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“Pelletherm v2 M01”.

1. Ash container Figure 3 5 Cross section view of hot water pellet boiler of series Pelletherm 45v2 The flue gasses duct and streamlines are visualized as well p 16 54 4 Installation process Norms and recommendations Basic requirements for installation of hot water pellet boiler of series Pelletherm v2 The room dedicated to mount the boiler should be supplied with fresh air supply duct necessary for optimal combustion process as well as room ventilation Installation of the unit in inhabitable premises including dwelling corridors 1s not allowed The hot water boiler should be connected to the heating system by authorized personal only Installation and service procedures of solid fuel hot water boilers should be performed by authorized qualified and certified personal ONLY The hot water pellet boiler of series Pelletherm v2 should be connected to heating system supplied with OPENED or CLOSED expansion vessel In case the heating system is equipped with closed expansion vessel then the system should be equipped with over pressure safety valve which opens at pressure exceeding the operating one of the hot water boiler 0 25 MPa and this overpressure safety valve should be certified according to PED 97 23 Both the entire heating system and the boiler should be totally filled with circulating fluid water and air free before operating the boiler Maintenance procedures of the boiler s
2. F3 1A F Auger F1 6 3A F2 800mA F Ignition Fan EXT5 fresh air Ash scraper control F4 1A F RX Flue gas fan option Ash scraper control Ash scraper Ignition Fan fresh air Auger Flue gas fan option Ash scraper TD thermo disc in inlet cleaning device pellet tube 95 C Figure 6 2 Electrical scheme of the control board of hot water pellet boiler of series Pelletherm v2 M01 p 53 54 WARRANTY CONDITIONS The producer guarantees correct and reliable operation of the unit ONLY when installation and maintenance requirements are completed The warranty period of the boiler starts from date when the warranty form 1s filled and stamped by the authorized organization THE WARRANTY OF THE UNIT IS NOT VALID in case one of the following is fulfilled e Unit damages caused by incorrect handling transport and or loading unloading which are not organized by the producer e Failures caused by natural disasters Earth quakes fires floods etc e Unsatisfied installation maintenance and service requirements which are described in this manual and its annex e Repairing of any failure of the unit performed by unauthorized technicians or the end user e Any changes in the design of the boiler e Incorrect heating system project design and implementation e Failures caused by factors for which the producer could not be blamed and or has no contro
3. Figure 3 1 External view of hot water pellet boiler of series Pelletherm v2 The unit is designed and assembled in two main modules the heat exchanger the left one and the fuel hopper module the right one These modules are easily detachable and could be assembled onsite 1f necessary The producer reserves the right to make changes of the design of the hot water boiler of series Pelletherm v2 without obligations to inform the clients for that process p 14 54 Fuel hopper Control board display and keyboard Fuel proportioner Fuel transport auger Burner s ash cleaning aa Figure 3 2 Partly sectioned view of hot water pellet boiler of series Pelletherm v2 M01 front view Flue gases exit duct External fuel delivery la orifice Figure 3 3 External view of hot water pellet boiler of series Pelletherm v2 top view p 15 54 Tertiary pass of flue gasses TEIG TEE YN mu m mm lt 4 MEE Specialized pellet burner equipped with ash cleaning mechanism Ash container Figure 3 4 Cross section view of hot water pellet boiler of series Pelletherm 30 v2 The flue gasses duct and streamlines are visualized as well jes Tertiary pass of flue gasses Secondary pass of flue gasses Primary pass of flue gasses i7 i T s al scat Specialized pellet burner equipped with ash cleaning mechanism
4. Figure 4 4 Back side view of heat exchanger connections of hot water pellet boiler Pelletherm 45 v2 p 22 54 5 Hot water boiler installation and starting procedures ATTENTION The unit should be installed adjusted and verified ONLY by trained and authorized staff 5 1 Basic fuel requirements e The fuel pellet shaped should be dry The unit producer recommends that the fuel should be stored in dry and well ventilated rooms e It is strongly forbidden to store the fuel in close region of the boiler the minimal safety distance between the fuel and the appliance is 400 mm e The unit producer recommends an optimal distance between the boiler and the fuel container to be at least 1000mm It is recommended to store the fuel in room next to that where the boiler is installed e At the installation procedure of the unit as well as the fuel storage one fire prevention recommendation should be considered It is also recommended to install a fire extinguisher in a safe and easy accessible place In principle heating systems which are hydraulically opened to the atmosphere allow direct contact between the circulating fluid in most cases it is water and the air During the heating season the water content in the expansion vessel absorbs oxygen from the atmosphere though the free surface The increased oxygen content in the water threatens the metal of the unit as well the pipes Through the free surface of the expansio
5. The boiler is automatic and the thermal comfort achieved is close to that originating from exploitation of fully automatic boilers for example liquid or gas fuel as well as electric boiler which makes is applicable in heating systems equipped with programmable room thermostat The unit is equipped with automatic fuel ignition system and another one for burner s grate ash cleaning The design of the heat exchanger is optimized and realizes three way flue gas duct thus allowing intensive heat exchange rate and high efficiency of the boiler above 90 and reduced fly ash particles emission to the chimney Automatic unit operation Hot water boiler could be connected to programmable room thermostat weekly programmable which guarantees maximal thermal comfort and economical fuel consumption The unit utilizes solid biomass fuel in shape of pellets wood pellets dried nuts cherry nuts for example which have ash contents higher that the limits defined in following norms ENplus EN 14961 2 2010 ONORM M7135 DIN 51731 n DINPlus High efficiency Low pollutant contents in the flue gases The unit is applicable for domestic hot water heating purposes Automatic fuel feeding system transported from the built in daily hopper to the burner The control operating module can operate the function of additional external fuel feeding system which deliver fuel to the built in fuel hopper from external one Simplified ma
6. lt 3 0 A gt 3 0 Table 2 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in boiler s producer company where A ash contents dry basis DU mechanical durability p 11 54 The European wood pellets standard EN 14961 2 2010 defines wood pellets certificate ENplus for pellets utilized in boilers and appliances for domestic heating systems The certificate EN B is applied for pellets utilized in industrial boilers In principal the ENplus standard defines two quality classes Al n A2 The class Al is highly restricted considering the ash content The class A2 the limit of the ash content of the wood pellets is higher up to 1 5 For industrial boilers the certificate EN B is applicable which defines fewer restrictions on the pellets quality Dimension ENplus Al ENplus A2 mm 6 ED 6 1 4 arameter Diameter mm mm _ 3 15 lt L lt 40 3 15 lt L lt 40 kgm 600 6o ength il qa ulk density l J kg 2165 ow calorific value Moisture content Dust Mechanical durability lt 10 gto p U wa 0 0 0 Ash content e 0 M975 e975 C 3 0 i 0 Mm o7 SS ec E1200 E00 Mm oo koo koos 0 05 S03 kos mgkg 10 kio mgkg c10 s10 mgkg jst st mg kg g05 kos mgkg koi sot mgkg 10 gio mgkg
7. p 27 54 p 28 54 assistance 1s performed for example bunker s charge with fuel solving a problem etc and the boiler is restarted In case that the fuel has been ignited the boiler goes into nominal operation mode which is performed by periodic fuel transport to the combustion chamber of the boiler followed by a certain interval utilized for fuel combustion The periods for fuel charge and combustion are predefined in the operating firmware of the control module the thermal capacity of the boiler is however changed by setting the operating stage of the boiler ATTENTION The choice of the maximal thermal capacity stage 5 is not recommended this stage is available in order to utilize relatively low calorific value fuel or temporary demand of increased heat consumption rate It is recommended to operate the boiler in the operating range of 1 to 4 thermal capacity stages at 4 stage the boiler achieves its nominal thermal capacity At approaching the temperature of the boiler s circulating water set point the control module decreases the boiler s operating thermal capacity 1 e the control module operates the boiler in modulating mode At decreasing the temperature of the circulating water the boiler s control module restores the set thermal capacity In case that the START signal goes off for any reason room thermostat for example etc the boiler will go into stand by mode following the algorit
8. page 1 Hot water pellet boiler of series Pelletherm v2 description properties and AAVANAGES cc cccccccccssssccccceeseeccecaaesecceeeeeeeeceesaeeeeeeseaaaeeeees 5 The unit could utilize following types of fuel cc ecceececeeeeeeeeees 5 The unit is equipped with 0000nn000ooennnsseennssseerossserrssssserssssssressseeressseeres 6 The unit is supplied with amp ooo ec cccccccsseccceceeecccecaeeeeeeeeaeeeeeesesaeeeeeeeaas 6 2 Hot water boiler of series Pelletherm v2 technical data 8 Table 2 1 Thermal and technical data for hot water pellet boiler of series Pelletherin v2 Willizine WOO Pe llCISssigscescancevechecwnin getnenaraagedaaesanbewnnieweeineedes 9 Table 2 2 Dimensions and technical data for hot water pellet boiler of series Be We UNG a 2 eeeaccet ct oie es ade A O tata eo eh iaeaa ats etnias O 10 Table 2 3 Recommended solid fuel properties wood pellets 00 1 Table 2 4 Pellets classification considering their physical properties based on fuel proximate analysis according to fuel evaluation methods developed and applied in boiler s producer COMPANY cceccceessssesseeseeseseeeeeeeceeeeeeeees 11 Table 2 5 ENplus European standard for wood pellets cccceeeeees 12 3 Description of hot water pellet boiler of series Pelletherm v2 13 4 Installation PIOCESSs seesciccced ouatecncaoiesartienaonded
9. 10 sto 1 not more that 1 of the wood pellets should be with length of 40 mm the maximal pellet length is 45 mm 2 determined on dry mass 3 the particles are lt 3 15 mm fine particles before fuel delivery 4 in case the test measurements are performed with Lignotester than the limit value is gt 97 7 M w Ash melting point temperature ii N N Ne w 1 4 N Table 2 5 ENplus European standard for wood pellets p 12 54 3 Description of hot water pellet boiler of series Pelletherm v2 The heat exchanger of the boiler complies with the acting requirements for such kind of units defined in operating norm EN 303 5 2000 Heating boilers for solid fuels hand and automatically fired nominal heat output up to 300 kW Terminology requirements testing and marking The unit consists of Main part of the unit is heat exchanger In the combustion chamber of this exchanger is mounted specialized grate burner designed for horizontal fuel feeding The heat exchanger is welded construction of carbon steel plates and steel pipes The lower part of the exchanger is designed as combustion chamber The burner is mounted in this chamber and conditions efficient combustion process High temperature stainless steel burner mounted in the combustion chamber of the heat exchanger Ash container positioned in the lower part of the combustion chamber below the burner Fuel hopper is
10. it is necessary to wait until the temperature of the circulating water 1s moderate and the heat exchanging surfaces are cooled down to safe levels and the ash cleaning procedure could start 2 4 Cleaning the ash of the heat exchanger surfaces Before the ash cleaning it 1s necessary to open the top cover of the heat exchanger body Unscrew the fixing nuts and remove the flue gas duct lid Figure 2 2 The top cover of the heat exchanger is lifted up The fixing nuts should be unscrewed and flue gases duct lid should be removed p 4 14 ae g ee ae i EJ O Eo an a lt 7 a sA FY IR Bi ne Sek ot T at i 4 K Nyi 7 t a a a d x ai ZW RN OWI ETE AR EL LF i Ce a ek ee T Figure 2 3 The flue gases duct lid is detached the ash residue is clearly seen on the boiler s heat exchanger surfaces Utilize appropriate tool to clean to grate the ash and char deposition off the internal surfaces of the boiler s body ATTENTION the practice shows that the ash grating is connected with intensive release of fly ash thus it is highly recommended to wear air breathing protective mask as well as appropriate clothing in order to minimize any lung issues and cloth staining p 5 14 fo Sains We ys Rie RE ETT Pa 42 ae SNS ye TEN TOM MENSI Set Figure 2 5 Brushing the ash layer of the heat exchanger surfaces The next
11. In case of power supply break down the boiler will go into the same state of the unit before the interruption ATTENTION During the operation of the boiler when the door of the combustion chamber is opened it is possible to observe smoke leakage through the transport auger tract as well as the pellet hopper Because of these reasons the opening of that door is not recommended The same processes could be observed at the transition periods during spring and autumn seasons when the chimney s draught is reduced due to high ambient temperature COMMENTS p 26 54 o At the period of fuel ignition an electrical heater is activated The heater will be deactivated when there is combustion process in the combustion chamber monitored by a photosensor e During the very first starting period of the unit it takes time to fill the auger volume with fuel According to the settings of the unit the first ignition may fail If this is the case please restart the unit by switching OFF and ON by the main POWER switch and check the ignition process gain e The boiler is operating controlled by predefined algorithm loaded in the process control module 5 2 4 Boiler s operating algorithm The boiler starts its nominal operation 1f the following conditions are fulfilled e Available power supply e Activated START indicated on the control module s display or presence of signal to operate in case the boiler is controlle
12. http www greenecotherm eu ANNEX I1 Hot water pellet boiler of series Pelletherm v2 end user maintenance procedures Document edition 12 05 2012 12 29 1 General principals The fuel of the hot water pellet boiler of series Pelletherm v2 is wood pellets or any other verified and described in the user manual of the boiler and the residual of the combustion process is mineral ash The quantity of the ash depends on the fuel mineral mass content 1 e fuel s quality The practice shows that main part of the ash residue is collected in the ash hopper of the boiler however ash is deposited on the heat exchanging surfaces as well and other surfaces that are in direct contact with the flue gases the burner the flue gas fan etc The ash residue quantity collected in the main ash hopper positioned in the combustion chamber should be cleared periodically considering the operating mode of the boiler as well as the fuel quality The practice shows that according to the ash in that hopper should be cleaned thrown away periodically between one and five days the fuel should cover the requirements depicted in the user manual of the boiler It is advisable to clean the convective part of the heat exchanger by utilizing the applied the specialized lever it should be plugged in the profiled orifice and swing the lever in both direction several times which actually will activate the semi mechanized cleaning syst
13. Unexpected risks The unit is designed and produced according to the requirements of the operating EU safety norms However in spite of that possible risks are considered as a result of the operating process of the boiler it is possible to get risks as follows Cauterization risks caused by high temperatures as a result of the combustion process in the combustion chamber and or direct access to the front door of the combustion chamber at manual cleaning processes of the surfaces of the burner and or combustion chamber or ash residue cleaning accumulated in the ash tray or any unburned fuel material smoldering in the ash tray Electrical shock risks at indirect contact The boiler is connected to the power circuit and its operating modules are separated in specialized electric control box equipped with required protective and short circuit preventive devices It is obligatory to perform boiler ground connection by authorized personal technician o Fingers injuring risks at opening closing the doors caps of the boiler at maintenance and cleaning process of the unit It is recommended to use appropriate individual resources for self protection Suffocation risks due to flue gas uncontrolled emissions in the boiler s room in case when the chimney draught is insufficient in case that the convective part of the boiler is clogged or in case that the flue gas duct is not fully tightened and gas leaks are possible p 46 54 5 10 Op
14. buttons could have other functionality which is dynamically indicated on the display of the controller 3 2 2 Hot water boiler power supply e The boiler should be connected to the chimney according to the installation s project This duct should be sealed and verified that there is no flue gases leakage e The boiler should be connected to the heating system the system as well as the water jacket of the heat exchanger should be filled with circulating liquid free of air the control modules valves pumps motor valves etc should be checked for functionality as well e The unit should be connected to the main power supply according to the safety rules and appropriate norms e The hopper should be filled with pellets in order to transport fuel material by the pellet feeding auger to the burner It s recommended to set the pellet hoper lid closed in order to preserve uncontrolled air penetration to the combustion chamber through this tract The boiler s main POWER switch is positioned on its back side it switches ON and OFF the main power supply of the boiler 5 2 3 Hot water boiler very first start The unit is switched on by the main POWER supply switch The unit gets activation signal by switching ON the START and goes into automatic operating mode it goes through ignition mode if needed If the START switch is OFF then the boiler goes into stand by mode and waits until new command arise
15. chai em casstts Beate aie meth aateiaien neta aeclnveaiasemeceaie aioe wneecteaiamneeseeaenenect 35 5 2 8 2 User menu items of the control module of hot water boiler of Series Peletherm V2 MOL sai castonssaaasnscaeensendonsansasadbanecaunasadoassaaendeanedcnoasions 37 5 2 9 User menu items in control module of the hot water boiler of series Peleth erm V2 MOL oroen E 37 5 2 9 1 Menu item EFFECT LEVEL 0 000 ccc eeseeeeees 37 Table 5 1 Operating thermal capacity of the hot water boiler of series Pelletherm v2 MO inc iscsineesacnsancvveb saceideacbadsnediesdiaensaczenondhbaaueteneibedoienears ack 38 5 3 Adjustment of the thermal capacity of the boiler 0000000 0 39 5 3 1 Decreasing the thermal capacity of the hot water boiler 39 sR PA Increasing the thermal capacity of the hot water boiler 39 5 4 Stopping the operating mode of the hot water boiler of series Pelletherm VAMO I icsxepcecasiaoeh raced ane a N E 40 5 4 1 Stopping the operating mode of the hot water boiler of series Pelletherm v2 M01 by switching OFF the START switch 40 5 4 2 Stopping the operating mode of the hot water boiler of series Pelletherm v2 M01 by setting the menu item of its control module 41 5 5 Turning OFF the hot water boiler of series Pelletherm v2 M01 by external control mod le eers len cuactwatvandsaearacevinsh bnibanseste teat vacesaumised mes vted Sean 43 Emerg
16. for air ventilation of the boiler s room This will allow efficient operation of the boiler and optimal operation of the entire heating system resulting in low fuel consumption rate and low pollutant emissions as well as increased overall reliability of the system s components NOTES e During the nominal thermal load of the boiler regular cleaning process is activated and the ash residue remained on the grate of the burner is removed away and is deposited in the ash container positioned on the bottom of the combustion chamber It should be noted that before the ash removal process the fuel delivery to the burner is paused while the fans are working thus ensuring conditions for utilization of the char remained on the grate of the burner A decrease of the thermal capacity of the boiler could be noticed however e Ifa circulating pump is installed in order to transport the heat energy of the boiler to the consumers it is recommended to control the inflow temperature to the boiler to be above 60 C In case of low inflow p 34 54 temperature level condensation of water vapor could be observed on the internal heat exchanging surfaces please consider that water vapor is one of the final products of the combustion process and always persist in the flue gases of the boiler e It 1s not recommended to operate the hot water boiler at thermal capacity lower than the minimal thermal load as such regimes are not optimal and thus have l
17. fuel transport auger is not functioning burner s grate It is necessary to perform adjustment of the operating parameters and the air flow rate the adjustment should be performed by authorized technician It is necessary to contact the service company and help of a authorized technician 1s required It is necessary to clean thoroughly the heat exchanger surfaces of the boiler It is necessary to perform adjustment of set point temperature which controls the circulating pump of the heating system It is recommended to adjust the set point temperature to minimum of 65 C It is necessary to clean thoroughly the flue gas fan and its casing It is necessary to perform adjustment and tightening of the combustion chamber s door as well as any other lids eventually change the heat resistant ropes this should be performed by authorized technician only The door s safety switch 1s active this door should be closed The fuel transport mechanism should be checked this should be performed by authorized technician only p 49 54 14 Other failures It is necessary to consult not described authorized technician and above eventually service maintenance should be performed Table 5 2 Description of operation faults of the hot water boiler of series Pelletherm v2 causes and methods for repairing Description of the error Method of repairing 1 10 Unsuccessful fuel ignition Clean
18. fuel consumption rate 5 3 2 Increasing the thermal capacity of the hot water boiler The thermal capacity of the boiler is increased by increasing the thermal capacity operating set stage which results in increased thermal capacity of the boiler as well as increased fuel consumption rate p 39 54 NOTES e At any change of the thermal capacity set point of the boiler its operating algorithm automatically makes changes of the operating values for the air flow rate supplied by the air fan as well as the fuel flow rate which allows optimal operation in wide thermal capacity range of the boiler e The default values of the operating parameters of the hot water boiler of series Pelletherm v2 M01 are derived at the following conditions the fuel is wood pellets with diameter d 8 mm ENplus A1 see table of wood pellets ENplus classification e The ash content mineral incombustible content in the fuel does not influence significantly the gross calorific value of the fuel but requires specialized design of the burner in order to achieve optimal and efficient combustion process Following this one should test the applicability of a fuel for combustion process in the current design of the burner and if positive result is achieved to be massively utilized as fuel material However many aspects of the unit operation should be considered e The producer preserves its right to change any factory preset value of the operating pa
19. local heat consumption e Fuel hopper charging the fuel is poured out in the hopper of the boiler and the hopper s cap should be closed in order to prevent uncontrolled air penetration to the burner through this section e Ash cleaning procedure it is recommended to clean periodically the ash residue at least once per day the convective heat exchanger part of the unit by manually swinging the cleaning lever for semiautomatic ash cleaning process Covering this requirement will ensure effective heat exchanging process and will sustain optimal operating conditions of the boiler Detailed ash cleaning and maintenance procedures are described in ANNEX 1 of this manual ATTENTION regular cleaning of the ash residue deposited on the heat exchanging surfaces of the boiler will ensure long life reliable exploitation period economic and efficient performance of the unit p 45 54 5 9 Safety and unexpected risks Risks could arise at the exploitation of the boiler The hot water pellet boiler of series Pelletherm v2 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 e Hot water pellet boiler of series Pelletherm v2 is operating incorrectly e The unit is installed by unauthorized unqualified personal e The safety instructions described in this manual are not followed and fulfilled
20. mounted aside of the boiler s heat exchanger Beneath the hopper is mounted a fuel auger separator which also acts as fuel proportioner followed by horizontal transport auger The fuel proportioner prevent the so called back fire process 1 e ignition of the fuel in the hopper by the hot flue gases in the auger duct in case of abnormal situations Fresh air fan is mounted on the air duct of the burner The fan 1s equipped with position adjustable flap in order to set the air flow rate Additionally the air duct is equipped with flaps for individual adjustment of the primary and secondary air flow rates These flaps are factory set and in principal need no adjustment Inflow and outflow connections to from the heating system of the supply and return circulating water are internal threads positioned in the rear side of the heat exchanger Draining connection is internal thread diameter G2 and is positioned on the lower part of rear side of the heat exchanger An appropriate drainage valve should be connected p 13 54 e Flue gases exit duct is positioned in the upper rear side of the heat exchanger after the flue gases fan concerning the flue gases track utilized for forced flue gases extraction e Boiler s heat exchanger is covered with decorative covers isolated with mineral wool plates ensuring low heat losses to the ambient environment e Outer decorative covers are carbon steel plates color painted details
21. operation of the boiler should be activated In case the net calorific value of the utilized fuel 1s known then it could be introduced in the operating parameters of the control module as well The factory default value for the net calorific value of the wood pellets is 4 8 kWh kg After the fuel specification data has been introduced these data changes should be saved by appropriate choice of menu item indicated on the control module s display follow the onscreen instructions to proceed utilizing the appropriate buttons indicated below the text After these adjustments the boiler s operating parameter are defined and controlled thermal capacity complying the appliance producer specifications are achieved The producer reserves the right to make changes if the factory default values of the operating parameters without prior notice end users or service technicians Adjustment of the boiler according to the heat consumption It is highly recommended to adjust the operating thermal capacity of the hot water boiler of series Pelletherm v2 in order to achieve high efficiency and reliable operation of the unit The adjustment process consists of individual adjustment of the operating thermal capacity stage of the boiler as shown on Table 5 1 p 33 54 At the thermal capacity operating stage adjustment of the boiler the adjustment of the air flow rate supplied by the air fan is not required as the operating mode of the fan
22. the burner s grate Check for fuel available in the hopper and the auger charged Ask for help an authorized technician operation of the boiler se E photosensor The control board ambient Switch off the boiler and let the unit to temperature is above get cooled defined limit Ask for help an authorized technician The circulating water The circulating water has low temperature sensor has temperature high danger of freezing measured temperature and mechanical damages levels below 5 C Ask for help an authorized technician to check the entire heating system The circulating water The circulating water has hazardous temperature sensor has high temperature and there is high risk measured temperature of overheating of the heating system above 120 C Ask for help an authorized technician to check the entire heating system 7 16 Control board faulty Ask for help an authorized technician operation aR Air control relay failure Ask for help an authorized technician 9 19 The air fan does not rotate Ask for help an authorized technician 10 20 The air fan does not run at Ask for help an authorized technician the designed rotation speed 11 21 The initial fuel ignition Check the presence of fuel and the has failed proper operation of the auger Ask for help an authorized technician p 50 54 External auger failure Ask for help an authorized technician The photosensor does not Ask for h
23. the keyboard are used to indicate the current status of the boiler as well as adjustment of its operating parameters The adjustment of the parameters however should be performed by authorized trained technician only p 29 54 5 2 6 Description of the initial menu the starting process and the adjustment of the control module of boiler of series Pelletherm vv M01 Control module firmware version GREEN ecoTHERM number Figure 5 2 Initial menu shown on the boiler s display of series Pelletherm v2 MO1 start up process After the boiler s software has been loaded into the control module which actually takes several seconds the display indicates a question should the boiler be activated Activate Activate ENTER Figure 5 3 Menu item shown on the display at start up procedure of the hot water boiler of series Pelletherm v2 M01 indicating reminding question In order to start the boiler press the button S as shown on the figure above After the boiler has been activated the display indicates the following message p 30 54 TEST BLOWING 32 Figure 5 4 The display indicates information for the current operating mode of the control module in the case the control module performs functional check procedure of the fans COMMENTS e TEST BLOWING indicates the operating mode in the example the control module performs initial air fan blowing whic
24. 1 Hot water pellet boiler of series Pelletherm v2 description properties and advantages Pelletherm v2 is steel plate hot water pellet boiler which uses solid biomass fuel in shape of pellets The boiler is designed to be connected to local hot water heating systems as well as heating up domestic hot water The boiler uses wood pellets as well as other type shape of biomass the resulting heat energy from thermo chemical conversion i e combustion process is transmitted to the circulation water in its water jacket and the heat energy is transported to the heating system consumer The hot water pellet boiler of series Pelletherm v2 includes hot water boiler 1 sp ash tray l sp foot screws for installation and leveling 8 sp pair of working gloves Isp working apron l sp instruction manual I sp annex of the instruction manual I sp The unit could utilize following types of fuel e Wood pellets having diameter 6 up to 14 mm categorized in the range of A AB B BC C CD E EF according to the methodology developed for pellets properties estimation in boiler s producer company e Pre dried nuts cherries for example e Fuel mixture pellets and nuts for example mixture ratio could be 50 50 e Pellets produced of any other solid biomass for example olive husk residue e Other solid biomass based pellets but confirmation for these fuels utiliza
25. USER MANUAL of hot water pellet boiler of series Pelletherm v2 M01 http www greenecotherm eu Producer ZMM Haskovo Plc Address Bulgaria Haskovo 6300 Saedinenie 67 blvd Phone 359 800 15 145 Fax 359 38 603070 e mail ereenecotherm erato bg home page www greenecotherm eu Thank You for buying hot water pellet boiler of series Pelletherm v2 This manual will help You to use and maintain the unit properly The boiler s producer company requires the installer technicians which will perform the installation maintenance and service procedures of the boilers of series Pelletherm v2 to be trained and certified by the producer NOTE in the following document is used the designation Pelletherm v2 which includes all the models of the hot water pellet boilers Pelletherm 30v2 and Pelletherm 45 v2 applicable for any boiler s modifications ATTENTION IN INTEREST OF YOUR PERSONAL SECURITY IT IS OBLIGATORY TO READ THOROUGHLY AND CAREFULLY THIS INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY ACTIONS WITH THE BOILER MOUNTING CONNECTING ETC IN CASE THE REQUIREMENTS DEPICTED IN THIS MANUAL ARE NOT SATISFIED FAILURES OF THE UNIT COULD BE EXPECTED OR EVEN FATAL CONSEQUENCES FOR WHICH THE PRODUCER COMPANY DOES NOT TAKE RESPONSIBILITY Hot water pellet boiler of series Pelletherm v2 M01 user manual document version 15 05 2012 13 17 CONTENTS
26. as the top lid covering the flue gases duct of the heat exchanger in order to ensure high reliability and efficiency of the appliance 3 Recommendations and requirements It is highly recommended to perform the above described procedure of ash deposition cleaning as it will ensure high efficiency and reliability of the boiler It is recommended to ash clean the unit on a period of a month of operation but it is necessary to clean the ash on operation period of no more than two months considering the operating mode of the boiler as well as the ash content of the raw fuel ATTENTION e After each cleaning procedure the boiler should be checked out the correct attachment of the element the air tightness of the lids and the boiler s functionality e At the end of the heating season it is necessary to perform thorough ash cleaning of the boiler because the mineral ash acts as corrosive reagent and reduces the reliability of the boiler It is recommended to take away of the fuel hopper any pellets of other fuel if utilized as the pellets could absorb moisture from the ambient air and cause clogging of the fuel transport auger issues with the ignition etc The above depicted ash cleaning procedure is OBLIGATORY In case that the ash cleaning and boiler s maintenance procedures are not followed it is possible to decrease the efficiency and performance reliability of the boiler even operation failure could be achieved for examp
27. ata for hot water pellet boiler of series Pelletherm v2 utilizing wood pellets p 9 54 Parameter Dimension Value eae ofhehrwaertoier _ an Se Wei ght 460 575 Water jacket capacity dw 95 O Fuel hopper capacity dw ___ 52 kg 100 kg wood pellets __ ae ee 1375 x 1380 Class according to EN303 5 according to EN 303 5 Operating overpressure of the MPa 0 25 circulating water Heating system expansion vessel Opened or closed up to type 0 25MPa Factory tested overpressure Recommended circulating water temperature Minimal recommended return water temperature Draught B 0 1 0 2 Supply return flow ne A T a Hydraulic losses biai saadan the circulating 295 5 O4 water at nominal thermal capacity Power supply a E LI N PE 50Hz 230V Electrical capacity VA 120 250 at ignition process Electric protection IP20 Table 2 2 Dimensions and technical data for hot water pellet boiler of series Pelletherm v2 p 10 54 Parameter Dimension Value Pellet s characteristic size Recommended fuel net calorific value low MJ kg heating value kWh kg Wood pellet class ENplus A1 ENelue a2 ENplus B Ash content See Table 2 4 and Table 2 5 Moisture content Max 8 10 Table 2 3 Recommended solid fuel properties wood pellets SB 06 lt A 51 0 DU gt 97 0 1 0 lt A lt 2 0 1 0 lt A lt 2 0 Df 20 lt 4 lt 30 2 0 lt A
28. boiler e The producer reserves the right to change the values of the operating parameters which are controlling the boiler without prior notice e In Table 5 1 are described the factory default values of the thermal capacity stages of the boiler used to obtain optimal operating conditions p 32 54 e The tabled stages for the thermal capacity of the boiler define its thermal capacity e The initial adjustment of the boiler is realized by authorized trained service technician after that no additional adjustment by the end user is required e The following text describes the procedure for determining the fuel supply rate and determining the thermal capacity of the boiler O O O Deze rate Power on the boiler Empty the burner s grate from any fuel particles Empty and clean the ash container and put it back into its position Performed by authorized technician only select the Advance menu and activate the operating parameter Stoker adj NOTE the access to this advanced menu is restricted by password and is accessible by authorized technician only Then the boiler s transport auger will operate continuously for a predefined period of 6 minutes The collected on the burner s grate and eventually in the ahs container fuel quantity should be weighted and introduced in the operating parameter of the control module following the onscreen information After the initial fuel flow rate measurement the nominal
29. d by remote room programmable thermostat e No alarm signals are available e The boiler s fuel transport auger is charged and filled with fuel and its bunker is charged with fuel as well If the above described conditions are satisfied then the control board performs algorithm as follows e The fuel transport auger is activated the electric heater 1s activated and the fans are running simultaneously e After a factory set predefined period of time has ran out during this period the so called initial fuel mass has been charged to the combustion chamber the electric motor of the fuel transport auger will be stopped the ignition heater is active however e After certain period of time the photosensor of the boiler should recognize stable combustion process by the emitted visible light and the electrical ignition element will be powered off This is followed by graduate increment of the thermal capacity 1 e the fuel flow rate of the boiler and after certain period of time the nominal thermal capacity will be reached In case that the photosensor does not sense intensive light 1 e there is no combustion process or it is rather lean than the control board of the boiler will initiate new attempt to start the unit the above described algorithm will be repeated The total number of ignition attempts 1s however limited In case that this limit has been passed then boiler will go into alarm mode and will not function until manual
30. door is opened then the motor of the fuel transport auger will be powered off for safety reasons this door should be kept closed p 24 54 5 2 1 Interface control board of hot water pellet boiler of series Pelletherm v2 M01 Button ats function depends on the Operating menu item Button its function depends on the operating menu item Button Exit Button Enter START switch Figure 5 1 Interface board LCD display and keyboard for control and monitoring of the hot water pellet boiler of series Pelletherm v2 M01 Interface control board devices description e Button S selects the menu item and for confirmation of any changes e Button decreases the value of operating parameter of the burner s controller e button increases the value of operating parameter of the burner s controller e Button Esc rejects any change of operating parameter also exits from operating item of the controller s menu e START switch sends START STOP signal to the process control module e Emergency thermostat protects the boiler from exceeding emergency temperature level and boiler overheating This thermostat is factory preset to switch off the unit at water temperature in the boiler above 95 C e Main POWER switch switches ON and OFF the main power supply of the boiler p 25 54 NOTE the described
31. e this stage is dedicated for cases of low quality fuel i e with lower than required net calorific value of the fuel or in case the heat demand exceeds the thermal capacity of the boiler It is recommended to operate at the highest thermal capacity stage no more than 10 hours for the entire heating season in order to sustain high reliability of the boiler as high thermal capacity operating modes result in increased thermal loads of the modules of the unit and decrease its life span e The practice shows that the factory set values for the operating parameters does not require additional adjustment even if the fuel has been changed during the exploitation period of the boiler The producer reserves the right to change the values of the operating parameters of the hot water boiler s control module without prior notice NOTES e The values of the operating parameters which define the thermal capacity of the boiler are determined by the following conditions the utilized fuel is wood pellets with diameter d 8 mm class ENplus Al see the fuel properties table e The content of ash mineral incombustible matter in the fuel does not change significantly the net calorific value but requires special design of the boiler s burner in order to achieve reliable and efficient combustion process That s why the applicability and the effective utilization of certain fuel should be verified and after approval should be utilized in the
32. e burner s grate After the burner s grate has been thoroughly cleaned it is necessary to clean the ash beneath the grate p 11 14 EXPLANATION the burner s grate is detached by lifting and alongside pulling action It is possible to have difficulties when detaching the grate due to the deposited ash and eventually any thermal deformation of the details It is necessary to take care at the grate removal procedure and to keep the ash grating element not damaged it is not necessary to apply excessive force in order to remove away the grate Ash grating element moved forward backward by special mechanism Figure 2 14 Detaching the grate of the specialized burner p 12 14 Figure 2 15 Cleaning the ash residue fallen beneath the grate of the burner The next steps are to take away the ash hopper placed on the bottom of the combustion chamber to deposit away the ash residue in special fire protected container The cooled down ash could be utilized as soil fertilizer Figure 2 16 Tacking the ash hopper out of the combustion chamber p 13 14 2 5 Attachment and assembly of the elements detached at the ash cleaning procedure The attachment procedure should be done in reverse sequence of the steps depicted in the previous sections of the manual ATTENTION it is necessary to ensure air tightness if the lids of the flue gases duct of the boiler these are the lid of the ash deposition secondary zone as well
33. e into account that the presence of liquid in the heating system as well in the boiler will prevent oxidation process of the metal surfaces corrosion and system failures 5 2 Starting hot water boiler of series Pelletherm v2 procedure Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manual e Any intervention in the working process of the unit which could lead to unit s failure and or dangerous and health threatening situations are strongly prohibited e The unit should be checked by the maintenance staff or any trained personal regularly e 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 e Any adjustments of thermal capacity higher than the nominal thermal load of the units are not allowed e The ash deposited in the combustion chamber of the boiler should be collected in fireproof containers and cooled down to ambient temperature The cooled ash should be disposed in appropriate waste containers Please take into account that the mineral ash result of wood biomass pellets could be considered as soil fertilizer and dispersed for agricultural purposes for example e The door of the fuel hopper section of the boiler is equipped with a safety switch and in case the
34. eccereee TE ET 17 4 1 Hot water pellet boiler connection methodology 00 20 4 1 1 Connecting to the chimney cccccccceccccecceseeeeeeeeeeaeeees 20 4 1 2 Connecting to the heating System cccecccccceseeeeeeeees 20 5 Hot water boiler installation and starting procedures 23 5 1 Basic fuel requirements ccccccccccccccsssecceeceseeeceeeaeeeceesaeeeeees 23 5 2 Starting hot water boiler of series Pelletherm v2 procedure 24 5 21 Interface control board of hot water pellet boiler of series FEelethermi V2 MOL irs ic puniisrncetanrsarsdeonettaducusent ar a 25 5 2 2 Hot water boiler power supply ccccccccssseeceeeeeeeeeees 26 52 Hot water boiler very first start cc ccccccccesseecceeeeeeeees 26 3204 Boiler s operating algorithm cc cccccccceseeceeeeeeeeees 27 5 2 5 Operating control parameters of the boiler of series Eeleth erm y2 M0 cccssat sate soncuniacounneruaddseigeusteniewneswigeati ned O EAEE 29 5 2 6 Description of the initial menu the starting process and the adjustment of the control module of boiler of series Pelletherm vv M01 30 S2 Adjustment of the boiler according to the heat consumption rae oaa A A O R 33 5 2 8 Nominal operating mode of the boiler ccceeeeeee 34 5 2 8 1 Operating mode of the hot water boiler of series Pelletherm YAMO
35. elp an authorized technician get dark at the final combustion process 24 Loss of light of the Ask for help an authorized technician photosensor at normal 14 Operation of the boiler and unsuccessful fuel ignition after the initial ignition process Table 5 3 Description of the error codes stored in the LOG list of the menu item of the control module of the hot water boiler of series Pelletherm v2 M01 Text shown on the control module s display IGNITION Failure at ignition Check if fuel is available and check FAILED the auger s operation In case there is fuel ask for help an authorized technician 2 LOST FIRE IN Flame loss at Restart the boiler COMBUSTION normal boiler s Check the connection of the auger Description Method of repairing operation power supply ask for help an authorized technician FAULT disconnection transport auger LOW disconnection sensor the 5 PHOTOSENS Problems atiCheck the condition of photosensor photosensor replace if necessary operation this procedure should be done by authorized technician only TEMP SENSOR High temperature Check the condition of the hot OVERHEAT estimated by _ the water boiler cool down the unit photosensor Table 5 4 Error description shown on the hot water boiler of series Pelletherm v2 MO1 control module display p 51 54 5 11 Hot water boiler warranty form completion The applied WARRANTY FORM s
36. em equipped with mixing valve and heat accumulator Pelletherm v2 Return valve 4 Returnvalve 17 Automatic circulating water 6 Controlvalve charger 8 Controlvalve 9 Three way mixing valve Table 4 1 Designation of the elements indexed on figure 4 2 p 19 54 NOTE According to EN 303 5 the heat accumulator is obligatory module of a heating system equipped with solid fuel hot water boiler The dimensioning of the heat accumulator tank is described in the above mentioned standard The boiler producer could assist in appropriate designing of that module as well 4 1 Hot water pellet boiler connection methodology 4 1 1 Connecting to the chimney After the boiler has been positioned and leveled utilizing the leveling screws installed in the lower corners of the heat exchanger as well as the fuel hopper module the unit should be connected to an appropriately sized and designed chimney 4 1 2 Connecting to the heating system After the flue gas duct of the boiler is connected to a chimney the boiler should be connected to the heating system utilize appropriately sized fitting according to the preliminary prepared project p 20 54 f j 150 F 111 170 5 g Li i ce F 111 z ah ig G1 1 2 G 1f2 Figure 4 3 Back side view of heat exchanger connections of hot water pellet boiler Pelletherm 30 v2 p 21 54 G1 1 2 109 6 1258 13 8 G1 1 2
37. em of the boiler The total ash cleaning procedure should be performed once per month advisably but not more that two months period of hot water boiler s operation The period between ash cleaning of the boiler should be clarified at practice as it depends mainly on the fuel quality 2 Hot water boiler ash cleaning procedure ATTENTION it is strongly recommended to have self protection utilize gloves protection glassed and appropriate clothing as the risk of injuries is high at high temperatures of the surfaces in the combustion chamber of the unit The following sections will describe the cleaning ash cleaning procedures in details p 2 14 Figure 2 1 Working gloves and working apron provided for easy and safe cleaning process of the ash residue 2 1 How to stop the operation mode of the hot water boiler The nominal operation of the boiler should be stopped by switching off its operating mode refer to the boiler s user manual for more details After the boiler has been stopped it takes time until the fuel which is burning in the burner will be entirely combusted and the heat exchanger is cooled down to safe levels of the temperature 2 2 Switch off the boiler Utilize the boiler s POWER switch to turn off the power supply of the unit For more details please refer to the boiler s user manual p 3 14 2 3 Cooling down the boiler After the boiler is switched off it should be cooled down
38. ency Doler StoP ecc35cs cui eateries hale and RL es 43 5 6 Menu item indicating list of the latest 10 errors arose from the operation of the hot water boiler of series Pelletherm v2 MO1 44 5 7 Restarting the operation of a hot water boiler of series Pelletherm SA MOL aE nd aloe anes tuck ons seers E E neeeatnaabing 45 5 8 Showing and teaching the end user about the maintenance and Adjustment PPO COO UE CS onanoi a 45 5 9 Safety and unexpected risks 200 00 cccceeccccccceeeeeceecaeeeceeeaaeeeeees 46 5 10 Operation faults and their repairing cc eeeeeeeeeeeeeeeeeeeeees 47 Table 5 2 Description of operation faults of the hot water boiler of series Pelletherm v2 causes and methods for repairing ccccceeeeeeceeeeeeeeeees 50 Table 5 3 Description of the error codes stored in the LOG list of the menu item of the control module of the hot water boiler of series Pelletherm v2 MO aene N NO 51 Table 5 4 Error description shown on the hot water boiler of series Pelletherm v2 M01 control module display cccccccccsceccceeeeeeeeeeeeeees 51 5 11 Hot water boiler warranty form completion ccccccseeeees 52 5 12 Actions after the unit is not in exploitation anymore 52 6 Electrical scheme of automatic pellet boiler of series Pelletherm v2 MOT ponn E E OE E A 52 WARRANTY CONDITIONS encrena a e N as 54 p 4 54
39. eration faults and their repairing 1 Low Insufficient heat Adjustment of boiler s thermal in capacity capacity 1s required temperatures the heat supplied rooms High temperatures in the heat supplied rooms The boiler is active but no combustion process Difficult ignition fuel Boiler s emergency overheating Cause Low set point temperature of the boiler s _ circulating temperature set point Low set point temperature of the remote room thermostat af connected High set point temperature of the boiler s circulating water temperature set point High temperature remote thermostat connected START not present set point of the room if signal is Low quality fuel Absence of heat consumption or incorrect adjustment of the boiler s thermal capacity Stage or operating poor operation of the heating installation Method for repairing It is necessary to increase the set point of the boiler s circulating water temperature up to 85 C It is necessary to increase the set point of the room thermostat It 1s necessary to decrease the set point of the _ boiler s circulating temperature set point it 1s recommended to keep it above 60 C It 1s necessary to decrease the set point of the room thermostat It is necessary to check the status of the operation signal of any of the following room thermostat or START switch It is necessary to re
40. exchanger body as well as fuel hopper charging Figure 4 1 Positioning of hot water pellet boiler of series Pelletherm v2 the minimal distances between the unit and any walls obstacles of the boiler s room are shown e The hot water boiler should be positioned in the boiler s room according to the requirements for attaching electrical appliances to the power circuit the unit should be positioned in a way that will provide easy access to the power supply plug 230V 50Hz ATTENTION the installation process of the boiler is finalized by performing so called hot tests procedure of the heating system and the warranty card is filled with the required information p 18 54 The recommended principal hydraulic scheme for connecting the hot water pellet boiler of series Pelletherm v2 to the heating system is snow on the following figure 8 24 23 16 9 10 l EF i of f j j i j f i Coldtap 187 f t j water i y Pa _ t i ml Tt j M 4 ee f S To heating l T i nee Die a L f a system Domestic hot A T gt i S water e OOO al From heating system Tap water ico a 4 l X i i i i i i i i F iF ji 1 fis l 10 14 l 3 l 1 12 d be i j7 8 Figure 4 2 Recommender principal hydraulic scheme for connecting the hot water pellet boiler of series Pelletherm v2 to the heating syst
41. h is dedicated to blow away any residues on the burner s grate e 32 indicates shown on the display in the lower right corner above the S button the temperature of the boiler s circulating water in degrees Celsius e FC 0 indicates the intensity of the luminosity of the photosensor in percents the current value is indicated in the lower right corner of the display above the button ESC Figure 5 5 The display indicates information about the operating mode of the boiler in the example the control module is in fuel ignition process mode p 31 54 COMMENTS e After the initial ash residue air blowing by the fan the control module of the boiler starts to supply the initial amount of fuel and starts the process of fuel ignition The display indicates the operating mode IGNITION 1 this is the first attempt indicated by number 1 for fuel ignition which is realized for a duration defined in the operating software e The control module of the boiler is preprogrammed in the producer s factory with factory default values for the operating parameters considered to be optimal for most of the common cases of boiler s operation The control module operates at discreet thermal capacity stages which are adjusted to predefined thermal capacities of the unit The maximal thermal capacity stage however is adjusted to allow higher thermal capacity of the boiler than the nominal on
42. hm described above In case that in stand by mode the boiler receives START signal the control board will perform the above described algorithm in order to initiate ignition and continue into nominal thermal capacity mode The same operating algorithm will be performed when the temperature of the circulating water is below the temperature set point In case the first fuel dose is not ignited due to any reason the control board of the unit will automatically start new ignition procedure The total number of ignition attempts is limited to 2 factory preset value In case of two failures at ignition there could be fuel particles on the burner s grate which should be cleaned ATTENTION if the accumulated fuel is not cleaned after ignition failures any new attempt to ignite the fuel particles will be accompanied with intensive smoke release and eventually blast ignition which could eventually result even in mechanical damages of the boiler as well as the chimney duct In case that during nominal operation the photosensor does not recognize active combustion process the initial fuel ignition procedure is started automatically e In case the total number of ignition attempts has been exceeded for example when the fuel in the boiler s hopper has been consumed the boiler will go into alarm mode and the control module s display will indicating that manual assistance and restart of the unit is required as well After the reason for a
43. hould 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 unit 5 12 Actions after the unit is not in exploitation anymore After the lifetime period of the unit has been completed then it should be treated properly in order to preserve environment contamination The unit should be dismounted and disassembled by environmentally safe methods This requirement is most commonly completed by appropriate components recycling considering separate waste disposal and utilization methods 6 Electrical scheme of automatic pellet boiler of series Pelletherm v2 M01 Figure 6 1 show electrical scheme of hot water pellet boiler of series Pelletherm v2 M01 p 52 54 NOTE The variants thermostat or NTC water sensor must be chosen in advanced menu by service technician with password Default NTC water sensor cs PER EE sae tao teehee kas he See Seek Ses Des El See ek Bee eet BOILER Sys 220 V 50Hz a ae thermostat i i gt Ta L D t acdn Not Used brown N Overheat of the water r f Filter suppressor l C 100nF 500VAC R 220 Ohms Photo ee E sensor N thermostat option Attention Remove the bridge when use room thermostat K14K15K16K17 K18 Fan sensor Hall sensor revolution control Transformer NTC sensor
44. hould be performed by trained adult persons which have read the user manual of the unit Installation procedure of the boiler requires engineering project for the heating system prepared according to the acting local norms and recommendations as follows To the heating system EN 303 5 2000 Heating boilers Part 5 Heating boilers for solid fuels by hand and automatically fired nominal heat output of up to 300 kW Terminology requirements testing and marking To the chimney Fire prevention requirements To the power circuit EN 60335 1 1997 Household and similar electrical appliances safety Part 1 General requirements p 17 54 e Appliance positioning in order to achieve comfortable maintenance o Minimal distance of 1000mm in front of the unit and any wall should be provided o Minimal distance of 400mm from the rear wall of the unit and any wall should be provided o Minimal distance of 500mm from the right hand side of the unit and any wall should be provided in order to guarantee easy access to the fuel transporting auger o Minimal distance of 300mm from the left hand side of the unit and any wall should be provided in order to guarantee easy access at servicing of the flue gas fan of the unit o Minimal distance of 500mm above of the unit and any ceiling wall should be provided in order to guarantee easy access to the fuel s hopper as well as enough room for cleaning purposes of the heat
45. in case of rejection press the ESC button use the and in order to navigate to other menu items Make final comb YES Figure 5 12 The control module s display indicates operating question for choosing the options for activating the stopping process of the hot water boiler of series Pelletherm v2 M01 In order to activate the final combustion process one should press the S button found below the YES label indicated on the control module s display In case of rejection then one should press the ESC button found below the NO label found below In case that the boiler will not operate for a relatively long period of time it is recommended to shut it down by the POWER switch and clean the ash deposited in the combustion chamber beneath it as well as other surfaces of the combustion chamber ATTENTION e Incase the boiler will not operate for a long period of time then thorough ash deposit cleaning procedure should be performed The ash layer acts corrosively on the unit carbon steel surfaces which will lead to a decrease of the lifetime of the boiler s main module It is obligatory to perform service procedures and preventive observations of the unit by trained service personal only as well as thorough cleaning at the end of the heating season Completing these requirements will ensure long exploitation duration of the boiler and its high efficiency and
46. intenance and service procedures Minimized running costs p 7 54 p 8 54 Hot water boiler of series Pelletherm v2 technical data e Thermal and technical data for hot water pellet boiler of series Pelletherm v2 utilizing wood pellets are given in Table 2 1 e Dimensions and technical data for hot water pellet boiler of series Pelletherm v2 are given in Table 2 2 e Recommended solid fuel properties wood pellets are given in Table 2 3 e Pellets classification considering their physical properties based on fuel proximate analysis are shown in Table 2 4 e ENplus the European standard for wood pellets is shown in Table 2 5 Vawe Pelletherm Pelletherm Model of the hot water boiler ae 30v2 MOI eee Mol Nominal thermal capacity Thermal capacity operation range Sane F a Utilized solid fuel e Wood pellets e Pre dried cherry nuts e Other dried nuts ENplus ENplus B producer classification methodology caer om o Te nominal thermal capacity Fresh air flow rate required for effective combustion process and boiler operation mh 42 50 63 75 Mass flow rate of the exhaust gases ee agen ae me rate the unit is PAE in a pean heating D A E E a Flue gases temperature at nominal C 110 120 140 150 thermal capacity The quantity depends on Solid fuel residue aT the ash contents in the raw fuel as well as operating conditions Table 2 1 Thermal and technical d
47. is controlled by the boiler s control module unit 5 2 8 Nominal operating mode of the boiler After the process of initial operation of the boiler the fuel on the burner s grate has been successfully ignited and the boiler s heat exchanger has been tempered and reached steady state operating mode it could be assumed that the heating unit is in operating mode appropriate for precise process adjustment At steady state operation the precise adjustments of the boiler should be done and or the boiler s operation should be checked and verified The thermal capacity stage of the boiler should be adjusted complying with heat consumption rate of heating system At nominal thermal capacity mode 1s performed the so called hot test of the entire heating system following the local legislation requirements and norms ATTENTION The air flow rate is substantial for the optimal operation of the boiler as well as the entire local heating system The air flow rate also influences the efficiency and the reliability of the system in case the air flow rate is below an optimal operating value i e air deficiency the fuel is not combusted efficiently and this results in decreased boiler s efficiency In case the air flow rate exceeds the optimal operating range this causes combustion chamber cooling and overall boiler s decreased efficiency as well The above shows that free access of the ambient air to the boiler should be designed also
48. it p 43 54 ATTENTION in case of emergency situation boiler overheating its emergency thermostat is activated In this case the boiler should be cooled down and the reason for such emergency situation should be investigated and preventive measures should be performed The emergency thermostat should be manually reset by unscrewing its preventive cap and its stem should be pressed until the thermostat switches back on a click sound is heard in this process then screw back its cap After the boiler is checked and the cause for overheating is determined and repaired restart the unit by turning off its power supply and then back on in order to run it in normal operating mode 5 6 Menu item indicating list of the latest 10 errors arose from the operation of the hot water boiler of series Pelletherm v2 M01 In order to check the last logged errors got at the operation of the hot water boiler one should enter the LOG menu item NOTE in the LOG menu item are shown only the latest ten 10 errors logged as result of the operation of the boiler In case of abnormal operation of the boiler arise the logged error codes are stored in FIFO first in first out mode and the error which exceed the capacity of the log list will be replaces with the next error log message thus the newest error code will be stored successfully LOG error 1 22 Figure 5 13 The boiler s control module display indicates the chose
49. it and results in total combustion of the char residues thus preserving its burner s reliability and efficiency 5 4 2 Stopping the operating mode of the hot water boiler of series Pelletherm v2 M01 by setting the menu item of its control module In order to stop the operation process of the boiler it is necessary to perform the following procedure e Press and hold the ESC button for more than 5 seconds e Choose YES at the question Make final combustion indicated on the control module s display If the choice is YES then the display indicates Final combustion and the control module performs process stopping of the boiler There is another way to stop the boiler s operation described below In order to stop the operation of an operating hot water boiler it is necessary to enter the menu item MAKE FINAL COMB of the boiler s control module NOTE use the above describe option for stopping the operation of the hot water boiler in order to follow the implemented control algorithm and to perform the final combustion of the fuel residue and oxidizing char found on its burner s grate MAKE FINAL COMB ENTER Figure 5 11 Choose the menu item MAKE FINAL COMB which is used to stop the operating mode of the hot water boiler of series Pelletherm v2 M01 p 41 54 NOTE in order to enter the menu item MAKE FINAL COMB One should press the button S
50. ize the combustion process as indicated on the display show on the figure below p 35 54 Figure 5 6 The control module display indicates the operating mode of the boiler transition mode transition process from fuel ignition to stabilized combustion process at low thermal capacity stage NOTE TRANS 10kKW indicates that the boiler is in intermediate operating mode operating at thermal capacity of 10kW After the transition mode the boiler s algorithm continues to operate in the defined operating mode as shown on the figure below Figure 5 7 The control module s display indicates information for the current operating thermal capacity stage at maximal thermal capacity NOTES e COMBUST 5 35kW indicates the operating thermal capacity stage of the boiler in the example the boiler operates at 5 thermal capacity stage its thermal capacity 1s 35 kW e 72 indicates the temperature of the circulating water C p 36 54 e FC 98 indicates the intensity of the flame measured by the photosensor 5 2 8 2 User menu items of the control module of hot water boiler of series Pelletherm v2 M01 At pressing and holding the S button the control module enters in user defined menu items and their operating parameter adjustment Exit the current menu item by pressing the Esc button COMBUST 5 75 Figure 5 8 Pressing the S but
51. l over them e Any malfunctions or damages which are not caused by the operation of the boiler itself but result in unit damages and its functionality Every warranty service operation should be noticed in its warranty service procedures list The warranty period of the unit is interrupted by the period during which the unit is warranty serviced by authorized technicians the period between failure notification and its repairing The warranty period of the unit is 24 months The warranty of the unit is valid when the original invoice document and the original warranty form are presented only p 54 54 ANNEX 1 Hot water pellet boiler of series Pelletherm v2 end user maintenance procedures Contents p l General Principals arenen ieee 2 2 Hot water boiler ash cleaning procedure ccccccccceseeeecceeeeeaeeeees 2 2 1 How to stop the operation mode of the hot water boiler 3 2 2 Switch off the boiler 000oooeeeeneseeneseessssrssrerersesssseserseeressssseesereeeees 3 2 3 Cooling down the boiler 000 0000eeeeeeesssseeenesssseeerssssseserrsssssrreressssese 4 2 4 Cleaning the ash of the heat exchanger surfaces 000 4 2 5 Attachment and assembly of the elements detached at the ash leanine POCO CIE Gis as cic passat rece tacts ees 14 3 Recommendations and requirements ccccccccessseeccceeeeeeseeeeeeeeaes 14
52. larm mode has been clarified and overcome the boiler should be restarted by switching it OFF and back ON the main power supply switch ATTENTION before starting up the boiler 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 also clean any ash residue in order to achieve optimal combustion process e In case that the power supply has been interrupted at its renewal the boiler will continue its operation automatically ATTENTION at operation the boiler periodically goes into final combustion mode and after combustion ash cleaning procedure is activated controlled by the Makc comb time operating parameter This parameter is in the Advance menu restricted for authorized technicians only with a password 5 2 5 Operating control parameters of the boiler of series Pelletherm v2 M01 The control board of the boiler has factory preset operating parameters values which in common case are satisfying the requirements of a unit and does not require any intervention and variation The optimal operating conditions however are achieved by setting the thermal capacity stage of the boiler The practice however confirms that the appropriate choice of the thermal capacity stage of the boiler in order to achieve continuous operation of the unit allows optimal operating conditions and optimal fuel consumption rate The control module s display and
53. le clogging of the ash cleaning mechanism flue gas fan blockage etc p 14 14 Instruction for cleaning pellet boiler Before cleaning the utility must be turned off and cooled down It is obligatory to use safety guards JE ia Pull the handle up and turn it left right Open left front door with several repeats Remove and clean the ash tray Remove burner head top cover and perform cleaning Remove lower fire grate and clean air inlet holes Install fire grate and cover back Clean the heat exchanger wall by scrapping them with the tool Unscrew both feather nuts Open the lid Remove heat exchanger front cover by pulling it forward Clean the ash residues Install the lid back Cleaning with the handle has to be performed on every refilling with pellets Cleaning the burner s fire grate has to be performed at least once per week or more often depending on fuel quality information by the fuel manufacturer Cleaning the heat exchanger walls has to be performed twice during the heating season or more often depending on fuel quality information by the fuel manufacturer Cleaning burner s head from ash residues has to be performed at least once per month but no longer than two months Cleaning set
54. n LOG menu item also the number of the error in the log list and its code number In order to exit the operating menu item press the ESC button In Table 5 3 one could find information for the error code number and detailed description in order to resolve a problem p 44 54 5 7 Restarting the operation of a hot water boiler of series Pelletherm v2 M01 The restarting of the boiler is required in case of failure modes for example the boiler has a start signal but its control module is operating in safe mode which is not allowing nominal operation of the unit The boiler control module s display indicates the error code number It is necessary to take precaution measures in order to solve the problem and to remove the cause for the failure After that the boiler should be restarted this is performed by switching off and back on the POWER switch It is recommended to check and eventually clean the grate of the burner before starting the unit again 5 8 Showing and teaching the end user about the maintenance and adjustment procedures It is necessary to show and teach the end user the maintenance procedures for operating the boiler efficiently and keep its reliability in high degree order Also the installer should demonstrate and teach the end user how to change the operative parameters of the control module of the boiler in order to operate the unit in different modes and heat capacities according to the
55. n vessel water evaporation is observed as well Considering these appropriate water should be added through the expansion vessel it must cover the requirements of norm BDS 15207 81 During the heating season regular checking of circulating water level in the expansion vessel should be performed by the end user The water content in the circulating system should be kept constant If additional water is required then precautions should be taken not to add air in the heating system as well The water utilized for filling purposes of the heating system should be decontaminated and air free and is not dedicated for any other purposes but as a circulating fluid only Any heating system drainage is inadmissible except when repairing modules sections of the system Practical experience shows that water level checkup should be performed regularly in a period of 14 days in order to sustain quasi constant water content In case that additional water is required the filling process should be performed carefully when the hot water boiler 1s cooled to the ambient p 23 54 temperature This precautions are induced due to prevent rising of thermal stress of the steel boiler s body and its damage leakage In case that the boiler as well as the heating installation will not be in exploitation for a long period then in order to prevent local water freezing and damages it 1s advisable to perform total drainage of the circulating water Please tak
56. nsor out of order 7 The flame looks Low quality pellets Fuel replacement IS opaque and recommended most probably the smoke IS moisture content is higher than observed at the required exit of the Inappropriate It is necessary to perform chimney operating parameters adjustment of the operating adjustment parameters of the unit and achieve efficient combustion process the adjustment should be performed by authorized technician Presence of Ineffective fuel It is necessary to clean the ash unburned fuel in combustion process residue deposited below the p 48 54 10 1 12 13 the ash tray Alarm absence of ash cleaning High temperature of the flue gases Gf flue gas thermometer 1s mounted Water condensates on the surfaces of the combustion chamber vapor Flue gases are emitted out in the boiler s room after certain period of exploitation The fuel transport mechanism is not functioning A problem in ash cleaning system The heat exchanging surfaces of the boiler are deposited with ash presenting heat resistive layer thus decreasing the heat exchanging intensity Low temperature of the inlet water flow The flue gas fan is clogged or even blocked by fly ash deposits Incomplete tightness of the combustion chamber s door or and other flue gas duct The door of the fuel hopper section is opened The door of the fuel hopper section is closed but the
57. nu level and going back to the main menu item At entering the menu item EFFECT LEVEL the end user could choose one of the five operating thermal capacity stages available at set as thermal capacity set point of the hot water boiler of series Pelletherm v2 M01 p 38 54 Effect level Figure 5 10 Choosing the operating thermal capacity stage of the hot water boiler of series Pelletherm v2 M01 control module NOTE use the buttons and in order to ce choose the desired operating thermal capacity stage of the pellet burner Press the button S in order to confirm the choice in order to exit from the operating menu item press the ESC button 5 3 Adjustment of the thermal capacity of the boiler The adjustment of the thermal capacity of the boiler is made by choosing the Operating thermal capacity stage which actually defines boiler s thermal capacity Information for the thermal capacity of the boiler at different stages of the thermal capacities is given in Table 5 1 ATTENTION n case the fuel has been changed for example the class of the pellets is changed this could cause additional adjustment of the boiler s operating parameters 5 3 1 Decreasing the thermal capacity of the hot water boiler The thermal capacity of the boiler is decreased by decreasing the thermal capacity operating set stage which results in reduced thermal capacity of the boiler as well as lowered
58. ol module performs so called controlled turning off procedure in which the unit fans are working and the boiler 1s cooled down and operating parameters are simultaneously monitored in case of emergency appropriate actions will be taken After the boiler has been cooled down to ambient temperature it should be switched off by turning off the unit POWER switch It is recommended to clean the deposited ash thoroughly of the boiler s heat exchanging surfaces e Emergency boiler stop In operating process of the boiler emergency situations could arise and the unit will go into alarm failure mode Such situations are detected by the process control board and it will go into automatic protective mode in order to be protected These modes are operated by appropriate preventive measures automatically taken by the boiler s control board and the alarm mode is indicated by appropriate message shown on the control module s display Detailed description of the error codes could be found in Table 5 3 Please check the error messages and refer this manual before taking any actions After the cause of the alarm situation is clarified take adequate actions for bringing back the boiler into normal operating conditions and restart it by switching off its POWER switch and back into ON Prior to powering ON the boiler clean the ash and char residue accumulated on the burner s grate 1n order to allow reliable ignition and operation of the un
59. ow efficiency of the unit e In case that continuous operation in low thermal load regimes are required then it is recommended to connect heat accumulator to the heating system which will ensure high efficiency economical and reliable operation of the boiler itself and the entire heating system in general e During the very first time of operation the boiler it is possible to observe water vapor condensation on the heat exchanging surfaces of the unit Practically this 1s one time process and will not affect the performance of the unit neither any problems will arise as well ATTENTION The air flow rate is crucial for optimal operation of the combustion process organized in the burner and the boiler overall operation effectiveness when the air flow rate is less than the optimal one then this insufficiency will result in incomplete combustion of the fuel as the supplied oxygen is less than required When the air flow rate is higher than optimal the result will be unsatisfying as well because the excessive air will lead to low temperatures in volume for controlled combustion and will result in incomplete combustion of the fuel s volatile gases released by the combustion process 5 2 8 1 Operating mode of the hot water boiler of series Pelletherm v2 M01 After the fuel ignition process has been done successfully the control module of the boiler continues its operation following factory preset algorithm in order to stabil
60. place the fuel most probably due to its high moisture content which could be above the required value for nominal operation of the boiler It is necessary to check the correct operation process of the heating installation and eventually appropriate adjustment of the operating thermal capacity stage of the boiler and or control valves of the installation this should be performed by authorized p 47 54 technician After the boiler is cooled down to ambient temperature and the reason for boiler overheating is serviced out the protective cap of the emergency overheating thermostat should be unscrewed its rod should be pressed until the thermostat is reset and it s cap should be screwed back The main POWER switch is turned OFF and back ON afterwards and the boiler 1s thus restarted No fuel ignition Absence of fuel in the The fuel hopper should be hopper charged Absence of fuel in the It 1s possible to manually restart the operation process of the boiler Fuel is present in the In case that the electrical heater burner but it s not is out of order or not operating ignited or it is fully then it should be replaced with incinerated and the appropriate working one this combustion process should be performed by has extinguished 1 e authorized technician not present Abnormal operation The photosensor should be or malfunctioning of checked or replaced in case it is the photose
61. rameters of the boiler without a prior notice 5 4 Stopping the operating mode of the hot water boiler of series Pelletherm v2 M01 The stopping process of the hot water boiler could be done by setting off the boiler s START switch and or the remote room thermostat if installed The restoration of the nominal operation of the boiler is performed by changing the signal status into on position of the boiler s START switch or activating the room thermostat if attached In case the operation of the boiler is not required for a relatively longer period of time then it is highly advisable to clean thoroughly the boiler s combustion chamber as well as the burner s grate then power off the hot water boiler of series Pelletherm v2 M01 5 4 1 Stopping the operating mode of the hot water boiler of series Pelletherm v2 M01 by switching OFF the START switch Use the boiler s START switch to switch ON and run the operation of the boiler and respectively to switch the unit OFF and stop its process At switching OFF the boiler s operation its control module s display indicates FINAL COMBUSTION ATTENTION at switching OFF the boiler use the START switch DO NOT switch off the unit by its POWER switch The reason for the requirement is p 40 54 that the START switch activates controlled switching off procedure of the boiler s control module which also cools down the un
62. reliability e Jn case there is signal to stop the operation of the boiler the fuel delivery stops but the boiler s fans continue to run That s why at stop signal the boiler continues to operate and the combustion process will continue to p 42 54 release heat energy which makes the system quite inert This particular feature should be concerned especially when a local heating system is equipped with radiators with thermostatic control valves or any other control elements which stop the flow of the circulating fluid and thus the released in the combustion process heat energy could not be transferred dissipated and thus the hot water boiler could be overheated That s why in case the hot water boiler of series Pelletherm v2 operates in a local heating system which have heating elements with thermostatic valves these valves should not be cutting the heating fluid flow rate but should allow a minimal flow rate in order to allow heat dissipation in any way It 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 hot water boiler of series Pelletherm v2 M01 by external control module The boiler is turned off by changing the START switch into OFF position During the boiler s working process in OFF state the boiler s contr
63. step of the cleaning procedure is to clean the ash deposits on the third part of the flue gases duct of the boiler p 6 14 E aN E a eee ets Ea saat GEL LDL NE eT ces a l y ASAI ES y f Figure 2 6 Cleaning the ash deposits off the heat exchanger surfaces as well as off the ash cleaning mechanism The ash should be thoroughly cleaned off the metal parts from the cleaning mechanism and the heat exchanger as well p 7 14 EXPLANATION the ash particles laid on the horizontal surface of the heat exchanger at the flue gas pipes side could be cleared by a specialized vacuum cleaner or it could be swept down through the pipes to the surfaces underneath the ash will be cleaned from the surfaces underneath Detailed description will be shows in the next sections The next step of the cleaning procedure is to clean the internal surfaces of the pipes of the heat exchanger this is done by manual movement of the pipe s ash cleaning mechanism Ash cleaning lever used to clean the ash residue off the pipe s heat exchanger surfaces Figure 2 7 Attachment of the heat exchanger pipes ash cleaning actuating lever The next step is to detach the front face panel of the heat exchanger in order to get access to the lid of the second ash deposition zone of the boiler the area right above the burner and below the pipes p 8 14 Figure 2 8 Detaching the front panel of the heat exchanger The next s
64. tep is to unscrew the fixing nuts of the lid which closes the secondary ash deposition zone of the three way flue gas duct of the heat exchanger Notice that the lid is tightened in order to prevent any flue gases leakage or ambient air both in and out of the flue gas duct Figure 2 9 The lid of the secondary ash deposition zone is detached and the ash layer should be cleaned away p 9 14 Figure 2 10 Cleaning of the ash in the secondary deposition zone of the heat exchanger right beneath the pipes of the heat exchanger EXPLANATION it is recommended to position the ash hopper in a position which will allow easy collecting of the ash residue The next step is to clean the ash and char residue deposited in the burner ATTENTION before lifting up the cover of the burner it is necessary to make a safety check 1 e to verify that the temperature of the burner s details is low enough to handle and continue with the manipulations It is strongly recommended to get measures for self protection Figure 2 11 Lift of the burner s arc lid EXPLANATION the lid of the burner is freely mounted and no fixing items are used It is positioned by special locking pins fixed to the lower part of the burner in its front side p 10 14 Figure 2 12 Ash and char cleaning procedure of the material laid on the burner s grate Figure 2 13 Brushing and cleaning the ash residue and any other char remaining particles on th
65. tion need testing and approval by boiler s producer company laboratory p 5 54 p 6 54 The unit is equipped with e Steel plates welded heat exchanger for heating up the circuit water e Flue gas fan e Fresh air supplying fan e Burner s ash removal mechanism removes the ash residuum out of the burner s grate e Daily fuel hopper with capacity of about 100 kg e Operating module which controls the functions of the unit and 1s adjustable to the specific need of a heating system as well as the properties of the fuel e Ash residue container with capacity of approximately 5 kg e Manually driven semi automatic ash cleaning system this system cleans the ash deposited on the internal surface of the pipes of boiler s convective section The unit is supplied with e Automatic fuel ignition system e Automatic burner s ash removal system e Semi automatic ash deposited on the surfaces of the heat exchanger pipes cleaning system e Automatic fuel feeding auger system Unit s advantages The hot water boiler is designed to utilize solid biomass fuel making it environmentally friendly CO neutral and does not contribute to the global warming process result of fossil fuel utilization The specific price of the heat energy delivered by solid biomass utilization is less dependent on the world fuel market trends and practically the heat energy price is competitive to the conventional energy sources
66. ton allows to choose menu item of the boiler s control module 5 2 9 User menu items in control module of the hot water boiler of series Pelletherm v2 M01 5 2 9 1 Menu item EFFECT LEVEL EFFECT LEVEL ENTER Figure 5 9 Menu item EFFECT LEVEL choice of the operating thermal capacity stage of the boiler p 37 54 In this menu item the operating thermal capacity stage of the boiler is chosen and it will operate at this stage until the circulating water set point is reached followed by thermal capacity modulation In the following table are presented the factory defined thermal capacity stages and their corresponding thermal capacity of the hot water boiler of series Pelletherm v2 M01 Thermal capacity of the hot water boiler kW Thermal capacity stage Table 5 1 Operating thermal capacity of the hot water boiler of series Pelletherm v2 M01 NOTE It is highly recommended to exploit the hot water boiler of series Pelletherm v2 M01 at thermal capacity stage not exceeding the 4 including the 5 thermal capacity stage is designed to operate only in high heat consumption rates for short periods of time In order to chose the menu item EFFECT LEVEL one should press the button below ENTER button S In order to go into another menu item one should press the button found below the displayed arrow Use the button ESC in order to return to upper me

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