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Pelltech PV1000agri User Manual

Pellet burner
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PV1000agri pellet burner
User manual
POOLELI - DRAFT
DK9401A1

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Summary of Contents for Pelltech PV1000agri

  • Page 1 PV1000agri pellet burner User manual POOLELI - DRAFT DK9401A1...

  • Page 2: Table Of Contents

    PV1000agri pellet burner Description 1/ 50 Main components 1 Contents Description ............................4 Main components ......................... 5 Specifications ..........................7 Installation ............................10 Prerequisites ..........................10 Burner ............................11 Water sprinkler ..........................20 External auger ..........................21 Pellet storage ..........................22 Electrical connections ........................
  • Page 3 2/ 50 Main components Tables Table 1 PV1000agri connectors ( * optional extras) ................... 22 Table 2 Info menu description ........................30 Table 3 Summary of burner statuses ......................30 Table 4 List of tests in TESTING status ......................31 Table 5 Cleaning parameters ........................

  • Page 4: Description

    2 Description PV1000Agri is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. Due to the unique design of the burning chamber you can use industrial pellets to fuel the burner. You cannot use any other form of fuel to run this burner.

  • Page 5: Main Components

    PV1000agri pellet burner Description 4/ 50 Main components 2.1 Main components DK9401A1 www.pelltech.eu...
  • Page 6 Igniter Igniter´s purpose is to ignite loaded fuel making the burning process start. Igniter is installed on the burner together with igniter holding pipe. PV1000agri has total four igniters. Brick temperature A sensor to adjust burner start up speed according to temperature rise. Brick temperature sensor rise speed must be controlled to extend its lifetime.

  • Page 7: Specifications

    PV1000agri pellet burner Description 6/ 50 Specifications burner checks batteries condition and does not start the next working cycle if the batteries voltage is too low. Internal feeder Hollow spiral connected to feeder motor to transport pellets into burning chamber. Screw is screw not tightened to motor, but has small slack.
  • Page 8 PV1000agri pellet burner Description 7/ 50 Specifications Figure 1 Dimensions Figure 2 Dimensions DK9401A1 www.pelltech.eu...
  • Page 9 PV1000agri pellet burner Description 8/ 50 Specifications Figure 3 Dimensions DK9401A1 www.pelltech.eu...

  • Page 10: Installation

    PV1000agri pellet burner Installation 9/ 50 Prerequisites 3 Installation 3.1 Prerequisites In order to install the burner, the boiler must meet to the following requirements:  Recommended to use three pass boilers.  The construction of the boiler must make it possible to open the door of the boiler with the burner connected and removing ash from the furnace.

  • Page 11: Burner

    PV1000agri pellet burner Installation 10/ 50 Burner 3.2 Burner Mount the burning chamber on the inner side of the boiler door. Figure 5 Use 6 M12x60mm bolts, spacers and distance nuts respective to the bolts Figure 6 DK9401A1 www.pelltech.eu...
  • Page 12 PV1000agri pellet burner Installation 11/ 50 Burner Install the insulation rope between the burning chamber and the boiler door. The rope must be installed near the outer perimeter of the burning chambers back wall. Figure 7 Grate holders installation Install the burning chambers...
  • Page 13 PV1000agri pellet burner Installation 12/ 50 Burner Connect the static grate holders with the side stone holders separately and install them together into the burning chamber as a frame. Fix them with M8x16mm bolts to the burning chamber. Figure 9 Connect the moving grate holders with M6x12mm bolts.
  • Page 14 PV1000agri pellet burner Installation 13/ 50 Burner Install the burning chambers front brick holders, use M8x16mm bolts. Figure 11 DK9401A1 www.pelltech.eu...
  • Page 15 PV1000agri pellet burner Installation 14/ 50 Burner Release the igniter tube screws and while inside the holders pull the tubes out about half of the total length. Move the air separator to its correct position (according to the boiler door thickness) and fix it with screws.
  • Page 16 PV1000agri pellet burner Installation 15/ 50 Burner Install the ceramic sealing strips on the boiler door. Fix them temporarily in position with any ordinary cellophane tape (scotch). Cut away the excessive sealing on the perimeter of the air chamber. Figure 13...
  • Page 17 PV1000agri pellet burner Installation 16/ 50 Burner Push the igniter tubes through the burning chambers back wall and fix them in position with M4 screws. Figure 15 Connect the linear actuator with the moving grate holder. Use 27x2,5mm pipe (length 240mm),...
  • Page 18 PV1000agri pellet burner Installation 17/ 50 Burner Push the stone temperature sensor through the hole in the burner body and the pipe on the burning chambers back wall, isolate it from the air flow (accessible from the burning chamber side) with...
  • Page 19 PV1000agri pellet burner Installation 18/ 50 Burner Install the ceramic paper on the back wall of the burning chamber. Install the back wall stones on the burning chambers back wall. ATTENTION!: Care must be taken not to damage the temperature...

  • Page 20: Water Sprinkler

    PV1000agri pellet burner Installation 19/ 50 Water sprinkler Install the 6 side bricks. Install the 6 arc-stones. ATTENTION!: The arc-stones are numbered, they must be installed as pairs! Figure 21 3.3 Water sprinkler Water sprinkler is main safety element against back burning. It is strongly recommended to install sprinkler system.

  • Page 21: External Auger

    The auger is connected to the burner with a special hose (∅ 80), which is made from easily melting material that acts as a safety measure against back-burning. PV1000Agri pellet burner´s fuel consumption at full power is about 208-222 kg of pellets per hour ( 3,3-3,7 kg per minute ). External auger´s productivity must be at least 270kg of pellets per hour.

  • Page 22: Pellet Storage

    All safety regulation must be taken into consideration according to the local laws. It is recommended to wear a respirator when handling pellets. Refilling must be carried out before the storage runs empty. 3.6 Electrical connections Table 1 PV1000agri connectors Name Color, type Signals...
  • Page 23 PV1000agri pellet burner Installation 22/ 50 Electrical connections * optional extras Figure 24 Connector markings Burner is designed to work at 230V. Boiler should be equipped with thermostat or external switch between plug X11 pin T1 and T2 for turning on/off the pellet burner.
  • Page 24 PV1000agri pellet burner Installation 23/ 50 Electrical connections DK9401A1 www.pelltech.eu...
  • Page 25 PV1000agri pellet burner Installation 24/ 50 Electrical connections DK9401A1 www.pelltech.eu...
  • Page 26 PV1000agri pellet burner Installation 25/ 50 Electrical connections DK9401A1 www.pelltech.eu...

  • Page 27: Commissioning

    PV1000agri pellet burner Installation 26/ 50 Commissioning 3.7 Commissioning Prior to the initial start-up of the burner make sure that:  The burner is connected to the boiler  The boiler thermostat is installed and is functioning properly  The feeding auger of the burner is installed and connected to the burner ...

  • Page 28: Operation And Maintenance

    PV1000agri pellet burner Operation and maintenance 27/ 50 User interface 4 Operation and maintenance 4.1 User interface The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log etc. Yellow light (2) shows the presence of flame in burning chamber. Or if blinking, the burner is out of normal operation.
  • Page 29 PV1000agri pellet burner Operation and maintenance 28/ 50 User interface Figure 26 Main menu structure Status info screen displays last events (burner states) and their duration. The duration is in form mm:ss (’m’ in the middle) or hh:mm (’h’ in the middle). For example “Igniting 01m25 means the burner ignition state lasted 1minute and 25 seconds.

  • Page 30: Starting And Stopping

    It can take as long as 20minutes. 4.3 Statuses and parameters PV1000agri pellet burner operates in many different states, which are called “Status”. Current and previous statuses can be seen from user interface panel (chapter 4.1). Burner changes its status based on input signals from sensors and user.

  • Page 31: Table 4 List Of Tests In Testing Status

    PV1000agri pellet burner Operation and maintenance 30/ 50 Statuses and parameters End Blow Pellet coals in burning chamber is burned, flame has disappeared Waiting Wait signal from boiler thermostat Waiting In this status, the burner is waiting signal from boiler thermostat. There is no limit time for waiting status.

  • Page 32: Table 6 Loading Parameters

    PV1000agri pellet burner Operation and maintenance 31/ 50 Statuses and parameters again. Actuator min. If smaller, then actuator is stopped and running current direction can be changed. Max. move time Maximum time to move actuator to one direction. Max. cleaning Maximum „Cleaning“...

  • Page 33: Table 7 Ignition Parameters

    PV1000agri pellet burner Operation and maintenance 32/ 50 Statuses and parameters Igniting In ignition cycle the igniter is heated up and fan blows hot air thru pellets in burning chamber. Hot air ignites pellets. Igniter is working periodically at ignition time to avoid overheating.

  • Page 34: Table 9 Heat-Up Parameters

    PV1000agri pellet burner Operation and maintenance 33/ 50 Statuses and parameters “Heat up” cycle is needed for slow heating of the burning chamber and to minimize thermal stress in ceramic stones. “Heat up” mode is selected from main menu between “ON”, “OFF” or “AUTO”.
  • Page 35 PV1000agri pellet burner Operation and maintenance 34/ 50 Statuses and parameters main Par 5 Par 35 virtual main 1000 Par 6 Par 36 Power level can be selected in main menu. Power Selected power level selection for burning time can be automatic or fixed on some main level.

  • Page 36: Table 11 Hold Flame Parameters

    PV1000agri pellet burner Operation and maintenance 35/ 50 Statuses and parameters Slow down In “Slow down” mode, the burner power is reduced step-by-step to 1 level after boiler thermostat is switched OFF. This mode can be used only is systems with high and stable power demand. Using “Slow down”...

  • Page 37: Table 12 End Burn Parameters

    PV1000agri pellet burner Operation and maintenance 36/ 50 Statuses and parameters Par 8 Fan @hold flame Primary fan speed at hold flame Par 39 Fan 2 min Secondary fan minimum speed. Used at “Ignition”, “Preburn”, “Heat up”, “Hold flame” and “End blow” time.

  • Page 38: Cleaning

    PV1000agri pellet burner Operation and maintenance 37/ 50 Cleaning External auger control 4.4 Cleaning Pellet burner requires systematic maintenance. The maintenance period depends on the quality of the pellets and heating intensity. To clean the burner: 1. Turn off the burner by turning the thermostat to 0.
  • Page 39 PV1000agri pellet burner Operation and maintenance 38/ 50 Replacing components ......... DK9401A1 www.pelltech.eu...

  • Page 40: Optional Components

    PV1000agri pellet burner Optional components 39/ 50 GSM Modem 5 Optional components 5.1 GSM Modem Modem enables users to receive burner error messages via SMS. Boiler room must have GSM coverage in order to use the modem. Preconfiguring SIM card Before inserting the SIM card to burner, SIM card must be preconfigure.

  • Page 41: Flue Gas Fan

    PV1000agri pellet burner Optional components 40/ 50 Temperature sensor Insert the SIM and push it with the tool slightly inside until the spring snaps in. Removing the tool, the SIM shall remain inside the GT863-PY. For removing the SIM, push the tool slightly inside until the spring is released so that it pushes the SIM outside when the tool is retracted.

  • Page 42: Common Problems And Solutions

    PV1000agri pellet burner Common problems and solutions 41/ 50 6 Common problems and solutions Problem description Possible cause and solution DK9401A1 www.pelltech.eu...

  • Page 43: Annex A - Parameters

    PV1000agri pellet burner Annex A – Parameters 42/ 50 7 Annex A – Parameters Parameter Unit Burner Default Min. Max. Description name model Par 1 FAN @level 1 PV350 PV500 PV700 PV1000 Par 2 FAN @level 3 PV350 PV500 PV700...
  • Page 44 PV1000agri pellet burner Annex A – Parameters 43/ 50 UP CYCLE DOWN CYCLE PELLET NORMAL PV350 PV500 PV700 PV1000 PELLET LIGHT PV350 PV500 PV700 PV1000 PELLET HEAVY PV350 PV500 PV700 PV1000 LOADING FEED PV350 PV500 PV700 PV1000 LOADING 2 FEED...
  • Page 45 PV1000agri pellet burner Annex A – Parameters 44/ 50 PV500 PV700 PV1000 FAN 2 @level 11 PV350 PV500 PV700 PV1000 FAN 2 BASE FAN 2 MIN PHOTOCELL Photocell sensitivity 100% = infinity flame LEVEL PRE-BURN TIME PRE-BURN CYCLE FEED CURRENT PV350 Feeder max.
  • Page 46 PV1000agri pellet burner Annex A – Parameters 45/ 50 HEAT UP PV350 Power at „HEAT UP“ POWER PV500 PV700 PV1M HEAT UP TEMP °C Stone temperature to reach at „HEAT UP“ TEMP BASE °C BURNER TYPE PV350 PV350/PV500/PV700/PV1M DK9401A1 www.pelltech.eu...

  • Page 47: Annex B - Burner Status Change Logic

    PV1000agri pellet burner Annex B – Burner status change logic 46/ 50 8 Annex B – Burner status change logic Status Next Status Change conditions Waiting Testing Signal from boiler thermostat Testing Loading All tests are done successfully Battery error...
  • Page 48 PV1000agri pellet burner Annex B – Burner status change logic 47/ 50 Burn end End blow Burn end (15*rot. + 10rot.) plus time 30sec. is reached Burning Signal from boiler Thermostat, feeder made less than 8 rot and previous state was BURN...

  • Page 49: Annex C - Controller Board Description

    PV1000agri pellet burner Annex C – Controller board description 48/ 50 9 Annex C – Controller board description Fuses F4=6A, F10=2A DK9401A1 www.pelltech.eu...
  • Page 50 PV1000agri pellet burner Annex C – Controller board description 49/ 50 Connector Description LoPr  Boiler pressure sensor connection. Must be connected to tube on left feeder tube. FANx-1 Prim/sec fan speed sensor +5V power FANx-2 Prim/sec fan speed sensor GND...
  • Page 51 PV1000agri pellet burner Annex C – Controller board description 50/ 50 X5-1 Grate cleaning motor position feedback X5-2 X5-3 not connected X5-4 Grate cleaning motor X5-5 Grate cleaning motor X5-6 not connected X6-1 DC input X6-2 DC input X6-3 DC input...

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