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GreenEcoTherm Pelletherm V.5/GENERATO Series Manual For Installation And Operation

Automated pellet hot air generator
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MANUAL
FOR INSTALLATION AND OPERATION
OF AUTOMATED PELLET HOT AIR GENERATOR FROM
SERIES
Pelletherm V.5/GENERATO
http:// www.greenecotherm.eu
page 1/47

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Summary of Contents for GreenEcoTherm Pelletherm V.5/GENERATO Series

  • Page 1 MANUAL FOR INSTALLATION AND OPERATION OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES Pelletherm V.5/GENERATO http:// www.greenecotherm.eu page 1/47...
  • Page 2 Telephone +359 800 15 145 +359 38 603070 e-mail greenecotherm@erato.bg home page www.greenecotherm.eu The manufacturing company thanks you for the contribution of your choice. 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.

  • Page 3: Table Of Contents

    CONTENT page. DESCRIPTION AND ADVANTAGES OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”....................4 TECHNICAL DATA FOR HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”....................6 CONSTRUCTION DESCRIPTION OF AUTOMATED HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”.............. 10 MOUNTING AND INSTALLATION................16 4.1.

  • Page 4: Description And Advantages Of Hot Air Generator From Series "Pelletherm V.5/Generato

    1. DESCRIPTION AND ADVANTAGES OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. The series “Pelletherm V.5/GENERATO” are steel made biomass hot air generators used for drying installations and heating of domestic, office, industrial premises and public facilities. The hot air generators from series “Pelletherm V.5/GENERATO” utilize fuel, described below, as the produced heat energy is transferred to the heat carrier –...
  • Page 5 The price of the produced heat energy from biomass utilization in the form of wood pellets as local energy source is less influenced by the global fuel prices and the value of the produced energy is competitive compared to the conventional heat sources; The appliance is automated and provides comfort during operation approaching other automated appliances (for example appliances utilizing gaseous fuel or electrical heating devices), providing availability for programming its operation by programmable room...

  • Page 6: Technical Data For Hot Air Generator From Series

    TECHNICAL DATA GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. Heating technical data for hot air generator from series “Pelletherm V.5/GENERATO” operating with wood pellets are presented in Table 2.1. Parameters for the heating air, supplied to the air distribution heating system are presented in Table 2.2.
  • Page 7 Parameter Dimension Value Hot air generator model GENERATO 30 GENERATO 40 GENERATO 50 Nominal heating output Temperature at nominal heating ºC 70 – 80 70 – 80 70 – 80 output Temperature at minimum heating ºC 35 – 42 35 – 42 35 –...
  • Page 8 Recommended fuel parameters – wood pellets, for generators from series “Pelletherm V.5/GENERATO” are presented in the next table. Parameter Dimension Value Granule size 6 – 14 Fuel recommended caloricity (lower heat for MJ/kg >17.2 burning) kWh/kg >4.7 ENplus-A1, ENplus- Wood pellets category according to ENplus A2, ENplus-B A, AB, B, BC, C, CD, Wood pellets category...
  • Page 9 With the acceptance of the new European Union wood pellets standard (EN 14961-2) in 2010, new certificates, ENplus for pellets used in boilers for domestic purposes and EN-B for industrial pellets used in industrial boilers, are introduced. The standard ENplus defines two quality categories: A1 and A2.

  • Page 10: Construction Description Of Automated Hot Air Generator From Series "Pelletherm V.5/Generato

    CONSTRUCTION DESCRIPTION OF AUTOMATED HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. The generator consists of the following components/modules: The main part of the appliance is the generator body (heat exchanger) with mounted burner, which is designed on the principle of fire-grate burning and horizontal fuel feeding; The heat exchanger is welded construction from steel plates and pipes.
  • Page 11 Figure 3.1. General view of the automated hot air generator from series “Pelletherm V.5/GENERATO”. The generator construction is designed on module principles (on the left side is the heat exchanger, the right side consists of: fuel hopper, burner with transport auger, ash cleaning mechanism and control module), which provide availability for easy transportation and installation of the appliance;...
  • Page 12 Convective fans Flue gasses outlet Heat exchanger body Fuel hopper Tube bundle with turbolators Fuel proportioning device(section-closed) Fuel feeding (transport) auger Ash cleaning system for the burner Specialized burner with ash residues Ash residues Hot air outlet cleaning mechanism container Figure 3.2.
  • Page 13 Flue gasses outlet tube (to chimney) Inlet external auger Hot air outlet Figure 3.3. View of the automated hot air generator from series “Pelletherm V.5/GENERATO” – top view. Flue gasses outlet tube (to chimney) Hot air outlet page 13/47...
  • Page 14 Figure 3.4. Cross-section view of the automated hot air generator from series “Pelletherm V.5/GENERATO” – left view. Figure 3.5. View of the automated hot air generator from series “Pelletherm V.5/GENERATO” – top view. Figure 3.6. View of the automated hot air generator from series “Pelletherm V.5/GENERATO” – front view.
  • Page 15 Flue gasses outlet tube Heating air inlet section (after the fans) Convectional tube bundle Internal chamber for heating of the inlet air Heat exchanger combustion chamber Opening for mounting of specialized burner Directing elements of the combustion chamber plate Heat-insolated bottom of the heat exchanger body Outlet tube for distribution of the heated air...

  • Page 16: Mounting And Installation

    4. MOUNTING AND INSTALLATION. 4.1. GENERAL CONDITIONS: For observance of the safety conditions the following requirements must be taken into account: Unpacking, moving and installation of the generator must be carefully performed by trained servicing technicians, by protecting the outer surfaces or damage to the appliance; When transporting the appliance, please observe the information presented on its package;...

  • Page 17: Installation Of The Generator

    It is recommended to keep all kind of flammable objects or materials (wooden beams and furniture, curtains, flammable liquids) at safety distance (at least 1 m) away from the generator. Before initializing the generator in operation the chimney draught must be checked and also to provide reliable connecting of the appliance to the chimney.

  • Page 18: Connecting The Generator To A Chimney

    Positioning of additional hopper for storage of wood pellets – this hopper must be installed (or build) in a way providing its easy accessing for refueling. Also during building of the hopper the fuel transport auger installation requirements must be observed (tilt, place for fuel intake, manhole zone for easy cleaning of unusual impurities and fine fraction).
  • Page 19 • The connection pipeline must be cylindrical, without local changes in its sections (narrowing or extensions). The chimney diameter must not be smaller than the generator flue outlet. The chimney and the flue-pipeline must be insolated externally with suitable material (usually mineral wool), so they are secured from cooling of the flue gasses, respectively from chimney draught decrease;...
  • Page 20 Roof tilt Horizontal range of the Minimum Vertical range of the angle flue gasses spreading chimney height flue gasses spreading zone from the roof ridge over the roof zone 1.85 1.00 0.50 1.50 1.30 0.80 1.30 2.00 1.50 1.20 2.60 2.10 Table 4.1.

  • Page 21: Сonnecting The Generator To An Air-Funnel For Supplying The Heating System With Hot Air

    4.6. СONNECTING THE GENERATOR TO AN AIR-FUNNEL FOR SUPPLYING THE HEATING SYSTEM WITH HOT AIR Following is connecting the hot air generator from series “Pelletherm V.5/GENERATO” to the air distribution heating installation, according to preliminary prepared technical project. Neighbor heated Chimney premises Separating wall...
  • Page 22 Figure 4.3. Heat exchanger’s Inlet/outlet muffs view, of the hot air generator from series “Pelletherm V.5/GENERATO”. Explanation: It is recommended that the pipeline length, through which the heated air is supplied to the heating system, is as minimum as possible and with minimum number of bends. The recommended total length of the pipeline is 3 meters.

  • Page 23: Initializing The Appliance In Operation

    INITIALIZING THE APPLIANCE IN OPERATION WARNING: The generator must be initiated in operation only by specialized company, authorized for performing such activities; The installation finalization and the performance of the so called “hot tests” of the generator and the heating system have to be marked in the product warranty card, where is mandatory to fill all fields.

  • Page 24: Interface Control Panel Of Automated Pellet Hot Air Generator From Series "Pelletherm V.5/Generato

    During operation of the generator its cover panels and also some of its other elements are heated to relatively high temperatures. Therefore the handling personal should be careful not to touch these surfaces and to use personal protection equipment in case of necessity. Please inform other people that might have contact with the operating appliance;...
  • Page 25 Thermometer - hot air Thermostat – hot air Figure 5.2. Panel with controlling thermometer and thermostat of the hot air generator from series “Pelletherm V.5/GENERATO”. Interface control panel elements and their function: “POWER” switch – is used for main on and off switching of the generator; Hot air thermostat –...

  • Page 26: Connection Panel Of Hot Air Generator From Series

    5.2.2. CONNECTION PANEL GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” Additional auger Room thermostat Power supply Figure 5.3. Connection panel of hot air generator from series “Pelletherm V.5/GENERATO”. Connection panel elements and their function: Power supply – connector to main electrical installation; Additional auger –...

  • Page 27: Generator Switch On

    5.2.4. GENERATOR SWITCH ON. Switching on the generator is performed by the switch –“POWER”. The appliance activates and switches to automatic waiting mode – pressing the switch “START” starts its operation. In case the “START” switch was preliminary pressed, then the appliance starts operation immediately. If the generator has been operated (or is in “hot reserve”), but the electrical power supply has been interrupted, then it starts automatically.

  • Page 28: Parameters For Operation Adjustment Of The Generator

    5.2.5. PARAMETERS FOR OPERATION ADJUSTMENT OF THE GENERATOR. In next table are presented the parameters which are used for adjustment of the appliance operation. Not. Description Recommended value Dimension GENERATO 30 GENERATO 40 GENERATO 50 Period of time for pellets feeding in stable operation Т4 seconds...
  • Page 29 NOTE: During the choice of control parameter other parameters from the menu appear on the display, which are not presented in the above table. These parameters are subject to change by trained servicing personal and their change from the end customer is not recommended; In the next table are presented parameters, which take part in the adjustment of the appliance operation.
  • Page 30 and economic burning process. Therefore the suitability and effectiveness of certain fuel must be tested and after positive results to be utilized in the appliance; The moisture (water) content affects significantly the fuel caloricity. Practically the water content in the wood pellets changes in narrow limits (between 6 to 10%) therefore the pellets have relatively constant parameters.

  • Page 31: V.5/Generato" According To The Heating Output, Consumed By The Heated Building/ Consuming Aplliances

    5.2.6. ADJUSTING GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” ACCORDING TO THE HEATING OUTPUT, CONSUMED BY THE HEATED BUILDING/ CONSUMING APLLIANCES. For optimum, reliable and efficient operation of the appliance it is recommended to adjust it in comply with the heat energy consumption which will be covered. The heat output needed for providing heat comfort in the building can be accepted as linear function of the temperature load ∆Т...
  • Page 32 Т ∆Т Ratio T4/T6 Т4* Heating Т6 environment output Seconds Seconds 0.325 0.244 0.195 0.098 Table 5.5. Adjustment of the parameters T4 and T6 in comply with the heating output of generator model „GENERATO 50”. ,where: Т – average temperature in the heated premises, [ rooms Т...
  • Page 33 4.00 0.240 3.60 0.200 3.20 2.80 0.160 2.40 2.00 0.120 1.60 1.20 0.080 0.80 0.40 0.040 12.0 16.0 20.0 24.0 28.0 32.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0 Топлинна мощност на генератора, [kW] Топлинна мощност на генератора, [kW] Figure 5.4. Relation of the parameters for adjustment (time for fuel feeding – T4 and the ratio T4/T6) and the heating output of generator model “GENERATO 30”, utilizing wood pellets.

  • Page 34: Changing The Control Module Operation Parameters

    5.2.7. CHANGING THE CONTROL MODULE OPERATION PARAMETERS. Algorithm for changing a parameter from the control module program, for hot air generator from series “Pelletherm V.5/GENERATO”: In the next lines is presented the algorithm for visualization and relevant change (only if necessary!) of parameter from the customer allowed access group: Press the green button (●) marked as Menu/OK on the controller.
  • Page 35 SHIFT Figure 5.7. Outer view and notation of the control module buttons. If attempted to access another submenu, for example “MONITORING”, the controller expects entering of a password. The display shows: PASSWORD CLEAR 0/5 0000 5 = maximum attempts for entering the password SHIFT + OK = EXIT Figure 5.8.

  • Page 36: Nominal Opearation Mode Of The Generator

    5.2.8. NOMINAL OPEARATION MODE OF THE GENERATOR. After starting the generator (the fuel in the burner is fired successfully) and the generator has heated the circulations air in the heating installation, then it can be stated that the appliance has reached nominal operation mode.

  • Page 37: Regulating The Generator Heating Output

    5.3. REGULATING THE GENERATOR HEATING OUTPUT. The heating output regulation of the generator can be performed by adjusting the fuel feed rate (consumption), transferred to its burner and also by adjusting the firing air flow rate. The fuel consumption regulation is determined by the values of parameters (T4 – period of time for fuel feeding in stable mode and T6 –...

  • Page 38: Adjustment Of Parameters For Supplying The Heating Air Funnel System

    5.3.3. ADJUSTMENT OF PARAMETERS FOR SUPPLYING THE HEATING AIR FUNNEL SYSTEM. If the air funnels distribution system has installed elements for regulation of the operation mode (air flow direction and flow rate control), then the operating parameters of the heated air passing through this elements can be adjusted.

  • Page 39: Introducing The User With The Appliance Maintenance And Adjustment Procedures

    5.6. INTRODUCING THE USER WITH THE APPLIANCE MAINTENANCE AND ADJUSTMENT PROCEDURES. It is necessary that the user is well familiar with the presented operation manual of the appliance, and also with its operation principles, adjustments and regulations, and its maintenance methods. Refueling the generator hopper –...
  • Page 40 Period of time, Activity Explanation Warning [days] Cleaning of the ash After removing Make sure that all elements deposits in the components from the and components of the combustion chamber generator (swirl elements generator are cooled down. and the tube bundle of and burner cover), their the heat exchanger correct positioning and...

  • Page 41: Safety And Unpredicted Risks

    After every heating season the generator must be completely cleaned from the ash residues. Cleaning of the chamber after the tube bundle can be performed by unscrewing and removing the top cover. After that the combustion chamber and the burner have to be cleaned.

  • Page 42: Failures And Troubleshooting

    5.9. FAILURES AND TROUBLESHOOTING. Failure Reason Troubleshooting Low temperature in Insufficient heating output It is necessary to adjust the the heated premises appliance operating parameters – to be performed by trained customer or specialist Low temperature assigned It is necessary to increase the to the operating thermostat operating thermostat assigned of the generator...
  • Page 43 requirements or the used fuel is with improper properties – consultation with servicing company is recommended; Overheating of the Lack of heating load or Correct operation checks must be generator incorrect adjustment of the performed over the heating generator heating output or installation and eventual the operation of the heating adjustment of the operation...

  • Page 44: Completion Of The Appliance Warranty Card

    Insufficient firing air quantity Check the firing air feeding fan working order and its adjustment; Check for access of external air needed for firing – check and provide access of fresh air to the generator room; Presence of Inefficient fuel combustion The appliance operation unburned fuel in the parameters must be adjusted –...

  • Page 45: Wiring Diagram Of The Appliance

    6. WIRING DIAGRAM OF THE APPLIANCE. The wiring diagram of the automated hot air generator from series “Pelletherm V.5/GENERATO” is presented on Figure 6.1 and Figure 6.2. 220 V Overheating Motors, transformer, thermostat, plates ~ 100 М5 М6 40 VA Fuse2 + (12 - 14)V - Pw Fuse1...
  • Page 46 I1 – input flame sensor Power supply I3 – Start I6 –sensor back fire in auger (option) I8 – pellet level-capacitive sensor POWER SUPPLY STEP-PS/1AC/24DC/0,5 IB - Actuator- Potentiometer N (2) UNIT PHOENIX CONTACT )nevai L1 (1) (INPUT 85 – +24 V-St -24V-St GERMANY...
  • Page 47 WARRANTY CONDITIONS The manufacturing company guarantees correct and trouble free operation of the appliance only if the installation and operation requirements during initialization and maintenance are observed. The warranty period of the automated hot air generator from series „Pelletherm V.5/GENERATO” starts considered from the date of completing and stamping its warranty card.

This manual is also suitable for:

Pelletherm v.5/generato 30Pelletherm v.5/generato 40Pelletherm v.5/generato 50

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