ZMM Haskovo GP 32cs Instruction Manual Download

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Instruction manual

for installation and operation of

Automatic pellet burner of series

“GP cs”

http:// www.greenecotherm.eu

Summary of Contents for GP 32cs

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: ...g 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 B...

Page 3: ...es 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 synchroniz...

Page 4: ...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 Automat...

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...

Page 6: ...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 w...

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 all...

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 Utili...

Page 9: ...kg 18 18 1 Weight fuel transport auger kg 12 12 main module mm 250 572 485 250 630 485 Overall dimension of the unit WxDxH fuel transport auger mm 220x1520x110 220x1520x110 Power supply 1PEN 50Hz 230V...

Page 10: ...pany 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...

Page 11: ...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 D...

Page 12: ...ustion 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 cham...

Page 13: ...er 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...

Page 14: ...tosensor 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 cha...

Page 15: ...tting 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 planni...

Page 16: ...ition 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...

Page 17: ...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 precauti...

Page 18: ...s 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...

Page 19: ...gy 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 r...

Page 20: ...hich 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 dim...

Page 21: ...oject 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...

Page 22: ...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 bu...

Page 23: ...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 45 Pellet hopper BP Figure 4 6 Isometric view o...

Page 24: ...eries 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...

Page 25: ...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...

Page 26: ...ount 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...

Page 27: ...ntiometer 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 pr...

Page 28: ...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...

Page 29: ...nnected 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...

Page 30: ...nsor 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 therma...

Page 31: ...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...

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...

Page 33: ...nes 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 p...

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 oper...

Page 35: ...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 guarante...

Page 36: ...or 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 T...

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...

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...

Page 39: ...ty 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 f...

Page 40: ...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...

Page 41: ...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 mo...

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 pr...

Page 43: ...cian 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...

Page 44: ...re 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 incr...

Page 45: ...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 achi...

Page 46: ...les 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 we...

Page 47: ...gs 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 burne...

Page 48: ...ust 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 d...

Page 49: ...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 emer...

Page 50: ...r 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 Electric...

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...

Page 52: ...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 th...

Page 53: ...thorized 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 sig...

Page 54: ...y 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 look...

Page 55: ...on 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 necess...

Page 56: ...ombustion 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...

Page 57: ...cribed 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 EXPLANA...

Page 58: ...s 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...

Page 59: ...RRANY 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...

Page 60: ...rner 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...

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 Repair...

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