Important Instructions, Keep for Future Use

Manual

Installation and Operation of

Automated Pellet Burner SMB 50 Series

Important instructions, keep for future use!!!

ﻬ Mareli Systems Company expresses its gratitude to customers who have purchased our products.

ﻬ This manual is provided by Mareli Systems Company to assist the team who will install, set up, and service this equipment, as well as the customer who will operate it.

ﻬ Mareli Systems Company requires that the technicians who will perform the above procedures shall have passed a training course in the operations related to this product.

CAUTION!For your safety it is necessary to read carefully in details this manual along with the operation and installation manual of automated pellet burner before you start any actions on its installation, set-up, and operation. The same applies to the pellet hopper installation and operation manual, in case the equipment has one. Non-compliance with instructions and violating applicable norms and directives may lead to damages and unforeseen consequences, for which Mareli Plast Company shall not be held liable.

DO NOT DISPOSE OF IN CONTAINERS FOR HOUSEHOLD WASTE!

This mark on the pellet burner means that it must be disposed of only in designated places for waste collection and recycling. The disposal of this appliance falls under the regulation of the European Directive on waste electrical and electronic equipment (WEEE). Dear customers, let us contribute together to the preservation of the environment.

This appliance is not intended for use by physically, sensory or mentally disabled people or people with insufficient knowledge and experience (including children).Installation must be performed by a qualified specialist in the field of heating installations or by an authorized by Mareli company repair shop. The location and the connection method of the burner should be carefully chosen by following the safety instructions. Install away from flammable items!

Never try to make any changes on the burner! The use of flammable liquids for inflaming is prohibited! Maintenance of the burner must be carried out by an adult who is familiar with the operation conditions. Bringing of highly flammable and vaporisable liquids in the room with working burner is strictly prohibited. Children must not be left unattended in the room of the combustion system.

Safety distances:

When installing the burner safety distances from a minimum of 200 mm must be observed, if there is no stone wool for wall and cladding insulation applied. This distance applies to the fireplaces and flues located in the vicinity of materials of B and C flammability class. The safety distance shall be doubled if the camera is located in the vicinity of materials of СЗ flammability class.

1. Description and Advantages of Automated Pellet Burner SMB 50 Series.

Pellet burners of these series designed for the utilization of wood pellets represent welded steel structure. The resulting heat is being absorbed by the heat exchange surface of the boiler body and is then transmitted to the coolant in the heating system. These burners are used for heating in local heating systems and also for water heating for domestic needs.

The automated pellet burner can utilize the following types of fuel:

Wooden pellets 6 and 8 mm in size, class A;

The automated pellet burner is a compact module structure consisting of the following components:

Burning chamber, which provides conditions for optimal burning process and is manufactured of high quality alloyed steel.

Automated mechanical cleaning.

Burning chamber grate, easy to dismount, allowing removal of ash residue.

Electric heater to kindle the fuel.

Fan supplying air for combustion.

Photo sensor to monitor the combustion process.

 An automated pellet burner equipped with a control panel;

Control unit that monitors and controls burner operation and led indication for the operating mode;

Fuel screw conveyor connector feeding the screw conveyor itself;

Interface panel equipped with light indicators;

Transparent panel which visualizes the work of the controller and its mode;

Facility Advantages

It is designed to utilize biomass, which makes it environmentally friendly;

The price of the heat energy generated by the biomass utilization as local energy source is affected to a small extent by the global fuel prices and thus the value of the generated heat energy is competitive to that generated from the use of conventional heat sources;

The facility is automated and provides comfort during operation;

Automatic operation enables adjustment of the work with room thermostat (weekly programmer), which ensures maximum thermal comfort and fuel economy;

Opportunity for energy utilization of biomass in the form of pellets;

High efficiency;

Low level of harmful emissions;

Compact design enabling simple installation and easy maintenance for cleaning and servicing;

Minimum operating costs;

Basic information for the automated pellet burner:

The automated pellet burner shall be mounted horizontally secured by M8 screws.

The pellet burner is a standalone module, which can be mounted to a range of already installed boilers and thus currently used fuel with the so-called densified bio-fuel such as wood pellets can be replaced.

The pellet burner is equipped with a control panel.

Wood pellets enable the easy automation of the process of combustion and highly effective utilization of their energy. During utilization of wood pellets, as well as any other solid fuel, ash residue remains, but its quantity is less in comparison to that remaining during wood or coal utilization due to the pellet composition. And the price of the heat energy from the wood pellets is competitive compared to that generated from other energy carriers. The operation of automated pellet burner corresponds to the functionality of any automatic fossil fuel burner (i.e. gas, diesel, fuel oil): it switches on automatically, fuel ignition is automatic, maintenance of efficient fuel process is precisely controlled by the built-in control module. These are features which enable comfort operation by the already popular automated facilities utilizing fossil fuels, and at the same time the bio-fuel is a product of biomass - eco-friendly and at attractive price.

The automated pellet burner consists of:

Burning chamber which provides conditions for optimal burning process and is manufactured of high quality alloyed steel;

Distributive air duct which ensures even supply of air for combustion and cooling the burner elements.

Housing and outer decorative cover are made of sheet steel and treated with high quality tinted coating.

Picture 1

Electrically driven screw conveyor (Picture 1) which transports fuel to the burner depending on the burner operation mode. The screw conveyor consists of a geared motor with electric motor, a pipe transporting fuel until it reaches the hole, through which it is supplied to a flexible pipe. The flexible pipe is made of specific heat-resistant material (which in the case of combustion does not separate toxic substances) and connects the screw conveyor with the pellet burner.

Installation must be performed by a qualified specialist in the field of heating installations. The location and the connection method of the burner should be carefully chosen by following the safety instructions. Install away from flammable items!

Never try to make any changes on the burner! The use of flammable liquids for inflaming is prohibited! Maintenance of the burner must be carried out by an adult who is familiar with the operation conditions. Bringing of highly flammable and vaporisable liquids in the room with working burner is strictly prohibited. Children must not be left unattended in the room of the combustion system.

Combustibility Classes table
Flammability classes of construction materials / Construction materials with flammability classes
A - non-combustible / Granite, sand,concrete,ceramics, etc.
B - flame retardant / Acumin, isomin, heraclit, basalt tiles, GRP, novodur.
C1 - hardly flammable / Deciduous wood material, plywood, werzalit, etc.
C2 - medium flammable / Coniferous wood, cork slabs, rubber flooring
C3 - highly flammable / Chipboard, cellulose materials, polyurethane, polystyrene, etc.

2. Constructive measures for safety improvement

The burner is controlled by a microprocessor.

The process of ignition is monitored by a photo sensor, if not initially ignited a microprocessor provides a second dose of pellets and start ignition again. If after 2 ignition attempts no flame is detected, the burner runs in purge mode.

If pellets in the feeding hopper run out during operation the burner will not start.

The flexible pipe for transport of pellets is made of heat-resistant material. A temperature sensor for above 90° is fitted to the feeding pipe of the burner. If the temperature sensor registers during operation a temperature higher than 90° the screw conveyor stops and the burner switches off. Even when the temperature falls below 90° no new switch on will follow. Intervention of burner operator is required.

Measures for safe operation of the burner

The equipment operation process is monitored by controller. It controls the ignition and combustion processes and these are monitored by the photo sensor and the temperature sensor. In case of two failed attempts for ignition the burner shuts down.

A sensor is installed in the burner to prevent the fuel from reverse combustion, so called "backfire". In case of backfire, the controller will shut down the burner, switching to emergency mode.

In case of the above situation, unplug the controller from power supply, take all safety measures, such as preventing fire and thermal shock, then carefully clean the burner. It is advisable to call an authorized service technician to establish whether the equipment is safe. There is a risk of sensor damage and melting the flexible pellet feeding tube. To prevent backfire, the burner should be checked if it is cleaned, if the settings are proper, and if the burner installation requirements are met.

If during operation the connector is removed or not well adjusted, the burner shuts down automatically.

3.Instructions for connection (installation) to a boiler:

The pellet burner can be attached to a steel or cast iron hot water boiler with a power from 15 to 50 kW. The minimum depth of the combustion chamber should be 450 mm. The automated pellet burner has no secondary air supply.

The distance between the flame and the cooling surface of the boiler must be at least 150 mm.

The facility is deployed so that there will be enough space for cleaning, removing ash from the burner, the boiler and the exhaust pipe.

No items must be placed thereon, leaning or propping against is prohibited, in order not to break the seal. There is a risk of breakage and breach of the burner integrity, as well as to distort its horizontal position, as a result of which - its proper work.

The installation hole of the pellet burner must be 128 mm wide, and 121 mm high.The size of the door which to be joined to must enable incision of the installation hole mentioned above (if there is no such).

The burner is placed in the boiler door hole designated for it with the appropriate seal. It shall be attached securely with M8 screws.

The connection between burner and boiler must be properly sealed, so that no leakage of exhaust gases in the room occur. During installation the equipment should be in optimum horizontal position, the pellet feeding hose should be taut and the clamps must be tight.

After positioning the boiler in the designated place, it must be levelled with anti vibration pads. The fuel hopper is positioned at the right/left side of the boiler and levelled accordingly. Levelling must be very precise as connecting orifices have too little tolerance. Both objects are to be joined by 4 М8 bolts.

The burner is mounted to the side of the boiler in the opening under the pellet hopper to the pre-assembled intermediate flange and tightened with braces.

Appendix 1

-Reconstruction of hot water boiler with automated burner

1. Cut a hole in the available door (if there is no such planned). The sizes described in the instructions should be observed.
2. Thoroughly clean the interior walls of the boiler from ash residue, soot, etc., which would have led to appearance of thermal resistance during facility operation. After cleaning, the drawer for collection of the ash from the combustion chamber must also be taken out.
3. Then, mount and securely attach a pellet burner to the door through M8 screws (which are screwed, where the thread is made on the door itself), which holds the burner to the door.

Explanation:: It must be checked whether sealing ropes of

the doors fit snugly to the boiler housing. If any gaps are found, the corresponding sealing rope must be replaced and ensure the density of this zone;

1. Install the fuel supply conveyor, which feeds the automated pellet burner.

The fuel supply conveyor must be installed in such a way so that fuel can be freely extracted from the hopper – from its lowest point. In the event that the hopper is made/assembled on site, it is recommended to make a manhole for servicing the rowing area of the screw conveyor. The screw conveyor pipe itself also must be fastened, so as to ensure against upheaval and possible change of the screw conveyor axis angle against the horizontal plane.

Explanation: The tilt angle (between the screw conveyor axis and the horizontal plane) of the screw conveyor has a direct effect on its performance, i.e. the fuel flow which it will provide at a specified operating mode. That is why adjustment of the burner settings is likely to be required upon change of this angle, in order to insure specific heating power.

1. Provide the power supply directly through a plug. Before connecting to the power the burner must be earthed through a 4 mm2 copper wire with yellow-green insulation.

Power supply is provided through a Schuko type plug directly in the mains.

CAUTION!

The burner control unit should be plugged in an outlet, which must be earthed. There is a risk of electric shock in the absence of earthed plug! The manufacturer bears no responsibility!

Pellets are stored in a hopper. The purchased from Mareli Company hopper has a 45-degree tilt. The screw conveyor pipe must be placed therein.

The screw conveyor draws pellets from the hopper and feeds the burner through a flexible connection. Dosing is controlled by the control unit by changing the operating time of the screw conveyor. The initial loading of the screw conveyor with pellets (filling the screw conveyor pipe) is carried out when the screw conveyor plug is connected to a normal 230V/50Hz outlet. As pellets start to fall through the flexible connection, the plug is shifted to the burner.

Important:For ensuring normal operation of the burner a 20 Pa chimney draught is required. After starting the burner, wait for about 3 hours for the chimney to be warmed up and measure the draught. Install additional chimney fan (controlled by the control unit of the burner) if necessary.

4. Maintenance and operation of the pellet burner

Requirements for the characteristics of the fuel, which is used for operation of a pellet burner SMВ 50

The following table shows requirements for the characteristics of wood pellets utilized in automated pellet burner.

Parameter / uom / Value
Typical grain size / mm / 6-8
Recommended calorific value of fuel (lower calorific value) / МJ/kg / >17.2
kWh/kg / >4.7
Category of wood pellets / А
Ash content / % / See Table 2
Humidity / % / Max 8-10%

Table 1

The following table shows classification of wood pellets depending on their physical parameters - according to an evaluation methodology applied by Mareli Company;

Table 2

A d - ash content in dry mass

DU - Mechanical resistance

Pellets are stored in a pellet hopper at a dry and ventilated place.

Appendix 2

Technical data

Mareli Pellet Burner SMB 50
Rated power / kW / 10-50
Power consumption during ignition / W / 350
Power consumption during operation / W / 60
Height H / mm / 230
Width W / mm / 230
Depth D / mm / 643
Screw conveyor size / mm / 1500/75
Efficiency / % / 92
Necessary chimney draught / Pa / 20
Weight / kg / 25
Fuel type / Pellets Φ6-Φ8
Average fuel consumption / kg/h / 1.3 – 8.0
Noise Level / dB / 56 ±3 dB
Power supply / V/Hz / 230/50
Performance in ambient temperature / ºC / from 5º to 40º
Humidity at 30°C / % / 85

Basic information on the joint operation of the system which the automated pellet burner applies to depends on:

Heat output to which the burner is set;

The degree of contamination of heating surfaces of the heater, for which it is intended for.

The seal degree of the door and covers of the combustion chamber (condition of sealing ropes);

Chimney draught;

Good chimney draught is essential for proper functioning of the heating system. Boiler capacity and economical operation depend largely on it. The heater can only be connected to a chimney with a good draught.

Attention!

Suffocation hazard due to lack of oxygen in the installation room.

• Ensure sufficient fresh air supply through holes out.

Risk of injury/damage to equipment due to lack of combustion air can lead to tar and noxious gas formation.

• Ensure sufficient fresh air supply through holes out.
• Notify the user of the installation that these holes must remain open.

NOTES:

When using the circulation pump for the transmission of heat energy from the hot water boiler to the heating system it is not recommended that the return („cold“) water's temperature is lower than 60oC, since a local (in the heat exchanger of the boiler) overcooling of flue gases and condensing water vapour, which is one of the end products of fuel combustion, is possible.

Continued operation of the burner is not recommended when the heat rating is less than 50% of the nominal, since such operating modes are not efficient and not cost effective, unless the combustion process is not set up exactly in such operating mode.