(346880241) DK9601B1 - PV350 user manual

PV350 pellet burner

User manual

DK9601B1

1 Contents2 Description ............................................................................................................................................ 5

3 Installation ............................................................................................................................................. 6

3.1 Prerequisites.................................................................................................................................. 6

3.2 Burner ............................................................................................................................................ 7

3.3 Water sprinkler.............................................................................................................................. 9

3.4 External auger ............................................................................................................................. 10

3.5 Pellet storage............................................................................................................................... 11

3.6 Electrical connections.................................................................................................................. 11

3.7 Commissioning ............................................................................................................................ 14

4 Operation and maintenance ............................................................................................................... 15

4.1 User interface .............................................................................................................................. 15

4.2 Starting and stopping .................................................................................................................. 17

4.3 Statuses and parameters............................................................................................................. 18

4.4 Cleaning ....................................................................................................................................... 26

5 Optional components .......................................................................................................................... 27

5.1 GSM Modem ............................................................................................................................... 27

5.2 Flue gas fan.................................................................................................................................. 28

5.3 Oxygen sensor ............................................................................................................................. 30

5.4 ERR output................................................................................................................................... 30

5.5 External boiler temperature sensor (TMP1) ............................................................................... 31

5.6 Ash removal system .................................................................................................................... 32

6 Annex A Parameters ......................................................................................................................... 33

7 Annex B Burner status change logic ................................................................................................. 37

PV350 pellet burnerp 1/ 408 Annex C Controller board description .............................................................................................. 39

DK9601B1www.pelltech.eu

Tables

Table Connectors........................................................................................................................................ 12Table User interface controls ..................................................................................................................... 15Table Info menu description ...................................................................................................................... 17Table Summary of burner statuses ............................................................................................................ 18Table List of tests in TESTING status........................................................................................................... 18Table Cleaning parameters......................................................................................................................... 19Table Loading parameters and timing........................................................................................................ 19Table Ignition parameters and timing ........................................................................................................ 20Table Pre-burn parameters ........................................................................................................................ 21Table Heat-up parameters ......................................................................................................................... 21Table Power levels ...................................................................................................................................... 22Table Hold flame parameters ..................................................................................................................... 24Table End burn parameters ........................................................................................................................ 24Table End blow parameters........................................................................................................................ 25Table Burner setup parameters ................................................................................................................. 30Table External temperature sensor types .................................................................................................. 31Table Controller board fuses ...................................................................................................................... 40Table Controller connectors X1 and X2 ...................................................................................................... 40Table Extension board X1 ........................................................................................................................... 41

S a f e t y p r e c a u t i o n s

Do not start the burner before it is connected to the boiler and the boiler is connected to the chimney.

It is recommended to wear a respirator while handling pellets.

The boiler room where the burner is installed must fulfill all rules and recommendations given by authorities.

All electrical connections must be done by trained professionals.

No flammable materials must be stored near the burner.

W a r n i n g s

Changing the construction of the burner without written permission from the manufacturer is forbidden.

Use only spare parts provided or approved by the manufacturer in order to avoid any damage to the burner and dangers resulting from it

Welding is allowed only after disconnecting the burner from electric supply. The circuit board must be removed from the burner.

Do not open any boiler door while the burner is in operation.

2 Description

PV350 is a pellet burner that is intended to be used with 6 or 8mm wood pellets. Due to the unique design of the burning chamber you can use 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.

PV350 pellet burnerDescriptionp 4/ 40The burner is equipped with a safety thermostat, a melting hose, temperature sensor, sprinkler system with pressure switch and auxiliary battery for protection against back-burning.

3 Installation

3.1 Prerequisites

In order to install the burner, the boiler must meet to the following requirements:

Recommended to use three pass boilers. The construction of the boiler must make it possible to open the door of the boiler with the burner connected and removing ash from the furnace. If the door of the boiler is too narrow for opening it with the burner, then extra hinges must be installed. To ensure negative pressure in the furnace, a flue gas fan should be installed. The boiler must be positioned in a way that there is enough space for cleaning the burner, theboiler, 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 500 m per hour (ca. 400 cm2 air inlet opening).

In order to install the burner to the boiler door, there must be mounting holes as shown below.

Note: If the burner is installed to the boiler, the door or the installation flanges thickness should be 8-14mm.

PV350 pellet burnerInstallationPrerequisitesp 5/ 40

D hole for burning chamber neckD1 flange bolt ring diameter

Unit PV 350mm 290 mm 330 D2bolt holes mm 4x13 a bolt hole offset angle

deg -

Figure 1 Boiler door mounting hole

angle between bolt holes deg 90

PV350 pellet burnerInstallationBurnerp 6/ 403.2 Burner

Figure 2

Figure 3

Install the burning chamber to the boiler door (or flange) using M12x45 bolts, spacers and coupling nuts. Use supplied thermal seal.

Install the backside using M12x70 bolts and washers to the burning chamber coupling nuts. Sealing felt must be placed between pellet burner and boiler door (or flange). The tube of internal screw must go through hole on the back wall of burning chamber.

Figure 4The tips of the igniters must reachas deep into the burning chamber as internal the feeding screw. Ensure the tips of the igniters are not touching any metal parts inside the burning chamber. Fix the igniters in place with a screw.

Check igniter positioning in the burning chamber.

Figure 5

Install the grates and the ceramic chamber bricks on to the burning chamber in order as shown on Figure 6

Figure 6

3.3 Water sprinklerWater sprinkler is main safety element against back burning. It is strongly recommended to install sprinkler system. 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.

PV350 pellet burnerInstallationWater sprinklerp 8/ 40In case of back burning, sprinklers will open and extinguish fire in feeder tubes. Flow control valve limits the amount of water flowing into burner after the reservoir is emptied. The burning chamber must be cleaned from wet ash and pellets before turning the burner back on again.

Figure 7 Sprinkler installation

3.4 External auger

The external auger transports pellets from the pellet container to the burner. The burner controls thework of the auger. The auger is connected to the burner with a special hose ( 80), which is made fromeasily melting material that acts as a safety measure against back-burning. PV350i pellet burners fuelconsumption at full power is about 77 - 80 kg of pellets per hour ( 1.3 kg per minute ). External augers productivity must be at least 120kg 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 the auger must not exceed 45 The end of the exit tube of the auger and the input of the burner must not be aligned. Therecommended minimal horizontal distance is 20cm. The distance between the input of the burner and the exit tube of the auger must be at least

PV350 pellet burnerInstallationExternal augerp 9/ 4060cm vertically recommended distance is 80-200cm.

Hose between auger and burner must be strait, otherwise pellets can block the auger. Fallingangle must me between 65 and 85.

Figure 8 External auger installation

3.5 Pellet storagePellets must be stored in a dry and ventilated room that is separated from the boiler room. A purpose built silo is recommended. All safety regulation must be taken into consideration according to the local 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

Following connections must be done by the installer:

1-phase supply to Y1 3-phase supply to Y2 External auger to Y3 Boiler thermostat to Y1

Burner is designed to work at 230V single phase supply (connector Y1). External auger is supplied by separate 3-phase power (connector Y2).

Boiler should be equipped with thermostat or external switch between pin T1 and T2 in plug Y1 for turning on/off the pellet burner.

PV350 pellet burnerInstallationPellet storagep 10/ 40Internal feeder is equipped with motor thermal protection, which prevents motor from overheating. As soon as the nominal trip temperature (TNF) of the sensor setpoint 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.

Table 1 Connectors

PV350

y1Power inputblack/brown230V 16A

y2Power inputblack380V 4A

y3Pellet augerblack0,55kW 1,6A

y4Secondary fanwhite0,15kW 0,65A

y5Primary fanwhite0,15kW 0,65A

y6Lambda sensorgreen

y7External inverterblack

y8Flue gas fanblack2 x 320V 0,75kW max 4A

y9Ignitorsblack500W 2,2A x 2

Y5 Y4

Y6 Y3Y8 Y2

Y9 Y1

PV350 pellet burnerInstallationElectrical connectionsp 11/ 40Figure 9 External connector markings


3.7 Commissioning

Prior to the initial start-up of the burner make sure that:

The burner is connected to the boiler The boiler thermostat is installed and is functioning 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 neutral wires in power cable are connected properly. Extension board is connected to main controller by 2 wires as shown below.

TMP3

TMP2

PV350 pellet burnerInstallationCommissioningp 13/ 40Figure 10 Extension board connection

4 Operation and maintenance

4.1 User interface

The burner is controlled via user interface on the front panel. LCD screen (1) displays settings menu, event log etc. Yellow light (2) shows the presence of flame in burning chamber. Or if blinking, the burner is out of normal operation. Status can be seen on log screen. Green light (6) indicates if there is fuel in the burner. To move in menus, use up and down buttons, to change parameter, press OK, to go back to STATUS MENU press ESC button.

Figure 11 User interface

1 Display2 Yellow led, showing the flame in the burner3 GSM modem antenna4 Burner operation light, showing if the boiler thermostat sends a signal to the burner.5 Burner on/off switch with power indication light6 green led, showing the fuel in the burner

Table 2 User interface controls

ButtonPush timeAction

OK3sReset error, resume normal operationReset counter (only in counter screen in info menu)

ESCMove back in menu by one levelCancel change (in parameter edit mode)

OK+ESC>3sBurner reset

PV350 pellet burnerOperation and maintenanceUser interfacep 14/ 40


Figure 12 Main menu structure

ButtonPush time Action in the menu

OKless then 3sec. Moving forwardConfirm settings (when blinking)

OKmore then 3sec. Counter reset

ESCless then 3sec. Moving backCancel option (when blinking)

OK+ESCmore then 3sec. Burner reset

Status info screen displays last events (burner states) and their duration. The duration is in form mm:ss (m in the middle) or hh:mm (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.

I n f o m e n u

Info menu is useful to troubleshoot various problems. It gives access to some input signals and internal parameters. Use up and down arrows to scroll through info menu.

Note: Comma , is used as decimal separator.

Table 3 Info menu description

Screen text Description

PV350 pellet burnerOperation and maintenanceStarting and stoppingp 16/ 40Pwr 00/350 kW Current and maximum power. Max power can be changed from main menu.Tstn=1810C T1=26850C

Tstn fire brick temperature, T1 - PTFan=10/132 14/15 10 primary fan actual speed, 13 primary fan setpoint speed. Actualspeed is controlled to match setpoint speed. 2 - Base air value.Controller tries to keep speed setpoint + base air. In this case controller keeps speed 15rps. Speed unit is rps (revolutions per second).14/15 same as above for secondary fan. Base air setting is same 2p=-0,2/-15Pa Burning chamber pressure value. -0,2 is current measured pressure and -15 is setpoint. Controller regulates flue gas fan speed to keep thispressure. Depends also on PAR60 value.Total=10 kg Roughly the amount of pellets burnt. It is measured by counting internal feeder rotations. Number is reset by firmware upgradeCount=12,1 kg180/254

Roughly the amount of pellets burnt, resettable by user.U=25V68 I=0.0A U - DC power voltage 25V68 means 25.68V. I Feeders and/or grate motor currentVer=2.02c 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 TESTING-state. If this is the first run, external auger needs to fill up with pellets. It can take as long as 20minutes.

4.3 Statuses and parametersPV1000agri pellet burner operates in many different states, which are called Status. Current and previous statuses can be seen from user interface panel (chapter 4.1). Burner changes its status based on input signals from sensors and user. Below are given the statuses in order of typical working cycle.

Table 4 Summary of burner statuses

Status Short descriptionWaiting Waiting signal from boiler thermostatTesting Thermostat is switched on, testing battery, fans, feeder, level sensors, draftCleaning Ash removing from burning chamberLoading Loading pellets with auger into burner and by feeder into burning chamberIgniting Igniter is turned on, pellets ignitingPre-burn Flame is recognized, small amount of pellets is added by feederHeat up Burning chamber Ceramic is heated upBurning Normal burning operationHold flame Thermostat is switched off, small flame is held aliveEnd burn Thermostat is switched off, feeder is cleaned upEnd Blow Pellet coals in burning chamber is burned, flame has disappearedWaiting Wait signal from boiler thermostat

W a i t i n g

In this status, the burner is waiting signal from boiler thermostat. There is no limit time for waitingstatus. Only internal feeder is working periodically at Waiting time rotations after every 2 minutes.When signal comes from the thermostat, burner will go to Testing.

T e s t i n g

At Testing time, burner integrity and important device functioning is checked.

Table 5 List of tests in TESTING status

Test namePar nr.Test conditions

Battery voltage-Battery loading is turned OFF and feeder is turnedON - voltage must be greater than 12V

Feeder currentPar 46Feeder is turned ON feeder current must besmaller than Par 46

DraftPar 62All fans are turned on. Draft must be under Par 62

PV350 pellet burnerOperation and maintenanceStatuses and parametersp 17/ 40

Primary fanPar 4Fan must rotate faster than 35rot = 38 (Par4) - 3

Secondary fanPar 4Fan must rotate faster than 35rot = 38 (Par4) - 3

C l e a n i n g

In Cleaning cycle, the linear actuator moves the grates and pushes out from burning chamber the ashand residues. The cleaning cycle has been divided into 3 steps:

1. Grates are pulled fully in to actuator end limit.2. Grates are pushed fully out to actuator end limit.3. Grates are pulled back in to the half way.

Table 6 Cleaning parameters

Par namePar nr.ValueUnitTest conditions

Cleaning cycleintervalPar 480...250minBurning time between Cleaning cycles. If 0then cleaning is turned off. If burned longer then2x Par 48 then forced cleaning is made.

Actuator max. currentPar 470.2..6AActuator maximum current level. If greater, then actuator is stopped and cleaning cycle is started again.

L o a d i n g

In the Loading cycle, pellet auger is turned on. When pellet level in the burner reaches to level sensors, internal feeder is started. Feeder loads correct amount of fuel into burning chamber needed for ignition. Loaded fuel amount is measured by counting internal feeder rotations. Loading cycle is ended when feeder is made correct amount of rotations, fixed in parameter PAR24 (loading feed rot.)

Table 7 Loading parameters and timing

Par Nr. Parameter nameDefaultvalueUnit Comment

Par 24Loading feed35..40rotFeeder rotations neede to load pellets intoburning chamber. Depends from burner model.

Par 25Loading 2 feed5rotFeeder rotations for second loading.

-Max loading time5minMaximum regular loading time

-First loading timeafter manual start20minMaximum loading time after manual start.

-Auger start3sAuger Start delay if no fuel in burner

-Auger stop3sAuger Stop delay if fuel in burner


- Feeder start1sFeeder Start delay if fuel in burner

- Feeder stop4rotFeeder rotations made without fuel levelbefore stopped

At the Loading time, external auger holds permanent fuel level in the feeder tube. Depending of the level sensor signal, the auger is turned ON or OFF.

Internal feeder work is also depending on fuel level sensor signal.

Maximum loading time is limited by 20 minutes after manual (first) start because extra time for external auger filling is needed. In next loadings, maximum time is limited by 5 minutes.

If maximum loading time is exceeded and silo selection on burner is used, the pellet delivery will be switched on other auger. In single pellet delivery system No pellets error will occur.

I g n i t i n g

In ignition cycle the igniter is heated up and fan blows hot air thru pellets in burning chamber. Hot air ignites pellets. Igniter is working periodically at ignition time to avoid overheating.

Igniter is preheated already in the end of loading cycle. When internal auger has made 10 rotations (full load rotations* - 12) the igniter is turned on for preheating. If the igniter has been turned on more than 1 minute at loading time, the igniter is turned off.

Table 8 Ignition parameters and timing


Par 24Fan @ignition25rpsPrimary fan speed at ignition

-Max ignition time255sekMaximum ignition time

-First loading time20minMaximum loading time after manual start.

-Auger start3secAuger Start delay if no fuel in burner

-Auger stop3secAuger Stop delay if fuel in burner

-Feeder start1secFeeder Start delay if fuel in burner

-Feeder stop4rotFeeder rotations made without fuel level before stopped

P r e - b u r n

The purpose of pre-burn status is to get correct burning and flame after ignition. There is minimum fuel amount added periodically at pre-burn time. Fans are working with same speed as at ignition.

Table 9 Pre-burn parameters


Par 8Fan@ignition20rpsPrimary fan speed at ignition and preburn

Par 39Fan 2 min7rpsSecondary fan minimum speed. Used atIgnition, Preburn, Heat up, Hold flameand End blow time.

Par 41Preburn time25sDelay between pellet feedings at Preburn

Par 42Preburn cycles6xNumber of pellet feeding cycles at Preburn

-Preburn feed1/2rotFeeder turns at each feeding

H e a t u p

Heat up cycle is needed for slow heating of the burning chamber and to minimize thermal stress in ceramic stones.

Heat up mode is selected from main menu between ON, OFF or AUTO.

Table 10 Heat-up parameters


Par 70Heat up time20minMaximum cycle time

Par 71Heat up power30...70kWDepends from burner model

Par 72Heat uptemperature500CCeramic stone minimum temperature

When Heat up is mode is ON - burner will leave from Heat up cycle after heat up time is exceeded(stone temp. is not measured)

When Heat up is mode is AUTO - burner will leave from Heat up cycle after heat up time isexceeded or stone temp. is higher than setpoint (PAR72)

B u r n i n g

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 parameters 1...6 and secondary fan speed in parameters 31...36. The fan speed for virtual levels is calculated as average from previous and next main level speed.

Power Level level typePower by burner model (kW) Air parametersPV350 PV500 PV700 PV1000 Primary Secondary1 main 100 160 200 250 Par 1 Par 31PowerlevelTable 11 Power levels

2virtual120200250320--

3main150240300400Par 2Par 32

4virtual170280350470--

5main200320400550Par 3Par 33

6virtual220360450620--

7main250400500700Par 4Par 34

8virtual270440550770--

9main300480600850Par 5Par 35

10virtual320520650920--

11main3505607001000Par 6Par 36

76Selected power54321

Par 17

2 2 2

Burning time min

Power level can be selected in main menu. Power level selection for burning time can be automatic or fixed on some main level. When power level is fixed, the power is slowly raised to selected level and will be there until boiler thermostat is switched off.Figure 13 Burning at fixed power

In Automatic Power mode (POWER = AUTO in main menu), the operation power is selectedautomatically depending of burning cycle length.

98 Thermostat ON OFF7

Power level6Operation power543

Testing

Max power (par 14) New operation power

Par 152 Par 151

Par 15

LoadingIgniting End burn Pre-burn

Burning2 2 2 30 30

Waiting

Burning

Time(min)

Figure 14 Burning when power selection = AUTO

S l o w d o w n

In Slow down mode, the burner power is reduced step-by-step to 1 level after boiler thermostat is switched OFF. This mode can be used only is systems with high and stable power demand. Using Slow down mode in systems with low thermal inertia or unstable power demand, there will be risk of system overheating. The Slow down mode is recommended to use together with Hold flame. Slow down

Powerlevelmode can be switched ON or OFF from main menu.

76543 Par 1821

Slow

Thermostat ON

Operation power

Par 17

Thermostat OFF

Burn end

ORHold flameBurning

down Burning

Slow down

Status/time

Figure 15 Slow down mode

H o l d F l a m e

Hold flame mode purpose is to avoid burner start-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 then Par 11, then Hold flame mode is switched on. If Hold flame is longer than Par 12, hold flame mode is turned off

Hold flame is also used as intermediate state before cleaning or after Slow down

Table 12 Hold flame parameters

DK9601B1www.pelltech.euPar

DefaultNr.Parameter namevalueUnit Comment

Par 8Fan @hold flame10rpsPrimary fan speed at hold flame

Par 39Fan 2 min7rpsSecondary fan minimum speed. Used at

Ignition, Preburn, Heat up, Hold flameand End blow time.

Par 11Hold flame ON15minShort Waiting limit.

Par 12Hold flame OFF60minMaximum time in Hold flame

E n d b u r n

The End burn cycle is needed to stop the burner. All pellets inside the burning chamber and feeder tubes are burned. Pellet feeding frequency and fan rotation speed (power level) is same as in Burning status. If burner goes to End burn from other states (example Hold Flame), first power level is selected. Burner works in End burn until feeder tube is empty - feeder has made as many turns as selected in Par 26. End burn is used in case of some errors.

Table 13 End burn parameters


Par 26End burn feed50..80rotFeeder rotations neede to clean feeder pipe. Depends from burner model.

-Minimum feed20rotIf less rotations maid and boiler thermostat is

switched ON then back to Burning

E n d b l o w

The End blow cycle is needed to finish unburned pellet coals in the burning chamber. Burner will wait the flame disappearing in burning chamber. In Par 27 is fixed the time, how long the fans continue to blow after flame disappearing.

Table 14 End blow parameters


Par 9Fan @end blow20rpsFan speed at End blow

Par 39Fan 2 min7rpsSecondary fan minimum speed. Used atIgnition, Preburn, Heat up, Hold flameand End blow time.

Par 27End blow time2minTime to blow air after flame is disappeared

-Max. End blowtime15minMaximum time when flame must disappear inEnd Blow

4.4 Cleaning

Pellet burner requires systematic maintenance. The maintenance period depends on the quality of the pellets and heating intensity.

The boiler must be cleaned weekly. For more information about cleaning the boiler, please see boiler's user manual.

The burner should be cleaned about two times in a season. To clean the burner:1. Turn off the burner by turning the thermostat to 0.2. Let the burner cool down for at least 1 hour.3. Open the boiler's door to gain access to the burning chamber4. Remove the grates and clean them from any residues. Make sure all holes on the grates areclean.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. Put back the grates.8. Close the boiler's door to finish the maintenance and turn the thermostat to desired temperature.

PV350 pellet burnerOperation and maintenanceCleaningp 25/ 40The connection between the boiler and chimney must be completely airtight. There mustn't be any extra draught in the smoke draft of the boiler. All cleaning and maintenance openings must be closed with covers.


5 Optional components

PV350 pellet burnerOptional componentsGSM Modemp 26/ 405.1 GSM Modem

Figure 16 Modem

Modem enables users to receive burner error messages via SMS. Boiler room must have GSM coverage in order to use the modem.

P r e c o n f i g u r i n g S I M c a r d

Before inserting the SIM card to burner, SIM card must be preconfigure. That can be done by inserting the SIM card to a mobile phone and making following actions:

SIM card must the activated by the mobile operator SIM card pin code must be turned off Mobile operators messaging center number must be correct In SIM cards phonebook, there must be only the numbers, where the messages from the burnerwill be sent. The number of receiving contacts is limited to 5.

I n s e r t i o n a n d r e m o v a l o f t h e S I M c a r d

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 when the product is in power saving mode.

To insert and remove the SIM, a plastic strip of the same width of the SIM and appropriate length of ca. 50-100 mm shall be prepared as a tool. The figure printed on the panel shows the position of the cut edge and the direction, how the SIM shall be inserted.

Insert the SIM and push it with the tool slightly inside until the spring snaps in. Removing the tool, theSIM shall remain inside the GT863-PY. For removing the SIM, push the tool slightly inside until the springFigure 17 SIM card insertion

is released so that it pushes the SIMoutside when the tool is retracted.

Burners GSM modem menu can be accessed in the PARAMETERS menu, parameter no. 52

L E D i n d i c a t o r s

The GT863-PY Terminal has 2 LED indicators, one for Power, one for Status.

Power LED When on, the green Power LED indicates 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 LED indications

LED statusDevice Status

permanently ona call is active

fast interrupt sequence(period 0,5s, Ton 1s)Net search / Not registered / turning off

slow interrupt sequence(period 0,3s, Ton 3s)Registered full service

permanently offdevice off

5.2 Flue gas fan

The burner needs stable under-pressure in burning chamber for correct operation. Simplest way to assure this is use the flue gas fan. With flue gas fan the burner can control and hold constant underpressure.

Selected flue gas fan must provide the maximum flue gas amount and exceed the pressure provided by boiler, cyclone and chimney. The flue gas capacity for burned pellets can be calculated by simplified formula.

PV350 pellet burnerOptional componentsFlue gas fanp 27/ 40

V Capacity range in m/h

P Burner max power in kW

Tfg flue gas absolute temperature in K Troom - room absolute temperature in K Lambda excess air ratio

PV burners are designed to work at lambda values 1.2...1.5 - for calculations choose value of 1,5.

Flue gas fan must be installed between boiler and chimney. If cyclone is used then flue gas fan must be installed between cyclone and chimney to avoid overpressure in cyclone and smoke leakage.Depending of burner configuration (inverter included or not) the electrical connections can be different. In case of frequency inverter has already been installed to the burner, the fan can be directly connectedto the burner through connector Y8. Fan must be connected to burner with 3 wire cable (3x1,5mm).Internal inverter output is 3 x 230V. When used fan motor is a three phase motor (3 x 230/380V) then it has to be connected as triangle.

In case of burner is without inverter, the external inverter for flue gas fan can be used.

Inverter must be chosen by fan motor parameters and available power supply. The inverter must be switched to sink logic (negative common).

To connect the inverter with burner there is connector Y9 with 3 output signals:

T1 - burner DC common (ground), must be connected with inverter input common.

S3 - run command, must be connected with F (forward) pin on inverter input. Burner will connect this pin to ground when fan must run.

PV350 pellet burnerOptional componentsOxygen sensorp 28/ 40 B4 0 10V output for fan speed, must be connected with inverter analog input.

5.3 Oxygen sensorFollowing instruction is applicable for firmware version 3.86.

In order to use the oxygen sensor, two parameters must be set up:

Table 15 Burner setup parameters

ParameterDescriptionUnitValue

NrNameDefMinMax

66Oxygen type0 no sensor1 420mA = 025% oxygen2 420mA = 020% oxygen- 002

67Oxygen setDesired oxygen level in flue gas- 6412

For EP0006 sensor board, the PAR66 value must be 1. Some third party oxygen sensors use 420mAoutput for 020% oxygen. In this case, value 2 must be selected.

If PAR66 is set to 0 (no sensor), fan2 is driven by air table (PAR31 PAR36). Fan2 also switches back to table if oxygen level reading is below 3% or over 19%

Oxygen level control starts 5min after entering into BURNING status. It can take about 10min for oxygen level to stabilize.

Oxygen level can be seen in INFO-menu next to pressure reading. The value on the screen must bedivided by 10 to get the real value. For example O2=113 means oxygen value 11.3%.

5.4 ERR outputErr output relay on the controller board adds various functions:

PAR50 value Description1 Normally open circuit. Only connected in ERROR state.2 Normally closed circuit. Only disconnected in ERROR state3 Connected circuit in PREBURN, HEATUP, BURN and HOLD FLAME4 not used5 not used

The relay is capable of switching 5A@250VAC

Figure 18 ERR output location

5.5 External boiler temperature sensor (TMP1)

External temperature sensor enables the burner to maintain constant water temperature. Following actions must be done to enable temperature hold mode (THM):

1. Mount external temperature sensor to boiler according to boiler manufacturer instructions

2. Connect the sensor to TMP1 connector on controller board.

3. Choose PAR53 value (sensor type ) according to Table 16

4. Set desired temperature PAR54. It should be lower than boiler thermostat temperature.Otherwise the boiler thermostat would force the burner to stop before reaching PAR54 value.

5. Optionally change PAR55 the hysteresis of desired temperature.

THM activates if PAR53 value is larger than 1 and BURNING status has lasted longer than PAR15 value (typically 30min). The burner will change its output power according to current measured temperature and the rate of temperature change. New power level is selected after every time interval specified in PAR17.

Table 16 External temperature sensor types

PAR53Sensor typeTemp minTemp maxFunction

0No sensor---

10..2.5V0C (0.5V)125C (1.75V)Internal overtemperature sensor(PAR43)

20..2.5V0C (0.5V)125C (1.75V)Boiler temperature control

PV350 pellet burnerOptional componentsExternal boiler temperature sensor (TMP1)p 30/ 40


After activating THM, following row is displayed on INFO-screen: T=22.3/705200o

22.3 Actual measured temperature70 Setpoint temperature (PAR54)5 Setpoint hysteresis (PAR55) - Shows if actual temperature is increasing or decreasing200o Forecasted temperature after 10min

5.6 Ash removal system

The burner can control external ash removal motor via grate motor connector. 24V NO relay must be connected in parallel to grate motor. During cleaning cycle, the relay is powered and switches on external boiler ash removal motor.

24V Ash removal motor control

PV350 pellet burnerOptional componentsAsh removal systemp 31/ 40Figure 19 Connecting ash removal control relay

6 Annex A Parameters

ParNrParameternameUnitBurnermodelDefaultMin.Max.Description

Par 1FAN @level 1rpsPV350242030

PV500221550

PV700281550

PV1000241550


PV500251550

PV700321550

PV1000301550


PV500321550

PV700341550

PV1000341550


PV500401550

PV700371550

PV1000381550


PV500431550

PV700401550

PV1000421550


PV500461550

PV700421550

PV1000451555

Par 7FAN START%17080240Initial speed for prim., sec. and flue gas fan to start. 0=100%, 255=0%

Par 8FAN IGNITIONrps201535

Par 9FAN BURN ENDrps201040

Par10FAN HOLDFLAMErps10714

Par11HOLD FLAMEONmin15530

Par12HOLD FLAME MAXmin603090

Par13MIN POWERkWPV350100100/150/200/250/300/350

PV500160160/240/320/400/480/560

PV700200200/300/400/500/600/700

PV1000250250/400/550/700/850/1000

Par14MAX POWERkWPV350350100/150/200/250/300/350

PV500560160/240/320/400/480/560

PV700700200/300/400/500/600/700

PV10001000250/400/550/700/850/1000

PV350 pellet burnerAnnex A Parametersp 32/ 40


Par15POWER UPmin155120

Par16POWER DOWNmin301545

Par17UP CYCLEmin213

Par18DOWN CYCLEmin213

Par21PELLET NORMALg/nPV3508050100

PV500160120250

PV700160120250

PV1000160120250

Par22PELLET LIGHTg/nPV3507550100

PV500150120250

PV700150120250

PV1000150120250

Par23PELLET HEAVYg/nPV3508550100

PV500170120250

PV700170120250

PV1000170120250

Par24LOADING FEEDrotPV350352080

PV500352080

PV700402080

PV1000402080

Par25LOADING 2FEEDrot5115

Par26BURN END FEEDrotPV350502080

PV5006530120

PV7007040120

PV10008020120

Par27END BLOW TIMEmin2115

Par30FAN 2 ONAUTOON/OFF/AUTOAUTO for normal operation

Par31FAN 2 @level 1rpsPV35015580

PV50015580

PV70013580

PV100016540


PV50020580

PV70023580

PV100022550


PV50030580

PV70032580

PV100030555


PV50036580

PV70039580


PV100038555


PV50040580

PV70041580

PV100042555


PV50046580

PV70043580

PV100046555

Par38FAN 2 BASE%10065140

Par39FAN 2 MINrps7520

Par40PHOTOCELLLEVEL%9050100Photocell sensitivity 100% = infinity flame

Par41PRE-BURN TIMEs251580

Par42PRE-BURNCYCLEx6210

Par46FEED CURRENTAPV3503,01,09,9Feeder max. Current.

PV5006,01,09,9

PV7006,01,09,9

PV10006,01,09,9

Par47GRATECURRENTA2,00,26,0Grates actuator max. Current

Par48CLEANINGCYCLEmin300250Cleaning cycle delay.

Par50ERROR RELAY1151 NO 2- NC 3 Pump control 4 not used5 used for cleaning air control

Par52SMS COUNTx105

Par53TEMP TYPE002Temp. Sensor action type: 0-no sensor, 1- overheat sensor, 2-temp. holding sensor

Par54TEMP LEVELC7030105Temp. Holding setpoint

Par55TEMP HYSTC5210Temp. Holding hysteresis

Par58BASEFREQUENCYHz504563Power grid frequency (for triac operatedfans)

Par60FLUEGAS TYPE202Flue gas fan/ underpressure control type: 0- no-fan, no-control, 1 - no-fan butcontrolled underpressure, 2 - inverter, 3 -230V triac

Par61DRAFT SET-Pa80250Draft setpoint

Par62DRAFT ERROR+Pa10020Draft error level

Par63DRAFT BASE%11050150Draft sensor calibration value

PV350 pellet burnerAnnex A Parametersp 34/ 40

Par70HEAT UP TIMEmin20060Max. Time for HEAT UP cycle.

Par71HEAT UPPOWERkWPV3503010100Power at HEAT UP

PV5004010100

PV7005010100

PV1M7010150

Par72HEAT UP TEMPC500250900Stone temperature to reach at HEAT UP

Par73TEMP BASEC200100

Par99BURNER TYPEPV350PV350/PV500/PV700/PV1M

7 Annex B Burner status change logic

StatusNext StatusChange conditions

WaitingTestingSignal from boiler thermostat

TestingLoadingAll tests are done successfully

Battery errorBattery voltage is too low

Fan errorFan does not reach 40* rps at pre-burn

Level errorThe level sensor recognizes pellets in the feeder

LoadingIgnitionLoading (22* rot.) made by feeder

No pelletsMaximum loading time (5 or 20 min.**) is reached

Burn endFlame detected and unknown start conditions

Loading 2IgnitionPrevious state was ignition and rotations (3* rot.) made by feeder

Pre-burnPrevious state was hold flame and rotations (3* rot.) made by feeder

IgnitionPre-burnFlame recognized

Loading 2Max ignition time (255* sec) is reached and load 2 is not done

Ignition errorMax ignition time (255* sec) is reached and load 2 is done

Pre-burnBurningPre-burn cycles (3*x40*sec.) is done and continuous flame isrecognized more than 10 seconds

Loading 2Pre-burn cycles is done and flame is NOT recognized and load 2 is NOTdone

No flamePre-burn cycles is done and flame is NOT recognized and load 2 is done

BurningBurn endNO Signal from boiler thermostat (hold flame is NOT allowed)

Hold flameNO Signal from boiler thermostat (hold flame is allowed)

Burn endMaximum burning time (4 hours) is reached

Burn end -> Endblow ->Level errorFuel level is continuously detected in time of 8 feeder rotations

Burn end -> Endblow ->No pelletsFuel level is not detected in 4 min.

No flameNo Flame more than 2 minutes

Hold flameLoading 2Signal from boiler thermostat

Burn endMax keep flame time (1 hour) is reached

PV350 pellet burnerAnnex B Burner status change logicp 36/ 40

Burn endEnd blowBurn end (15*rot. + 10rot.) plus time 30sec. is reached

BurningSignal from boiler Thermostat, feeder made less than 8 rot and previous state was BURN

End BlowWaitingNo Flame 1 min. and RUN command is active

StoppedNo Flame 1 min. and RUN command is NOT active

No flameMax cleaning time (5 min.) is reached

Level errorNo Flame 1 min. and error is set From: Burn-> Burn end-> End blow->Level error

No pelletsNo Flame 1 min. and error is set From: Burn-> Burn end\-> End blow->No pellets

No PowerWaitPower exist and RUN command is active

StoppedPower exist and RUN command is NOT active

BurningIf Burned before No Power and less than 15 min in No Power

Any otherWaitingRUN command is activated

8 Annex C Controller board description

X1 ERR

X2

PV350 pellet burnerAnnex C Controller board descriptionp 38/ 40

UART

PROG

TMP1

FAN TMP2TMP3BUT FDR

CONTR

TRS RSV

BUT User interface buttonsCONTR LCD contrast and viewing angle adjustmentFAN Primary air fan speed feedback sensorFDR Secondary air fan speed feedback sensorTRS Fuel level sensor transmitter (black marking) RSV Fuel level sensor receiver (white marking) TMP1 External boiler temperature sensor

TMP2 Pressure sensor (via extension board) TMP3 Lambda sensor (via extension board)UART RS232 interface for external modem (5V signal levels).

GND Tx Rx+5V

Figure 20 Modem connector

Table 17 Controller board fuses

FuseRatingFunction

F11AExternal auger

F21AFan

F31AFlue gas fan

F43A quickIgniter

F53A quickController and feeder motor

X1 DescriptionX2 Description1 Igniter1 Ash removal -Table 18 Controller connectors X1 and X2

2Igniter2Ash removal +

3N3Battery positive terminal

4Flue gas fan4Battery negative terminal

5Mains transformer5Flame sensor

6Mains transformer6Flame sensor

7Fan7Feed screw - (black)

8L8Feed screw + (red)

9Thermostat9Mains transformer

10External auger10Mains transformer


Table 19 Extension board X1

X1 Description1 Lambda +1 2 Lambda -3 +27.2V4 Ground5 Inverter F6 -7 Inverter CC8 Inverter VIA9 -1 10 -

TMP1 not connectedTMP2 connected to TMP2 on main board1 TMP3 connected to TMP3 on main board

Figure 21 Extension board

(346880241) DK9601B1 - PV350 user manual

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Transcript of (346880241) DK9601B1 - PV350 user manual