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ZMM Haskovo GP 25cs Instruction Manual

Automatic pellet burner of series gp cs
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Instruction manual
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Summary of Contents for ZMM Haskovo GP 25cs

  • Page 1 Instruction manual for installation and operation of Automatic pellet burner of series “GP cs” http:// www.greenecotherm.eu p. 1/61...
  • Page 2 ZMM Haskovo Plc. Producer Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd. Address +359 800 15 145 Phone +359 38 603070 greenecotherm@erato.bg e-mail www.greenecotherm.eu home page Thank You for buying our product – automatic pellet burner of series „GP”. This manual will help You to use and maintain the unit properly.

  • Page 3: Table Of Contents

    Table of contents Page 1. Automatic pellet burner of series “GP” – description and advantages .. 5 2. Automatic pellet burner of series “GP” technical data ......8 3. Description of the construction of automatic pellet burner of series “GP”........................12 Main properties..................
  • Page 4 5.7. Description of the active thermo stickers, showing the condition of the system......................43 5.8. Removal and attachment of the burner’s grate at maintenance and cleaning procedure of the pellet burner of series “GP” ......45 5.9. Showing and teaching the end user about the maintenance and adjustment procedures of the burner ............

  • Page 5: Automatic Pellet Burner Of Series "Gp" - Description And Advantages

    1. Automatic pellet burner of series “GP” – description and advantages “GP” is automatic pellet burner, which utilizes wood pellets. The burner is designed to be installed on already operating heating boilers or other equipment, thus allowing fuel switch procedure to a renewable energy sources - biomass.
  • Page 6  removable grate of the combustion chamber, allowing easy access and ash cleaning;  photosensor, which gives information for the status of the combustion process to the control unit and allows dynamic operation of the burner;  interface panel, equipped with light indicators; ...
  • Page 7  the resulting heat energy, based on organized combustion process of renewable energy source - biomass, is less influenced by the global trend of the energy sources and as result the price is competitive, compared to price of the popular energy sources; ...

  • Page 8: Automatic Pellet Burner Of Series "Gp" Technical Data

    2. Automatic pellet burner of series “GP” technical data 2.1. Thermal and technical data of automatic pellet burner of series “GP”, utilizing wood pellets are given in Table 2.1; 2.2. Dimensions and technical data of automatic pellet burner of series “GP” are given in Table 2.2;...
  • Page 9 * EXPLANATION : the automatic pellet burner of series “GP” is designed to utilize wood pellets, which have properties, defined in the referred ENplus norm. As an temporal exception (for several hours) it is allowed to utilize pellets, which are not covering the required class of the fuel, practically in such cases the fuel has low quality and high ash content, which leads to more frequent ash residue cleaning of the burner’s grate, as well as the heat exchanger’s walls;...
  • Page 10 Classification of wood pellets, considering their physical properties (based on fuel proximate analysis) – according to fuel evaluation method, developed and applied in pellet burner producer company is show on the following table. Pellet’s category      ...
  • Page 11 The approval of the new EU standard for wood pellets (EN 14961-2) was at mid 2010 and introduces new certificates ENplus for pellets, utilized in domestic heating appliances, the certificate EN-B is applied for industrial boilers. The standard ENplus defines classes of the wood pellets, which could be considered as qualifications: А1 and А2.

  • Page 12: Description Of The Construction Of Automatic Pellet Burner Of Series "Gp

    3. Description of the construction of automatic pellet burner of series “GP” 3.1. Main properties The pellet burner of series “GP” consists of the following elements/modules:  The basis part of the pellet burner is the main unit, which consists of: ...
  • Page 13  Reversible liquid crystal thermo sticker, which indicates the operating temperature of the burner’s main body at the spot of the sticker. This thermometer should be used to estimate the real condition of the appliance as well as the flue stack draught and the requirement for ash deposition cleaning;...
  • Page 14 Interface panel “Back fire” safety alarm thermo-probe Photosensor Combustion chamber Control board of the burner Flap and air supply fan Power supply cable Auger power supply plug Figure 3.2 Section view of the elements of the main unit of the burner; Control board monitoring transparent window Fuel delivery pipe and “back fire”...
  • Page 15 Irreversible thermo sticker Reversible luquid crystal sticker Figure 3.4. View of the side of the burner with attached liquid crystal thermo sticker; COMMENTS :  Reversible liquid crystal thermo sticker indicates the operating temperature of the spot around the sticker. This temperature is indicative for the operating mode of the pellet burner and the hydraulic losses of the flue gases, passing through the heating appliance to the flue stack.

  • Page 16: Specific Design Measures In Order To Increase The Safety Operation Of The Burner

    In case the fuel transport auger should be supported, the an option should be utilized – a telescopic support, which could support the weight of the auger and the length could be adjusted in order to achieve the required installation angle and the overall stability of the auger;...
  • Page 17 controlled amount of fuel, which is utilized at the combustion process and possibility of back fire is strongly reduced; o Sensor of “back fire” alarm thermo-probe, which is positioned on the fuel delivery pipe of the main unit, activates at surface temperature levels above 90 –...

  • Page 18: Installation Of Automatic Pellet Burner

    Installation of automatic pellet burner Requirements and recommendations. 4.1. Some basic requirements for correct installation of automatic pellet burner of series “GP” :  The burner should be positioned in order to guarantee comfort maintenance and easy access for cleaning procedures; ...

  • Page 19: Installation Of The Burner

    4.2. Installation of the burner The installation process of the burner should be based on authorized project, which governs the requirements of acting norms and recommendations.  In case that the heat consumer unit is solid fuel hot water boiler, that the requirements are depicted in norm EN 303-5/2000 - „Heating boilers.
  • Page 20 Figures 4.2, 4.3. and 4.4. show the overall and detailed dimensions of the main unit of the burner, which should be considered at preparing a project and installation of the appliance. Figure 4.2. Overall and characteristic dimensions of the main unit – side view;...

  • Page 21: Arrangement And Installation Of The Pellet Burner's Modules

    Figure 4.4. Overall and characteristic dimensions of the main unit of pellet burner of series „GP cs” – front view; 4.4. Arrangement and installation of the pellet burner’s modules  The main unit of the burner should be installed in horizontal position on a heat energy consumer appliance.
  • Page 22 be positioned at 45 – the angle between the axis of the auger and the horizontal plane, in order to provide optimal operating conditions for the electric motor and efficient combustion process in the combustion chamber of the main unit. The lower section of the auger should be positioned in the fuel bunker and appropriate measures should be taken in order to prevent fuel discharge through gaps between the auger’s pipe and the wall of the bunker.
  • Page 23 Pellet hopper „BP” о Figure 4.5. A principal scheme for installation of fuel transport auger (the axis of the auger should be inclined at 45 by the horizontal plane); EXPLANATION : the auger is installed with additional supporting telescopic element, which is an option for the kit of the pellet burner of series “GP”; Figure 4.6.

  • Page 24: Information, Considering The Installation Of The Automatic Pellet Burner Of Series "Gp" And Its Operation With Hot Water Boilers

    4.5. Information, considering the installation of the automatic pellet burner of series “GP” and its operation with hot water boilers. The automatic pellet burner of series “GP” is a separate module (which requires electrical power supply and a signal for operation), which could be installed on an appliance –...

  • Page 25: Initial Steps And Starting Of Pellet Burner Of Series "Gp

    5. Initial steps and starting of pellet burner of series “GP” Attention : The burner should be installed, adjusted and verified ONLY by trained staff of an authorized company. 5.1. Basic fuel requirements  The fuel should be dry. The unit producer recommends that the fuel should be stored in dry and well ventilated rooms;...

  • Page 26: Interface Control Board Of Automatic Pellet Burner Of Series "Gp Cs

     The end-user should not perform any interventions, repairs, etc. of the unit. In case that warning and failures arise, check the failures table (applied at the end of this manual) and call the service support if the case is not described there;...

  • Page 27: Color Scale For Synchronization Of The Air Flow Rate With The Thermal Capacity Of The Burner

    5.2.2. Color scale for synchronization of the air flow rate with the thermal capacity of the burner Color scale, which is used to adjust the position of the air control flap Lever to adjust the position of the air control flap Figure 5.2.

  • Page 28: Switching On The Burner Of Series "Gp

    water boiler, than the control device is practically the operating thermostat of the boiler. Description of the power supply cable is as follows: o black – (single phase 220-230 VAC, 50/60 Hz) – this wire should be connected to appropriate connection point of the heat energy consumer and has power supply through the main switch of the appliance of 220V.
  • Page 29 COMMENTS :  At operation of the burner, the air control flap position should be adjusted to the position of the potentiometer, which controls the thermal capacity of the burner, use the color scale to synchronize the positions of the control elements, in order to ensure optimal operating conditions and high efficiency;...

  • Page 30: Burner's Operating Algorithm

    5.2.5. Burner’s operating algorithm The burner starts its nominal operation if the following conditions are fulfilled:  The main unit of the burner is installed at the heat energy consumer appliance;  Available power supply;  Start signal is available (the “START” indicator is lit); ...
  • Page 31 combustion are connected and only the charge period is changed by the position of thermal capacity potentiometer position. ATTENTION : The thermal capacity potentiometer should not be in any case positioned at the maximal value (i.e. in the red zone of the scale) as this will result in set-point of thermal capacity of the burner, exceeding its nominal load.

  • Page 32: Operating Control Parameters Of The Burner Of Series "Gp

    ATTENTION : before starting up the burner of series “GP” it is necessary to check if the grate of the burner contains unburned/raw fuel and ash, if available these residues should be cleared away;  In case that the power supply has been interrupted, at its renewal the burner will continue its operation automatically;...
  • Page 33 Tables 5.1 and 5.2 give detailed information about the number of LED blinking signals and the corresponding values of the operating parameters of the burner’s control board (according to the type of the burner) : Symbols: P1 – potentiometer, which defines the operating period for transporting initial fuel doze to the combustion chamber of the burner;...
  • Page 34 Pellet burner „GP 25” Number of LED Potentiometer number blinking Operating period Index [seconds] 1.50 1.65 1.82 2.18 2.83 150* 3.68 4.79 6.22 450* Table 5.1. Description of the operating parameters of the burner’s control board of pellet burner type “GP 25”. NOTE: The maximal index value of LED blinking of parameter P2 is 7;...
  • Page 35 Pellet burner „GP 32” Number of LED Potentiometer number blinking Operating period Index [seconds] 1.50 1.65 1.82 2.18 2.83 150* 3.68 4.79 6.22 7.46 8.21 450* Table 5.2. Description of the operating parameters of the burner’s control board of pellet burner type “GP 32” (the nominal thermal capacity is 32kW).
  • Page 36 combustion process, the optimal combustion process should be stable, no unburned char particles should be observed as well. The practice shows, that the factory set values do not need any onsite adjustment, regardless the difference of the fuels utilized; The producer reserves the right to change the specification and/or the default values of the operating parameters of the unit without prior notice;...
  • Page 37 o Switch ON the burner and set START signal (by the control unit of the energy consumer) ON as well; o Unplug the photosensor by drawing until it is out of the sensor’s handler and the control board of the burner will analyze this mode as nominal operation one (i.e.

  • Page 38: Adjustment Process Of The Burner, According To The Heat Demand Of A Consumer

    The producer reserves the right to change the default (factory defined) values of operating parameters of the burner without prior notice; 5.2.7. Adjustment process of the burner, according to the heat demand of a consumer It is recommended to make appropriate adjustments of operating parameters of the burner of series “GP”...

  • Page 39: Nominal Thermal Load Of The Burner Of Series "Gp

    5.2.8. Nominal thermal load of the burner of series “GP” After the pellet burner has been started successfully (the fuel in the combustion chamber is ignited) and the heat consumer unit, which demands heat energy is heated up and tempered, one could assume that the system: burner- heat consumer unit are in steady-state mode and thermally tempered.

  • Page 40: Decreasing Thermal Capacity Of The Burner

    Information about the thermal capacity of the pellet burner of series “GP” at different values of the thermal capacity parameter P2 is shown in the following table. Thermal capacity of the pellet burner , [kW] Type GP 25 GP 32 [number of LED blinking] 11.0 11.0...

  • Page 41: Stopping The Pellet Burner Of Series "Gp

    EXPLANATION : In case of changing the thermal capacity of the burner it is required to adjust the air flow rate as well, by adjusting the position of air flow control flap. In principal a decrease of the thermal capacity will require lower air flow rate and vice versa.

  • Page 42: Turning Off The Automatic Pellet Burner Of Series "Gp

    is recommended to install a heat accumulating tank parallel to the circuits of the heating system in order to achieve a buffer effect and to decrease any variations of the consumption of heat energy by the heating system; 5.5. Turning OFF the automatic pellet burner of series “GP” The pellet burner is turned off by changing the “START”...

  • Page 43: Restarting The Operation Of A Pellet Burner Of Series "Gp

    heat consumer) boiler is checked and the cause for overheating is determined and repaired, restart the burner by turning off its power supply and then back on in order to run the burner in normal mode;  in case of alarm mode – fuel delivery pipe overheating, the alarm thermo- probe of the burner’s main module is activated and the control board switches into alarm mode.
  • Page 44 Figure 5.4. View of the reversible thermosticker, used to measure the spot temperature – initial condition, at normal room temperature; Figure 5.5. View of the reversible thermosticker, used to measure the spot temperature –condition at increased burner’s body temperature – in the range of 60 –...

  • Page 45: Removal And Attachment Of The Burner's Grate At Maintenance And Cleaning Procedure Of The Pellet Burner Of Series "Gp

    cleaning of the residue, also the ash deposits on the internal surfaces of the chimney. Figure 5.8. View of the irreversible thermosticker, used to mark an alarm overheating of the pellet’s delivery pipe – initial condition, the active segment is white, the temperature has not reached activation level of 104 Figure 5.9.
  • Page 46 Combustion head of the burner’s main module Inclined grate of the burner’s main module Grate of the burner Figure 5.10. Side view of the burner’s main module with detached grate; NOTE : the grate of the burner should be taken out of the burner’s head after the burner has been cooled down to safe temperature levels, in order to be cleaned thoroughly.
  • Page 47 Combustion chamber of the main module of the burner Inclined grate of the burner’s main module 1. Initial positioning of the burner’s grate 2. Final positioning of the burner’s grate Legs of the burner’s grate Figure 5.11. Cross-section of the burner, showing the position of the grate at the attachment process;...

  • Page 48: Showing And Teaching The End User About The Maintenance And Adjustment Procedures Of The Burner

    ATTENTION : grate is positioned into its final position and fits well to the inclined grate of the burner Figure 5.12. Final position of the grate, positioned in the burner’s main module (shown as cross-section); 5.9. Showing and teaching the end user about the maintenance and adjustment procedures of the burner It is necessary to show and teach the end user the maintenance procedures for operating the burner efficiently and keep its reliability in high degree order.
  • Page 49 Figure 5.13. Pair of working gloves, committed in order to perform easy and safe cleaning procedure of the pellet burner’s main module;  cleaning procedure of the flexible hose, connecting the fuel transport auger and the main unit of the burner– it is recommended to clean periodically this hose, as during the fuel transport fine particles are deposited on the internal surface of the hose, which eventually could impede the fuel transport though it.

  • Page 50: Safety And Unexpected Risks

    5.10. Safety and unexpected risks Risks could arise at the exploitation of the burner of series “GP”: The automatic pellet burner “GP” is designed according to the safety requirements of the operating European standards and norms. However safety and unexpected risks could arise in situations like following: ...

  • Page 51: Operation Faults And Repairing Procedures

    5.11. Operation faults and repairing procedures No Operation fault Cause Method of repairing 1. In case that the Insufficient heat Adjustment of operating parameters burner capacity is required – this should be installed on a burner performed by authorized technician hot water boiler set-point It is necessary to increase the set-...
  • Page 52 6. Heat consumer Absence of heat It is necessary to check the correct unit emergency consumption operation process of the system: overheating incorrect burner-heat consumer unit adjustment of the eventually appropriate adjustment of parameters of the the operating parameters of the burner burner–...
  • Page 53 Abnormal The photosensor should be checked, operation cleared if necessary adjusted or malfunctioning of replaced in case it is out of order; the photosensor 8. The burner is No power supply Check the status of “POWER” not running or it indicator, positioned on the interface stops panel of the burner.
  • Page 54 The main module After the main unit is cooled down is in alarm mode, to ambient temperature, the reason due to alarm for this emergency situation should thermo-probe be clarified and necessary steps activation should be taken in order to sustain (overheating of the operating conditions for the burner.
  • Page 55 11. The operation of Photosensor Check condition the burner is not malfunctioning functionality of the photosensor stable The operating Check the position of the heat parameters of the capacity potentiometer control board have Check the operating parameters of been changed the burner’s control board –...
  • Page 56 pipe of the main most of the cases it necessary * - module of the is a result of the performed by authorized technician; burner passage of hot flue gases 16. Blurred/melted Incorrect stopping It is required to clean the external photosensor procedure of the surface of the photosensor or...
  • Page 57 temperature exchanging the heat consumer surfaces in order the flue gases (if surfaces of the heat to decrease ash layer heat resistance; flue consumer thermometer is deposited with ash, mounted) presenting heat resistive layer, thus decreasing the heat exchanging intensity 22.
  • Page 58 Indication Meaning Method of repairing status Yellow LED is number Check the causes for lack of fuel permanently ignition trials ignition – see Table 5.4 active been reached now fuel ignition has Check the reason for failed ignition been achieved attempts –...

  • Page 59: Automatic Pellet Burner Of Series "Gp" Warranty Form Completion

    5.12. Automatic pellet burner of series “GP” warranty form completion. The applied WARRANTY FORM should be completed, by filling the required information in the appropriate fields. The assigned field for signatures and stamp should be completed as well in order to VALIDATE the WARRANY FORM of the automatic pellet burner of series “GP”.

  • Page 60: Electrical Scheme Of Automatic Pellet Burner Of Series "Gp

    6. Electrical scheme of automatic pellet burner of series “GP” Figure 6.1 shows the principal electrical scheme of automatic pellet burner of series “GP”. PELLET BURNER CONTROL BOARD APPLIANCE (BOILER) F2- T6,3A – Heater F3- FF 800mAH – Fan R = 220 Ohms F4- FF1,0 AH –...

  • Page 61: Warranty Conditions

    WARRANTY CONDITIONS The producer guarantees correct and reliable operation of the pellet burner of series “GP” ONLY when installation and maintenance requirements are completed. The warranty period of the pellet burner starts from date, when the warranty form is filled and stamped by the authorized organization. The warranty period of the pellet burner starts from date when it is started for very first time, but no longer than 18 months of the day of delivery.

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