ZMM Haskovo GP 25cs, Instruction Manual

Page 1: ...p 1 61 Instruction manual for installation and operation of Automatic pellet burner of series GP cs http www greenecotherm eu ...

Page 2: ...ng regimes of the burner 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 EV...

Page 3: ...ies 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 automatic pellet burner of series GP cs 26 5 2 2 Color scale for synchronization of the air flow rate with the thermal capacity of the burner 27 5 2 3 Automatic pellet burner power supply 27 5 2 4 Switching ON the burner of series GP 28 5 2 5 Burner s operating algorithm 30...

Page 4: ...5 9 Showing and teaching the end user about the maintenance and adjustment procedures of the burner 48 5 10 Safety and unexpected risks 50 5 11 Operation faults and repairing procedures 51 5 12 Automatic pellet burner of series GP warranty form completion 59 5 13 Actions after the burner is not in exploitation anymore recycling 59 6 Electrical scheme of automatic pellet burner of series GP 60 WARR...

Page 5: ... 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 b...

Page 6: ...e 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 color scale for easy manual adjustment of the air lo...

Page 7: ... of the heating system which guarantees optimal thermal comfort and reduced fuel consumption simplified adjustment procedure of the thermal capacity of the burner as well as the air flow rate which allows easy adjustment without need to be serviced by specialized technician and allows optimal operating conditions and high efficiency of the unit simplified installation procedure and initial adjustm...

Page 8: ...l thermal capacity kW 25 32 Thermal capacity operation range kW 5 25 5 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...

Page 9: ...18 18 1 Weight fuel transport auger kg 12 12 main module mm 250 х 572 х 485 250 х 630 х 485 Overall dimension of the unit WxDxH fuel transport auger mm 220x1520x110 220x1520x110 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 aut...

Page 10: ...mpany is show on the following table Pellet s category Ad DU A 6 0 d A 0 97 DU AB 6 0 d A 0 97 DU B 0 1 6 0 d A 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 Table 2 4 Pellets classification considering their physical properties where Ad ash contents dry basis DU mechanical durability ...

Page 11: ...he quality of the pellets is lower Parameter Dimension ENplus A1 ENplus A2 Diameter mm 6 1 6 1 Length mm 3 15 L 40 1 3 15 L 40 1 Bulk density kg m 600 600 Calorific value MJ kg 16 5 16 5 Moisture 10 10 Dust 13 1 3 Mechanical durability 97 5 4 97 5 4 Ash 2 0 7 1 5 Ash melting temperature C 1200 1100 Chlorine 2 0 02 0 03 Sulphur 2 0 05 0 05 Nitrogen 2 0 3 0 5 Copper mg kg 2 10 10 Chromium mg kg 2 10...

Page 12: ...bustion chamber Air supply fan equipped with Hall sensor for rotation speed monitoring Photosensor which monitors the intensity presence of the combustion process installed aside of the combustion chamber for easy access and cleaning Alarm thermo probe which stops and blocks burner operation in case of back fire process in the fuel delivery pipe Control board which monitors and controls the operat...

Page 13: ...ger consists of electric gear motor a transport pipe with one end in the fuel hopper and the other end is side opened and delivers fuel to the main unit though a aperture Flexible hose which is made of specific semitransparent thermal resistant material in case of combustion it does not emit toxic substances and does not sustain combustion process which connects the transport auger and the main mo...

Page 14: ...otosensor Power supply cable Auger power supply plug Control board of the burner Interface panel Flap and air supply fan Fuel delivery pipe and back fire safety thermo probe Grate of the combustion chamber Installation flange for attaching the main module to a consumer unit Control board monitoring transparent window Back fire safety alarm thermo probe ...

Page 15: ...etting light colored according to the temperature range of any individual thermo active segments However the increased temperature in this zone of the burner is indicator for the requirement for planning of ash cleaning procedure of the heating appliance and or the chimney At cooling down the main body of the burner the reversible sticker gets into its initial condition all segments are dark Irrev...

Page 16: ...nition trials the operation of the burner is stopped and alarm mode is indicated In case that fuel is consumed from the hopper than after the defined number of ignition trials the burner will go out in stop mode and alarm is indicated as well The flexible hose which connects the fuel transport auger with the main unit is transparent and is made of specific heat resistant material Information stick...

Page 17: ...e signals of the LEDs on the control board of the main unit The alarm mode is not automatically deactivated and needs manual restarting The cause of the alarm situation should be clarified and precaution measures should be taken before restarting the burner performed by switching OFF and back ON the main power supply of the burner o Reversible liquid crystal thermo sticker which shows the operatin...

Page 18: ...is performed by specialized trained personal of authorized companies Connection of the burner to the power supply and the control board should be performed by authorized technician only Before starting the burner the heat consumer unit at which the burner is attached should be thoroughly checked in order to guarantee safe operation of the system The maintenance of the burner should be performed by...

Page 19: ...ogy requirements testing and marking In case that the heat consumer is not hot water boiler than appropriate norm and requirements should be governed at preparing the installation project Fire safety requirements To the power supply EN 60335 1 1997 Household and similar electrical appliances safety Part 1 General requirements 4 3 Overall and attachment dimensions of the burner s main unit The inst...

Page 20: ...which should be considered at preparing a project and installation of the appliance Figure 4 2 Overall and characteristic dimensions of the main unit side view Figure 4 3 Overall and characteristic dimensions of the main unit of the pellet burner of series GP cs top view 567 for GP 25 cs 630 for GP 32 cs ...

Page 21: ...roject for installation of the burner as well as local arrangement of the units in order to ensure efficient and reliable system operation and easy access for cleaning and maintenance purposes The main unit of the burner should be attached to the heat energy consumer appliance The insulation gasket should be placed between the main unit and the heat energy consumer Fuel transport auger is position...

Page 22: ...d eventually its length could be decreased if necessary In order to achieve optimal operation of the fuel transport auger it is recommended to install a pellet hopper of series BP produced by pellet burner producer company as well ATTENTION any change of the position i e angle between the auger s axis and the horizontal plane practically influences changes the fuel flow rate and the thermal capaci...

Page 23: ...l plane EXPLANATION the auger is installed with additional supporting telescopic element which is an option for the kit of the pellet burner of series GP 45о Pellet hopper BP Figure 4 6 Isometric view of the fuel transport auger installed on pellet hopper with attached additional elements which increase its capacity up to 650kg of wood pellets ...

Page 24: ...series GP with most of the popular hot water boilers known on the market However considering the design of the boiler the system could require additional elements like flanges transition kits etc which allow efficient operation of the burner and the system in general thus increasing the reliability as well In ANNEX 1 of this user manual is shown information for the operating parameters of a system...

Page 25: ...e extinguisher in a safe and easy accessible place 5 2 Staring automatic pellet burner of series GP Basic requirements Any maintenance procedures should be performed in accordance with the described in this manual The operating mode of a system automatic pellet burner of series GP and a heat consumer should also cover the following requirement the operating pressure in the combustion chamber shoul...

Page 26: ...count that the mineral ash result of wood biomass pellets could be considered utilized as soil fertilizer and dispersed for agricultural purposes for example 5 2 1 Interface control board of automatic pellet burner of series GP cs Figure 5 1 Interface board equipped with indicator lamps and control elements of automatic pellet burner of series GP cs Interface board devices description POWER indica...

Page 27: ...entiometer in order to sustain the high combustion efficiency and reliability if the pellet burner of series GP cs 5 2 3 Automatic pellet burner power supply ATTENTION all installation and servicing procedure which are made on the electrical system of the pellet burner by removing the cover and or other protecting elements should be performed by authorized technician only The burner should be conn...

Page 28: ...f the main power supply o green yellow so called protective earth this wire should be reliably earthed The lower section of the fuel transport auger is positioned in the bunker appropriately positioned and charged with fuel 5 2 4 Switching ON the burner of series GP Switching the burner ON is performed by supply electrical power through the power supply box of the heat energy consumer where the bu...

Page 29: ...onnected to the operating plug of the main unit ATTENTION the control board of the burner monitors the presence and adequate operation of the transport auger and if the auger is not plugged in the main unit of the burner then the control board goes in alarm mode and the burner will not function In order to go in nominal operation mode it is necessary to plug the auger power supply in the contact p...

Page 30: ...ensor of the burner should recognize stable combustion process by the emitted visible light and the electrical ignition element will be switched off This is followed by graduate increment of the thermal capacity i e the fuel flow rate of the burner and after certain period of time the nominal thermal capacity will be reached In case that the photosensor does not sense intensive light i e there is ...

Page 31: ...o called operation cycle In case that the START signal goes off for any reason room thermostat for example etc the burner will go into stand by mode following the algorithm described above In case that in stand by mode the burner receives a START signal the control board will perform the above described algorithm in order to initiate ignition and continue into nominal thermal capacity mode In case...

Page 32: ... The adjustment of the operating parameters of the burner should be performed by a trained authorized technician ATTENTION any adjustment actions which require detachment of the burner s cover and any possibility of contact with high voltage elements should be performed by authorized technician only Description of LED indication positioned on the control board of the unit Green and yellow LEDs are...

Page 33: ...ines operating period for ignition of the initial fuel doze P5 potentiometer which defines operating value of the photosensor sensitivity EXPLANATION A common criteria for the quality of a combustion process is its natural color In case that this color is rather dark yellow and smoke eddies are observed this indicates that the fuel flow rate exceeds the optimal one for the current air flow rate an...

Page 34: ... 1 65 60 90 1 2 60 1 82 90 135 2 3 75 2 18 120 180 3 4 90 2 83 150 225 4 5 105 3 68 180 270 5 6 120 4 79 210 315 6 7 135 6 22 240 360 7 8 150 270 405 8 9 165 300 450 9 Table 5 1 Description of the operating parameters of the burner s control board of pellet burner type GP 25 NOTE The maximal index value of LED blinking of parameter P2 is 7 ...

Page 35: ...t burner type GP 32 the nominal thermal capacity is 32kW NOTES the values indicated with this symbol show the default factory preset values of the operating parameters which in most cases will guarantee reliable and effective operation of the burner A good criteria for the efficient operation of the burner is the color of the flame When the flame s color is dark yellow some smoke is visible as wel...

Page 36: ...for combustion process in the current design of the burner and if positive result is achieved to be massively utilized as fuel material However many aspects of the unit operation should be considered The producer preserves its right to change any factory preset value of the operating parameters of the burner without a without prior notice Tables 5 1 and 5 2 contain values of the operating paramete...

Page 37: ... flow rate m fuel divide fuel flow rate per hour on 3600 where 1 hour 3600 seconds and achieve m fuel 0 001472 kg s o Determine consider the gross calorific value of the fuel for example wood pellets have calorific value Hpellets 17 2 MJ kg 17200 kJ kg In case other dimension of the calorific value is more convenient to apply for example kWh kg then the calculation is as follows common wood pellet...

Page 38: ... order to ensure efficient and safe ignition process and reliable operation of the pellet burner It is highly recommended to perform adjustment of the air flow rate by adjusting the position of the air control flap in order to achieve optimal combustion process i e low pollutant concentrations pollutants are CO unburned hydrocarbons NOx in the flue gases and low air excess ratio The adjustment pro...

Page 39: ...ity of the system ATTENTION Air flow rate considerably influence the operating mode of the burner and the overall system performance and efficiency if the air flow rate is less than required than the fuel is partially unburned due to low mixing intensity and decreased combustion efficiency In case that the air flow rate exceeds the optimal air flow rate for the operating thermal capacity of the bu...

Page 40: ...f the operating parameters requirement could arise in order to achieve thermal capacity and high efficiency of the system i e the thermal capacity by the potentiometer and the air flow rate by the flap 5 3 1 Decreasing thermal capacity of the burner Thermal capacity of the burner is decreased by turning the position of the potentiometer positioned on the interface panel of the burner in direction ...

Page 41: ...f time then thorough ash deposit cleaning procedure should be performed The ash layer acts corrosively on the carbon steel surfaces which will lead to a decrease of the lifetime of the burner s main module It is obligatory to perform service procedures and preventive observations of the unit by trained service personal only as well as thorough cleaning at the end of the heating season Completing t...

Page 42: ... situations are detected by the process control board and it will go into automatic protective mode in order to be protected as well as the heat consumer unit These modes are operated by appropriate preventive measures automatically taken by the control board of the main module and the alarm mode is indicated by the LEDs of the control board and eventually will identify it Please check the status ...

Page 43: ...ician 5 6 Restarting the operation of a pellet burner of series GP The restarting of the burner is required in case of failure modes for example the burner has a start signal and the START indicator is lit but the control module of the burner is operating in safe mode which is not allowing nominal operation of the burner The LEDs on the control module of the burner show information for the current...

Page 44: ...ure the spot temperature condition at increased burner s body temperature in the range of 70 75o C Figure 5 7 View of the reversible thermosticker used to measure the spot temperature condition at increased burner s body temperature in the range of 80 85o C EXPLANATION the reversible thermosticker should be checked on regular basis recommended at any maintenance procedure of the heating appliance ...

Page 45: ...s necessary to check and make the appropriate maintenance service actions prior to start the burner again This thermosticker should be changed after the successful operation of the burner has been achieved the check and service of the burner is performed by authorized technician only The activation of this thermosticker could happen in cases like flowing hot flue gases though the pellet s pipe due...

Page 46: ...oles which conduct the air though the grate which will allow efficient combustion process and optimal air cooling of the grate After thorough cleaning of the ash residue out of the burner s grate as well as other unburned fuel particles and or slagging material the grate should be carefully installed back on its initial position The grate s installation is made in two steps first incline the grate...

Page 47: ...egs touch the bottom of the burner s combustion chamber 2 slide the grate until it fits below the inclined grate of the burner and there is no gap between the grate and the inclined detail of the burner Combustion chamber of the main module of the burner Legs of the burner s grate Inclined grate of the burner s main module 1 Initial positioning of the burner s grate 2 Final positioning of the burn...

Page 48: ...just the thermal capacity of the burner according to the estimated heat consumption and initial fuel transport auger charging combustion chamber and grate cleaning it is recommended at least once per day or a longer period is appropriate to stop the burner turn off the START signal of the burner wait until the char has been incinerated and the burner cooled down After the combustion chamber has be...

Page 49: ...h eventually could impede the fuel transport though it Furthermore the deposited layer of fine fuel particles could be ignited in case that hot flue gases are exhausted though this hose in case of emergency the way to restart the burner after the cause for malfunctioning failure of the burner has been determined and the problem has been solved the starting of the burner should be performed by rest...

Page 50: ...er at manual cleaning processes of the surfaces of the burner i e its combustion chamber or ash residue cleaning or any unburned fuel material smoldering on the grate of the combustion chamber Electrical shock risks at indirect contact The burner is connected to the power supply and its operating modules are separated in a section of its main module equipped with required protective and short circ...

Page 51: ... In case that the burner is installed on a hot water boiler and there is high temperatures in the heat energy supplied rooms High set point temperature of the remote room thermostat if connected It is necessary to decrease the set point of the room thermostat 3 The burner is active but no combustion process START signal is not available It is necessary to check the status of the START signal of bu...

Page 52: ...l hopper should be charged Then manually charge the fuel transport auger until new fuel comes out of the exit side of the auger and back plug its cable onto the burner s main unit Absence of fuel in the burner s combustion chamber It is possible by manually restarting to achieve nominal operation process of the burner If this approach results in stable ignition then it is necessary to increase the...

Page 53: ...uthorized technician only Check for tightness of electrical joints of the control board it should be performed by authorized technician only 8 The burner is not running or it stops Absence of START signal to the burner s main unit Check the status of START indicator it should be lit Check the wiring and connection of the burner s main unit and the power supply box of the heat consumer s power supp...

Page 54: ...ty fuel Fuel replacement is recommended most probably the moisture content is higher than required for nominal operation of the burner see the requirements in the fuel properties table 9 The flame looks opaque and smoke is observed at the exit of the chimney Inappropriate operating parameters adjustment It is necessary to perform operating parameters adjustment and achieve efficient combustion pro...

Page 55: ...ion of the pipe s alarm thermostat Low draught or high ash deposition of the appliance It is necessary to make thorough cleanup of the ash deposited on the appliance eventually the chimney It is necessary to restart the burner A possible problem solution is to install an additional flue gas fan serially to the heating appliance and or change of the chimney performed by authorized technician 14 Inc...

Page 56: ...combustion chamber of the burner especially on the grate The burner is operating at thermal capacity higher than the nominal one Decrease the thermal capacity of the burner by changing the set point of the heat capacity potentiometer 19 Alarm mode of the burner s control board Alarm mode of the operating conditions of the burner Check LED indications depicted in the following table Get help by aut...

Page 57: ...scribed above It is necessary to consult authorized technician and eventually service maintenance should be performed Table 5 4 Automatic pellet burner of series GP faults and repair procedures EXPLANATION the overheating of the pellet delivery pipe is most commonly due to increased ash deposition layer on the heat exchanging surfaces on the appliance on which the burner is installed in case of de...

Page 58: ...ss has been lost during nominal operation mode Check the status of the photosensor ask for help of a service if necessary 3 Green LED is permanently active Unsuccessful fuel ignition Check the reasons see Table 5 4 4 Fast blinking red LED The rotation sensor Hall sensor is not properly connected or the air fan is not working Service assistance by authorized technician is required The fuel transpor...

Page 59: ...ARRANY FORM of the automatic pellet burner of series GP 5 13 Actions after the burner is not in exploitation anymore recycling When the lifetime period of the unit has been completed then it should be treated properly in order to preserve environment contamination The unit should be dismounted and disassembled by environmentally safe methods This requirement is most commonly completed by appropria...

Page 60: ...urner of series GP K 1 K 2 K 3 K 4 K 5 K 6 T 0 operating BOILER N 220 V Neutral L 220 V Phase PE PELLET BURNER CONTROL BOARD Fotosensor T 0 alarm APPLIANCE BOILER POWER START Yellow green Gray or blue Black Brown F2 F3 F4 F2 T6 3A Heater F3 FF 800mAH Fan F4 FF1 0 AH Auger Cable GP Version December 2010 R 220 Ohms C 100nF 500VAC K 7 K 8 K 9 K 10 K 11 K 12 Heater Fan Auger Thermo sensor R 220 Ohms C...

Page 61: ... not organized by the producer Failures caused by natural disasters Earth quakes fires floods etc Unsatisfied installation maintenance and service requirements which are described in this manual Repairing of any failure of the unit performed by unauthorized technicians or the end user Any changes in the design of the burner Incorrect installation and or improper functioning due to operator client ...