Instruction for Installation and Operation GP 25kW; 32 kW

Instruction manual for installation and operation of automatic pellet burner of series “GP IV” http:// www.greenecotherm.eu p. 2/66 Thank You for buying our product – automatic pellet burner of series „GP”. This manual will help You to use and maintain the unit properly. NOTE : in this manual is used the symbol “GP” for the entire range of pellet burner, which includes the models “GP25 IV” and “GP32 IV”. The automatic pellet burners of series “GP IV” are modification of the well-known pellet burners of series “GP”. In the manual, however will be used a common symbol “GP”. ATTENTION IN INTEREST OF YOUR PERSONAL SECURITY IT IS NECESSARY TO READ THOROUGHLY AND CAREFULLY THIS INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY ACTIONS WITH THE BURNER – INSTALLATING, CONNECTING, OPERATING, ETC. IN CASE THAT REQUIREMENTS, DEPICTED IN THIS MANUAL ARE NOT SATISFIED, FAILURE OF THE UNIT COULD BE EXPECTED, OR EVEN FATAL CONSEQUENCES, FOR WHICH THE PRODUCER COMPANY DOES NOT TAKE RESPONSIBILITY. Producer ZMM Haskovo Plc. Address Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd. Phone +359 800 15 145 Fax +359 38 603070 e-mail greenecotherm@erato.bg home page www.greenecotherm.eu Instruction manual for installation and operation of automatic pellet burner of series “GP IV” (Version : 28.11.2012 ?. 14:30) p. 3/66 Table of contents Page 1. Automatic pellet burner of series “GP” – description and advantages .. 5 2. Automatic pellet burner of series “GP” technical data ............................ 8 3. Description of the construction of pellet burner of series “GP”............ 12 3.1. Main properties.................................................................................... 12 3.2. Specific design measures in order to increase the safety operation of the burner ....................................................................................................... 16 4. Installation of automatic pellet burner..................................................... 18 4.1. Some basic requirements for correct installation of automatic pellet burner of series “GP” :.................................................................................. 18 4.2. Installation of the burner .................................................................... 19 4.3. Overall and attachment dimensions of the burner’s main unit ...... 19 4.4. Arrangement and installation of the pellet burner’s modules ........ 21 4.5. Information, considering the installation of the automatic pellet burner of series “GP” and its operation with hot water boilers. .............. 24 5. Initial steps and starting of pellet burner of series “GP” ....................... 25 5.1. Basic fuel requirements....................................................................... 25 5.2. Staring automatic pellet burner of series “GP” ............................... 25 5.2.1. Interface control board of pellet burner of series “GP IV” ..... 26 5.2.2. Automatic pellet burner electrical power supply ...................... 27 5.2.3. Switching ON the burner of series “GP” ................................... 27 5.2.4. Burner’s operating algorithm ..................................................... 28 5.2.5. Operating control parameters of the burner of series “GP” ... 31 5.2.6. Description of the initial menu, the starting process and the adjustment of the control module of pellet burner of series “GP IV” .. 31 5.2.7. Adjustment of the pellet burner, according to the heat consumption rate ........................................................................................ 35 5.2.8. Nominal operating mode of the burner ...................................... 35 5.2.8.1. Operating mode of the burner of series “GP IV” .................. 36 5.2.8.2. User menu items of the control module of pellet burner of series “GP IV”............................................................................................. 37 5.2.9. User menu items in control module of automatic pellet burner of series “GP IV” ........................................................................................ 38 5.2.9.1. Menu item „EFFECT LEVEL”............................................... 38 5.3. Adjustment of the thermal capacity of the burner........................... 40 5.3.1. Decreasing the thermal capacity of the pellet burner ............... 40 5.3.2. Increasing the thermal capacity of the pellet burner ................ 40 5.4. Stopping the operating mode of the burner of series “GP IV”....... 41 5.4.1. Stopping the operating mode of the pellet burner of series “GP IV” by switching OFF the “START” switch............................................... 41 p. 4/66 5.4.2. Stopping the operating mode of the pellet burner of series “GP IV” by setting the menu item of its control module.................................... 41 5.5. Turning OFF the automatic pellet burner of series “GP IV” by external for the burner control module ....................................................... 44 5.6. Menu item, indicating list of the latest 10 errors, arose from the operation of the pellet burner of series „GP IV” ........................................ 45 5.7. Restarting the operation of a pellet burner of series “GP” ............. 46 5.8. Description of the active thermo stickers, showing the condition of the system........................................................................................................ 46 5.9. Removal and attachment of the burner’s grate at maintenance and cleaning procedure of the pellet burner of series “GP” ............................. 48 5.10. Showing and teaching the end user about the maintenance and adjustment procedures of the burner .......................................................... 51 5.11. Safety and unexpected risks ............................................................ 52 5.12. Operation faults and repairing procedures................................... 54 5.13. Automatic pellet burner of series “GP” warranty form completion....................................................................................................... 63 5.14. Actions, after the burner is not in exploitation anymore (recycling). ...................................................................................................... 63 6. Electrical scheme of automatic pellet burner of series “GP IV” ........... 64 WARRANTY CONDITIONS .......................................................................... 66 p. 5/66 1. Automatic pellet burner of series “GP” – description and advantages “GP” is automatic pellet burner, which utilizes wood pellets. The burner is designed to be installed on already installed heating boilers or other equipment, thus allowing fuel switch procedure to a renewable energy sources - biomass. The installed burner operates on wood pellets and the thermal energy, resulting from the optimized combustion process is directed to the heat exchange surfaces of a boiler or another thermal consumer. The kit of the pellet burner of series “GP” consists of: • Main module with detachable grate – 1 sp.; • Fuel transport auger – 1 sp.; • Flexible hose– 1sp. with fixing brackets – 2sp.; • Pair of working gloves – 1sp.; • User manual – 1sp.; • Transport package of the main module – 1sp.; • Transport package of the transport auger – 1sp.; The burner could utilize following types of fuel • Wood pellets, class ENplus-A1; • Wood pellets, having diameter 6 and 8 mm, categorized in the range of: A, AB, B (according to the methodology, developed for pellets properties estimation in pellet burner producer company); • Pre-dried pits (from cherries for example); • Fuel mixture – pellets and pits (for example mixture ratio could be 50% - 50%); • Other solid biomass based pellets, but these fuels need testing and approval in pellet burner producer company laboratory; The unit is equipped with • microprocessor module, which controls the functions of the unit and is adjustable to the specific needs of a heating system; • integrated display and keyboard, which indicates the operating mode of the burner, the keyboard is used to make changes of the values of the operating parameters; • auger, which transports fuel from a bunker to the main unit; p. 6/66 • fresh air supplying fan, equipped with a Hall sensor, which returns information to the control unit; • electric heater, which ignites the fuel; • combustion chamber, which gives environment for efficient combustion process; • removable grate of the combustion chamber, allowing easy access and ash cleaning; • photosensor, which gives information for the status of the combustion process to the control unit and allows dynamic operation of the burner; • reversible thermo sticker, indicating the operating mode of the system and the requirement of ash deposition cleaning of the appliance and/or the flue stack; • irreversible thermosticker, indicating alarm overheating of the burner, which could precondition act of no-warranty service of the unit; The burner is equipped with • automatic fuel ignition system; • automatic fuel transport system – from bunker to the combustion chamber of the main unit; • safety system, which blocks its operation in case that at any circumstances the fuel delivery pipe is preheated above certain temperature safety level; • photosensor, which allows dynamic monitoring of the combustion process status; • transition system, which modulated the air supply fan operation at ignition process; • thermal capacity modulating system, which controls both the air supply fan operation as well as the fuel dozing in order to obtain optimal operation and low fuel consumption; • the control module could periodically perform procedure of final combustion and air driven grate de-ashing of the burner and will continue operation with new fuel ignition; Advantages of the burner • the burner automatically utilizes renewable energy source – biomass, which makes it environmental friendly and does not contribute to the global warming and pollution; • the burner is installed in order to apply the so called “fuel switch process” for appliances, utilizing fossil fuels – diesel, natural gas, LPG, coal; • the burner’s design allows easy installation on manual fed boilers – such as those, designed for coal, wood logs. The heating system and the p. 7/66 boiler/equipment however need minor redesign and reconstruction in order to allow such fuel switch process; • the resulting heat energy, based on organized combustion process of renewable energy source - biomass, is less influenced by the global trend of the energy sources and as result the price is competitive, compared to price of the popular energy sources; • the burner operates automatically and achieves operation comfort, delivered by operating of fossil fuel burners – working with liquid and gaseous fuel, which permits remote control by programmable room thermostat; • the burner’s control module performs automatic fuel ignition procedure; • automatic operation of the burner, which allow variable thermal capacity operation, operation with standard room thermostat (or weekly programmable thermostat), which allows maximal thermal comfort and optimized fuel consumption; • modulation of the operating process, which allows optimal working conditions and sustaining high combustion efficiency; • the modulation of the controlled combustion process allows intensified technical work at installation and simplified adjustment; • simplified installation procedure and initial adjustment, which guarantees faster assembly and unified approach; • opportunity to utilize biomass, pellet shaped as well as other dried nuts, according the appropriate fuel table; • high efficiency; • low pollutant emissions; • automatic fuel transport from a bunker, built according to the local units arrangement and need of the client (the bunker is not part of the burner equipment delivery); • simplified maintenance and service; • minimal operating costs; p. 8/66 2. Automatic pellet burner of series “GP” technical data 2.1. Thermal and technical data of automatic pellet burner of series “GP”, utilizing wood pellets are given in Table 2.1; 2.2. Dimensions and technical data of automatic pellet burner of series “GP” are given in Table 2.2; 2.3. Recommended solid biomass fuel properties – wood pellets, are given in Table 2.3; 2.4. Pellets classification, considering their physical properties (based on fuel proximate analysis) are shown in Table 2.4; 2.5. The European standard for wood pellets ENplus is shown on Table 2.5; Parameter Dimension Value Model - GP 25 IV GP 32 IV Nominal thermal capacity kW 25 32 Thermal capacity operation range kW 7 – 25 10 – 32 Utilized solid fuel • Wood pellets; • Pre-dried cherry nuts; • Other dried nuts; Utilized wood pellets, complying ENplus ENplus-A1* Utilized pellets, complying pellet burner producer classification methodology A, AB, B* Wood pellets fuel consumption rate at nominal thermal capacity kg/h 5.3 6.8 kg/h 45 – 50 57 – 64 Fresh air flow rate, required for effective combustion process and boiler operation m3/h 39 – 44 50 – 56 Averaged wood pellets consumption rate (the unit is operating in a popular heating system) kg/h 3.6 4.7 Air excess ratio ? 1.5 – 1.6 Solid fuel residue ash The quantity depends on the ash contents in the raw fuel, as well as operating conditions Table 2.1 Thermal and technical data of automatic pellet burner “GP”, utilizing wood pellets; p. 9/66 * EXPLANATION : the automatic pellet burner of series “GP” is designed to utilize wood pellets, which have properties, defined in the referred ENplus norm. As an temporal exception (for several hours) it is allowed to utilize pellets, which are not covering the required class of the fuel, practically in such cases the fuel has low quality and high ash content, which leads to more frequent ash residue cleaning of the burner’s grate, as well as the heat exchanger’s walls; Parameter Dimension Value Type - GP 25 IV GP 32 IV main module kg 17 17 Weight fuel transport auger kg 8.5 8.5 main module mm 250 ? 627? 485 Overall dimension of the unit (WxDxH) fuel transport auger mm 184x1520x107 184x1520x107 Power supply - 1PEN ; 50Hz; 230V; at nominal load A 0.2 0.2 Power consumption rate at ignition A 4.5 4.5 Electrical capacity VA <100 + 1100 (at ignition process) Electric protection - IP20 Table 2.2 Dimensions and technical data of automatic pellet burner “GP IV” Parameter Dimension Value Pellet’s characteristic size mm 6 – 8 MJ/kg >17.2 Recommended fuel net calorific value kWh/kg >4.7 Class of wood pellets (ENplus) ENplus-A1 Wood pellets category A, AB, B* Ash content % See Table 2.4. Moisture content % Max. 8 – 10% Table 2.3 Recommended solid biomass fuel properties – wood pellets * See the notes above; p. 10/66 Classification of wood pellets, considering their physical properties (based on fuel proximate analysis) – according to fuel evaluation method, developed and applied in pellet burner producer company is show on the following table. Pellet’s category Ad DU A %6.0=dA %0.97=DU AB %6.0=dA %0.97dA %0.97=DU EF %0.3>dA %0.97