Ekoterm GP 20 18 sc, Installation, Operation And Maintenance Manual

Page 1: ...Pellet burner GP xx sc 1 MANUAL FOR INSTALLATION OPERATION AND MAINTENANCE OF AN AUTOMATED PELLET BURNER FROM SERIES GP XX SC www greenecotherm eu ...

Page 2: ...s well as to the customer that will operate it The manufacturing company requires that the technicians performing the above mentioned procedures had successfully passed the product s technical training Manufacturer Ekoterm Proekt EAD Address Bulgaria 6300 Haskovo 67 Saedinenire blvd Phone 359 800 15 145 Fax 359 38 60 30 45 E mail sales ecotherm bg Web site www ecotherm bg Edition 11 July 2017 ...

Page 3: ...23 6 2 9 OPERATION MODES OF A PELLET BURNER FROM SERIES GP XX SC 23 6 2 10 USER MENUS IN THE CONTROL MODULE OF A PELLET BURNER GP XX SC 25 6 2 11 MENU EFFECT LEVEL 25 6 2 12 ACTIVATION OF OPTION OPERATION WITH HEAT ACCUMULATOR BUFFER 27 6 3 ADJUSTMENT OF THE BURNER S HEATING OUTPUT 28 6 3 1 DECREASING THE BURNER S HEATING OUTPUT 28 6 3 2 INCREASING THE BURNER S HEATING OUTPUT 28 6 4 STOPPING THE O...

Page 4: ...ns regarding environment protection Provisions regarding installation start and adjustment All harmonized provisions of the European Union applicable for your country Please strictly observe the presented safety instructions in order to avoid any risks or harms to people properties and environmental polluting Please pay attention to the following symbols in the present manual book Danger This symb...

Page 5: ...c The automated pellet burner from series GP xx sc can utilize wood pellets with diameter Ø 6 8mm from classes A1 A2 and B according to standard EN ISO 17225 2 2014 or categories A AB B BC and C according to the manufacture company s classification The pellet burner from series GP xx sc is equipped with Microprocessor controller managing the burner s modules Display panel with keyboard used to man...

Page 6: ...cording to the heating output chosen by the user Automatic self adjustment of the system according to the transport auger s feeding rate productivity to specific climate conditions and to the fuel s caloricity Indication of the heat carrier or water temperature in the boiler Availability to save the current adjustments and to restore the factory settings Passwords for limiting the access to certai...

Page 7: ...he pellets ash content and on the burner s operation mode The automated pellet burner from series GP xx sc is designated for utilization of wood pellets complying with the classification of standard EN ISO 17225 2 2014 classes A1 A2 and B and also with the developed classification by the manufacture company The dimensions and technical parameters of the automated pellet burner from series GP xx sc...

Page 8: ... 0 97 DU BC 0 1 6 0 d A 0 97 DU C 0 2 0 1 d A 0 97 DU CD 0 2 0 1 d A 0 97 DU D 0 3 0 2 d A 0 97 DU DE 0 3 0 2 d A 0 97 DU E 0 3 d A 0 97 DU EF 0 3 d A 0 97 DU where Ad ash content of dry mass DU mechanical resistance Parameter Dimension Class A1 Class A2 Class B Length L mm 3 15 L 40 3 15 L 40 3 15 L 40 Diameter D mm 6 1 8 1 6 1 8 1 6 1 8 1 Moisture М 10 10 10 Ash A dry 0 7 1 2 2 0 Buck density BD...

Page 9: ...ped with sensor for controlling of the rotation frequency and also for adjustments Photic sensor which monitors the burning process mounted on the burner s side and with availability for easy cleaning Emergency temperature sensor for protection from the so called back fire in the main module s pellets feeding pipe Control module which monitors and manages the burner s operation Display panel with ...

Page 10: ...eding inlet pipe to combustion chamber Flange for mounting of the main module to an appliance Combustion chamber Emergency sensor for back fire protection Main module housing Combustion chamber s fire grate Socket for power supply and control of the transport auger Photic sensor Interface panel display keyboard ...

Page 11: ... performed only by adult persons which are well familiar with the appliance s manual for operation The mounting of the burner to a boiler consumer appliance can be performed through bolts or studs and nuts The tightening of the burner has to be performed by a tool for example wrench It is not allowed to fix it through handles or others The fixing and dismounting operations of the burner must be pe...

Page 12: ...d 5 2 present the overall dimensions of the burner s main module which have to be taken in mind during the mounting and installation of the appliance Figure 5 1 Main module s overall dimensions of a pellet burner from series GP xx sc Figure 5 2 Overall dimensions of the burner s main module ...

Page 13: ... provide optimal operation of the auger s electric motor and of the burning process In order to ensure optimal operational conditions of the fuel transport auger it is recommended to use a pellet hopper produced by the burner s manufacture company This hopper is not included in the standard delivery kit of the pellet burners from series GP xx sc Change of the auger s tilting angle leads to changes...

Page 14: ...e shows that the heat energy consuming appliance is most frequently a hot water boiler used in local heating installation The manufacture company has accomplished continues tests for compatibility reliability and efficiency of the burner in co operation with series of popular hot water boilers Depending on the hot water boiler model additional transition modules and components might be used in ord...

Page 15: ...nce and attendance of the burner must be performed in accordance to the manual for maintenance and operation The operation mode of the system a pellet burner from series GP xx sc and a heat energy consumer must provide minimum under pressure pressure lower than the atmosphere s in the appliance s combustion chamber within range 5 20Pa Non compliance with the above requirement might lead to emergen...

Page 16: ...above presented buttons of the burner s interface control panel might have another function which will be described on the display panel 6 2 2 CONNECTING AND POWER SUPPLYING OF THE BURNER All activities over the burner s electrical installation adjustments requiring dismounting of cover panels or other components which protect from direct contact with electrical parts must be performed only by qua...

Page 17: ... not be performed If necessary to stir spread or remove the fuel then proper tools and personal protection equipment must be used When initiating the burner to operation for the first time the auger fuel feeding device must be filled with pellets this is continues process requiring time Therefore the auger must be connected to external power supply through its standard plug and to wait until the f...

Page 18: ...g The times for fuel feeding and pauses are adjusted in the control module s software The burner heating output can be changed by selecting one of its output levels The maximum heating output level 5 th of the burner is not recommended This level should be chosen only in cases when the used fuel type is with lower caloricity value or when higher heating output is temporarily needed The recommended...

Page 19: ... which the burner is also connected Before starting the burner s fire grate has to be checked for presence of unburned fuel and ash If so the fuel and the ash residues have to be removed If the power supply has been interrupted the burner will start automatically when the supply restores During operation the burner might transit to final combustion and blowing if the relevant option for cleaning d...

Page 20: ...ded after a few seconds the display panel shows a question whether to start the burner Activate Figure 6 3 Menu for starting a pellet burner from series GP xx sc through inviting question To start the burner s operation press the button S as presented on the figure After starting the burner s operation a message is shown on the display panel as presented on the next figure S _ ESC Activate ENTER S...

Page 21: ... left corner of the display panel over the button S the water temperature in the hot water boiler degrees Celsius The temperature value is displayed if a water temperature sensor is installed and the option is activated from the controller menu FC 0 shows the light intensity of the photоsensor in percent it is shown at the lower right corner of the display panel over the button ESC Figure 6 5 The ...

Page 22: ... pellets are with diameter Ø 6 8mm quality classes A1 A2 and B according to standard EN ISO 17225 2 2014 or category A AB B BC and C see Tables 3 3 and 3 4 The tilting angle between the longitudinal axis of the transport auger and the horizontal plane is 45o The ash content mineral inflammable mass does not change significantly the fuel s calorific value but requires special construction of the bu...

Page 23: ...NAL OPERATION MODE OF THE BURNER After completion of the burner s starting process the fuel in the burner s combustion chamber is successfully ignited and the consuming appliance to which the burner is mounted and which utilizes the generated heat energy has been tempered it can be accepted that the system is in nominal operation mode Adjustments and checks of the burner have to be performed in no...

Page 24: ...of 10kW After completing the transition mode the burner transits directly to normal operation mode as presented on Figure 6 7 Figure 6 7 The display shows information about the burner s heating output level as in this case it is the maximum heating output mode COMBUST 5 35kW indicates the burner s heating output level in this case 5th level providing heating output of 35 kW 72о indicates the curre...

Page 25: ...o choose a submenu from the burner s controller press the button S 6 2 11 MENU EFFECT LEVEL Figure 6 9 Menu EFFECT LEVEL choice of a heating output level of a burner from series GP xx sc This menu is used to choose the heating output level for operation of the burner The heating output levels values achieved by the burner are presented in Table 6 1 S _ ESC COMBUST 5 35kW 75o FC 98 S _ ESC EFFECT L...

Page 26: ...or short periods of time To enter the menu EFFECT LEVEL press the button under ENTER S To switch to another menu press the button under the arrow on the display The button ESC is used to exit the menu and to return to the main menu When entering the menu EFFECT LEVEL the user can choose one of the 5 levels of heating output for operation of the burner Figure 6 10 Choice of heating output level of ...

Page 27: ... in facilities with heat accumulator During the operation with heat accumulator is selected Temp BC Room In this case operates three NTC sensors Sensor A water temperature in the boiler Sensor B water temperature at the upper part of the heat accumulator Sensor C water temperature at the lower part of the heat accumulator Sensors B and C are called DUAL SENSOR and they are with common connector th...

Page 28: ...t can be performed through decrease of the burner s heating output level as the heating output assignment decreases and respectively the fuel consumption decreases too 6 3 2 INCREASING THE BURNER S HEATING OUTPUT It can be performed through increase of the burner s heating output level as the heating output assignment increases and respectively the fuel consumption increases too When changing the ...

Page 29: ...witch START and not through stopping the appliance s power supply The reason is because through the switch START the burner performs controlled stopping which includes cooling of the appliance and complete fuel combustion as this process preserves the appliance s reliability 6 4 2 STOPPING THE OPERATION OF A PELLET BURNER FROM SERIES GP XX SC THROUGH A MENU FROM ITS COTROLLER KEYBOARD The followin...

Page 30: ...nd are used to scroll through the other menus Figure 6 13 The controller s display panel shows a message asking to start the stopping process of a pellet burner from series GP xx sc To perform fuel final combustion press the button S positioned under the message YES To cancel the process of final combustion or to return to previous menu press the button ESC positioned under the message NO S _ ESC ...

Page 31: ...orms the so called controlled stopping during which the firing air feeding fan continues to operate and the control module monitors for emergency signals After cooling of the burner it has to be switched OFF through its power supply It is also recommended to clean the system burner and consuming appliance from the ash deposits 6 5 1 EMERGENCY SHUT DOWN OF A PELLET BURNER FROM SERIES GP XX SC Durin...

Page 32: ...e burner it is necessary to enter the menu LOG The menu LOG shows a list only with the last 10 failures which have occurred during operation of the burner In case a new failure occurs it replaces the oldest one in the list Figure 6 14 The controller s display panel shows the chosen menu LOG together with the failure sequence number and code To exit this menu press the button ESC Table 7 2 provides...

Page 33: ...erature within a range of 60 65o C Figure 6 16 View of the reversible self restoring temperature sticker used to indicate the operational temperature in the burner s zone to which it is stuck up the example shows condition of increased temperature within a range of 65 75o C Figure 6 17 View of the reversible self restoring temperature sticker used to indicate the operational temperature in the bur...

Page 34: ...ored It is necessary to determine the cause for its activation to perform the relevant corrective measures and after that to replace the sticker with new one to be performed by a servicing technician The activation of this sticker might occur in cases of increased resistances in the chimney tract or decreased chimney draught as well as by presence of hot flue gasses in the flexible pipe between th...

Page 35: ...assword protected Example for typical settings Time between two cleanings Max comb Time 4 hours Number of cleanings Iterations 2 These settings should be changed when using fuels with higher ash content the time between two cleanings should be decreased 6 10 USER INTRODUCTION WITH THE MAINTENANCE AND ADJUSTMENTS PROCEDURES OF A PELLET BURNER FROM SERIES GP XX SC The users must read in details the ...

Page 36: ...o the power supply network and the controlling modules are positioned in specially designed section all equipped with the necessary components for overload and short circuit protection The ground connection of the burner is mandatory and must be performed by an authorized technician Opening of the protection cover panel of the burner by unauthorized staff is forbidden Risk from fingers injuries du...

Page 37: ... for normal operation of the appliance 5 The fuel ignition is accompanied by abnormal noise Insufficient chimney draught It is necessary to check the condition of the chimney and of the appliance to which the burner is mounted and to clean the ash deposits After cleaning it might be necessary to adjust the operational parameters of the system ask for servicing assistance 6 Overheating of the appli...

Page 38: ...an t transit to stable operation mode Improperly oriented photic sensor Change the photic sensor s position for monitoring of the burning process by turning it around its longitudinal axis The photic sensor s surface is dirty Clean the contaminations dirt from the photic sensor carefully The photic sensor has defected its surface seems to be burned Replace the photic sensor with new one ask for se...

Page 39: ...ontroller s display panel Trouble in the operation of the burner Check the meaning of the indicated failure code in the next table If necessary look for consultation intervention by servicing technician 20 The burner has stopped but after a new start it operates again The photic sensor submits faulty information to the controller Check the fuel quantity over the fire grate Look for assistance or c...

Page 40: ...lp to check the heating installation 15 ERROR SENSOR A OVERHEAT The temperature sensor A has measured value over 95o C Circulating water is with dangerously high temperatures and is possible overheating of the heating system and equipment Seek service help to check the heating installation 16 ERROR OPTO COUPLER Board error Seek service assistance 17 ERROR OVER PRESSURESENS Not used 18 ERROR FAN 1 ...

Page 41: ...istance to check the heating installation 30 ERROR SENSOR B OVERHEAT The temperature sensor B measured value over 95o C Circulating water is with dangerously high temperature and possible overheating of the heating system and equipment Seek service assistance to check the heating installation 31 ERROR SENSOR C LOW TEMP The temperature sensor C has measured value below 5o C The circulation water is...

Page 42: ...tickers 4 TEMP SENSOR LOW The temperature sensor is switched OFF Check connection of NTC sensor 5 PHOTOSENS Photic sensor failure Check the photic sensor condition replace it if necessary to be performed by a servicing technician 6 TEMP SENSOR OVERHEAT High temperature indicated by the temperature sensor Check the hot water boiler s condition cool the appliance down 8 WIRING DIAGRAM OF AN AUTOMATE...

Page 43: ...Pellet burner GP xx sc 43 Figure 8 1 Wiring diagram of a pellet burner from series GP xx sc ...

Page 44: ... transport and or unloading not performed by the manufacturing company Emergencies caused by natural disasters earthquakes fire floods and etc The requirements for installation operation and periodical maintenance presented in the present manual book are not observed Attempts to recover defects performed by the buyer or by other unauthorized persons Changes in the pellet burner s modules construct...