GreenEcoTherm - Pellets Hot Air Generators- Instruction for Installation and Operation

page 1/47 MANUAL FOR INSTALLATION AND OPERATION OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES Pelletherm V.5/GENERATO http:// www.greenecotherm.eu page 2/47 The manufacturing company thanks you for the contribution of your choice. The manufacturing company provides this manual in help to the team that will install, adjust and service this system, as well as to the customer that will operate it. The manufacturing company requires that the technicians performing the above presented procedures has passed training course for the activities performed with the product. EXPLANATION: The notation “Pelletherm V.5/GENERATO” has been used in the current manual, which includes the hot air generator models GENERATO 30”, ”GENERATO 40” and „GENERATO 50”. WARNING IN THE INTEREST OF YOUR SAFETY IT IS RECOMMENDED AND TO READ CAREFULLY AND TO BECOME FAMILIAR WITH THIS MANUAL, BEFORE YOU TAKE ANY ACTIONS FOR INSTALLATION AND OPERATION OF THIS APPLIANCE. NON COMPLIANCE WITH THE INSTRUCTIONS DESCRIBED BELOW, MAY LEAD TO DAMAGES AND FATALITIES, FOR WHICH THE MANUFACTURING COMPANY DOES NOT TAKE RESPONSIBILITIES. Manufacturer ZMM Haskovo PLC. Address 67 Saedinenie, 6300 Haskovo, Bulgaria Telephone +359 800 15 145 Fax +359 38 603070 e-mail greenecotherm@erato.bg home page www.greenecotherm.eu MANUAL FOR INSTALLATION AND OPERATION OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES Pelletherm V.5/GENERATO (EDITION : 14.12.2012 ?. 10:55) page 3/47 CONTENT page. 1. DESCRIPTION AND ADVANTAGES OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”.............................................................................................. 4 2. TECHNICAL DATA FOR HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”.............................................................................................. 6 3. CONSTRUCTION DESCRIPTION OF AUTOMATED HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. ............................................................. 10 4. MOUNTING AND INSTALLATION................................................................................ 16 4.1. GENERAL CONDITIONS:............................................................................................... 16 4.2. NORMS AND REGULATIONS. ...................................................................................... 16 4.3. INSTALLATION OF THE GENERATOR. ..................................................................... 17 4.4. POSITIONING OF THE GENERATOR FOR EASY MANUPULATION. ................. 17 4.5. CONNECTING THE GENERATOR TO A CHIMNEY. ................................................ 18 4.6. ?ONNECTING THE GENERATOR TO AN AIR-FUNNEL FOR SUPPLYING THE HEATING SYSTEM WITH HOT AIR ......................................................................................... 21 5. INITIALIZING THE APPLIANCE IN OPERATION ...................................................... 23 5.1. GENERAL FUEL REQUIREMENTS ......................................................................... 23 5.2. INITIALIZIATION OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” IN OPERATION. ............................................. 23 5.2.1. INTERFACE CONTROL PANEL OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”..................................... 24 5.2.2. CONNECTION PANEL OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” ............................................................................................ 26 5.2.3. GENERATOR POWER SUPPLY................................................................................. 26 5.2.4. GENERATOR SWITCH ON. ......................................................................................... 27 5.2.5. PARAMETERS FOR OPERATION ADJUSTMENT OF THE GENERATOR. ..... 28 5.2.6. ADJUSTING THE GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” ACCORDING TO THE HEATING OUTPUT, CONSUMED BY THE HEATED BUILDING/ CONSUMING APLLIANCES. .............................................................. 31 5.2.7. CHANGING THE CONTROL MODULE OPERATION PARAMETERS. .............. 34 5.2.8. NOMINAL OPEARATION MODE OF THE GENERATOR...................................... 36 5.3. REGULATING THE GENERATOR HEATING OUTPUT. ...................................... 37 5.3.1. DECREASING THE GENERATOR HEATING OUTPUT. ....................................... 37 5.3.2. INCREASING THE GENERATOR HEATING OUTPUT. ......................................... 37 5.3.3. ADJUSTMENT OF PARAMETERS FOR SUPPLYING THE HEATING AIR FUNNEL SYSTEM. ....................................................................................................................... 38 5.4. STOPPING THE GENERATOR OPERATION. ....................................................... 38 5.5. GENERATOR SWITCH OFF. ..................................................................................... 38 5.6. INTRODUCING THE USER WITH THE APPLIANCE MAINTENANCE AND ADJUSTMENT PROCEDURES. ................................................................................................ 39 5.7. CLEANING THE GENERATOR. ................................................................................ 39 5.8. SAFETY AND UNPREDICTED RISKS. .................................................................... 41 5.9. FAILURES AND TROUBLESHOOTING. ................................................................. 42 5.10. COMPLETION OF THE APPLIANCE WARRANTY CARD. ................................... 44 5.11. ACTIVITIES AFTER THE APPLIANCE LIFE CYCLE PERIOD EXPIRY. .......... 44 6. WIRING DIAGRAM OF THE APPLIANCE................................................................... 45 page 4/47 1. DESCRIPTION AND ADVANTAGES OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. The series “Pelletherm V.5/GENERATO” are steel made biomass hot air generators used for drying installations and heating of domestic, office, industrial premises and public facilities. The hot air generators from series “Pelletherm V.5/GENERATO” utilize fuel, described below, as the produced heat energy is transferred to the heat carrier – ambient air. The heated air from the appliance is transferred to neighbor premises through air funnels from the heating installation. The appliance utilizes the following fuel types: ? Dry nuts (from cherries, from morello); ? Wood pellets with diameter 6, 8 to 14 mm, category ENplus-A1, ENplus-A2 and ENplus-B according to standard EN 14961-2, or from category A, AB, B, BC, C, CD, E, EF according to the manufacturing company methodic; ? Mixture of pellets and nuts (for example in 50% - 50% ratio); ? Pellets from other biomass (for example residues from the extraction of olive oil); ? Pellets from other biomass, but after approved test in the hot air generator manufacturing company laboratory; The standard delivery kit of the generator “Pelletherm V.5/GENERATO” includes: ? Hot air generator – 1pc; ? Ash-tray – 1pc; ? Legs for installation and leveling – 8pcs; ? Pair of working gloves – 1pc; ? Working apron – 1pc; ? Installation and operation manual for the system – 1?c; The appliance is equipped with: ? Steel made heat-exchanger for heating of the heat-carrier – ambient air; ? Fan supplying air for firing; ? Fans for forced convection of the air heated by the generator; ? Daily fuel hopper with volume 150 dm3 which is able to store around 100 kg wood pellets. The presented data is tentative because the real capacity of the fuel hopper depends on the fuel bulk density, which in other hand depends on the particles size (wood pellets) and their water content; ? Control module, by which the operation parameters can be changed, in accordance to the needs and specifics of every single installation and customer; ? Ash residues container with capacity up to 5 kg; The appliance is fitted with: ? Automatic fuel firing system; ? Ash residues automatic system for cleaning of the burner zone; ? Transport auger system for automatic fuel feeding; Advantages of the hot air generator: ? The generator is designated to utilize different types of solid wood biomass, which feature makes it flexible with regards to the used fuel and ecologically clean, it also does not contributes to pollution and global warming of the planet; ? Availability for heating neighbor premises by distributing the heated air out of the appliance through outlet funnel; page 5/47 ? The price of the produced heat energy from biomass utilization in the form of wood pellets as local energy source is less influenced by the global fuel prices and the value of the produced energy is competitive compared to the conventional heat sources; ? The appliance is automated and provides comfort during operation approaching other automated appliances (for example appliances utilizing gaseous fuel or electrical heating devices), providing availability for programming its operation by programmable room thermostat; ? Lack of water or other liquid as heat carrier, which feature provides opportunity for installation in heating systems that are jeopardized from circulations water freezing, respectively from emergency situations; ? The appliance is equipped with automatic fuel ignition system and automatic system mode for cleaning the ash from the burner; ? Automatic operation of the generator, availability for adjusting its operation by room thermostat and weekly programmer, which guarantees maximum heat comfort and fuel economy; ? Availability for control of the heated air distribution by some of the heated air distributor outlets; ? Unpretentious to the quality of used fuel – availability for burning different types of biomass: in form of wood pellets, dry nuts from cherries and others, which have ash content over the defined values in standards ENplus (EN 14961-2:2010), ONORM M7135, DIN 51731 and DINPlus; ? Automatic fuel feeding from integrated hopper; ? Option for automatic refueling of the integrated hopper from external (external wood pellet hopper); ? High efficiency; ? Simple maintenance, servicing and minimum operation expenses; ? The generator construction provides easy dismounting and mounting, according to the transportation specifics, as well as for the boiler room, where the system will be installed; ? Adjusting the heat output in wide range; ? Automatic fuel feeding. Patented utility model of feeding device for solid fuels, eliminating the “back-fire” factor and self-ignition of the fuel; ? Microprocessor-based module for control of the generator operating parameters and control panel with interface display; ? Mechanical cleaning system for the heat-exchanger tube bundle; ? Components from prestigious European manufacturers; ? Ecological operation – carbon emissions level complying with the most strict European requirements; ? Quick air heating; ? No risk of freezing of the heating installation; ? Standard equipped with fans with pressure noise level 61-64,6 dB; ? Option – fans with pressure noise level 55dB; page 6/47 2. TECHNICAL DATA FOR HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO”. Heating technical data for hot air generator from series “Pelletherm V.5/GENERATO” operating with wood pellets are presented in Table 2.1. Parameters for the heating air, supplied to the air distribution heating system are presented in Table 2.2. Dimensions and technical data of the hot air generator from series “Pelletherm V.5/GENERATO” are presented in ?able 2.3. Recommended fuel type parameters are presented in ?able 2.4. Classification of wood pellets depending on their physical parameters is presented in ?able 2.5. The European standard for wood pellets EN 14961-2 is presented in ?able 2.6. Parameter Dimension Value Hot air generator model - GENERATO 30 GENERATO 40 GENERATO 50 Nominal heating output kW 30 40 50 Heating output range kW 9–30 12 – 40 15 –50 Used fuel - Wood pellets; Dry cherry nuts; Other dry nuts. Pellets category according to standard EN 14961-2 - ENplus-A1, ENplus-A2, ENplus-B Categories of used wood pellets (according to the appliance manufacturing company classification) - A, AB, B, BC, C, CD, D, DE Wood pellets consumption at nominal heating output kg/h 6.6 8.9 11.1 Hot air temperature at nominal heating output ?C 80-90 80-90 80-90 Hot air mass flow rate m3/s 0.46 0.66 0.72 Efficiency at nominal output mode ? 94.0 94.0 94.0 Residues from burned fuel Ash The quantity depends on the fuel type and quality Table 2.1.Heating technical data of hot air generators from series “Pelletherm V.5/GENERATO” operating with wood pellets. page 7/47 Parameter Dimension Value Hot air generator model - GENERATO 30 GENERATO 40 GENERATO 50 Nominal heating output kW 30 40 50 Temperature at nominal heating output ºC 70 – 80 70 – 80 70 – 80 Temperature at minimum heating output ºC 35 – 42 35 – 42 35 – 42 Air volume flow rate, distributed to the heating system m3/h 1652 2376 2592 Heated air velocity m/s 6.0 8.6 9.3 Heated air outlet pressure Pa 22 45 53 Table 2.2. Heating air parameters, distributed to the air distribution heating system. EXPLANATION: ? The presented data for the heated ambient air and the air flow heating output are tentative and depend on the environment temperature and mostly by the air funnel length and entire air distribution system resistance; ? The data in the table are determined in 20o C temperature of the environment air; Parameter Dimension Value Value Value Model --- GENERATO 30 GENERATO 40 GENERATO 50 Weight kg 508 508 508 l 150 150 150 Fuel hopper capacity kg 100 kg wood pellets 100 kg wood pellets 100 kg wood pellets Generator overall dimensions: W ? L ? H mm 1900 x 1040 x 1900 1900 x 1040 x 1900 1900 x 1040 x 1900 Recommended ambient temperature in the operating room ºC 20 20 20 Minimum air temperature in the operating room ºC 14 14 14 Chimney draught Pa 14 - 20 14 - 20 14 - 20 Flue pipe diameter mm 149 149 149 Connection links Hot air outlet diameter mm 310 310 310 Power supply - 50Hz; 230V; 50Hz; 230V; 50Hz; 230V; Electrical output VA <820 <1300 (with ignition) <820 <1300 (with ignition) <820 <1300 (with ignition) Environment protection index - IP20 IP20 IP20 Table 2.3. Dimensions and technical data for hot air generator from series “Pelletherm V.5/GENERATO”. page 8/47 Recommended fuel parameters – wood pellets, for generators from series “Pelletherm V.5/GENERATO” are presented in the next table. Parameter Dimension Value Granule size mm 6 – 14 MJ/kg >17.2 Fuel recommended caloricity (lower heat for burning) kWh/kg >4.7 Wood pellets category according to ENplus --- ENplus-A1, ENplus-A2, ENplus-B Wood pellets category --- A, AB, B, BC, C, CD, E, EF Ash content % See table 2.4 and Table 2.5. Water content % Max. 8 – 10% Table 2.4. Recommended fuel parameters. Pellets category Ad DU A %6.0=dA %0.97=DU AB %6.0=dA %0.97dA %0.97=DU EF %0.3>dA %0.97 1.5 m Under: > 1.5 m Away from: > 0.3 m Over : Doors, windows, flue pipelines, hollow space and others. > 1.5 m Away from: Flue gas outlet points Table 4.2. Main prescriptions for positioning of the firing air supply channel of the generator. page 21/47 4.6. ?ONNECTING THE GENERATOR TO AN AIR-FUNNEL FOR SUPPLYING THE HEATING SYSTEM WITH HOT AIR Following is connecting the hot air generator from series “Pelletherm V.5/GENERATO” to the air distribution heating installation, according to preliminary prepared technical project. Figure 4.2. Example of diagram for air distribution system, through which the generator from series “Pelletherm V.5/GENERATO” supplies air to the heating system. Chimney Separating wall Funnel for heated air supplying from the generator to neighbor premises or to the heating system Neighbor heated premises Channel for returning the cooled air back to the generator page 22/47 Figure 4.3. Heat exchanger’s Inlet/outlet muffs view, of the hot air generator from series “Pelletherm V.5/GENERATO”. Explanation: It is recommended that the pipeline length, through which the heated air is supplied to the heating system, is as minimum as possible and with minimum number of bends. The recommended total length of the pipeline is 3 meters. It is recommended that the heated air distribution system has installed static grilles, which can regulate the direction and the flow rate of the heated air. WARNING: ? The presence of bends leads to increase of the pipeline hydraulic resistance, through which the heated air is transferred to the neighbor premises. Therefore it is recommended that the number of such bends or changes of the channel direction are minimum; ? During the hot air transferring channel realization the heat expansion of the pipeline should be taken in to account, when fixing it to the carrying construction and also its heating caused by the hot air flowing through it; page 23/47 5. INITIALIZING THE APPLIANCE IN OPERATION WARNING: ? The generator must be initiated in operation only by specialized company, authorized for performing such activities; ? The installation finalization and the performance of the so called “hot tests” of the generator and the heating system have to be marked in the product warranty card, where is mandatory to fill all fields. 5.1. GENERAL FUEL REQUIREMENTS ? In order to achieve complete fuel burning it is necessary to use only fuel complying with the requirements presented in the used fuel parameters description tables – wood pellets. The manufacturing company recommends to store the fuel in dry and ventilated premises; ? It is forbidden to store the fuel next to the generator or at distance less than 1000 mm; ? The recommended distance between the generator and the stored fuel is minimum 1500 mm. It is preferably to store the fuel in neighbor premises; ? Generator installation and fuel storage must comply with the fire safety requirements; ? It is recommended to store the wood pellets in sacks, because they have hygroscopic properties and when they contact with the surrounding air, which contains water vapors, the pellets absorb moisture, swell, easily crash and also separate more smoke during burning, which stain the heat exchanging surfaces of the appliance; WARNING: The usage of fuel which does not correspond to the presented requirements may lead to: o Clogging of the burner or/and the appliance flue pipeline; o Increased fuel consumption; o Decreased heating output of the appliance; o Staining the heat exchanging surfaces of the generator with soot and tar; o Presence of unburned fuel in the ash residues; o Fuel transport auger blocking and stopping the operation of the appliance; 5.2. INITIALIZIATION OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” IN OPERATION. GENERAL CONDITIONS: ? The generator maintenance must comply with the operation and maintenance instructions; ? Before initialization of the appliance in operation must be secured that all its moving parts and elements are at their exact position; ? Any intervention in the operation of the appliance, which might endanger the health of the handling personal or other indirect connected persons is intolerable; ? During operation of the generator it should be checked periodically by its handler/user; ? The user must not perform repairs to the appliance. If a problem during the generator operation occurs, then ask for professional assistance from the servicing company; ? It is forbidden to exceed the generator nominal heating output; ? It is forbidden to use any type of fuels or flammable liquids in order to ignite the fuel in the generator; ? Any changes over the appliance construction are strictly forbidden; ? During operation of the generator its combustion chamber door must be closed, which ensures its reliable and optimum operation; page 24/47 ? During operation of the generator its cover panels and also some of its other elements are heated to relatively high temperatures. Therefore the handling personal should be careful not to touch these surfaces and to use personal protection equipment in case of necessity. Please inform other people that might have contact with the operating appliance; ? The ash residues from the burning process must be gathered in fireproof containers with covers and after cooling to the ambient temperature they must be dumped in the appropriate places for such purposes. The ash residues from wood fuel (shaving or pellets) can be used to fertilize the soil; ? The generator’s hopper feeding door is equipped with shut down device and when it is opened the fuel feeding mechanism stops – this door must be closed during operation of the appliance; 5.2.1. INTERFACE CONTROL PANEL OF AUTOMATED PELLET HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” Table 5.1. Interface panel with controlling and managing gauges of hot air generator from series “Pelletherm V.5/GENERATO”. Operation control module of the appliance Switch “START” Alarm (operation failures) Switch “POWER” page 25/47 Figure 5.2. Panel with controlling thermometer and thermostat of the hot air generator from series “Pelletherm V.5/GENERATO”. Interface control panel elements and their function: ? “POWER” switch – is used for main on and off switching of the generator; ? Hot air thermostat – is used for adjustment of the heated air temperature upper limit, up to which the generator operates and supplies heat energy to the heating installation. It is also called an operation thermostat; ? Thermometer – hot air – serves for indication of the heated air temperature in the generator heat exchanger; ? “START” switch – is used for “START/STOP” command to the ignition control module (respectively termination) of the burning process; ? Operation control module of the appliance – is used for controlling the generator, according to preliminary installed program; ? Alarm (operation failures) – serves for indication of emergency situations during operation of the generator; Thermometer - hot air Thermostat – hot air page 26/47 5.2.2. CONNECTION PANEL OF HOT AIR GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” Figure 5.3. Connection panel of hot air generator from series “Pelletherm V.5/GENERATO”. Connection panel elements and their function: ? Power supply – connector to main electrical installation; ? Additional auger – connector for additional auger for refueling the generator hopper; ? Room thermostat – connector for room thermostat; 5.2.3. GENERATOR POWER SUPPLY ? The generator must be connected and sealed to the chimney in comply with the prepared project; ? The generator heat exchanger unit must be linked to the air distribution heating installation in comply with the prepared heating technical project; ? The generator must be linked to the electrical installation by observing the safety technique rules; ? The generator hopper must be full so the fuel feeding device can transfer the fuel to the burner zone. It is recommended that the hopper cover is always closed, in order to prevent penetration of unorganized air through this section of the generator; EXPLANATION: During the generator initial start up and also when the entire fuel from the hopper is exhausted, the transport auger is empty, as additional period of time is needed for its refilling with fuel – multiple restarting of the appliance might be necessary until the first fuel particles appear in the burner fire-grate zone; Additional auger Power supply Room thermostat page 27/47 5.2.4. GENERATOR SWITCH ON. Switching on the generator is performed by the switch –“POWER”. The appliance activates and switches to automatic waiting mode – pressing the switch “START” starts its operation. In case the “START” switch was preliminary pressed, then the appliance starts operation immediately. If the generator has been operated (or is in “hot reserve”), but the electrical power supply has been interrupted, then it starts automatically. WARNING: During operation of the generator with opened combustion chamber door, an occurrence of smoke or flue gasses in the transport auger and the fuel hopper are possible. Therefore it is not recommended to open that door during the transition operation modes of the appliance (especially in the fuel ignition period and warming of the generator). The same effect can be noted during the transition seasons – autumn and spring, when the natural chimney draught is decreased due to the high environment temperatures. EXPLANATION: ? During fuel ignition mode a module activates – electrical heating element. This heating element stops its operation after reaching a certain temperature of the flue gasses, which is indicated by a thermostat mounted in the flue gasses outlet tube of the appliance. This thermostat is adjusted to activate within temperature range of 90-100 o C; ? During the appliance initial start of operation the auger (fuel feeding) device must be filled with fuel particles (wood shavings, pellets), which takes some time. Therefore if the generator does not fire the fuel at the first attempt for starting, a restart of this process is required, which can be performed by the switch “POWER” with additional pressing; ? The generator operates with preliminary programmed operation algorithm, which is realized by specialized software installed in the control module. The program is password protected from unauthorized access. For the user (respectively well familiar with the current manual) additional group of controlling and adjusting parameters are allowed. All other parameters are protected (locked) from unauthorized access with password; ? When the assigned temperature of the air in the heated premises is reached, the controller of the generator automatically switches to “STOP” mode and the burning process gradually dies out; ? During initial start up of the generator it is recommended to provide ventilation of the heated premises, because during warming of the appliance there is possibility for extraction of substances with bad smell (so called “burning” of the painted surfaces); ? After complete equilibration of the system (i.e. the generator is in stable operation mode and the air temperature in the heated premises does not change sensibly) it is recommended to adjust the hot air distribution, transferred through the air distribution funnel; ? Full closing of the air funnel section, for transferring the heated air to the heating system, should not be allowed; page 28/47 5.2.5. PARAMETERS FOR OPERATION ADJUSTMENT OF THE GENERATOR. In next table are presented the parameters which are used for adjustment of the appliance operation. Recommended value Not. Description GENERATO 30 GENERATO 40 GENERATO 50 Dimension ?4 Period of time for pellets feeding in stable operation mode – determines the generator heating output 3.3 4.5 5.2 seconds ?6 Period of time for pellets burning in stable operation mode – determines the generator heating output 16.0 16.0 16.0 seconds Table 5.1. Description of the parameters which are used for adjustment of the generator from series “Pelletherm V.5/GENERATO” operation mode at nominal heating output, when utilizing wood pellets. WARNING: The manufacturing company guarantees efficient and reliable operation of the appliance ONLY within its operation range. Therefore if the values of parameters T4 and T6 are changed, when utilizing wood pellets, it is important that their ratio (T4/T6) is within the following range: - “GENERATO 30” 206.0163.3640.05168.0=====TT, where 0.05168.0= determines the lower heating output limit, corresponding to around 9 kW, and the ratio 206.0163.3= determines the nominal heating output of the generator; -“GENERATO 40” 281.0165.4640.084164.1=====TT, where 0.084164.1= determines the lower heating output limit, corresponding to around 12 kW, and the ratio 281.0165.4= determines the nominal heating output of the generator; - “GENERATO 50” 325.0162.5640.098166.1=====TT, where 0.098166.1= determines the lower heating output limit, corresponding to around 15kW, and the ratio 325.0162.5= determines the nominal heating output of the generator; page 29/47 NOTE: During the choice of control parameter other parameters from the menu appear on the display, which are not presented in the above table. These parameters are subject to change by trained servicing personal and their change from the end customer is not recommended; In the next table are presented parameters, which take part in the adjustment of the appliance operation. They must be changed only in case of good knowledge of the appliance operation and from qualified personal. Recommended value Notation Description GENERATO 30 GENERATO 40 GENERATO 50 Dimension ?1 Period of time for feeding the ignition doze of pellets 150 150 150 Seconds ?2 Period of time determining the maximum time for ignition 900 900 900 Seconds ?4* Period of time for fuel feeding in stable mode – determines the generator heating output 3.3 4.5 5.2 Seconds ?5 Period of time for burning after stop command 30?:00 s 30?:00 s 30?:00 s Minutes: Seconds ?6* Period of time for burning in stable mode – determines the generator heating output 16.0 16.0 16.0 Seconds ?7 Period of time for burning the initial doze 100 100 100 Seconds ?9 Period of time for cleaning. WARNING: changes only the time between two cleanings – t? tA=00.02 t? = 02.00 h:m tA=00.02 t? = 02.00 h:m tA=00.02 t? = 02.00 h:m Hours: Minutes ?B Period of time for determining the hysteresis of the hopper fuel level 60 60 60 Seconds ?? Period of time for afterburning before cleaning 400 400 400 Seconds C Ignition attempts counter (C-1) (EXPLANATION: at ?=4 the system performs three additional attempts for ignition); 4 4 4 Number Table 5.2. Description of the parameters for operation adjustment of the generators from series “Pelletherm V.5/GENERATO” at nominal operation mode during utilization of wood pellets. The manufacturing company reserves its rights to change the appliances adjustments, without informing the end customers. NOTES: ? The ash content does not change significantly the fuel chemical heat of combustion (its caloricity), but requires specialized construction of the burner, in order to provide efficient page 30/47 and economic burning process. Therefore the suitability and effectiveness of certain fuel must be tested and after positive results to be utilized in the appliance; ? The moisture (water) content affects significantly the fuel caloricity. Practically the water content in the wood pellets changes in narrow limits (between 6 to 10%) therefore the pellets have relatively constant parameters. The water content in the wood pellets changes more significantly depending on the resource characteristics, from which are manufactured, the production methods, their storage and transportation. The practice shows that if the fuel water content increases the appliance efficiency decreases respectively and also leads to increased concentration of harmful emissions from the burning process products; ? The control module factory settings are presented in the tables which ensure optimum operation parameters and reliable operation of the generators from series “Pelletherm V.5/GENERATO” in nominal heating output mode; ? The values of the presented parameters T4 and T6 are most frequently subject to change – they determine the appliance operation mode and heating output; ? The values of the main parameters ?4 and ?6 are subject to change depending on the fuel type. Therefore when changing the fuel type they must be checked and adjusted. Not complying with that requirement may lead to emergency situations which decrease the reliability and life time of the appliance; ? The heating output adjustment of the generators from series “Pelletherm V.5/GENERATO” can be performed by determining the fuel consumption (the fuel quantity fed to the burner for a determined period of time), as the fuel caloricity and the appliance efficiency coefficient are also rendered into account; Example of this method: o Determine the fuel consumption (for one hour)- mpellet=8.9 kg/h. Calculate the instant pellet consumption, divided to 3600 (1 hour = 3600 sec) and result is m’pellets = 0.002472 kg/s; o Fuel caloricity renders an account – Hpellets = 17.2 MJ/kg = 17200 kJ/kg. Another dimension for the fuel caloricity can be used – kWh. The wood pellets, which comply with the requirements for efficient utilization, have caloricity of 4.77 kWh/kg (equal to 17.2 MJ/kg); o The appliance efficiency coefficient renders into account at nominal output – ?generator=94%=0.94; o Calculate the heating output of the generator – by using the generator efficiency, the fuel caloricity in [kJ/kg] and the instant fuel consumption, within the following definition: 9.39002472.0*17200*94.0'** === pelletsmHpelletsgeneratorPgenerator ? kW. In case the fuel caloricity is calculated with dimension kWh/kg, then the formula would be: 9.399.8*77.4*94.0"*'* === pelletspellets mHgeneratorPgenerator ? kW; o Analogically the appliance heating output for utilization of other fuel type or for other heating output can be determined; The manufacturing company reserves its rights to change the appliances adjustments, without informing the end customers. page 31/47 5.2.6. ADJUSTING THE GENERATOR FROM SERIES “PELLETHERM V.5/GENERATO” ACCORDING TO THE HEATING OUTPUT, CONSUMED BY THE HEATED BUILDING/ CONSUMING APLLIANCES. For optimum, reliable and efficient operation of the appliance it is recommended to adjust it in comply with the heat energy consumption which will be covered. The heat output needed for providing heat comfort in the building can be accepted as linear function of the temperature load ?? (the difference between the average room temperature and the environment temperature). Therefore it is recommended to perform periodical adjustment of the appliance operation parameters. EXPLANATION: ? The data presented in the following tables are based on average rooms temperature ?rooms =20[oC]; ? The value of T4 parameter is determined with condition that the value of parameter T6 is constant; ?environment ?? Ratio T4/T6 ?4* Heating output ?6 oC oC - Seconds kW Seconds -15 35 0.206 3.3 30 -10 30 0.169 2.7 24 -5 25 0.125 2.0 18 0 20 0.050 0.8 9 16 Table 5.3. Adjustment of the parameters T4 and T6 in comply with the heating output of generator model „GENERATO 30”. ?environment ?? Ratio T4/T6 ?4* Heating output ?6 oC oC - Seconds kW Seconds -15 35 0.281 4.5 40 -10 30 0.211 3.4 27 -5 25 0.169 2.7 21 0 20 0.084 1.4 12 16 Table 5.4. Adjustment of the parameters T4 and T6 in comply with the heating output of generator model „GENERATO 40”. page 32/47 ?environment ?? Ratio T4/T6 ?4* Heating output ?6 oC oC - Seconds kW Seconds -15 35 0.325 5.2 50 -10 30 0.244 3.9 30 -5 25 0.195 3.1 24 0 20 0.098 1.6 15 16 Table 5.5. Adjustment of the parameters T4 and T6 in comply with the heating output of generator model „GENERATO 50”. ,where: ?rooms – average temperature in the heated premises, [oC]; ?environment – outside environment temperature, [oC]; ??= ?rooms – ?environment - temperature load, [oC]; WARNING: If it is necessary to operate the generator at minimum heating output, then the adjusted heating output must not be below the minimum presented in its technical specification – the heating output restrictions must be observed and to adjust the minimum value of the ratio: ? 05.064=TT utilization of wood pellets – „GENERATO 30”; ? 084.064=TT utilization of wood pellets – „GENERATO 40”; ? 098.064=TT utilization of wood pellets – „GENERATO 50”; EXPLANATION: The parameters values which define the generator heating output are determined for operation with fuel that complies with the requirements presented in the technical characteristics table of the appliance. In case the fuel is from another type, other size or water content, then these parameters must be adjusted again, by observing the requirements presented above. The necessity of changing other parameters respectively must be checked also – for example the value of parameter T1 – or the value for the period of time between two cleanings – parameter-T9. page 33/47 0.400.801.201.602.002.402.803.203.604.004.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0???????? ??????? ?? ??????????, [kW]????? ?? ???????? ?? ???????? [???????] 0.0400.0800.1200.1600.2000.2404.0 8.0 12.0 16.0 20.0 24.0 28.0 32.0 36.0???????? ??????? ?? ??????????, [kW]????????? ?4/?6 Figure 5.4. Relation of the parameters for adjustment (time for fuel feeding – T4 and the ratio T4/T6) and the heating output of generator model “GENERATO 30”, utilizing wood pellets. 1.001.502.002.503.003.504.004.505.005.506.0010.0 14.0 18.0 22.0 26.0 30.0 34.0 38.0 42.0???????? ??????? ?? ??????????, [kW]????? ?? ???????? ?? ???????? [???????] 0.0600.1000.1400.1800.2200.2600.3000.3400.38010.0 14.0 18.0 22.0 26.0 30.0 34.0 38.0 42.0???????? ??????? ?? ??????????, [kW]????????? ?4/?6 Figure 5.5. Relation of the parameters for adjustment (time for fuel feeding – T4 and the ratio T4/T6) and the heating output of generator model “GENERATO 40”, utilizing wood pellets. 1.001.502.002.503.003.504.004.505.005.506.0022.0 26.0 30.0 34.0 38.0 42.0 46.0 50.0???????? ??????? ?? ??????????, [kW]????? ?? ???????? ?? ???????? [???????] 0.0600.1000.1400.1800.2200.2600.3000.3400.38022.0 26.0 30.0 34.0 38.0 42.0 46.0 50.0???????? ??????? ?? ??????????, [kW]????????? ?4/?6 Figure 5.4. Relation of the parameters for adjustment (time for fuel feeding – T4 and the ratio T4/T6) and the heating output of generator model “GENERATO 50”, utilizing wood pellets. page 34/47 5.2.7. CHANGING THE CONTROL MODULE OPERATION PARAMETERS. Algorithm for changing a parameter from the control module program, for hot air generator from series “Pelletherm V.5/GENERATO”: In the next lines is presented the algorithm for visualization and relevant change (only if necessary) of parameter from the customer allowed access group: 1. Press the green button (?) marked as Menu/OK on the controller. A list of menus appears; 2. With buttons arrow up (?) or down (?) from the menu choose the option - “PARAMETER”; 3. Arrow up (?) must be pressed several times until reaching the desired timer for – ?4 or ?6; NOTE: Do not attempt to change other parameters, except those for which the influence over the appliance operation is well known; 4. With button arrow right (?) choose the field in which the time is marked – the value of the chosen parameter; 5. With button arrow down (?) or up (?) the value can be changed. Note: If the buttons arrow down (?) or up (?) are hold continues the values start to change quicker; 6. After adjusting the desired time the button Menu/OK must be pressed; 7. On the control module display appears message “CONFIRM CHANGES?”. With the arrows down (?) or up (?) position the mark over “Yes” or “Not”. Choose “Yes” by pressing the green button marked as Menu/OK, to confirm the change, or choose “Not”, to cancel the change of settings; IMPORTANT If the user is not convinced that changes are necessary or a change was made involuntarily, then the answer “Not” must be chosen in order to cancel the change; 8. Press the green button, marked Menu/OK on the control board, one more time to exit the parameters menu. After that the control module visualization display shows normal operation mode; NOTE: If a wrong parameter change was done, choose answer “NO”, when going through step “CONFIRM CHANGES? – Changes will be canceled; By using the described method every parameter for adjustment of the appliance operation can be changed. NOTES: ? A failure might occur during operation (for example fail to ignite, fuel depletion and others), which is shown on the control module display. Restarting of the appliance operation can be performed by switching the “POWER” button after removing the reason for failure; ? The user is allowed to work with submenu “PARAMETER”. Password is not required The access to the service submenus is restricted with password, known only by trained servicing specialist, familiar with programming of such control module; page 35/47 Figure 5.7. Outer view and notation of the control module buttons. If attempted to access another submenu, for example “MONITORING”, the controller expects entering of a password. The display shows: Figure 5.8. Menu displayed on the control module screen. It is necessary to exit this mode. The method is presented on the screen, (press together the buttons „SHIFT” and „OK”, by pressing „SHIFT” and without releasing it also press the button „??”). Submenu appears which can be exited by pressing the button arrow left (?). EXPLANATION: If the procedure for exiting this menu is not performed correctly, then the user can make up to 5 attempts for entering a password. After the fifth (5) attempt the flowing message appears on the control module screen: Figure 5.9. Information which appears on the control module display after reaching the limit of attempts for entering password and transiting to the service menu. The message on the control module screen means that it is necessary to wait for period of 30 minutes as the appliance remains switched on. After expiry of this period (30 minutes) the above presented procedure must be performed – it is necessary to press together the buttons „SHIFT” and „??”. On the control module screen appears a submenu which can be exited by pressing button arrow left (?). Another method is to wait at least 30 minutes and to restart the appliance and the alarm will reset automatically. EXPLANATION: The user can work only with submenu “PARAMETER”. SHIFT OK PASSWORD CLEAR 0/5 0000 SHIFT + OK = EXIT 5 = maximum attempts for entering the password PASSWORD CLEAR ERROR 5/5 >>> 30 MINUTES page 36/47 5.2.8. NOMINAL OPEARATION MODE OF THE GENERATOR. After starting the generator (the fuel in the burner is fired successfully) and the generator has heated the circulations air in the heating installation, then it can be stated that the appliance has reached nominal operation mode. The operation adjustments of the appliance should be performed in nominal mode. By the parameters presented in Table 5.1 and 5.2 (and if necessary – change of the parameters in Table 5.3, 5.4 and 5.5) the appliance operation mode can be adjusted, according to the used type of fuel. Together with this by using the air flap, positioned on the inlet side of the fan for supplying air, the air flow rate extracted to the burner, for realization of optimum burning process, must be also adjusted. During nominal operation mode the so called “hot test”, adjustment of the appliance and the heating air distribution installation must be performed, in accordance to the acting legal regulations. NOTES: During nominal operation mode the generator performs automatic cleaning of the ash residues from the burner zone, by stopping the fuel feeding but still supplies air, in order to ensure complete combustion of the fuel located in the burner. EXPLANATION: The period between two cleanings of the burner can be determined by the value of parameter T9, presented in Table 5.2. During the time for performance of cleaning the generator temporarily decreases its heating output; ? Continues operation of the appliance below its minimum heating output, presented in the technical data tables of the generator, is not recommended, because such operation modes are not efficient and economic; ? When using the generator for heating premises with relatively low ambient temperature (below 10o C), it is recommended to adjust its heating output to minimum, in order to ensure smooth heating of the appliance and to protect it from thermal loads and deformation of its steel components; ? It is recommended to operate the generator at minimum heating output mode, in order to ensure optimum heat loads of its construction components and long life time; ? Continues operation at maximum heating output of the appliance is not recommended, because the heated air temperatures can reach increased values, which may lead to the so called “air frying” and unpleasant smells; ? During the generator first operation start, specific smells are possible to occur, resulting from the burning of its internal painted surfaces. Therefore it is important to ensure intensive ventilation of the heated premises. This single process does not affect or cause problems to the appliance and the system operation; WARNING: The firing air flow rate is vital for the operation mode of the appliance and its efficiency- when the air quantity is less than the optimum, it leads to partial incomplete combustion of the fuel, and also to extraction of harmful substances in the flue gasses (one of them is the carbon oxygen). When the air quantity is higher than the optimum levels, then it results in cooling of the burning zone and again to partial incomplete combustion of the fuel. Therefore the necessary firing air quantity must be provided near the generator – see the technical data table of the appliance; EXPLANATION: In case the fuel burning flame is red, low (with low intensity) or is accompanied with release of smoke, this means that the firing air flow rate must be increased, by adjusting the fan air regulation flap or it is necessary to clean the burner from the gathered ash or scale under its fire-grate, which will ensure optimum air flow rate for the burning process passing through the burner. Therefore it is recommended to use specialized device – gas analyzer, in order to achieve correct adjustment of the burning process, optimum operation parameters and economic operation mode of the appliance. page 37/47 5.3. REGULATING THE GENERATOR HEATING OUTPUT. The heating output regulation of the generator can be performed by adjusting the fuel feed rate (consumption), transferred to its burner and also by adjusting the firing air flow rate. The fuel consumption regulation is determined by the values of parameters (T4 – period of time for fuel feeding in stable mode and T6 – period of time for burning the fuel in stable mode) which define the appliance operation mode, and also by the used fuel type – wood pellets. WARNING: When changing the used fuel type (for example from one type of pellets to another) the parameters values, that determine the heating output and operation mode of the appliance, must be adjusted, by rendering into account the recommended values for the desired fuel type. 5.3.1. DECREASING THE GENERATOR HEATING OUTPUT. It is performed by decreasing the value of parameter T4, which leads to decreased fuel consumption. The same effect (of decreasing the heating output) can be achieved by increasing the value of parameter T6; 5.3.2. INCREASING THE GENERATOR HEATING OUTPUT. It is performed by increasing the value of parameter T4, which leads to increased fuel consumption. The same effect (of increasing the heating output) can be achieved by decreasing the value of parameter T6; EXPLANATION: ? When changing the heating output, respectively the fuel consumption, it is recommended to change the adjustment of the air flow rate regulation flap, used for the burning process. Decreasing the air flow rate can be performed by partial closing of the flap, positioned on the firing air fan inlet side. And opposite – increasing the air quantity transited to the burner can be achieved by opening the air fan flap; ? Only one parameter change is recommended – T4, which determines the heating output of the appliance; WARNING: ? Adjustment of the parameters, which determine the generator heating output, must be performed by trained users/personal, in order to achieve optimum burning process and efficient fuel utilization. Also should be careful when changing the fuel, from one type of pellets to another, because they have different caloricity and density. It is recommended that the change of the appliance heating output is performed by trained personal, with the assistance of gas-analyzer; ? When changing the parameters T4 and T6 their ratio must be determined and to be checked in comply with the values presented in Table 5.1, 5.2, 5.3 or 5.5, depending on the fuel type. If this ratio is not within the presented limits, then one of the parameters (T4 or T6) values should be changed, so the requirement for T4/T6 ratio is fulfilled, according to the used fuel type; page 38/47 5.3.3. ADJUSTMENT OF PARAMETERS FOR SUPPLYING THE HEATING AIR FUNNEL SYSTEM. If the air funnels distribution system has installed elements for regulation of the operation mode (air flow direction and flow rate control), then the operating parameters of the heated air passing through this elements can be adjusted. The heated air temperature can be changed also by adjustment of the generator heating output. EXPLANATION: It is recommended to perform this process smoothly and gradually, which can ensure the expected distribution of heat energy, provided by the co-operation of the appliance and the air funnels distribution system. 5.4. STOPPING THE GENERATOR OPERATION. Stopping the appliance operation can be performed by using the switch “START”. Recovering the generator operation can be performed by switching on the same switch. In case operation is not further necessary, the appliance must be cleaned from the ash deposits over its heated surfaces. WARNING: In case the generator operation is no further needed, then entire ash cleaning from its heat exchanging surfaces must be performed, because of their corrosive influence over the steel components, which decreases the generator body life time. At the end of the heating season it is also necessary to perform prophylaxis by specialized servicing company. Observing these procedures ensures long term life cycle and reliable operation of the generator. 5.5. GENERATOR SWITCH OFF. WARNING: The appliance switching off can be performed by positioning the switch “START” in its initial position – “switch off”. This is the recommended method of switching off, because it performs the so called “controlled switch off”, during which the fans operate and the emergency signals are controlled by the generator control module. After the generator cools down it must be switched off by the “POWER” button, which is located on the appliance control board. It is also recommended to clean the appliance from the ash deposits. It is forbidden to stop the generator by the button “POWER” during operation • Emergency stopping of the generator During the generator operation it is possible that emergency situations occur, which will lead to the generator emergency mode. Some of these situations are identified by the appliance controller, as it automatically starts preventing procedures. An information messages appear on the appliance control module, which inform the customer about the emergency type, accompanied with a light lamp indication – “ALARM”, positioned on the generator control board; If emergency situation occurs, then the information message should be read/checked and following measures should be taken. After the generator cools down to the ambient temperature it is necessary to identify the reason for the emergency and to ask for servicing assistance. After that the generator operation has to be restarted, by switching off and on the “POWER” button. page 39/47 5.6. INTRODUCING THE USER WITH THE APPLIANCE MAINTENANCE AND ADJUSTMENT PROCEDURES. It is necessary that the user is well familiar with the presented operation manual of the appliance, and also with its operation principles, adjustments and regulations, and its maintenance methods. ? Refueling the generator hopper – the fuel must be loaded in the generator hopper, after that the hopper cover must be closed, in order to prevent unorganized access of air through this module. In case external auger is installed, for refueling of the hopper, then the external hopper, from which the auger intakes fuel, must filled, the auger must be filled with fuel and the automatic refueling system operation must be checked. ? Refueling of the external wood pellets hopper – dump the pellets in the hopper and spread them equally for more effective usage of the hopper capacity. The external auger (which takes fuel from this hopper and transports it to the generator’s hopper) must be filled with fuel and the automatic refueling system operation must be checked; ? Cleaning the appliance from the ash residues – the customer must clean the ash residues, gathered in the generator’s container, periodically (at least once per week). This ensures effective and reliable operation of the appliance. Detailed procedure for cleaning the generator is presented in ATTACHMENT 1 from the current manual book; 5.7. CLEANING THE GENERATOR. For maintaining high efficiency and reliability of the generator operation it is necessary to clean it from the ash deposits – mineral remaining from the burning process. The used fuel quality directly influences the quantity of ash residues and respectively the necessity of cleaning. Before cleaning the appliance must be switched off and cooled to ambient temperature, for safety reasons and protection from burning. It is also necessary that there is no presence of burning coals, which may lead to fire. It is recommended to unplug the generator from the power supply before cleaning. The ash residues cleaning have to be performed manually by using brush and other cleaning tools. After the cleaning it is recommended to dump the ash residues in specialized containers; WARNING: Regular cleaning of the heat exchanging surfaces of the generator ensures its reliable and long term operation. The recommended intervals for cleaning of the appliance are presented in the following table. page 40/47 Period of time, [days] Activity Explanation Warning 7 – 10 Cleaning of the ash deposits in the combustion chamber and the tube bundle of the heat exchanger After removing components from the generator (swirl elements and burner cover), their correct positioning and installation must be ensured. Make sure that all elements and components of the generator are cooled down. Check and ensure that the ash has completely burned and cooled. Switch off the generator from its power supply plug. At the end of the heating season Remove completely the fuel from the hopper and from the auger. Perform complete cleaning of the ash deposits in the generator. Look for service company assistance to perform technical maintenance and servicing of the appliance, as well as preparation for the next heating season. Cleaning the generator from the ash deposits protects it from corrosion. The technical checks of the appliance provide opportunity for service planning, repairs, replacement of components and to maintain its functionality. After fulfilling the procedure for complete cleaning and technical servicing of the appliance. Perform functional tests and ensure reliable operation of the generator. Table 5.6. Recommended periods for cleaning of automated wood pellets hot air generator from series „Pelletherm V.5/GENERATO”. EXPLANATION: ? Cleaning of the ash deposits from the generator burner must be performed in accordance to the recommended period, by switching off and cooling the generator before that. The burner has to be cleaned from the ash deposits (it is necessary to use cleaning tool for the sticky deposits in order to ensure free flow of the air through the burner fire-grate orifices). The fire-grate and the cover of the burner must be correctly positioned during their mounting; ? Cleaning of the ash, gathered in the combustion chamber, must be performed when the generator has cooled down completely; ? Cleaning of the external steel covers and surfaces must be performed with wet soft towel. Usage of organic solvents or other substances is strictly forbidden, because they can damage the painted surfaces of the generator; ? At the end of the heating season it is also recommended to clean the air funnel, through which the heated air is transferred to the heating system, because it might be full with dust and other particles. page 41/47 ? After every heating season the generator must be completely cleaned from the ash residues. Cleaning of the chamber after the tube bundle can be performed by unscrewing and removing the top cover. After that the combustion chamber and the burner have to be cleaned. After cleaning, in opposite order, all components must be installed; WARNING: The annual servicing or maintenance of the appliance is important, in order to maintain its effective operation and also to comply with its warranty conditions. 5.8. SAFETY AND UNPREDICTED RISKS. Risks related to the appliance usage: The automated hot air generator from series “Pelletherm V.5/GENERATO” is designed and manufactured in compliance with the major safety European standards and directives. Danger conditions may occur in the following situations: ? The automated hot air generator from series “Pelletherm V.5/GENERATO” has been improperly used; ? The heating system does not comply with the requirements presented in the generator manual book; ? The appliance is installed by unqualified personal; ? The instructions for safe usage, presented in this manual, are not observed; Unpredicted risks: The appliance is designed and manufactured in comply with the acting safety standards. Although all possible risks, resulting from its improper usage, are preliminary considered, it is possible that the following situations may occur: ? Risks from burning process outside the generator – by opening the generator’s combustion chamber door it is possible that some hot particles drop out of it (hot ash or small burning coals), which may lead to fire in the generator room. Therefore it is important that the generator always operates with fully closed door. It should be opened only when necessary or/and when the appliance has cooled down to the ambient temperature; ? Risks of burning, caused by the high temperature from the burning process in the combustion chamber and/or access to this chamber door, while cleaning the burner zone or unburned material in the ash container; ? Risks of electrical shock from indirect contact. The generator is connected to the electrical network and the control modules are positioned in the control board, equipped with the needed safety devices protecting against overload and short circuit. The generator ground connection is mandatory and must be performed by an authorized technician; ? Risks of finger injuring during work of opening, closing and cleaning. It is recommended to use proper personal safety equipment; ? Risk of strangulation in case of insufficient chimney draught, clogging of the generator tube bundle, located in the heat exchanger unit, or improper sealing of the flue pipeline; page 42/47 5.9. FAILURES AND TROUBLESHOOTING. No Failure Reason Troubleshooting Insufficient heating output It is necessary to adjust the appliance operating parameters – to be performed by trained customer or specialist Low temperature assigned to the operating thermostat of the generator It is necessary to increase the operating thermostat assigned temperature value (the maximum recommended value is up to 90o C) Low temperature assigned to the room thermostat (if connected) It is necessary to increase the room thermostat assigned temperature value 1. Low temperature in the heated premises Incorrect adjustment of the generator operation mode and the air-funnel distribution system Adjustment of the air distribution components is necessary and the generator heating output also. Consultation with servicing specialist is required and/or changes over the heating system design. High temperature assigned to the operating thermostat of the generator It is necessary to decrease the operating thermostat assigned temperature value (the minimum recommended value is up to 60o C) High temperature assigned to the room thermostat (if connected) It is necessary to decrease the room thermostat assigned temperature value 2. High temperature in the heated premises Incorrect adjustment of the generator operation mode and the air-funnel distribution system Adjustment of the air distribution components is necessary and the generator heating output also. Consultation with servicing specialist is required and/or changes over the heating system design. 3. Insufficient or lack of hot air, supplied through the air-funnel distribution system to the heated premises Incorrect adjustment of the air distribution components Incorrect function of the heating system Adjustment of the air distribution components is necessary and also of the generator heating output. Consultation with servicing specialist is required and/or changes over the heating system design. 4. The generator is switched on but there is no burning process There is no assignment for operation Check the room thermostat assignment, the switch “START” and the operation thermostat. 5. Hard fuel ignition The fuel is with low quality or properties, not corresponding to the It is necessary to identify the reason – whether the control module settings need adjustment page 43/47 requirements or the used fuel is with improper properties – consultation with servicing company is recommended; Lack of heating load or incorrect adjustment of the generator heating output or the operation of the heating system Correct operation checks must be performed over the heating installation and eventual adjustment of the operation parameters – to be performed by specialist. After cooling of the appliance and removing the problem, the generator has to be restarted. 6. Overheating of the generator Incorrect adjustment of the generator operation mode and the heating air-funnel distribution system The air distribution heating system has to be adjusted and eventually checked for functioning. Lack of fuel in the hopper The fuel hopper has to be refueled and to reset the generator. Lack of fuel in the burner zone The process of initial ignition can be renewed by restarting the generator operation. It is recommended to increase the time for initial fuel doze feeding- parameter T1, presented in Table 5.2 (is recommended to be performed by specialist), by rendering the fuel type into account. Presence of fuel in the burner, but it is not ignited or it is unburned and again there is lack of burning process If the ignition heating element is not active or damaged, then it should be checked or replaced. If the ignition heating element is operating, then the time for firing of the initial doze T2 must be increased – as presented in Table 5.2 (to be performed by specialist). 7. No fuel ignition Incorrect adjustment of the flue gasses thermostat The flue gasses thermostat has to be checked, adjusted or replaced – it is necessary to ask for servicing assistance; The fuel parameters do not comply with the requirements It is necessary to change the operation mode settings, eventually to change the fuel, especially in case of increased water content. 8. The flame is “dark” and the chimney smokes dark Incorrect adjustment of the appliance parameters The appliance operation parameters have to be adjusted – to be performed by servicing specialist. page 44/47 Insufficient firing air quantity Check the firing air feeding fan working order and its adjustment; Check for access of external air needed for firing – check and provide access of fresh air to the generator room; 9. Presence of unburned fuel in the ash container Inefficient fuel combustion The appliance operation parameters must be adjusted – to be performed by specialist. 10. Alarm – no cleaning Failure of the automatic cleaning mechanism Servicing technician intervention is necessary. Dirty heat exchanging surfaces The heat exchanging surfaces of the appliance need cleaning. 11. High flue gasses temperature (if a thermometer is installed) High heating output of the appliance The heating output of the appliance has to be adjusted in comply with the heat consumption. The flue pipeline is dirty or clogged from ash Clean the flue pipeline. Clean the chimney from the ash and soot deposits. 12. Presence of smoke in the generator room after certain operation period Incomplete sealing of the generator combustion chamber door and the covers closing the flue pipeline It is necessary to tighten/fit the door and covers, sealing ropes replacement – to be performed by qualified technician. The hopper module door is opened The shut down device installed on the hopper door has been activated – the door has to be closed; 13. The fuel feeding mechanism is not operating The fuel hopper door is closed, but there is no fuel feeding Ask for servicing assistance – mechanical or electrical failures are possible. 14. Another, not presented failures Consultation with and/or intervention of servicing technician is required. Table 5.7. Description of the operation failures of the automated hot air generator from series “Pelletherm V.5/GENERATO” and methods for troubleshooting. WARNING: If a failure occurs the generator must be switched off and after that it must cool down to ambient temperature. After that the failure must be removed, by looking for and eliminating its cause. Only then the generator can be initiated in operation again. 5.10. COMPLETION OF THE APPLIANCE WARRANTY CARD. The attached WARRANTY CARD has to be completed by writing the necessary information in its fields. The signature and stamp fields have to be filled completely in order to ensure the appliance WARRANTY CARD VALIDATION 5.11. ACTIVITIES AFTER THE APPLIANCE LIFE CYCLE PERIOD EXPIRY. After expiry of the product life cycle, its extermination has to be performed in protective for the environment way. Its modules must be disassembled and transferred to second raw material redemption stations, by observing the principles for separate collection of wastes. page 45/47 6. WIRING DIAGRAM OF THE APPLIANCE. The wiring diagram of the automated hot air generator from series “Pelletherm V.5/GENERATO” is presented on Figure 6.1 and Figure 6.2. ?????? 6.1. Schematic electrical diagram for connecting the appliance to the power supply. L N PE 220 V ~ N N 10A FS1 1 2 L1 + (12 - 14)V - Pw (3) (12- 14V - Pw) (4) Fuse2 5A T1 40 VA L1 (1) N (2) Motors, transformer, thermostat, plates Fuse1 1A 36 N N Hot air fans ?5 ~1 ?6 ~1 950 C Overheating N ~ 1000 C L1A (1) page 46/47 )nevai I1 I2 I3 I4 I5 I6 I7 I8 I9 IA IB IC + - Q1 Q2 Q3 Q4 Q5 Q6 Q7 Q8 red blue yellow black green 10 ? 1? IB ACTUATOR Actuator (cleaner)- potentiometer +24 V-St +24V-St MA PROCESS CONTROL 6 SR2 A201 BD 7 9 8 14 ? / 0, 25W LA 12 1 P00-1 100 24 0 0 7 N Fan 1” & 2” air Ignation Feed N KM2 KM3 Actuator External pellet transport-option ~ 1 ~ 1 M1 M3 -24 V-St -24V-St -24V-St -24V-St KM2 KM3 KM2 KM3 +12V -12V -24 V-St +24 V-St Power supply T0A N Alarm T0W N L1 (1) N (2) Start T0R 3 5 6 6 6 4 5 6 5 10 11 12 21 25 26 I1 – input flame sensor I3 – Start I6 –sensor back fire in auger (option) I8 – pellet level-capacitive sensor IB - Actuator- Potentiometer ? 0W- thermostat hot air ? 0R - room thermostat ? 0FL - thermostat flue gas, adjusted to 85 – 900? ? 0FL KM1 LA2 ~ 1 M4 N Flue gas extraction fan 13 Capacitve sensor 5 + 24 V -St 6 -24V-St 14 KM4 -24V-St N N L1 220V~ N KM1 Ignition 27 250 W 28 C 2 C 1 +24 V-St -24V-St POWER SUPPLY UNIT (INPUT 85 – STEP-PS/1AC/24DC/0,5 PHOENIX CONTACT GERMANY 6 31 34 32 33 ~ 1 M2 22 23 L1A - 220Vac N KM4 24 Door 35 L1A - 220Vac Figure 6.2. Schematic wiring diagram of the appliance control board. page 47/47 WARRANTY CONDITIONS The manufacturing company guarantees correct and trouble free operation of the appliance only if the installation and operation requirements during initialization and maintenance are observed. The warranty period of the automated hot air generator from series „Pelletherm V.5/GENERATO” starts considered from the date of completing and stamping its warranty card. THE PRODUCT WARRANTY IS NOT VALID in the following situations: ? Damages over the appliance caused by improper storage, transport and/or unloading, which are not organized by the manufacturing company; ? Failures caused by natural disasters (earthquakes, fire, floods and others); ? The requirements for installation, operation and periodical maintenance, presented in the current manual book, are not observed; ? Attempts for removing any defect, performed by the buyer or other unauthorized persons; ? Changes over the appliance construction; ? Incorrect heating calculations and project design for mounting and installation of the generator; ? Failures for which the manufacturing company is not responsible/ which are not under control; ? Malfunctions and damages which are not caused by the generator itself, but have led to failure in its construction; Every warranty repair must be written in the product warranty card. The warranty period is interrupted for the period of time from the date of registering the warranty claim up to removal of the failure. The warranty period of the product is 24 (twenty four) months. The warranty is valid only when the purchase invoice and original warranty card are presented.