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Table of Contents
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Summary of Contents for Pelltech PV 100a
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Page 1: Table Of Content
Pellet burner PV 100a User manual... -
Page 2: Table Of Contents
PV 100a Table of content Table of content.............................2 Description.............................5 Fuel..............................7 Installation..............................7 Boiler requirements..........................8 Pellet container..........................11 Burner...............................12 External auger..........................20 Electrical connections........................21 Operation.............................23 Starting.............................23 Log..............................24 Settings.............................25 Refilling fuel............................27 Maintenance............................27 Working principle..........................29 Testing..............................29 Cleaning............................29 Loading.............................29 Igniting..............................30 Preburn.............................30 Burning.............................30 Auger control..........................30 Fuel level detection........................30 Output power levels ........................30... - Page 3 PV 100a Safety precautions Do not start the burner before it is connected to the boiler and the boiler is connected to the chimney. It is recommended to wear a respirator while handling pellets. The boiler room where the burner is installed must fulfill all rules and recommendations given by authorities.
- Page 4 PV 100a Package content The burner is shipped with following components included: 1. Burner 2. Bottom grate (smaller holes) 3. Upper grate (bigger holes) 4. Brackets for hose (2x) 5. Flange 6. Ceramic seal 7. 7-pole boiler connector 8. Hose 9.
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Page 5: Description
PV 100a Description PV 100a is a pellet burner that is intended to be used with 6 or 8mm wooden pellets. You cannot use any other fuel to run this burner. The unique construction of PV 100a allows it to be used with different boilers: liquid fuel, solid fuel and universal boilers. - Page 6 PV 100a Figure 2 Dimensions Table 1 Specification Unit PV 100a total length burner body length burning chamber length burning chamber width ⌀D1 burning chamber neck diameter ⌀D2 internal feeder inlet diameter total height burner housing height burning chamber height...
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Page 7: Fuel
PV 100a Fuel PV 100a uses premium wooden pellets as fuel. Wood pellets are concentrated and homogenized fuel made from sawdust and cutter shavings. Pellets are pressed with high temperature. No extra materials are added, pellets are held together by a natural ingredient found in wood – lignin. Pellets are CO2-neutral, renewable fuel. -
Page 8: Boiler Requirements
PV 100a • If there is not sufficient (less than 5Pa) negative pressure in the furnace, a draught fan should be installed for the exhaust gases. • The boiler room where the burner is installed must fulfill all rules and recommendations given by authorities. - Page 9 PV 100a Figure 4 Double hinges Boiler firebox length L (Figure 5) should be at least 2,5 x the length of the burning chamber. For PV 100a, minimum of 800 mm is acceptable (leaving L1 min. 480mm). The height should be enough to...
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Page 10: Pellet Container
PV 100a Minimum dimensions L and H for PV 100a: L≥800mm; H≥450mm. Figure 5 Boiler firebox requirements Burner is mounted to door using supplied oil burner flange. Bolt hole circle diameter and bolt sizes can be customized by using custom flanges. D1 and D2 given in Table 3 are only valid with supplied flanges. -
Page 11: Burner
PV 100a Burner In order to install the burner properly, you must go through the following steps: 1. Remove carefully ceramic stones and the transparent joil from stones. 2. 2. Remove upper and lower burning grates. - Page 12 PV 100a 3. Remove the bolts from bottom grate holder 4. Remove the cover of the burner by loosening 4 screws of the cover. There is no need to remove the screws...
- Page 13 PV 100a 5. Remove the M8 nut (13 mm wrench) that connects the halves of the burner. 6. Separate the halves of the burner by pulling the burning chamber and slightly rotating it at the same time.
- Page 14 PV 100a 7. Fix the flange of the burner to the door of the boiler. Put a ceramic seal on the neck of the burning chamber. Put the chamber neck through the boiler door and flange. The rear wall of the burning chamber has to lean on the door of the boiler.
- Page 15 PV 100a 9. Connect the burner body to the burning chamber like it was before disassembling: push the burner body and slightly rotate it at the same time. Be sure that the burner halves are correctly connected. 10. Fixate the halves of the burner with a M8 nut. The nut has to be rolled tight but not too hard.
- Page 16 PV 100a 11. Place back the burner cover and fix the screws again. 12. Place back the bolts and fix the bottom grate holder.
- Page 17 PV 100a 13. Place back the lower grate (smaller holes) and then the upper grate (bigger holes). 14. Place carefully back ceramic stones.
- Page 18 PV 100a Caution! After the installation of the burner always make sure that the end of the igniter is positioned through its opening and not stucked behind the dividing wall.
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Page 19: External Auger
PV 100a Pellet container The burner, the auger and the pellet container are a common system. The size and the location of the pellet container depends on the needs and possibilities of the specific boiler room. While choosing the pellet container you must keep in mind that: •... -
Page 20: Electrical Connections
PV 100a 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. - Page 21 PV 100a Chs – Chassis grounder M1 – Fan M2 – Flue gas fan* M3 – External auger M4 – Internal feeder M5 – Grate motor Ot – Safety thermostat R1 – Flame sensor SBB – Controller board Se – Igniter TR –...
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Page 22: Operation
PV 100a Operation The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log etc. Yellow light (2) shows the presence of flame in burning chamber. Or if blinking, the burner is out of normal operation. Status can be seen on log screen. Green light (3) indicates if there is fuel in the burner. -
Page 23: Log
PV 100a • The smoke duct is connected to the chimney, the dampers for smoke gases are open and there is sufficient draught. When the burner is operating, the negative pressure inside the boiler must stay between 4-6 Pa. To turn on the burner, switch on boiler main switch. If burner displays ’Stopped’, then go to settings menu and change parameter ’Burner’... -
Page 24: Settings
PV 100a the burner. The external auger has stopped, the internal feeder and fan are still working until all fuel is burned. END BLOW 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. - Page 25 PV 100a Table 6 Parameters menu Parameter Description Unit Value Name Default Min. Max. BURN AIR @50kW Fan speed at power level 1 BURN AIR @60kW Fan speed at power level 2 BURN AIR @70kW Fan speed at power level 3...
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Page 26: Refilling Fuel
Starting. Failing to do so will result ‘Fuel error’ due to fuel loading timeout. Maintenance Pellet burner PV 100a requires systematic maintenance. The maintenance period depends on the quality of the pellets and heating intensity. The average maintenance period is between 1 to 2 months. - Page 27 PV 100a Feed screw motor The condition of the feeding screw motor is crucial for safety. Therefore the motor must be replaced after every 2000 working hours or after 120-150 tons of pellets are burned or when the burner gives warning.
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Page 28: Working Principle
PV 100a Working principle Testing Before every startup the burner tests itself. At testing time fan is turned on at maximum power. If its speed doesn´t reach 30 rps, “fan error”will occure on display. Battery loading is turned off and feeder is turned on. -
Page 29: Igniting
PV 100a Igniting In ignition state the igniter is heated up and fan blows hot air through loaded pellets and ignites them. Igniter is turned off after every 50 seconds to avoid overheating it, and turned on again after 20s . -
Page 30: Hold Flame
Only the fan keeps on working with speed shown in par9 to burn out all coals. Feeder is turned off. This state lasts until no flame is recognized plus one minute. Table 7 Air table for PV 100a Power [kW]... -
Page 31: Controller Board Description
PV 100a Controller board description Figure 10 Controller board... - Page 32 PV 100a Table 8 X1 and X2 connectors Description Description Ash removal + Igniter Grate motor+ Igniter Grate motor- Battery positive terminal Flue gas fan Battery negative terminal Mains transformer Flame sensor Mains transformer Flame sensor Feed screw - (black)
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Page 33: Problems And Solutions
PV 100a Problems and solutions Error states Cause Action Stopped This is actually not an error condition. To turn burner on: Burner is turned OFF from menu. - hold down OK button at least 3s - change row BURNER from OFF to ON in... - Page 34 PV 100a...
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