MANUAL FOR INSTALLATION AND OPERATION OF A HEATING SYSTEM, CONSISTING OF HOT WATER WOOD PELLET BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV http:// www.greenecotherm.eu Page 1/44
Manufacturer Address ZMM Haskovo PLC. 67 Saedinenie, 6300 Haskovo, Bulgaria Telephone +359 800 15 145 Fax +359 38 603070 e-mail home page greenecotherm@erato.bg www.greenecotherm.eu The manufacturing company thanks you for purchasing the manufactured and delivered products. The manufacturing company provides this manual in help to the team that will install, adjust and service this system, as well as to the customer that will operate it. The manufacturing company requires that the technicians performing the above presented procedures has passed training course for the activities performed with the product. EXPLANATION: The notation Pelletherm v4 has been used in the current manual, which includes the hot water boiler models Pelletherm 18v4, Pelletherm 25v4 and Pelletherm 30v4, and also the notation GP IV for the pellet burners from series GP 25 IV and GP 32 IV. WARNING! In the interest of your safety it is recommended to read carefully and get well familiar with this manual, as well as with the automated wood pellet burner from series GP manual, (and also with the manual for installation and operation of the wood pellet hopper in case the system is equipped with such), before taking actions for installation, adjustment and operation. Non compliance with the below presented instructions, as well as with the acting legal regulations and directives, might lead to damages and unpredicted consequences for which the manufacturing company will not take responsibility. MANUAL FOR INSTALLATION AND OPERATION OF A SYSTEM, CONSISTING OF HOT WATER BOILER FROM SERIES PELLETHERM 18V4, PELLETHERM 25V4, PELLETHERM 30V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV (EDITION: 25.2.2013 Г. 12:58) Page 2/44
CONTENT Page. 1. DESCRIPTION AND ADVANTAGES OF THE SYSTEM: WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 5 2. DESCRIPTION OF THE SYSTEM: HEAT EXCHANGER BODY OF HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 7 2.1. DESCRIPTION OF THE HEAT EXCHANGER UNIT OF STEEL MADE WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4... 7 2.2. OVERAL INFORMATION ABOUT THE AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV... 8 3. TECHNICAL DATA FOR THE SYSTEM, CONSISTING OF WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 12 4. MOUNTING AND INSTALLATION OF THE SYSTEM.... 19 4.1. SPECIAL FEATURES AND REQUIREMENTS FOR INSTALLATION OF AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV TO STEEL MADE HOT WATER BOILER FROM SERIES PELLETHERM V4.... 19 4.2. MAIN INFORMATION FOR JOINT OPERATION OF THE SYSTEM: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 19 4.3. INSTALLATION AND MOUNTING OF THE SYSTEM S MAIN MODULES: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 19 4.3.1. MAIN REQUIREMENTS FOR INSTALLATION OF WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4.... 19 4.3.2. INSTALLATION OF THE SYSTEM.... 20 4.3.3. POSITIONING OF THE HOT WATER BOILER FROM SERIES PELLETHERM... 20 V4 FOR EASY OPERATION, SERVICING AND MAINTENANCE... 20 4.3.4. POSITIONING OF THE SYSTEM IN COMPLIANCE WITH THE... 20 REQUIREMENTS FOR CONNECTION TO THE MAIN ELECTRICAL SUPPLY NETWORK... 20 4.4. METHODIC FOR INSTALLATION OF THE SYSTEM MODULES... 21 4.4.1. CONNECTING TO A CHIMNEY... 21 4.4.2. CONNECTING TO THE HEATING INSTALLATION... 21 4.4.3. INSTALLATION OF AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV.... 22 4.4.4. MOUNTING THE FIRE-CLAY MADE DIRECTING BRICKS IN THE HEAT EXCHANGER S COMBUSTION CHAMBER.... 23 4.4.5. POSITIONING/CHECK OF THE ASH CLEANING SECTION COVER... 23 4.4.6. MOUNTING OF THE COVER PLATE IN FRONT OF THE FLUE GAS OUTLET... 24 4.4.7. MOUNTING OF THE BOILER S HORIZONTAL COVERS... 25 4.4.8. MOUNTING OF THE COVER OVER THE BOILER S CONVECTION TRACT... 26 4.4.9. MOUNTING OF THE COVER OVER THE BOILER S COMBUSTION CHAMBER.... 26 4.4.10. CONNECTING THE AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV TO THE BOILER... 27 4.4.11. MOUNTING THE FUEL TRANSPORT AUGER TO THE BURNER S MAIN MODULE.... 27 4.4.12. FILLING UP THE FUEL TRANSPORT AUGER.... 27 4.4.13. CONNECTING THE SYSTEM TO THE MAIN POWER SUPPLY.... 28 4.4.14. FINAL VIEW OF THE SYSTEM.... 28 4.4.15. RECOMMENDED HYDRAULIC DIAGRAM... 28 5. INITIALIZATION OF THE SYSTEM TO OPERATION... 30 5.1. MAIN REQUIREMENTS ABOUT THE USED FUEL.... 30 5.2. INITIALIZATION TO OPERATION OF THE SYSTEM: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED PELLET BURNER FROM SERIES GP IV.... 30 5.2.1. INTERFACE PANEL FOR CONNECTION AND CONTROL OF THE WOOD PELLET BURNER FROM SERIES GP IV. 31 5.2.2. POWERING THE BOILER FROM SERIES PELLETHERM V4.... 33 5.2.3. SWITCHING THE SYSTEM ON.... 33 5.2.4. PARAMETERS FOR BOILER OPERATION ADJUSTMENT.... 33 5.2.5. PARAMETERS FOR ADJUSTMENT OF WOOD PELLET BURNER FROM SERIES GP IV... 34 5.2.6. NOMINAL OPERATION MODE OF THE SYSTEM... 34 5.3. ADJUSTMENT OF THE SYSTEM HEATING OUTPUT... 35 5.3.1. DECREASING THE HEATING OUTPUT:... 35 5.3.2. INCREASING THE HEATING OUTPUT:... 35 5.4. ADJUSTMENT OF THE BURNING PROCESS.... 35 5.5. STOPPING THE SYSTEM OPERATION... 35 5.6. SWITCHING THE SYSTEM OFF... 36 5.7. INTRODUCING THE USERS WITH THE SERVICING AND ADJUSTMENT PROCEDURES OF THE SYSTEM... 36 5.8. SAFETY AND UNPREDICTED RISKS, RELATED TO THE SYSTEM USAGE:... 38 5.9. FAILURES AND TROUBLESHOOTING... 39 5.10. COMPLETING THE APPLIANCE WARRANTY CARD... 41 Page 3/44
5.11. ACTIONS AFTER EXPIRY OF THE SYSTEM LIFE CYCLE.... 41 6. WIRING DIAGRAM OF THE HOT WATER BOILER FROM SERIES PELLETHERM V4 IN COMBINATION WITH WOOD PELLET BURNER FROM SERIES GP IV... 42 WARRANTY CONDITIONS... 44 Page 4/44
1. DESCRIPTION AND ADVANTAGES OF THE SYSTEM: WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. The pellet boilers from series Pelletherm v4 are designated to utilize solid fuels biomass with pellet shape (other fuels are available as presented in the installation and operation manual of the automated wood pellet burner from series GP IV) as the boiler has a steel made construction. These boilers are used for local heating systems and also for heating of domestic water. The boiler utilizes wood pellets and other biomass, as described below, as the generated heat is accumulated by the heat exchanging surfaces of the boiler body and is transferred to the heat carrier in the heating system. The wood pellet hot water boiler from series Pelletherm v4 standard delivery kit includes: Heat exchanger 1 unit; Automated wood pellet burner from series GP IV 1kit; Ash tray 1pc; Boiler s bottom cover panel (between the second and third pass); Fire-clay made bricks 2 pcs; Flap 1pc; Door handle 1pc; Cleaning kit (scraper 1pc, hook 1pc); Electrical connectors for room thermostat 1pc, for extraction fan 1pc; Power supply cable 1pc; Nut and washer M10 2 pcs; Cuff for cleaning 1pc; Installation and operation manual of the system 1pc. The automated wood pellet burner, part from the system, is able to utilize the following fuel types: Wood pellets with diameter 6 and 8 mm, corresponding to category ENplus-A1, according to EN 14961-2:2010 (or category : A, AB, B according to the methodic developed and used by the appliance manufacturing company); Dry nuts (from cherries or sour cherries); Mixture of pellets and nuts (for example 50% - 50% ratio); Other biomass with pellet shape, but after approval from the appliance manufacturing company laboratory. The system consists of: Hot water boiler from series Pelletherm v4, which is steel made heat exchanger, for heating of the heat carrier, equipped with control panel board; Automated wood pellet burner from series GP IV. Advantages of the system: The system is designated to utilize biomass, which makes it ecologically clean and does not contribute to environment polluting and to global planet heating; The cost of the generated heat energy from biomass utilization as a local energy source is less influenced by the global fuel prices which makes the produced heat energy cost more competitive compared to the energy produced from conventional sources; The system hot water boiler from series Pelletherm v4 and pellet burner from series GP IV is automated and provides comfort during operation, close to other automatic hot water boilers (for example boilers utilizing liquid or gaseous fuels or electricity), which provides opportunity for usage in systems with programmable room thermostat; Page 5/44
Automatic system operation and availability for regulation by room thermostat (weekly programmer), which guarantees maximum heating comfort and fuel economy; Availability for energy utilization of biomass with pellet shape (wood pellets), dry cherry nuts and others more information is provided in the automated wood pellet burner from series GP IV manual book; High efficiency; Low levels of harmful emissions; Compact design providing availability for easy installation and maintenance (during cleaning and servicing); Availability for domestic water heating; Minimum operation costs. Page 6/44
2. DESCRIPTION OF THE SYSTEM: HEAT EXCHANGER BODY OF HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. The system consists of: Hot water pellet boiler from series Pelletherm v4; Automated pellet burner from series GP IV. 2.1. DESCRIPTION OF THE HEAT EXCHANGER UNIT OF STEEL MADE WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4. The steel made hot water pellet boiler from series Pelletherm v4 is designated for heating of local installations with natural or forced water circulation performed with or without circulations pump. The heat exchanger unit is module of the system designated for automatic utilization of pellets and for heating of the circulations water. The cleaning of the ash residues from the burning process can be performed manually through the combustion chamber s lower front door, by taking out the ash-tray and gathering its content in proper for the purpose containers. The burning process organization and the heat exchanging with the boiler body internal surfaces ensures high efficiency. The operation of the system: hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV depend on the chimney draught. The chimney draught depends on the chimney condition and on the flue gas temperature. The construction of the heat exchanging unit of hot water boiler from series Pelletherm v4 complies with the resistance requirements according to the acting standard for such appliances: EN 303-5/2000 Central heating hot water boilers part 5 Hot water solid fuel boilers with heating output up to 300 kw terminology, testing and notations. Figure 2.1. External view of steel made hot water pellet boiler from series Pelletherm v4. Page 7/44
The boiler consists of the following components/modules: The main module of the hot water boiler is the boiler body (heat exchanger), as the automated burner from series GP IV is mounted on its side. The heat exchanger is offered in two versions: so called left and right mounting. The automated pellet burner can be mounted only on the left or only on the right side of the boiler body; The heat exchanger unit construction is made of steel plates. The combustion chamber is designed in the front lower part of the heat exchanger, as the ash container is below it. The heat exchanger is with compact size related to the achieved heating output, because it has three pass design, which provides optimal heat exchanging and high efficiency; Fire clay made components mounted in the combustion chamber, which ensure optimal burning process and complete fuel combustion; The ash-tray is positioned at the bottom of the combustion chamber. The ash residues are gathered in it providing easy cleaning; The water inlet and outlet muffs are positioned at the boiler s back side and are inner threaded with size G1½, as through them the appliance can be connected to the heating system; The drain pipe is inner threaded with size G½ and a drain cock must be mounted on it; The flue outlet (with external diameter Φ149 mm) is positioned centrally in the top rear side of the boiler and serves for extraction of the flue gasses to the chimney; The steel made heat exchanger, its cover and doors are isolated with mineral wool, which limits the heating losses to the local environment; Manometer, positioned on the boiler body s front panel, indicates the circulations water pressure in the heat exchanger; External decoration side cover panels made of steel plates and painted with high quality color coating materials. 2.2. OVERAL INFORMATION ABOUT THE AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. The automated pellet burner from series GP IV has to be mounted horizontally on the hot water boiler from series Pelletherm v4 side (left or right mounting version) and is separate (individual) module from the system. The pellet burner from series GP IV is individual module, that can be mounted to various models of already installed hot water boilers (or another suitable heat energy consuming appliances) and to replace the used fuel type (for example diesel, oil, gas/natural gas, propane-butane, coals, firewood) with the so called densityficated(compressed) bio-fuel as wood pellets. The wood pellets provide easy automation of the burning process and highly efficient utilization of their energy. The wood pellets utilization, as with every other solid fuel, is accompanied with separation of ash, but its quantity is less compared with firewood or coal due to the pellets structure and content. At the same time the price of the heat energy, generated from wood pellets utilization is competitive compared with other energy carriers. The automated pellet burner from series GP IV operation corresponds to the functionality of every other fossil fuel automatic burner (for example: gas, oil, diesel): it automatically starts, ignites the fuel, the burning process is precisely controlled by the integrated control module. These are qualities that provide availability for achievement of operation comfort, the same as from the already popular automated appliances that utilize fossil fuels. The biomass fuel is ecological and with attractive price. Description of the burner s main components The automated pellet burner from series GP IV is with compact module construction, consisting of the following components: The major part of the appliance is the main module that consists of: Page 8/44
Combustion chamber, that provides conditions for optimal burning process and is made of high quality fire-proof steel; Fire-grate of the combustion chamber, that can be easily removed and provides availability for easy cleaning of the ash residues; Air distribution tract, that provides equal firing air distribution and cooling of the burner s components; Electrical heating element, used for initial fuel firing and positioned under the combustion chamber s fire-grate; Fresh (firing) air fan, equipped with sensor for determining the rotation velocity and providing availability for adjustment; Photo-sensor for monitoring of the burning process, positioned sideways for easier cleaning; Emergency temperature sensor for prevention of the so called back fire in the pellets inlet pipe; Control module, for monitoring and controlling of the burner operation; Fuel transport auger connector, used for powering the auger; Interface panel, equipped with display and keyboard for easy adjustment. Electrically powered external auger used for transportation of the fuel from the hopper to the burner. The auger consists of compact size motor-gear equipped with integrated overheating protection, pipe in which the fuel is transported to the flexible pipe drop zone; Flexible pipe made of special transparent thermo-resistant inflammable material (it melts but does not separate toxic substances) that connects the auger and the burner s main module. EXPLANATION: Up to date and detail information about the heating-technical data of the pellet burner from series GP IV is presented in the burner s manual book. Figure 2.2. External view of automated pellet burner from series GP IV. Page 9/44
External auger for fuel transportation from the hopper to the burner Flexible pipe Main module Figure 2.3. Positioning of the pellet burner s main module (side view). Main information about the fuel hopper The pellet hopper is the reservoir of the pellet kit that provides conditions for compact storing of the fuel, needed for long-term operation of the system and optimal conditions for operation of the burner s transport auger. In case the hopper is build/constructed at the customer s site then its construction must provide free (gravity) fuel flow to the auger s intake zone, easy refueling, cleaning and enough capacity for longer operation of the system. The manufacture company produces sectional (assembled) pellets hoppers, made of galvanized steel plates, with capacity: 250, 450 и 650 kg. Page 10/44
Figure 2.4. Sectional (assembled) sheet metal pellets hopper (the presented model is with 250kg capacity). Figure 2.5. Sheet metal pellets hopper 300L. Page 11/44
3. TECHNICAL DATA FOR THE SYSTEM, CONSISTING OF WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. Technical heating data for the system: heat exchanger unit of hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV operating with wood pellets is presented in Table 3.1; Technical data for the system: heat exchanger unit of hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV operating with wood pellets is presented in Table 3.2; The parameters of the recommended fuel available for utilization by the system are presented in the automated pellet burner from series GP IV manual book; Classification of the wood pellets and their physical parameters are presented in the automated pellet burner from series GP IV manual book. EXPLANATION: the hot water boiler from series Pelletherm v4 is produced in two models for mounting of the pellet burner so called left mounting (i.e. the burner is mounted on the boiler s left side when you look at the boiler frontally) and so called right mounting (i.e. the burner is mounted on the boiler s right side). Page 12/44
Parameter Dimension Value Model of the hot water boiler Pelletherm Pelletherm Pelletherm - 18v4 25v4 30v4 Model of the pellet burner - GP 25 IV GP 32 IV Nominal heating output of the system kw 15 25 30 Heating output adjustment range kw 7.5-15 7.5 25 9-30 Used fuel Wood pellets; Dry cherry nuts; Other dry nuts. Suitable wood pellets category according to standard ENplus ENplus-A1 Suitable pellets category (according to the appliance manufacturing company A, AB, B classification) Wood pellets consumption at nominal heating output kg/h 3.65 6.05 7.15 Required air quantity to achieve effective burning process kg/h 27 30 45 50 57-64 m 3 /h 24 27 39 44 50-56 Flue gas mass flow rate g/s 9.4 15.6 19.8 Average wood pellets consumption of the heating kg/h 2.5 4.1 4.9 system Efficiency in nominal operation mode 89 89 89 Excess air ratio λ 1.5 1.7 Flue gas temperature in nominal operation mode ºC 180 200 Residues from the burning The quantity depends on the fuel s ash content Ash process Table 3.1. Technical heating data of the system: heat exchanger unit of hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV operating with wood pellets. Page 13/44
Parameter Dimension Value Hot water pellet boiler model Pelletherm Pelletherm Pelletherm - 18v4 25v4 30v4 Automated pellet burner model - GP 25 IV GP 32 IV Boiler weight kg 160 180 190 System weight kg 192.2 212.2 222.2 Boiler water volume dm³ 44 50 60 Overall W-Wide 1008 1008 1008 dimensions of the system : W х D-Depth mm 776 776 776 D х H H-Height 883 963 1043 Boiler class - 3 Operation water overpressure in the boiler MPa 0.25 Type of the expansion tank in the heating system - Open or closed (pressure up to 0.25MPa) Boiler test overpressure MPa 0.4 Recommended operation water temperature in the boiler ºC 80 Minimum boiler inlet water temperature ºC 60 Chimney draught * hpa 0.1-0.2 * Connection Inlet/outlet water pipes G 1½ Drain pipe G ½ Flue outlet mm 149 Circulations water hydraulic resistance at nominal heating output hpa 1.86 2.38 3.24 Power supply voltage - L1, N, PE, 50Hz; 230V; System electrical output VA <100 + 1100 (with ignition) System electrical protection - IP20 Table 3.2. Technical data for the system: heat exchanger unit of hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV. * If the chimney draught operation parameters are lower than the above presented values it is necessary to install flue gas extraction fan. The system s overall dimensions are presented on the next figures. Page 14/44
W H Figure 3.1. View of hot water pellet boiler from series Pelletherm v4 (overall sizes) front view. D H Figure 3.2. View of hot water pellet boiler from series Pelletherm v4 (overall sizes and connection dimensions) burner s mounting flange side view. Page 15/44
W H Figure 3.3. View of the system (with presented overall and connection sizes): hot water pellet boiler from series Pelletherm v4 and pellet burner from series GP IV rear side view (the presented model is for left mounting of the burner). W D Figure 3.4. View of the system (with presented overall and connection sizes): hot water pellet boiler from series Pelletherm v4 and pellet burner from series GP IV top view (the presented model is for left mounting of the burner). Page 16/44
Boiler s top cover panel Boiler s convection tracts cover Boiler s combustion chamber cover Boiler s combustion chamber door cover panel Burner mounting flange Figure 3.5. View of the system: hot water pellet boiler from series Pelletherm v4 and pellet burner from series GP IV (the presented model is for left mounting of the burner). Page 17/44
Boiler s top cover panel Flue gas outlet to chimney Flue gas third pass of the boiler Flue gas second pass of the boiler Flue gas first pass of the boiler Boiler s combustion chamber Bottom cover cap of the baffle separating the convection tracts and the combustion chamber of the boiler Combustion chamber door of the boiler Ash container (tray) Figure 3.6. Cross section view of the hot water pellet boiler from series Pelletherm v4 with presented direction of the flue gasses and main construction modules (the presented model is for left side burner mounting). Page 18/44
4. MOUNTING AND INSTALLATION OF THE SYSTEM. 4.1. SPECIAL FEATURES AND REQUIREMENTS FOR INSTALLATION OF AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV TO STEEL MADE HOT WATER BOILER FROM SERIES PELLETHERM V4. The automated pellet burner from series GP IV has to be mounted to the heat exchanger unit of the hot water boiler Pelletherm v4. The boiler construction provides availability for left or right mounting of the burner, therefore the suitable combination should be chosen during the preliminary system installation project. During the mounting process a proper sealing between the modules/components must be ensured in order to prevent intake of unorganized air from the environment or exhaust of flue gasses. The following requirements must be also taken into account: Easy access for cleaning of the burner s fire-grate; Secured safe operation conditions and maintenance of the system reliability; Availability for adjustment and servicing of the system: heat exchanger of the pellet boiler from series Pelletherm v4 (for example when necessary to clean it), burner from series GP IV for adjustment, necessity for maintenance and regulation, transport auger for servicing and maintenance, fuel hopper for refueling and cleaning. 4.2. MAIN INFORMATION FOR JOINT OPERATION OF THE SYSTEM: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. The achieved heating output of the system: hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV depends on: The heating output adjusted for the burner operation; The contamination level of the boiler s heat exchanging surfaces; The sealing level of the door and combustion chamber s covers (the sealing ropes condition); The chimney draught. The efficiency coefficient of the system: hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV in nominal operation mode reaches 89% (depending on the specific system) it can be achieved by adjustment of the burner s operation parameters by the use of gas-analyzer (to be performed by an authorized servicing specialist). 4.3. INSTALLATION AND MOUNTING OF THE SYSTEM S MAIN MODULES: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. The boiler installation must meet the following regulations and requirements: 4.3.1. MAIN REQUIREMENTS FOR INSTALLATION OF WOOD PELLET HOT WATER BOILER FROM SERIES PELLETHERM V4. The boiler room, designated for installation of the system, must provide constant fresh air intake, needed for the burning process and ventilation; It is not allowed to install the system in living premises, including corridors; The installation of the hot water pellet boiler from series Pelletherm v4 to the heating installation must be performed by a qualified technicians only; The installation and maintenance of solid fuel appliances must be performed by specialized companies that had acquired legal rights for such activities; The hot water pellet boiler from series Pelletherm v4 must be installed to a heating installation with OPENED or CLOSED expansion tank. In case the system is with closed expansion tank Page 19/44
then a pressure safety valve must be installed, that opens if the pressure exceeds the boiler s operation pressure (0.25MPa) and this valve must be certified according to PED 97/23; Before initialization of the system to operation complete filling with water/circulations liquid and air-freeing of the heating installation must be performed; System servicing/handling must be performed by adult persons only, which are well familiar with the appliance operation manual book. 4.3.2. INSTALLATION OF THE SYSTEM. The installation of the system: hot water boiler from series Pelletherm v4 and automated wood pellet burner from series GP IV, requires preparation of preliminary project complying with the acting norms and regulations: For the heating system EN 303-5/2000 Central heating hot water boilers part 5: Central heating solid fuel hot water boilers with 300 kw maximum nominal heating output terminology, requirements, test and notation ; For the chimney; Fire safety prescriptions; For the electricity supply network - EN 60335-1/1997 - Safety of domestic electrical devices. 4.3.3. POSITIONING OF THE HOT WATER BOILER FROM SERIES PELLETHERM V4 FOR EASY OPERATION, SERVICING AND MAINTENANCE. The minimum free space for manipulation in front of the boiler must at least 1000 mm; The minimum allowed distance between the boiler s rear side and a wall must be at least 400 mm; The minimum distance between the boiler s side, where the automated burner from series GP IV main module is mounted and a wall must be at least 500 mm, in order to ensure free access to the burner itself, as the fuel transport auger and hopper position have to be also taken in to account. EXPLANATION: the requirements for installation and operation of the fuel transport auger that supplies the burner s main module are presented in the burner s manual book. The minimum distance between the boiler s opposite side, to which the automated burner from series GP IV main module is mounted and a wall must be at least 500 mm, in order to provide access to the heat exchanger covers and availability for its easy cleaning from the ash residues; The minimum free space over the hot water pellet boiler from series Pelletherm v4 must be at least 600 mm, in order to ensure free access to the heat exchanger s internal surfaces for ash deposits cleaning purposes; The minimum distance between the hot water boiler from series Pelletherm v4 and the pellets hopper must be at least 1000 mm, in order to ensure safe operation conditions and prevention of fire. 4.3.4. POSITIONING OF THE SYSTEM IN COMPLIANCE WITH THE REQUIREMENTS FOR CONNECTION TO THE MAIN ELECTRICAL SUPPLY NETWORK. The system must be positioned in a way that provides free access to the power supply socket box (230V/50Hz); Page 20/44
4.4. METHODIC FOR INSTALLATION OF THE SYSTEM MODULES After the hot water boiler from series Pelletherm v4 has been positioned it must be connected to the heating installation and to the chimney by observing the relevant requirements. For correct and reliable operation it is required to level the boiler horizontally, which will ensure its reliable air freeing. 4.4.1. CONNECTING TO A CHIMNEY. After installation and ground leveling of the boiler it must be connected to a chimney, by observing the requirements for effective and reliable operation of the system. Muff circulations water outlet Flue gas outlet pipe Muff circulations water inlet Draining muff Figure 4.1. Rear side view of hot water boiler from series Pelletherm v4 (the presented model is for left mounting of the pellet burner). 4.4.2. CONNECTING TO THE HEATING INSTALLATION. As next the hot water pellet boiler from series Pelletherm v4 must be connected to the heating installation by using proper fittings has to be performed according to the preliminary prepared technical project. Page 21/44
4.4.3. INSTALLATION OF AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV. EXPLANATION the installation of the pellet burner from series GP IV must meet the requirements presented in its manual book. The mineral wool sealing must be mounted carefully to the connection flange and serves for isolation and to decrease the heat flow from the boiler to the burner. Side opening for mounting of the pellet burner Mounting screws for pellet burner from series GP IV to the boiler Figure 4.2. View of the mounting flange for connecting the pellet burner to the hot water boiler (the presented boiler model is for right side mounting of the burner). After mounting of the burner the screws have to be tightened equally, so the sealing between its flange and the boiler body is guaranteed. Figure 4.3. View of mounted pellet burner from series GP IV. Page 22/44
4.4.4. MOUNTING THE FIRE-CLAY MADE DIRECTING BRICKS IN THE HEAT EXCHANGER S COMBUSTION CHAMBER. The fire clay bricks, delivered with the boiler kit, should be mounted in the heat exchanger s combustion chamber (during transportation of the system the bricks are packed and placed in the ash drawer inside the boiler s combustion chamber). Figure 4.4. The fire-clay components are mounted correctly in the combustion chamber of hot water boiler from series Pelletherm v4. 4.4.5. POSITIONING/CHECK OF THE ASH CLEANING SECTION COVER. Cover cap, closing the flue tract Figure 4.5. The boiler s cover cap after its second flue pass is positioned correctly. EXPLANATION: the correct positioning of the cover is very important with regards to the boiler s efficient and reliable operation. Therefore after the boiler installation its position has to be checked and also every time after cleaning of the ash residues. Page 23/44
4.4.6. MOUNTING OF THE COVER PLATE IN FRONT OF THE FLUE GAS OUTLET. The cover panel has to be positioned by placing it on the special welded supports on the one side and in contact with the boiler body wall on the other. EXPLANATION: this cover plate serves to direct the flue gasses from the second to the third flue pass and also in case of emergency situations it should be opened in order to decrease the pressure pulsations (for example in case of high pressure of the flue gasses in the boiler s flue tract. WARNING: this cover plate is operating under thermal loads, therefore it has symmetrical design. It is recommended to rotate the cover panel on every two to three operation weeks. The directing cover panel is placed over the boiler s side, before its correct positioning. Figure 4.6. The directing cover panel is dismounted and the boiler flue outlet can be clearly seen. Page 24/44
The directing cover panel is positioned correctly A hook for easier handling of the directing cover panel Figure 4.7. Directing cover panel correct positioning. 4.4.7. MOUNTING OF THE BOILER S HORIZONTAL COVERS. Figure 4.8. Covers positioning of hot water pellet boiler from series Pelletherm v4. Page 25/44
4.4.8. MOUNTING OF THE COVER OVER THE BOILER S CONVECTION TRACT. EXPLANATION: this cover is equipped with protection plate, made of stainless steel. Figure 4.9. Directing cover over the boiler s convection tract. 4.4.9. MOUNTING OF THE COVER OVER THE BOILER S COMBUSTION CHAMBER. EXPLANATION: this cover is equipped with isolating plane, designated for operation under high temperatures in the boiler s combustion chamber. Figure 4.10. Directing cover over the boiler s combustion chamber. Page 26/44
Figure 4.11. The directing covers of the boiler s flue tract are placed correctly. EXPLANATION: these covers are different and their positions must not be changed. 4.4.10. CONNECTING THE AUTOMATED WOOD PELLET BURNER FROM SERIES GP IV TO THE BOILER. EXPLANATION: on the rear side of the boiler s side cover are installed couplings for connecting to: the power supply, the burner, room thermostat. Depending on right or left mounting of the burner the couplings are positioned on the adjacent side cover panel of the boiler. WARNING: these connection couplings are equipped with component that prevents from disconnecting and it must be released. 4.4.11. MOUNTING THE FUEL TRANSPORT AUGER TO THE BURNER S MAIN MODULE. The fuel transport auger has to be mounted in accordance to the requirements presented in the burner from series GP IV manual book. EXPLANATION: The tilting angle (between the auger s pipe axis and the horizontal plane) influences directly its production rate, i.e. the fuel feeding rate that it will provide at certain operation mode. Therefore if this angle is changed it will be necessary to re-adjust the burner in order to provide certain heating output. 4.4.12. FILLING UP THE FUEL TRANSPORT AUGER. The fuel transport auger of pellet burner from series GP IV has to be connected to a standard power supply and the fuel hopper has to be filled with fuel. Then should you wait until the pellets start to drop from the auger s outlet. After that the auger has to be plugged off and then plugged in to the burner s main module, as the coupling is positioned on the burner s right side. After that the system can be switched on. The manufacture company reserves its right to make changes over the system s construction, without obligation to inform its customers. Page 27/44
4.4.13. CONNECTING THE SYSTEM TO THE MAIN POWER SUPPLY. The power supplying of the system, consisting of hot water boiler from series Pelletherm v4 and pellet burner from series GP IV, should be performed by the power supply cable attached to the product s delivery kit. EXPLANATION: The manufacture company reserves its right to make changes over the presented modules construction, without obligation to inform its customers; The fuel transport auger has to be filled with fuel at initial start of the pellet burner and also after complete depleting of the pellets within its volume this process is presented in the burner s manual book. This operation must be presented and explained to the customer. 4.4.14. FINAL VIEW OF THE SYSTEM. Figure 4.12. Final view of the system: hot water boiler from series Pelletherm v4 and automated pellet burner from series GP IV. 4.4.15. RECOMMENDED HYDRAULIC DIAGRAM. Schematic hydraulic diagram for connecting a hot water boiler from series Pelletherm v4 to a heating installation with OPENED expansion tank is presented on the next figure. Page 28/44
Figure 4.13. Recommended hydraulic diagram for connecting a hot water boiler from series Pelletherm v4 to a heating installation, mixing valve and a heat accumulator. Num Name 1 Hot water boiler from series Pelletherm v4 2 Safety valve 3 Boiler for domestic water 4 Retaining valve 5 Circulations pump 1 6 Safety valve 7 Opened or closed expansion tank 8 Ball valve 9 Three way mixing valve 10 Circulations pump 2 Num Name 11 Ball valve 12 Water filter 13 Thermo regulation valve TV 14 Retaining valve 15 Contact type thermostat 16 Heat accumulator 17 Water filling automatic device 18 Filling / Draining cock 22 Automatic air freeing device with flap 23 Safety valve 24 Retaining flap Table 4.1 Names of the components presented on figure 4.13. EXPLANATION: According to standard EN 303-5 the heat accumulator is mandatory part from the heating system, to which a solid fuel hot water boiler is installed. The sizing of the heat accumulator is performed by using the methodic described in this standard (EN 303-5), as the manufacture company calculation method can also be used. WARNING: The installation completion and performance of the hot tests of the system must be marked in its warranty card and also in the pellet burner from series GP IV warranty card, as all fields must be completed with the required information. Page 29/44
5. INITIALIZATION OF THE SYSTEM TO OPERATION. WARNING: The system, consisting of hot water boiler from series Pelletherm v4 and automated pellet burner from series GP IV, must be initiated to operation only by specialized company, authorized for such activities. 5.1. MAIN REQUIREMENTS ABOUT THE USED FUEL. To ensure complete burning only dry fuel has to be used that complies with the requirements for reliable operation, presented in the pellet burner s manual book. The manufacture company recommends to store the fuel in dry and ventilated premises; Fuel storing near the system (boiler and burner) at distance less than 400 mm is strictly forbidden; The optimal recommended distance, recommended by the manufacture company, is at least 1000 mm. Preferably the fuel should be stored in a neighbor premise; All fire safety requirements must be observed during installation of the system, consisting of hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV and storage of the fuel. It is recommended to place a fire-extinguisher at easy accessible and visible place. The heating systems with opened expansion tank allow direct contact between the heating (circulations) liquid and the surrounding atmosphere. During the heating season the water absorbs oxygen (through the contact surface between the water and the air), which increases the corrosive action of the circulations liquid over the steel surfaces, as water evaporation can also occur. For refilling only water complying with the circulations liquids requirements, according to standard BNS- 15207-81, should be used. Constant water quantity in the heating system must be maintained during the heating season. When refilling the system with water air intake should be prevented. The water should be used only for its designation. It is recommended to check the water quantity in the heating installation on every 14 days. The system should be refilled with water only when the hot water boiler has been cooled. This is necessary in order to protect the steel made heat exchanger from thermal tensions and damage. In case the installation will not be used and there is risk of local freezing of the circulations water, it is recommended to drain the water out. Also the presence of water in the heating installation and the boiler protects the steel surfaces from contact with the oxygen, respectively from corrosion. 5.2. INITIALIZATION TO OPERATION OF THE SYSTEM: HOT WATER BOILER FROM SERIES PELLETHERM V4 AND AUTOMATED PELLET BURNER FROM SERIES GP IV. GENERAL CONDITIONS: The hot water pellet boiler servicing/handling must be performed by observing the requirements presented in the operation and maintenance manual book; Any intervention over the system operation that might endanger the health of the servicing personal is strictly forbidden; During operation of the system it must be periodically checked by the servicing personal/customer; The user must not perform any repairs over the system s modules. If a problem occurs during operation ask for servicing assistance from the relevant retail company; Operation with heating output over the boiler s nominal output is not allowed; The ash residues left from the burning process have to be gathered in fire proof container equipped with covers and after cooling to ambient temperature it has to be dumped at proper Page 30/44
for the purpose places. The ash remaining from wood pellets utilization can be also used for soil fertilization. 5.2.1. INTERFACE PANEL FOR CONNECTION AND CONTROL OF THE WOOD PELLET BURNER FROM SERIES GP IV. The system, consisting of hot water boiler from series Pelletherm v4 and pellet burner from series GP IV, is controlled by a module, positioned on the burner. It is equipped with display and keyboard which serve for adjustment of the system operation parameters. More information is presented in the pellet burner from series GP IV manual book. Components of the interface control panel and their functions: Switch START serves to submit START/STOP signal to the main module of the pellet burner from series GP IV, which performs the relevant function through the burner s controller; Room thermostat connector serves to connect a programmable room thermostat that can control the system s operation. Such thermostat is optional equipment and is not delivered with the system s standard kit; Communication connector connector for connecting the pellet burner controller to the boiler; Pellet burner connector serves to connect the burner cable to the boiler; Emergency thermostat serves to protect the hot water pellet boiler from overheating. It is factory adjusted to stop the pellet burner from series GP IV power supply, in case the circulations water temperature is exceeded above the limit (adjusted in the factory to 95 o C); Switch POWER serves for central switching of the hot water boiler from series Pelletherm v4 and of the pellet burner from series GP IV; Electrical fuse central fuse positioned on the boiler s control panel; Power supply used to connect the central power supply cable and to provide electric power to the system; Grounding/Earthing used to connect the system to grounding cable, in compliance with the acting regulation requirements; Page 31/44
Switch START Room thermostat connector Communication connector Pellet burner connector Emergency thermostat Switch POWER Electrical fuse Power supply connector Grounding Figure 5.1. Scheme of the electrical couplings, installed on the boiler s interface panel. Page 32/44
EXPLANATION: Manometer serves to indicate the pressure of the circulations water in the boiler s heat exchanger. The manometer is positioned at the top left corner of the heat exchanger s front panel. 5.2.2. POWERING THE BOILER FROM SERIES PELLETHERM V4. The boiler must be connected to the electric installation by observing the safety technique rules and requirements. The boiler is standard delivered with a power cable equipped with coupling used for connecting the boiler; The fuel hopper (it is not part of the system: hot water boiler from series Pelletherm v4 and automated pellet burner from series GP IV) must be filled with pellets, in order the feeding device to transport them to the burner zone. 5.2.3. SWITCHING THE SYSTEM ON. System s switching on can be performed by the switch POWER, positioned on the hot water boiler from series Pelletherm v4. At operation assignment, defined by the assigned circulations water temperature in the boiler (and by assignment from room thermostat if connected), the automated pellet burner from series GP activates and transits to automatic stand by mode pressing the switch START starts it. In case the START was preliminary switched on, the pellet burner starts immediately. If the system has been operated (or is in the so called hot reserve ), but the power supply (electricity) has been interrupted, it starts automatically when the power supply recovers. WARNING: At initial start of the burner and insufficient chimney draught (for example when the chimney height is not enough and if it is dirty) there is possibility for excessive smoking from the boiler covers zone, positioned over the combustion chamber and the convective zone, or/and from the combustion door sealing. Therefore it is recommended to check the door proper closing, its sealing, the covers and also the chimney condition. The same situation may occur during transition seasons autumn and spring, when the natural chimney draught is low, due to the high environment temperature; If the ignition pellets doze is not adjusted correctly a smoking through the boiler s unsealed parts might occur. In such case it is necessary to adjust the ignition (primary) pellets doze of the burner to be performed by servicing technician. EXPLANATION: During the fuel ignition mode a module activates electric heating element (heater), positioned under the burner s tilted fire-grate. This component heats the fuel until it fires and the flame indicates by the photo-sensor of the burner. Detail information about the burner s construction and operation is presented in the GP IV manual book; The automated pellet burner from series GP IV operates with preliminary assigned algorithm, installed in the burner s control module. The burner s controller parameters adjustment must be performed only by trained servicing technician. 5.2.4. PARAMETERS FOR BOILER OPERATION ADJUSTMENT. The hot water pellet boiler from series Pelletherm v4 operation mode is determined directly by the burner s control module settings, defining the assigned circulations water temperature in the boiler. The boiler s inlet water temperature has to be also taken in to account, as it influences the system operation, its reliability and efficiency. WARNING: The manufacture company guarantees efficient and reliable operation of the system: hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV, ONLY within the system s operation range, presented in Table 3.2 from this manual. Page 33/44
5.2.5. PARAMETERS FOR ADJUSTMENT OF WOOD PELLET BURNER FROM SERIES GP IV. The parameters defining the operation mode and the heating output of the burner and respectively of the boiler are presented in the operation and installation manual of the pellet burner from series GP IV. The meaning, functions and how to change these parameters must be explained to the end user, in order to provide flexible and optimal usage of the appliance. WARNING: In case that the hot water boiler model is Pelletherm 18v4, then the pellet burner from series GP25 has to be adjusted not to exceed the nominal heating output of the boiler. NOTES: The heating output levels and adjustment procedures are presented in the pellet burner from series GP IV manual book; The parameters used for adjustment of the automated pellet burner operation are presented in its manual book these parameters must be changed only by trained servicing technician; The manufacture company reserves its right to change the parameter values without obligation to inform its customers; The heating output adjustment of the system: hot water pellet boiler from series Pelletherm v4 and pellet burner from series GP IV, can be performed by initial adjustment of the burner s operation parameters has to be performed by authorized servicing technician. During burner operation failure situations might occur for example unsuccessful attempt for ignition, depleting of the fuel hopper and others, which should be indicated on the burner s display panel. To reset its operation switch off and then back on the POWER switch, but after the reason for the failure has been removed; The ash content does not change significantly the fuel combustion heat value (its caloricity), but requires specialized construction of the burner in order to ensure effective and economic burning process. Therefore the suitability and efficiency of certain fuel type have to be tested and after positive results it should be utilized by the burner. The manufacture company reserves its right to change the automated pellet burner from series GP IV settings without obligation to inform its customers. 5.2.6. NOMINAL OPERATION MODE OF THE SYSTEM. After completing the process to start the pellet burner from series GP IV (the pellets are successfully fired) and the hot water boiler from series Pelletherm v4 has heated the circulations water in the installation, and the installation has been equal-tempered, it can be stated that the system is in nominal operation mode. Final adjustments of the modules operation should be performed in such mode. The so called hot test of the appliance and the heating installation should be performed in nominal heating output mode, according to the acting regulations. NOTES: If a circulations pump is used for transferring the heat energy from the hot water pellet boiler to the heating installation, the reverse (cooled) water temperature should not be lower than 60 o C, because there is possibility for overcooling of the flue gasses, respectively for water vapors condensation as a product from the fuel combustion; Page 34/44
Continues operation of the appliance below its minimum heating output is not recommended, as presented in Table 3.1, because such operation modes are inefficient and not economic; If necessary to operate the system for longer time, especially the hot water boiler from series Pelletherm v4, in heating output mode lower than the minimum, it is recommended to install and connect a heat accumulator (buffer), in order to ensure its efficient, economic and reliable operation (see Error! Reference source not found.); During the initial start up of the hot water boiler from series Pelletherm v4, water vapors condensation over the heat exchanger internal surfaces might occur. This one-time (single time) process does not cause troubles to the appliance operation. 5.3. ADJUSTMENT OF THE SYSTEM HEATING OUTPUT. The system s (boiler) heating output adjustment can be performed by adjusting the heating output level of the pellet burner from series GP IV. For detail information read the burner s manual book. WARNING: In case the used fuel type has to be changed it might be necessary to change the burner s heating output level. 5.3.1. DECREASING THE HEATING OUTPUT: It can be performed by decreasing the burner s heating output level. For detail information read the burner s manual book. WARNING: Do not decrease the burner s heating output below the system s minimum output, because such modes decrease its efficiency and reliability. 5.3.2. INCREASING THE HEATING OUTPUT: It can be performed by increasing the burner s heating output level. For detail information read the burner s manual book. WARNING: Do not increase the burner s heating output above the system s nominal output, because in such modes its efficiency and reliability are decreased and there is possibility for excessive heat loading of its modules and components, which might lead to emergency situations and thermal deformations. 5.4. ADJUSTMENT OF THE BURNING PROCESS. The pellet burner from series GP IV is factory adjusted to optimal operation parameters and it is not necessary to re-adjust it. The burning process adjustment has to be performed by trained and authorized servicing technician. The burning process, from the pellet burner, adjustment must provide flue gas parameters that comply with the requirements of standard EN 303-5 and with the system operation data. 5.5. STOPPING THE SYSTEM OPERATION. The system operation can be stopped by stopping the pellet burner. Detailed information is presented in the pellet burner from series GP IV manual book. Another method to stop the system operation is by using the switch START, positioned on the interface panel of the hot water boiler from series Pelletherm v4. To restore the system operation press this switch again. Page 35/44
WARNING: It is forbidden to stop the appliance by the switch POWER during operation! The recommended stopping by the switch START or by the burner display module provides controlled and safe stopping. After stop command the fans operation ensure readiness for next starting and preserve the photo-sensor from damage. In case operation of the system is no longer needed, then the boiler and the burner have to be cleaned from the ash deposits over the surfaces which contact with the flue gasses. EXPLANATION: The stopping mode of the pellet burner from series GP IV is presented in details in its operation and installation manual book. WARNING: In case the system should be stopped entire cleaning of the heat exchanger s walls and the burner s combustion zone from the ash deposits should be performed, because the ash has corrosive influence over the steel surfaces, which decreases the appliance life. At the end of the heating season not only cleaning but also prophylaxis has to be performed by specialized servicing company. Observance of these procedures ensures long life of the system s modules and their reliable operation. 5.6. SWITCHING THE SYSTEM OFF. The appliance switching off can be performed by stopping the pellet burner from series GP IV operation. This is the recommended method to switch off, because it ensures the so called controlled stopping, during which the automated pellet burner from series GP IV continues to monitor for emergency modes. After the boiler has been cooled down it has to be stopped by the switch POWER, positioned on the interface panel of the hot water boiler from series Pelletherm v4. It is also recommended to clean the boiler and the burner from the ash deposits. Emergency shut down. During operation of the system some of the modules (hot water boiler or pellet burner) might transit to emergency mode. Some emergencies might be indicated by the relevant module sensors which should perform automatic prevention procedures. WARNING: In case of emergency situation overheating of the hot water boiler from series Pelletherm v4 its emergency thermostat activates, positioned on the boiler s interface panel. The cause for the emergency must be identified and the relevant measures taken. The thermostat must be switched back manually, by unscrewing its protection cover cap and pressing its button, after that the cover cap must be screwed again. The pellet burner from series GP IV must be reset too by switching off and then back on the button POWER, positioned on the boiler s interface panel; In case of emergency situation with the automated pellet burner from series GP IV it transits to emergency mode, that stops its operation, followed by indication on the display panel. In such cases the indicated trouble code has to be checked in the burner s manual book and the relevant corrective measures should be taken, as described in its manual book; In case of emergency situation that is not presented in the automated pellet burner from series GP IV manual, neither in this manual, should you ask for assistance by the retail company which services and maintains the system. 5.7. INTRODUCING THE USERS WITH THE SERVICING AND ADJUSTMENT PROCEDURES OF THE SYSTEM. The users are required to read the installation and operation manual of the system and also the automated pellet burner from series GP IV manual book, to know how to operate, adjust and maintain its modules: Page 36/44
Refueling the pellets hopper the pellets have to be dropped in a hopper, from which the fuel transport auger intakes and transfers them to the burner s main module; Cleaning the hot water boiler from the ash residues. The cleaning of the ash residues should be performed by the use of protection equipment cuff, gloves and proper clothing. Periodically (at least once on every 72 hours) the user has to switch off the automated pellet burner from series GP IV, by observing the instruction in its manual book, wait until the boiler cools down to safe temperature, clean the ash deposits over its heat exchanging surfaces, scrap the ash out of the boiler, that are gathered in the tray positioned at its bottom part and after that in reverse order to close the boiler s door and covers, clean the burner and switch it back on, as described in its manual book. Figure 5.2. Protection equipment kit (cuff and gloves) for cleaning of the ash residues from the appliance. EXPLANATION: The gloves are part of the automated pellet burner from series GP IV standard equipment kit. Cleaning of the ash residues from the burner s fire-grate after the system has been switched off and cooled down to safe temperature values the combustion chamber door has to be opened, the burner s fire-grate taken out and cleaned from the ash residues. Then it must be positioned back and the boiler s chamber door closed. EXPLANATION: the combustion chamber door closes by the use of a handle. It is recommended not to use too much force in order to preserve the sealing rope elasticity. To open the door turn the handle clockwise (lift the handle up to open it). Page 37/44
Figure 5.3. Cleaning of the ash deposits from the hot water boiler walls. Figure 5.4. Cleaning of the ash residues from the hot water boiler. Open the combustion chamber door and take out the ash container, positioned at the bottom of the hot water boiler. The ash has to be gathered in fire-proof containers (or other proper containers), then place the ash tray back to its original position and close the door. The boiler covers have to be placed back too; WARNING: the regular cleaning of the hot water boiler heat exchanging surfaces and the pellet burner burning zone provide reliable and economic operation of the appliances and conditions for long-term usage of the system s modules. 5.8. SAFETY AND UNPREDICTED RISKS, RELATED TO THE SYSTEM USAGE: The separate modules of the system hot water pellet boiler from series Pelletherm v4 and automated pellet burner from series GP IV are designed and manufactured in compliance with the main safety requirements of the acting European standards and directives. Dangerous conditions might occur in the following situations: The hot water boiler from series Pelletherm v4 has been used improperly; The automated pellet burner from series GP IV has been used improperly; The system is installed by unqualified personal; The safety usage instructions, presented in this manual book, are not observed; The safety usage instructions of the automated pellet burner, presented in its manual book, are not observed. Page 38/44