go to PAR63 and by changing its value try to get ΔP close to 0. During calibration burner has to be in WAITING status, all doors and windows of boiler room opened, also boiler s door has to be opened. To install O 2 (λ) sensor a hole has to be drilled to bolier s smoke tube and sensor mounted into it. To activate O 2 (λ) sensor PAR66 has to be set to 1 (AV0001 sensor) or 2 (other sensors). PAR67 allows to pre-set oxygen level set-point. Sensor is connected to TEMP2 socket. 3.4 External boiler temperature sensor (TMP1) External temperature sensor enables the burner to maintain constant boiler s water temperature. To do that external temperature sensor has to be installed to relevant place, existing burner s temperature sensor to be disconnected from TMP1 connector and external sensor to be connected to controller s connector TMP1. In parameters menu PAR53 value has to choose bigger than 1. When temperature holding regime is activated, then burner will change its capacity according to water temperature and speed of temperature changing. Burner starts to change its capacity when BURNING status has lasted longer than set in PAR15. Capacity is changed after time set in PAR17. Following actions must be done to enable temperature hold mode (THM): 1. Mount external temperature sensor to boiler according to boiler manufacturer instructions. 2. Connect the sensor to TMP1 connector on controller board. 3. Choose PAR53 value (sensor type) according to Table 7. 4. Set requested temperature PAR54. It should be lower than boiler thermostat temperature. Otherwise the boiler thermostat would force the burner to turn off before reaching PAR54 value. 5. Optionally PAR55 - the hysteresis of requested temperature can be changed. THM activates if PAR53 value is bigger than 1 and BURNING status has lasted longer than PAR15 value (typically 30min). The burner will change its output power according to current measured temperature and the rate of temperature change. New power level is selected after every time interval specified in PAR17. Table 7 External temperature sensor types PAR53 Sensor type Temp min Temp max Function 0 No sensor - - - 1 0..2.5V 0ºC (0.5V) 125ºC (1.75V) Internal over temperature sensor (PAR43) 2 0..2.5V 0ºC (0.5V) 125ºC (1.75V) Boiler temperature control

PV100b / PV180b pellet burner page 22/ 40 After activating THM, following row is displayed on INFO-screen e.g.: T=22.3/70±5 200 o. It means following: 22,3 Actual measured temperature 70 Set point temperature (PAR54) ±5 Set point hysteresis (PAR55) - Shows if actual temperature is increasing or decreasing 200 o Forecasted temperature after 10min 4 Operation and service 4.1 User interface The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log and momentary status and error messages of the burner. Yellow LED (2) shows the presence of flame in burning chamber. In case it blinks, the burner is out of normal operation. Momentary state of burner is displayed in STATUS menu s lower row. To reach the lower row, push down ( ) button up to reaching requested row. Green LED (3) indicates existence of fuel in the burner. To move in menus and set parameters use up and down ( ) buttons. To approve parameters change press OK. To go back to STATUS menu, press ESC button. On Table 8 are described additional actions of buttons. Figure 1. 2-row 24 Front LCD panel display. of user interface 2. Yellow LED, indicates presence of the flame in the burning chamber. 3. Green LED, indicates existence of the fuel in the burner. 4. Plug for external auger connection. 5. Plug for boiler connection. 1. 2-row LCD screen 2. Yellow LED displays existance of flame in burning chamber 3. Green LED displays existence of fuel in burner s inlet tube 4. Socket of external auger 5. Socket of boiler Table 8 User interface control buttons Button Button s pressing time Action OK Less than 3 seconds Entering to sub-menu Setting confirmation (when blinks) OK More than 3 sec in INFO menu s Resetting pellets counter OK COUNTER submenu More than 3 sec in other menus (not in INFO menu) Resetting error status and switching burner ON

PV100b / PV180b pellet burner page 23/ 40 OK More than 3 sec in NO POWER Switching burner and battery OFF status ESC Less than 3 seconds Moving back in menu. Cancelling setting (when blinks) OK + ESC More than 3 seconds Burner s restart 4.2 Starting and stopping To turn on the burner, turn on boiler s main switch. If burner displays STOPPED, go to BURNER menu and set OFF to ON or push OK button down more than 5 seconds. The display shows WAITING. Now turn boiler thermostat to desired temperature. The burner goes to TESTING-state. If this is the first run, external auger needs to be filled up with pellets. It can take as long as 10-15minutes. To stop the burner, set BURNER from ON to OFF in main menu. Now the burner stops burning when all pellets in burning chamber are burnt and turns safely to STOPPED status. STATUS menu will display the changes: BURNING END BURN END BLOW STOPPED The stopping procedure may take up to 20 minutes. Caution! Do not turn off mains power to terminate burning process. Use the boilers thermostat for that. In order to complete burning procedure safely let the burner to burn all fuel in burning chamber. Never leave burner unattended when you had to stop boiler s work by turning boiler off from mains switch in any reason. 4.3 Refilling fuel The fuel storage must be refilled before it runs empty. Fuel can be added at any time during the operation. If the storage runs empty before new fuel is added, the burner must be restarted again. Starting will take now more time, because burner has to be filled with pellets. Turn burner OFF and then back ON. Failing to do so will result LEVEL ERROR due to fuel loading timeout. 4.4 Status description STATUS screen displays momentary state and log of last events (burner statuses) and their duration and error messages. Burner s statuses and error messages are described in Table 9 Table 9 Status description Status Message STOPPED WAITING TESTING CLEANING Description The burner is not turned on. The burner is turned on and waits for command from the thermostat of the boiler. Testing the fan, battery, and external feeder. In the end of TESTING burner starts the CLEANING procedure, during what the burning grates are moved back and forward in order to remove ash out of burning chamber. Lower grade moves with the help of motor down the upper grate. Ash falls to front of lower grate and is pushed out of burning chamber. To CLEANING the PAR48 has to be switched on.(0= CLEANING OFF).

PV100b / PV180b pellet burner page 24/ 40 LOADING LOADING2 IGNITING PREBURN BURNING HOLD FLAME END BURN END BLOW NO PELLETS NO FLAME OVERHEAT External auger loads necessary amount of pellets for ignition into burner. The amount of fuel loaded is measured by counting rotations of feeder auger. That depends on fuel level sensors: If sensor recognizes existence of pellets in burner, the feeder auger starts working. Feeder auger stops when there is not enough pellets in burner. External auger and level sensor keep during loading permanent level of pellets in feeder auger: If there are no pellets in the feeder auger, the external auger starts to work. When pellets are recognized during 5 seconds external auger will stop. Max loading time is limited to 5 minutes in normal conditions and 20 minutes after manual start. Igniter is preheated in the end of loading cycle. Second try if the first ignition was not successful. Loaded amount of pellets are in the burning chamber, igniter and fan are working till photocell recognizes flame. In ignition status igniter heats up, fan starts to blow hot air to pellets and they will be ignited. Igniter works cyclically. The purpose of pre-burn is to ignite pellets properly. Only the fan is working, the igniter is off. Pellets will start burning properly. That phase consists of 3 5 cycles. Between cycles small amounts of pellets will be added. Status of normal working: External auger works by level sensor, feeder auger and fan are working according to set power level. Photocell must see the flame. External auger keeps necessary level of pellets. The work of external auger is controlled by level sensor: External auger will be started when sensor detects that there are no pellets in burner after 2 turns of feeder auger. External auger will be stopped when pellets are detected. The purpose of this function is to reduce number of ignitions. The status can be AUTO, ON or OFF. When AUTO is selected then HOLD FLAME will switched on when time between 2 sequential WAITING statuses has been less than 15 minutes (Par 11). AUTO status lasts 1 hour and ends with burn end cycle. In that cycle, pellets are fed every 127 seconds and air is blown minimally. Boiler has reached an estimated temperature and boiler thermostat has turned off the burner. The external auger has stopped; the feeder auger and fan are still working until all fuel is burnt. When photocell doesn`t see any flame only the fan keeps on working with minimum speed in order to make sure there is no fuel in burner. Level sensor does not detect pellets. There might be too much saw dust inside the feeder auger. There is no flame in the burner more than 120 seconds during burning (solutions Temperature in the burner has reached pre-set temperature and burner turned itself off (solutions ch 6). IGN.ERROR Flame is not recognized after ignition cycle (solutions ch 6). LEVEL ERR Level dose not reached or level dose not disappear at burning time (solutions ch FEEDER ERR Jam in feeder or feeder rotation is not detected (solutions ch 6). GRATE ERROR When lower grate is got stuck, then it is tried to move it back and forward. If grate doesn t move such movements are tried again. After 1 minute unsuccessful trial

PV100b / PV180b pellet burner page 25/ 40 the lower grate moves back to initial position and GRATE ERROR is displayed. FAN ERROR Fan rotation problem (solutions ch 6). BATTERY Battery is not connected or is empty or is out of order. NO POWER Power supply is not detected or safety thermostat has turned burner out due to overheat or back burning. Burner works on battery. 4.5 Output power levels Burner has 6 pre-set output power levels. For every level, the program calculates correct fuel amount what depends on fuel s calorific value and burner s internal feeder productivity. The feeder productivity for normal, light and heavy pellets can be changed from main menu. For normal pellets it is 38 grams per rotation. Calculated amount of fuel is divided into periodic feeding cycles. In every cycle internal feeder makes half rotation. If the calculated cycle comes too short then the cycle length is doubled and fuel is fed with by full rotation of feeder. For every power level there is different pre-set fan rotation speed. (PAR1..PAR6). Burner chooses the output level between pre-set min and max powers. When burning time has been more than 30 min (PAR 15), next time burner takes one power level up, when burning time has been less than 15 min (PAR 16), next time burner takes one power level down. 4.6 Main menu and settings To enter to setting menu press OK. To go back to STATUS menu, press ESC button. Table 10 Main menu Menu Menu para- Description Default Options nr meter ENG settings 1 STATUS-> Submenu with status info 2 INFO-> Burner s info 3 BURNER Burner s turning ON/OFF OFF ON/OFF 4 HOLD FLAME Hold flame allowed OFF ON/OFF/AUTO 5 PELLETS Fuel quality options NORM NORM/LIGHT/HEAVY 6 POWER Power level selection AUTO PV100: AUTO/20/26/32/38/44/50 PV180: AUTO/100/110/120/140/160/180 7 BASE AIR Fan speed change at 0-2/-1/0/+1/+2/+3/+4/+5 once for all power levels 8 LANGUAGE Language options ENG Annex 3 List of languages 9 PARAMETERS -> Parameters menu Annex 2 List of parameters STATUS menu displays burner s momentary state, last events (burner states, their duration and error messages. The duration is in form mm:ss ( m in the middle) or hh:mm ( h in the middle). For example IGNITING 01m25 means that the burner ignition state have lasted 1minute and 25 seconds. Momentary state changes in every second or minute. All burner statuses are described in Table 9. NOTE! To separate decimals the comma (,) is used.

PV100b / PV180b pellet burner page 26/ 40 INFO menu displays main burner s indicators like: battery voltage: U=13V64 i.e. 13,64V when feeder motor works feeder auger motor s current: I=2,0 A firmware version and date: ver=3.88 31.10.13 total amount of pellets burnt: Total= kg (reset when firmware upgraded) interim amount of pellets burnt: Count= kg (reset from INFO menu press OK > 3 sec) selected and max power level : P= 100/180 kw (selected from POWER menu) burners temperature: T=23 o C fan s speed: F= F=28/38± 2 0/35 rps (28 actual speed of primary fan, 38 set-up speed of primary fan, ± 2 base air value, 0/35 same for secondary fan) burning chamber s pressure: -128,5 Pa Menu BURNER enables to turn burner ON or OFF. The main idea of HOLD FLAME function is to reduce permanent ON OFF cycles. This function is useful if burner s working time is much longer than stand by time. For example 1 hour of working time and 10 minutes of waiting time. In HOLD FLAME state the fan rotates slowly (PAR10) and small quantities of fuel are added to burner. Existence of flame is not checked. Such status lasts max one hour, after what burner ends usual cycle and stands by. If signal from boilers thermostat arrives before hour, burner goes to state BURNING. If HOLD FLAME is set to AUTO, it activates if two standby times have been shorter than set value in PAR11. HOLD FLAME turns off if flame has been hold more than PAR12 value. Menu PELLETS enables to select between 3 preset fuel quality options. Depending on fuel quality the weight of pellets and its caloric value may differ in same volume. Normal weight for pellets is 650..670 g/l (650..670 kg/m 3 ). By default burner calculates that one rotation pushes 70 gramms pellets (PAR21) to burning chamber. If pellets density is smaller i.e they are lighter (less than 600 g/l), then with one rotation less pellets will be delivered into burning chamber. Such mistake may to be compensated by selecting LIGHT from PELLETS menu. Now burner calculates that one rotation equals with 65 gramms of pellets (PAR22) and makes more rotations and delivers more pellets into burning chamber. If pellets are heavier than normal ( more than 700g/l) HEAVY has to be selected in PELLETS menu. Now burner calculates that 75 g of pellets is delivered with one rotation to burning chamber and delivers fewer pellets into burning chamber. In general case there is no need to make changes in PELLETS menu. Weight of pellets can be manually changed in PAR21..PAR23. Menu POWER determines caloric productivity of burner in kilowatts. Power is calculated by reading the rotations of the feeder auger, taking into account average caloric value of 1 kg of pellets. It is possible to pre-set particular (80; 100; or else) power level value or AUTO - automatically selected value. In AUTO status burner selects necessary power level depending on time what is needed to achieve pre-set temperature. Burner changes its capacity what is determined by parameters MIN POWER (PAR13) and MAX POWER (PAR14). If burner cannot achieve pre-set temperature in certain time (PAR15) it will raise its power automatically by one level and continues rising power up to reaching maximum level (PAR14) or boiler has achieved pre-set temperature. If boiler achieves pre-set temperature faster than set in PAR16 burner will work one power level lower in next cycle. Power will be reduced as long as burner has reached minimal power level (PAR13).

PV100b / PV180b pellet burner page 27/ 40 Menu BASE AIR changes speed of fan in all power levels by same number. It is reasonable to use base air to compensate different characters of particular heating systems. For example if draught is very good the fan will work with lower rotations in base air negative value. Menu LANGUAGE enables user to select between 17 languages. List of languages is in Annex 3. Menu PARAMETER gives overview of burner s default and min max settings. The menu enables fine tuning of the burner. Generally it is not necessary. Short description of parameters is given in Annex 2. 4.7 Regular maintenance The burning chambers of pellet burners PV100and PV180 are equipped with automatic self-cleaning and ash removing systems. When system works regularly, there is no need to clean the burning chamber separately. Only the boiler needs regular cleaning and maintenance. Despite burner has self-cleaning ash removing system, nevertheless the ash collects under and on grates. That s why at least twice a heating period the grates need cleaning. The frequency of maintenance depends on quality of pellets and intensity of heating. To clean the burning chamber: 1. Turn the burner off by switching from main menu BURNER to OFF. 2. Let the burner cool down for at least one hour. 3. Open boilers door, to enter to burning chamber. 4. Remove upper arc fire bricks. 5. Remove grates and clean them totally up. Make sure that all holes in grate were clean. 6. Place back grates. Make sure the grate to be placed correctly to holders. 7. To end the cleaning shut the boilers door and turn thermostat to required temperature and turn burner ON. Despite burner has self-cleaning system the boiler has to be cleaned from collected ash and nonburning residues. Manufacturer of pellet burners don t prescribe time period of cleanings. ATTENTION! BOILER HAS TO BE CLEANED FROM ASH AND NON-BURNING RESIDUES BEFORE THEY GET TOUCHED WITH BURNERS BURNING CHAMBER. The ash and non-burning residues are perfect heat insulators. If burning chamber is surrounded with ash and non-burning residues so its normal ventilation is distracted. It causes fast overheating, out-burning and deformation of the burning chamber. ATTENTION! DEFORMATION AND OUT-BURNING OF BURNING CHAMBER CAUSED BY NOT-IN- TIME MADE CLEANING IS NOT MANUFACTURING DEFECT AND IS NOT WARRANTY OBJECT. 4.8 Replacing the components Except replacing the igniter, it is recommended to turn to specialist when other components need replacing. Attention! Before opening the housing of burner turn it off from supply mains. Attention! Follow the polarity when connecting battery. Wrong connecting of the battery damages controller and is danger to people around. 4.8.1 Replacing igniter To replace igniter small (2,5..3 mm) flat screwdriver for connecting wires and 3mm hex wrench for replacing the igniter are needed. 1. Make sure that burner is out of mains supply.

PV100b / PV180b pellet burner page 28/ 40 2. Remove burners red cover. 3. Unroll igniter s wires from control board. 4. Unroll screw what fixes igniter with hex wrench thru the hole in burner s housing. Screw has to be loosening not removed. 5. Open boilers door to make access to burning chamber possible. 6. Push the igniter into burning chamber and take it out thru burning chamber. 7. Swirl igniter s wires and push them to igniters housing. 8. Push igniter into its housing that its end will be at same level with back wall of burning chamber. 9. Fix the screw again and make sure that igniter s end would not touch the back wall of burning chamber. 10. Reconnect wires. Polarity is not important. Fix wires with screw back to controller s board. 4.8.2 Resetting safety thermostat Attention! In order to replace thermostat the burner has to be turned off from supply mains. Safety thermostat is located on burners input tube. See component 13 in Figure 2. When burner is overheated the safety thermostat turns it off. Overheating may arise when draught in boiler is in wrong direction and pellets start back burning in feeder auger s tube. There may be two types of thermostats with reset button or without it. The safety thermostat without button resets itself in time being after overheat temperature disappearing. The safety thermostat with button has to be reset manually: 1. Make sure the burner has cooled down and disconnected from mains supply. 2. Remove burner s cover. 3. Press small button on thermostat. 4. Put cover back and connect supply mains. 5. Press OK for 5 sec and burner should start to work. 6. If burner s display would not screen and fuse F5 is well, the safety thermostat has to be replaced. Figure 25 Safety thermostat 4.8.3 Replacing fuses Burner s controller is protected against the errors of external devices with electrical fuses. Fuses may blow in case a foreign object gets into the fan or motor and blocks their work. Fuses are located in the controller upper part and are labelled as F1...F5. See Annex 1 Electrical diagrams. Replacing: 1. Make sure the burner is disconnected from power supply. 2. Remove burner s cover. 3. Remove the fuse and check its state with a tester or looking it against the light. 4. Replace the fuse with an equivalent one if necessary. The plastic cover of the fuse holder must be placed back directly not skewed. Otherwise the cover might push the holder s contacts far from each other and break the connection. In case the fuse blows again, the component which is connected to the fuse probably needs replacing.

PV100b / PV180b pellet burner page 29/ 40 Table 11 Fuses Fuse Values Function F1 1A External auger F2 1A Fan F3 2A Flue gas fan F4 3A Igniter F5 3A Controller, feeder auger motor and grate mover motor. 4.8.4 Replacing fuel level sensors Fuel level sensors consist of two parts optical sender and receiver, which are located on vertical part on opposite sides of feeder auger s tube. See component 4 Figure 2. Most recent mistake to level sensors is getting dirty. Firstly you may try to clean them. When cleaning, try to avoid scratching or making lenses opaque. Remember that lenses of sensors are made from plastic! Lens get dirty when draught in boiler misses and smoke moves thru inner auger back to burner. The black and heat cover lenses with opaque layer. It is not recommended to replace sensors before you are sure, that LEVEL ERROR is caused by sensors. Pellets falling into burner s inlet tube clean sensors enough. Sensors cleaned too often get broken faster. Sensors may be screwed out when lenses are not reached other ways. Replacement: 1. Make sure that burner is disconnected from mains. 2. Remove burner s red cover by loosening 4 screws (2 on both sides). 3. Disconnect sensors from controller and screw them out from tube. 4. Mount new sensors and notice that when connect plugs to socket: TRS is black sensor and RSV is white sensor. 4.8.5 Replacing flame sensor Flame sensor may get black or smelt in the case of back burning. Flame sensor consists from light sensitive resistor and transparent plastic housing. Housing is situated inside of black rubber nest. For replacement small screwdriver (2,5 3,5mm) is needed. For checking and changing: 1. Make sure that burner is disconnected from supply mains. 2. Remove burner s red cover by loosening 4 screws (2 on both sides). 3. Pull the sensor out and clean transparent part with soft cloth. 4. If sensor is smelted pull it out and replace. 5. Reconnect the wires. The polarity is not important. Screw terminal must be tightened so hard that when pulling the wires, they would not come out from under the screw. 4.8.6 Replacing battery When some blackouts have taken place in short time period, it may happened that battery is just empty and needs charging. In that case we have just to wait, up to battery is fully charged. In this case no battery replacement is needed. Battery has to be replaced when burner displays BATTERY LOW despite being charged or after every 5 years. As battery is the safety element the burner checks permanently its running order and doesn t start next working cycle when battery s voltage is too low. To replace battery:

PV100b / PV180b pellet burner page 30/ 40 1. Make sure that burner is disconnected from supply mains. 2. Remove burner s red cover by loosening 4 screws (2 on both sides). 3. Push battery in order to remove it from housing. (Double sided tape). 4. Disconnect wires from battery. 5. Replace battery. It is recommended to fix battery to base with new double sided tape. 6. Reconnect battery wires. CAUTION! ALLWAYS CONNECT RED WIRE WITH RED BATTERY CONTACT (+) AND BLACK WIRE WITH BLACK BATTERY CONTACT (-).WRONG CONNECTION WILL DAMAGE THE CONTROLLER AND MAY BE DANGER TO PEOPLE. 5 Status change logics Status Next Status Change conditions WAITING TESTING Boiler thermostat switches on. TESTING LOADING All tests are done successfully. BATTERY LOW Battery voltage is less than 12V. FAN ERROR Fan does not reach 40 rps at PRE-BURN. LEVEL ERROR The level sensor recognizes pellets in the feeder inlet. LOADING IGNITING Loading rotations (PAR24) made by feeder. FAN ERROR Fan speed does not reach 35 rps. NO PELLETS Maximum loading time (5 min. normal or 20 min. manual start) is reached. END BURN Flame detected but unknown start conditions. LOADING again. IGNITING PRE-BURN Flame recognized. LOADING 2 Max ignition time (255 sec.) is reached and load 2 is not done. IGN. ERROR Max ignition time (255 sec.) is reached and load 2 is done. LOADING 2 IGNITING Previous state was IGNITING, feeder made 3 rotations (PAR25). PRE-BURN Previous state was HOLD FLAME, feeder made 3 rot. PRE-BURN BURNING Max pre-burn time (PAR41) is reached and flame is continuously recognized more than 5 seconds. LOADING 2 Max pre-burn time (PAR41) is reached, no flame detected and LOADING 2 is not done. FLAME ERROR Max pre-burn time (PAR41) is reached, no flame detected and LOADING 2 is done. BURNING END BURN No signal from boiler thermostat (HOLD FLAME is OFF in main menu). HOLD FLAME No signal from boiler thermostat (HOLD FLAME is ON or AUTO in main menu). END BURN END BURN -> END BLOW ->LEVEL ERROR END BURN -> END BLOW ->NO Maximum burning time (4 hours) is reached. After 8 rot of feeder pellets are continuously detected in feeders inlet. Fuel level is not detected in feeders inlet in 4 min.

PV100b / PV180b pellet burner page 31/ 40 PELLETS FLAME ERROR Flame is not recognised more than 2 minutes. HOLD BURNING Boiler s thermostat has switched on. FLAME END BURN Max HOLD FLAME time (PAR12) is reached. END BURN END BLOW End of burning. Feeder made 15 * rot. + 10rot. Plus blow time 30sec. is reached. BURNING Boiler s thermostat has switched on, feeder has made less than 8 rot and previous state was BURNING. END BLOW WAITING No flame more than 1 min. and boiler thermostat is switched on. STOPPED No flame more than 1 min. and boiler thermostat is switched off. LEVEL ERROR No flame more than 1 min. Error from: BURN-> END BURN-> END BLOW>LEVEL ERROR. NO PELLETS No flame more than 1 min. Error from: BURN-> END BURN-> END BLOW->NO PELLETS. NO POWER WAITING Main supply exists and boilers thermostat is switched on. STOPPED Main supply exists and boilers thermostat is switched off. BURNING If BURNING was before NO POWER and less than 15 min in NO POWER. Any other WAITING Boilers thermostat is switched on. 6 Status durations State External auger Feeder auger Fan Igniter WAITING - ½ rot / 127s - - TESTING - 2 rot Maximum /10s - LOADING By fuel level PAR24-30...60 s LOADING 2 - PAR25 PAR8 - IGNITING - - PAR8 30/20 s PREBURN - - PAR8 - BURNING By fuel level By power level PAR1..PAR6 - HOLD FLAME By fuel level ½ rot / 127s PAR10 - END BURN - By power level PAR1..PAR6 - END BLOW - - PAR9 - STOPPED - ½ rot / 127s - - NO PELLETS - ½ rot / 127s - - FLAME ERROR - ½ rot / 127s - - OVERHEAT - ½ rot / 127s - - IGN. ERROR - ½ rot / 127s - - LEVEL ERROR - ½ rot / 127s - - FEEDER ERROR - ½ rot / 127s - - FAN ERROR - ½ rot / 127s - - BATTERY LOW - ½ rot / 127s - - NO POWER - ½ rot / 127s - -