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PV1000agri pellet burner

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Common problems and solutions

DK9401A1

www.pelltech.eu

6 Common problems and solutions

Problem description

Possible cause and solution

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Summary of Contents for PV1000agri

Page 1: ...PV1000agri pellet burner User manual POOLELI DRAFT DK9401A1 ...

Page 2: ...l auger 21 3 5 Pellet storage 22 3 6 Electrical connections 22 3 7 Commissioning 27 4 Operation and maintenance 28 4 1 User interface 28 4 2 Starting and stopping 30 4 3 Statuses and parameters 30 4 4 Cleaning 38 4 5 Replacing components 38 5 Optional components 40 5 1 GSM Modem 40 5 2 Flue gas fan 41 6 Common problems and solutions 42 7 Annex A Parameters 43 8 Annex B Burner status change logic 4...

Page 3: ...iption 30 Table 3 Summary of burner statuses 30 Table 4 List of tests in TESTING status 31 Table 5 Cleaning parameters 31 Table 6 Loading parameters 32 Table 7 Ignition parameters 33 Table 8 Pre burn parameters 33 Table 9 Heat up parameters 34 Table 10 Power levels 34 Table 11 Hold flame parameters 36 Table 12 End burn parameters 37 Table 13 End blow parameters 37 ...

Page 4: ...e industrial pellets to fuel the burner You cannot use any other form of fuel to run this burner The construction of the burner allows it to be used with different boilers liquid fuel solid fuel and universal boilers The burner is connected to the boiler using a connection plate The burner is equipped with a safety thermostat a melting hose temperature sensor sprinkler system optional and auxiliar...

Page 5: ...PV1000agri pellet burner p 4 50 Description Main components DK9401A1 www pelltech eu 2 1 Main components 14 15 13 5 15 1 2 3 4 5 6 7 16 17 5 18 20 7 12 11 10 9 8 19 21 ...

Page 6: ...s are moving to periodically clean the burning chamber 12 Fire bricks Heat resistant bricks that cover the burning chamber Bricks are necessary for proper airflow and combustion 13 Flame sensor Photocell s purpose is to recognize flame in the burning chamber 14 Level sensor Optical fuel level sensors recognize the fuel level in the vertical pipe Fuel is recognized when pellets pass the optical bea...

Page 7: ...s gearmotor lifetime 21 Pressure sensor connection Metal tube to connect pressure sensor input Pressure sensor measures draught in burning chamber and enables the controller to regulate flue gas fan speed 2 2 Specifications Parameter Unit PV1000agri L total length mm 1300 L1 burner body length mm 630 L2 burning chamber length mm 690 H total height mm 620 H1 burner chamber height mm 550 W total wid...

Page 8: ...PV1000agri pellet burner p 7 50 Description Specifications DK9401A1 www pelltech eu Figure 1 Dimensions Figure 2 Dimensions ...

Page 9: ...PV1000agri pellet burner p 8 50 Description Specifications DK9401A1 www pelltech eu Figure 3 Dimensions ...

Page 10: ...be positioned in a way that there is enough space for cleaning the burner the boiler the smoke pipe and removing the ash The burning chamber must not touch the bottom of the boilers furnace min 10cm distance needed The boiler room where the burner is installed must fulfill all rules and recommendations given by local authorities Boiler room must provide constant air supply of 1500 m per hour ca 16...

Page 11: ...urner p 10 50 Installation Burner DK9401A1 www pelltech eu 3 2 Burner Figure 5 Mount the burning chamber on the inner side of the boiler door Figure 6 Use 6 M12x60mm bolts spacers and distance nuts respective to the bolts ...

Page 12: ...r and the boiler door The rope must be installed near the outer perimeter of the burning chambers back wall Figure 8 Grate holders installation Install the burning chambers bottom panel 15x15mm insulation rope must be inserted to the slot in the panel with 6 M8x16mm bolts Install the burning chambers front panel heat shield use M8x16mm bolts ...

Page 13: ...pelltech eu Figure 9 Connect the static grate holders with the side stone holders separately and install them together into the burning chamber as a frame Fix them with M8x16mm bolts to the burning chamber Figure 10 Connect the moving grate holders with M6x12mm bolts ...

Page 14: ...PV1000agri pellet burner p 13 50 Installation Burner DK9401A1 www pelltech eu Figure 11 Install the burning chambers front brick holders use M8x16mm bolts ...

Page 15: ...DK9401A1 www pelltech eu Figure 12 Release the igniter tube screws and while inside the holders pull the tubes out about half of the total length Move the air separator to its correct position according to the boiler door thickness and fix it with screws ...

Page 16: ...nstall the ceramic sealing strips on the boiler door Fix them temporarily in position with any ordinary cellophane tape scotch Cut away the excessive sealing on the perimeter of the air chamber Figure 14 Mount the burner body on the boiler door using 4 M12x70mm bolts and respective washers ...

Page 17: ...he igniter tubes through the burning chambers back wall and fix them in position with M4 screws Figure 16 Connect the linear actuator with the moving grate holder Use 27x2 5mm pipe length 240mm M8x45mm bolt for the burning chamber side and a M6x25 socket set screw DIN914 45H on the actuator side ...

Page 18: ...e hole in the burner body and the pipe on the burning chambers back wall isolate it from the air flow accessible from the burning chamber side with ceramic sealing to prevent cold air from tampering with the measurements Figure 18 Install the 8 lower position grates with 5mm holes Install the 8 higher position grates with 7mm holes ...

Page 19: ...k wall of the burning chamber Install the back wall stones on the burning chambers back wall ATTENTION Care must be taken not to damage the temperature sensor Push the stone temperature sensor into the opening in the back wall stone Figure 20 Install the upper grate holder and 2 upper grates Fix the holder with M10 wing nuts ...

Page 20: ...upply line and pressure switch is used Pressure switch allows starting the burner only if water supply is present If no water is available on installation site reservoir can be filled manually In this case pressure switch is not connected to safety circuit as there is no pressure in water system In case of back burning sprinklers will open and extinguish fire in feeder tubes Flow control valve lim...

Page 21: ... acts as a safety measure against back burning PV1000Agri pellet burner s fuel consumption at full power is about 208 222 kg of pellets per hour 3 3 3 7 kg per minute External auger s productivity must be at least 270kg of pellets per hour The auger can be fixed to the storage or a ceiling depending on the conditions at the installation site Requirements for auger installation The raising angle of...

Page 22: ...cal laws It is recommended to wear a respirator when handling pellets Refilling must be carried out before the storage runs empty 3 6 Electrical connections Table 1 PV1000agri connectors Nr Name Color type Signals X11 Power thermostat black F brown F 230V 3A 230V X12 Main Power supply black F 3x380V 16A X13 Safety circuit white M 230V X14 Pellet auger 1 black M 3x380V 0 55kW 1 6A X15 Ash augers wh...

Page 23: ...th motor thermal protection which prevents motor from overheating As soon as the nominal trip temperature TNF of the sensor set point is exceeded the relay detects this variation and the output relay cuts off the power to the motor Burner can be equipped with optional lambda sensor It provides efficient control for optimal performance concentrating emissions and burning efficiency Lambda sensor ou...

Page 24: ...PV1000agri pellet burner p 23 50 Installation Electrical connections DK9401A1 www pelltech eu ...

Page 25: ...PV1000agri pellet burner p 24 50 Installation Electrical connections DK9401A1 www pelltech eu ...

Page 26: ...PV1000agri pellet burner p 25 50 Installation Electrical connections DK9401A1 www pelltech eu ...

Page 27: ...ioning properly The feeding auger of the burner is installed and connected to the burner The smoke duct is connected to the chimney the dampers for smoke gases are open and there is sufficient draught When the burner is operating the negative pressure inside the furnace must stay between 5 20 Pa Sprinkler system is connected and pressure switch connected to safety circuit chapter 3 3 Phase and neu...

Page 28: ... there is fuel in the burner Navigation buttons enable to move in menus and make changes in parameters setup Burner on off switch 4 can be used any time to turn on or off the burner Using this switch the burner will make all necessary action to safely stop or start the burning process Figure 25 User interface 1 4x20 character display 2 Yellow LED indicates if flame is detected in burning chamber 3...

Page 29: ...h in the middle For example Igniting 01m25 means the burner ignition state lasted 1minute and 25 seconds Last row of the log shows current state To reach the last row press the down button until you reach the current state The duration of current state updates every second or minute Info menu Info menu is useful to troubleshoot various problems It gives access to some input signals and internal pa...

Page 30: ...c 19 12 12 Firmware version and date 4 2 Starting and stopping To turn on the burner switch on boiler main switch If burner displays Stopped then go to STATUS menu and change parameter Burner from ON to OFF The display shows Waiting Now turn boiler thermostat to desired temperature The burner will go to Loading state If this is the first run external auger needs to fill up with pellets It can take...

Page 31: ...rent Par 46 3 6 A Feeder is turned ON feeder current must be smaller than Par 46 Draft Par 62 10 Pa All fans are turned on Draft must be under Par 62 Primary fan Par 4 38 rot Fan must rotate faster than 35rot 38 Par4 3 Secondary fan Par 4 38 rot Fan must rotate faster than 35rot 38 Par4 3 Cleaning In Cleaning cycle the linear actuator moves the grates and pushes out from burning chamber the ash an...

Page 32: ...llets into burning chamber Depends from burner model Par 25 Loading 2 feed 5 rot Feeder rotations for second loading Max loading time 5 min Maximum regular loading time First loading time after manual start 20 min Maximum loading time after manual start Auger start 3 sec Auger Start delay if no fuel in burner Auger stop 3 sec Auger Stop delay if fuel in burner Feeder start 1 sec Feeder Start delay...

Page 33: ...ime after manual start 20 min Maximum loading time after manual start Auger start 3 sec Auger Start delay if no fuel in burner Auger stop 3 sec Auger Stop delay if fuel in burner Feeder start 1 sec Feeder Start delay if fuel in burner Feeder stop 4 rot Feeder rotations made without fuel level before stopped Pre burn The purpose of pre burn status is to get correct burning and flame after ignition ...

Page 34: ...p time is exceeded or stone temp is higher than setpoint PAR72 Burning This is main operation status in burner operation Burner can operate on 11 different fixed power levels There are 6 main power levels which can be selected and adjusted Virtual power levels between main levels are for smoother operation they can t be adjusted or selected For every power level the primary fan speed is fixed in p...

Page 35: ...el is fixed the power is slowly raised to selected level and will be there until boiler thermostat is switched off In Automatic Power mode POWER AUTO in main menu the operation power is selected automatically depending of burning cycle length Figure 28 Burning when power selection AUTO Power level Burning time min Par 17 3 2 1 4 5 6 7 2 2 2 Selected power Power level Time min Par 17 Par 15 Max pow...

Page 36: ...art up procedures every time when burner is switched on from boiler thermostat In Hold flame mode minimum fuel and air amount is delivered into burning chamber Hold flame mode can be switched from burner main menu to ON OFF or AUTO When Hold flame is selected as AUTO then burner will turn the mode on or off depending of Waiting time If Waiting time between End blow and thermostat ON is shorter the...

Page 37: ...rns as selected in Par 26 End burn is used in case of some errors Table 12 End burn parameters Par Nr Parameter name Default value Unit Comment Par 26 End burn feed 50 80 rot Feeder rotations neede to clean feeder pipe Depends from burner model Minimum feed 20 rot If less rotations maid and boiler thermostat is switched ON then back to Burning End blow The End blow cycle is needed to finish unburn...

Page 38: ...s are clean 5 Remove the bottom panel to gain access under the grate movers to clean the ash from the burning camber 6 Reattach the bottom panel 7 Clean the boiler The frequency of cleaning the boiler depends on the type of the boiler and heating intensity For more information about cleaning the boiler please see boiler s user manual 8 Put back the grates 9 Close the boiler s door to finish the ma...

Page 39: ...PV1000agri pellet burner p 38 50 Operation and maintenance Replacing components DK9401A1 www pelltech eu ...

Page 40: ...essaging center number must be correct In SIM card s phonebook there must be only the numbers where the messages from the burner will be sent The number of receiving contacts is limited to 5 Insertion and removal of the SIM card The terminal has a built in toggle spring Push Push SIM holder accessible through a slot in the panel at the antenna side of the housing Do not insert or remove the SIM wh...

Page 41: ...icates that the supply voltage is arriving at the GSM Engine inside the GT863 PY Terminal Status LED Indication of network service availability The red Status LED is connected internally to the STAT_LED output of the module by an inverting circuit In addition to the status information obtainable via AT commands this LED shows information on the network service availability and Call status Status L...

Page 42: ...PV1000agri pellet burner p 41 50 Common problems and solutions DK9401A1 www pelltech eu 6 Common problems and solutions Problem description Possible cause and solution ...

Page 43: ...50 PV700 40 15 50 PV1000 42 15 50 Par 6 FAN level 11 rps PV350 46 30 60 PV500 46 15 50 PV700 42 15 50 PV1000 45 15 55 Par 7 FAN START 170 80 240 Initial speed for prim sec and flue gas fan to start 0 100 255 0 Par 8 FAN IGNITION rps 20 15 35 Par 9 FAN BURN END rps 20 10 40 Par 10 FAN HOLD FLAME rps 10 7 14 Par 11 HOLD FLAME ON min 15 5 30 Par 12 HOLD FLAME MAX min 60 30 90 Par 13 MIN POWER kW PV35...

Page 44: ...rot PV350 35 20 80 PV500 35 20 80 PV700 40 20 80 PV1000 40 20 80 Par 25 LOADING 2 FEED rot 5 1 15 Par 26 BURN END FEED rot PV350 50 20 80 PV500 65 30 120 PV700 70 40 120 PV1000 80 20 120 Par 27 END BLOW TIME min 2 1 15 Par 30 FAN 2 ON AUTO ON OFF AUTO AUTO for normal operation Par 31 FAN 2 level 1 rps PV350 15 5 80 PV500 15 5 80 PV700 13 5 80 PV1000 16 5 40 Par 32 FAN 2 level 3 rps PV350 20 5 80 P...

Page 45: ...0 250 Cleaning cycle delay Par 50 ERROR RELAY ON ON OFF Error relay action at error ON contact closed at error NO OFF contacts opened at error NC Par 52 SMS COUNT x 1 0 5 Par 53 TEMP TYPE 0 0 2 Temp Sensor action type 0 no sensor 1 overheat sensor 2 temp holding sensor Par 54 TEMP LEVEL C 70 30 105 Temp Holding setpoint Par 55 TEMP HYST C 5 2 10 Temp Holding hysteresis Par 58 BASE FREQUENCY Hz 50 ...

Page 46: ...w pelltech eu Par 71 HEAT UP POWER kW PV350 30 10 100 Power at HEAT UP PV500 40 10 100 PV700 50 10 100 PV1M 70 10 150 Par 72 HEAT UP TEMP C 500 250 900 Stone temperature to reach at HEAT UP Par 73 TEMP BASE C 20 0 100 Par 99 BURNER TYPE PV350 PV350 PV500 PV700 PV1M ...

Page 47: ...ion Pre burn Flame recognized Loading 2 Max ignition time 255 sec is reached and load 2 is not done Ignition error Max ignition time 255 sec is reached and load 2 is done Pre burn Burning Pre burn cycles 3 x40 sec is done and continuous flame is recognized more than 10 seconds Loading 2 Pre burn cycles is done and flame is NOT recognized and load 2 is NOT done No flame Pre burn cycles is done and ...

Page 48: ...N command is active Stopped No Flame 1 min and RUN command is NOT active No flame Max cleaning time 5 min is reached Level error No Flame 1 min and error is set From Burn Burn end End blow Level error No pellets No Flame 1 min and error is set From Burn Burn end End blow No pellets No Power Wait Power exist and RUN command is active Stopped Power exist and RUN command is NOT active Burning If Burn...

Page 49: ...PV1000agri pellet burner p 48 50 Annex C Controller board description DK9401A1 www pelltech eu 9 Annex C Controller board description Fuses F4 6A F10 2A ...

Page 50: ...mitter LED cathode X1 1 27VDC power output fused through F1 X1 2 Open collector output max 200mA 30VDC X1 3 Open collector output max 200mA 30VDC X1 4 Open collector output max 200mA 30VDC X1 5 Open collector output max 200mA 30VDC X1 6 Open collector output max 200mA 30VDC X1 7 Open collector output max 200mA 30VDC X1 8 Open collector output max 200mA 30VDC X1 9 Open collector output max 200mA 30...

Page 51: ...ected X6 1 DC input X6 2 DC input X6 3 DC input X6 4 DC input X7 1 MODBUS signal A X7 2 MODBUS signal B X7 3 MODBUS GND X8 1 DAC 0 10V output X8 2 DAC 0 10V output X8 3 DAC 0 10V output X8 4 DAC 0 10V output X8 5 27VDC power output fused through F5 X8 6 PT100 mA 2 56V input JP1 JP2 selects function X8 7 PT100 mA input JP3 JP4 selects function X8 8 DC input X8 9 Flame sensor input X8 10 Flame senso...

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