PV350 pellet

burner
User
manual
DK9601
B1

PV350 pellet burner

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1 Contents
2
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

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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
8
Annex C Controller board description
.............................................................................................. 39

DK9601
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www.pelltech.
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Tables
Table
Connectors.....................................................................................................................
................... 12
Table User interface controls
..................................................................................................................... 15
Table Info menu description
...................................................................................................................... 17
Table Summary of burner statuses
............................................................................................................ 18
Table List of tests in TESTING
status........................................................................................................... 18
Table Cleaning
parameters.....................................................................................................................
.... 19
Table Loading parameters and
timing........................................................................................................ 19
Table Ignition parameters and timing
........................................................................................................ 20
Table Pre-burn parameters
........................................................................................................................ 21
Table Heat-up parameters
......................................................................................................................... 21
Table Power levels
......................................................................................................................................
22
Table Hold fame parameters
..................................................................................................................... 24
Table End burn parameters
........................................................................................................................ 24
Table End blow
parameters.....................................................................................................................
... 25
Table Burner setup parameters
................................................................................................................. 30
Table External temperature sensor types
.................................................................................................. 31
Table Controller board fuses
...................................................................................................................... 40
Table Controller connectors X1 and X2
...................................................................................................... 40
Table Extension board X1
........................................................................................................................... 41

Safety precautions

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 fammable materials must be stored near the burner.

Warnings

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.

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Description

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.
The 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.

PV350 pellet burner

Installation
Prerequisites

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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 fue gas fan should be installed.
The boiler must 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 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 814mm.
Unit
PV 350
D hole for burning
mm
290 mm
330
chamber neck

D1 flange bolt ring

diameter
D2bolt holes

mm

4x13
a

bolt hole offset angle

angle between bolt holes

90

Figure 1 Boiler door

mounting hole

deg

deg

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Installation
Burner

3.2 Burner

Install the burning chamber

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

Figure
2

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 fange). The tube of
internal screw must go
through hole on the back
wall of burning chamber.
Figure
3

The tips of the igniters must

reach
as 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.

Figure 4

Check igniter positioning

in the burning chamber.

Figure 5

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Installation
Water sprinkler

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 sprinkler

Water 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 flled 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 fre 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.

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Installation
External auger

Figure 7 Sprinkler installation

3.4 External auger

The external auger transports pellets from the pellet container to the burner. The
burner controls the
work of the auger. The auger is connected to the burner with a special hose ( 80),
which is made from
easily
melting material
that acts as a safety measure against back-burning. PV350i
pellet burners
fuel
consumption 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. The
recommended minimal horizontal distance is 20cm.
The distance between the input of the burner and the exit tube of the auger
must be at least
60cm vertically recommended distance is 80-200cm.

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Installation
Pellet storage

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

Figure 8 External auger installation

3.5 Pellet storage

Pellets 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. Reflling 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.
Internal 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.

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Installation
Electrical connections

Burner can be equipped with optional lambda sensor. It provides efficient

control for optimal performance concentrating emissions and burning
efficiency.
Table 1 Connectors

PV350
y1 Power input
y2 Power input
y3 Pellet auger
y4 Secondary fan
y5 Primary fan
y6 Lambda sensor
y7 External inverter
y8 Flue gas fan
y9 Ignitors

black/bro
wn
black
black
white
white
green
black
black
black

230V 16A
380V 4A
0,55kW 1,6A
0,15kW 0,65A
0,15kW 0,65A

2 x 320V 0,75kW
max 4A
500W
2,2A x 2

Y4

Y5
Y6
Y8

Y3
Y2

Y9

Y1

Figure 9 External connector markings

PV350 pellet burner

Installation
Commissioning

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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 suffcient 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.

TMP
3

TMP2
Figure 10 Extension board connection

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Operation and maintenance

User interface

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 Display
2 Yellow led, showing the fame in the burner
3 GSM modem antenna
4 Burner operation light, showing if the boiler thermostat sends a signal to the
burner.
5 Burner on/off switch with power indication light
6 green led, showing the fuel in the burner
Table 2 User interface controls

Button
OK
OK

Push
time
<3
s
>3
s

ESC
OK+ES
C

>3
s

Actio
n
Enter submenu
Confrm settings (in parameter edit mode)
Reset error, resume normal operation
Reset counter (only in counter screen in info
menu)back in menu by one level
Move
Cancel change (in parameter edit mode)
Burner reset

DK9601
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Figure 12 Main menu structure

Butto Push time

Action in the menu
n
OK
less then 3sec.
Moving forward
Confirm settings (when blinking)
OK
more then 3sec. Counter reset
ESC
less then 3sec.
Moving back
Cancel option (when blinking)
OK+ES more then 3sec. Burner reset
C

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Operation and maintenance

Starting and stopping

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.

Info menu
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

Pwr 00/350 kW
0

Tstn=181 C
0
T1=2685 C
Fan=10/132 14/15
speed. Actual

p=-0,2/-15Pa
pressure and -

Total=10 kg
Count=12,1 kg
180/254
U=25V68 I=0.0A
Ver=2.02c 19/12/12

Description
Current and maximum power. Max power can be
changed from main menu.
Tstn fre brick temperature, T1 - PT
10 primary fan actual speed, 13 primary fan setpoint
speed 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 2
Burning chamber pressure value. -0,2 is current measured
15 is setpoint. Controller regulates fue gas fan speed to
keep this
pressure. Depends also on PAR60 value.
Roughly the amount of pellets burnt. It is measured by
counting internal feeder rotations. Number is reset by
frmware upgrade
Roughly the amount of pellets burnt, resettable by user.
U - DC power voltage 25V68 means 25.68V. I Feeders
and/or grate motor current
Firmware version and date

4.2 Starting and stopping

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Operation and maintenance

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 frst run, external auger needs to fll
up with pellets. It can take as long as 20minutes.

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Operation and maintenance

Statuses and parameters

4.3 Statuses and parameters

PV1000agri 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 description

Waiting
Waiting signal from boiler thermostat
Testing
Thermostat is switched on, testing battery, fans, feeder, level
sensors, draft
Cleaning
Ash removing from burning chamber
Loading
Loading pellets with auger into burner and by feeder into
burning chamber
Igniting
Igniter is turned on, pellets igniting
Pre-burn
Flame is recognized, small amount of pellets is added by
feeder
Heat up
Burning chamber Ceramic is heated up
Burning
Normal burning operation
Hold fame
Thermostat is switched off, small flame is held alive
End burn
Thermostat is switched off, feeder is cleaned up
End Blow
Pellet coals in burning chamber is burned, flame has
disappeared
Waiting
Wait signal from boiler thermostat
Waiting
In this status, the burner is waiting signal from boiler thermostat. There is no limit
time for waiting
status. 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.

Testing
At Testing time, burner integrity and important device functioning is checked.
Table 5 List of tests in TESTING status

Test name

Battery
voltage
Feeder
current

Par
-nr.

Test
conditions
Battery loading is turned OFF and feeder

is turned
ON - voltage
must
be greater
than 12V
Par 46 Feeder
is turned
ON
feeder current
must be
smaller than Par 46

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Draft

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Operation and maintenance

Statuses and parameters

Par 62 All fans are turned on. Draft must be

under Par 62

Primary fan
Secondary
fan

Par 4
Par 4

Fan must rotate faster than 35rot = 38

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

Cleaning
In Cleaning cycle, the linear actuator moves the grates and pushes out from burning
chamber the ash
and 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 name

Cleaning
cycle
interval
Actuator
max.
current

Par

Value Unit

nr. 48 0...25 min

Par
0

Par 47 0.2..6 A

Test

Burning timeconditions
between Cleaning
cycles. If 0
then cleaning is turned off. If burned
longer then
Actuator
maximum current level. If
greater, then actuator is stopped and
cleaning cycle is started again.

Loading
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, fxed in parameter PAR24 (loading feed rot.)

Table 7 Loading parameters and timing

Par Nr.
Parameter name

Par 24 Loading feed

Defau
Unit
Comment
lt
value rot Feeder rotations neede to load pellets
35..4

0
Par 25 Loading 2 feed
Max loading
time loading
First
time
after manual
Auger
start

5
5
20
3

into
burningrotations
chamber.for
Depends
burner
rot Feeder
second from
loading.
min Maximum regular loading time
min Maximum loading time after manual
start.
s
Auger Start delay if no fuel in burner
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Auger stop

Auger Stop delay if fuel in burner

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Feeder start
Feeder stop

1
4

s
rot

Feeder Start delay if fuel in burner

Feeder rotations made without fuel
level
before 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 (frst) start because
extra time for external auger flling 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.

Igniting
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 Nr.
name

Parameter

Par 24 Fan @ignition

Max ignition
time loading
First
time start
Auger
Auger stop
Feeder start
Feeder stop

Pre-burn

Defau
Unit
Comment
lt
value
25
rps Primary fan speed at ignition

255
20
3
3
1
4

sek
min
sec
sec
sec
rot

Maximum ignition time

Maximum loading time after manual
start. Start delay if no fuel in burner
Auger
Auger Stop delay if fuel in burner
Feeder Start delay if fuel in burner
Feeder rotations made without
fuel level before stopped

The purpose of pre-burn status is to get correct burning and fame 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 Nr.
Parameter name

Par 8 Fan@ignition
Par 39 Fan 2 min
Par 41 Preburn time
Par 42 Preburn cycles
Preburn feed

Defau
Unit
Comment
lt
value
20
rps Primary fan speed at ignition and

7
25
6
1/2

preburn
rps Secondary
fan minimum speed. Used
at
Ignition, Preburn, Heat up, Hold
flamebetween pellet feedings at
s
Delay
Preburn of pellet feeding cycles at
x
Number
rot Preburn
Feeder turns at each feeding

Heat up
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 Nr.
Parameter name

Par 70 Heat up time

Par 71 Heat up power
Par 72 Heat up
temperature

Defau
Unit
lt
value
20
min Maximum cycle time

30...7
0500

kW
C

Comment

Depends from burner model

Ceramic 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 is
exceeded or stone temp. is higher than setpoint (PAR72)

Burning
This is main operation status in burner operation.

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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 fxed 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.

Table 11 Power levels

Power by burner model (kW)

Air
Power
parameters
Level level PV350
PV500
PV700
PV1000
type
Primary
1
main
100 Secondary
160
200
250

levelPower

Par
2
3
4
5
6
7
8
9
10
11

7
6
5
4
3
2
1

1virtual
main
virtual
main
virtual
main
virtual
main
virtual
main

Par 31200
120
150
240
170
280
200
320
220
360
250
400
270
440
300
480
320
520
350
560

250
300
350
400
450
500
550
600
650
700

Selected power

Par 17

2 2 2

Burning time
min

Figure 13 Burning at fxed power

320
400
470
550
620
700
770
850
920
1000

Par
Par
Par
Par
Par

2
3
4
5
6

Par
Par
Par
Par
Par

32
33
34
35
36

Power level can be selected in main

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

Power level

In Automatic Power mode (POWER = AUTO in main menu), the operation power is
selected
automatically depending of burning cycle length.
9
8
7
6
5
4
3

Max power (par 14)

OFF

Thermostat ON

New operation power

Operation power
Testing
Par 15

2
1

Par 15 Par 15

Burning
2 2 2

30

Loading
Igniting
End burn Pre-burn

Burning

Waiting

Time(min)

30

Figure 14 Burning when power selection = AUTO

Slow down

levelPower

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 fame. Slow
down
mode can be switched ON or OFF from main menu.

7
6
5
4
3
2
1

Thermostat ON

Thermostat OFF

Operation power
Par 17
Par 18

Burning

Burn end
Slow
down

Figure 15 Slow down mode

Burning

Slow down

OR
Hold flame

Status/time

Hold Flame
Hold fame mode purpose is to avoid burner start-up procedures every time when
burner is switched on from boiler thermostat. In Hold fame mode, minimum fuel
and air amount is delivered into burning chamber. Hold fame mode can be
switched from burner main menu to ON, OFF or AUTO. When Hold fame 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 fame mode is switched on.
If Hold flame is longer than Par 12, hold fame mode is turned off

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

Table 12 Hold flame parameters

Par

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Defa
ult
Nr.

Parameter
name

value

Par 8 Fan @hold

flame
Par
Fan 2 min
39

10
7

Par
11
Par
12

15
60

Hold flame ON
Hold flame OFF

Unit

Comment

rps Primary fan speed at hold flame

rps Secondary fan minimum speed. Used at
Ignition, Preburn, Heat up, Hold
flame
blow limit.
time.
min and
ShortEnd
Waiting
min Maximum time in Hold flame

End burn
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 Nr.
Parameter name

Par
26
-

End burn feed

Defau
Unit
Comment
lt
value rot Feeder rotations neede to clean
50..8

0
Minimum feed

20

feeder pipe. Depends from burner

model.
rot If
less rotations maid and boiler
thermostat is

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switched ON then back to Burning

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

Table 14 End blow parameters

Par Nr.
Parameter name

Par 9
Par
39

Fan @end blow

Fan 2 min

Par
-27

End blow time

Max. End
blow
time

Defau
Unit
lt
valu
20
rps Fan speed at End blow

7
2
15

Comment

rps Secondary fan minimum speed. Used at

Ignition, Preburn, Heat up, Hold
flame
blow
min and
TimeEnd
to blow
air time.
after flame is
disappeared
min Maximum
time when flame must
disappear in
End Blow

PV350 pellet burner

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Operation and maintenance

Cleaning

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 chamber
4. Remove the grates and clean them from any residues. Make sure all holes on
the grates 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. Put back the grates.
8. Close the boiler's door to finish the maintenance and turn the
thermostat to desired temperature.
The 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.

DK9601
B1

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Optional components
GSM Modem

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

Preconfiguring SIM card

Before inserting the SIM card to burner, SIM card
must be preconfgure. 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 burner
will be sent. The number of receiving contacts is limited to 5.

Figure 16 Modem

Insertion and removal of t

he 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 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 fgure
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, the

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Optional components
GSM Modem

SIM shall remain inside the GT863-PY. For removing the SIM, push the tool slightly
inside until the spring
Figure 17 SIM card
is released so that it pushes the
insertion
SIM
outside when the tool is retracted.

PV350 pellet burner

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Optional components
Flue gas fan

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

LED indicators
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 status
Device Status
permanently on
a call is active
fast interrupt
Net search / Not registered /
sequence
turning off
(period
0,5s,
Ton
1s)
Registered full service
slow interrupt
sequence
(period
0,3s, Ton
permanently
off 3s) device 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 fue gas fan. With fue gas fan
the burner can control and hold constant under- pressure.
Selected fue gas fan must provide the maximum fue gas amount and exceed the
pressure provided by boiler, cyclone and chimney. The fue gas capacity for burned
pellets can be calculated by simplifed formula.

PV350 pellet burner

p 28/

40

Optional components
Oxygen sensor

V Capacity range in
m/h
P Burner max power
in kW
Tfg

fue

gas

absolute

temperature in K Troom - room

absolute

temperature

in

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
fue 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 connected
to 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 fue 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.

B4 0 10V output for fan speed, must be connected with

inverter analog input.

5.3 Oxygen sensor

Following instruction is applicable for frmware version 3.86.
In order to use the oxygen sensor, two parameters must be set up:
Table 15 Burner setup parameters

Parameter
Nr

Description

Unit

Name

Value
Def

Min

Max

66 Oxygen type

0 no sensor
0
2
0
1 420mA = 025%
oxygen
2 420mA = 020%
67 Oxygen set
Desired oxygen level in fue
4
12
gas
6
For EP0006 sensor board, the PAR66 value must be 1. Some third party oxygen
sensors use 420mA
output 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 be
divided by 10 to get the real value. For example O2=113 means oxygen value
11.3%.

5.4 ERR output

Err output relay on the controller board adds various functions:
PAR50 value
1
2
3
4
5

Description
Normally open circuit. Only connected in ERROR state.
Normally closed circuit. Only disconnected in ERROR state
Connected circuit in PREBURN, HEATUP, BURN and HOLD FLAME
not used
not used

The relay is capable of switching 5A@250VAC

PV350 pellet burner

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40
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Optional components
External boiler temperature sensor (TMP1)

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 specifed in PAR17.

Table 16 External temperature sensor types

PAR53 Sensor
type
0
No
sensor

Temp min
-

Temp max
-

DK9601
B1

Functio
n
www.pelltech.
eu

PV350 pellet burner

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0..2.5V

0C (0.5V)

0..2.5V

0C (0.5V)

125C
(1.75V)
125C
(1.75V)

DK9601
B1

Optional components
External boiler temperature sensor (TMP1)

Internal overtemperature sensor

(PAR43)
Boiler temperature control

eu

PV350 pellet burner

Optional components
Ash removal system

31/
40
p

After activating THM, following row is displayed on INFO-screen:

o
T=22.3/705200
22.3 Actual measured temperature
70 Setpoint temperature (PAR54)
5 Setpoint hysteresis (PAR55)
- Shows if actual temperature is increasing or decreasing
o
200 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

Figure 19 Connecting ash removal control relay

Ash removal motor control

PV350 pellet burner

Annex A Parameters

p 32/

40

6 Annex A Parameters
Par
Nr

Parameter
name

Unit Burner Defaul Min.

model t

Max.

Par 1 FAN @level 1

rps

Par 2 FAN @level 3

rps

PV350
PV500
PV700
PV100
0
PV350

24
22
28
24
28

20
15
15
15
20

30
50
50
50
36

25
32
30
32
32
34
34

15
15
15
20
15
15
15

50
50
50
40
50
50
50

36
40
37
38
42

20
15
15
15
30

40
50
50
50
50

43
40
42
46
46
42
45

15
15
15
30
15
15
15

50
50
50
60
50
50
55

170

80

240

Par 3 FAN @level 5

rps

Par 4 FAN @level 7

rps

PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0
PV350

rps

PV500
PV700
PV100
0
PV350

Par 5 FAN @level 9

Par 6 FAN @level 11 rps

PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0

Description

Par 7 FAN START

Par 8 FAN IGNITION

rps

20

15

35

Par 9 FAN BURN

END
Par
FAN HOLD
10
FLAME
Par
HOLD FLAME
11
ON
Par
HOLD
12
FLAME
MAXPOWER
Par
MIN
13

rps
rps

20
10

10
7

40
14

min

15

30

min

60

30

90

Par
14

kW

100
160
200
250
350
560
700
1000

100/150/200/250/300/350
160/240/320/400/480/560
200/300/400/500/600/700
250/400/550/700/850/1000
100/150/200/250/300/350
160/240/320/400/480/560
200/300/400/500/600/700
250/400/550/700/850/1000

MAX POWER

kW

PV350
PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0

DK9601
B1

Initial speed for prim., sec. and

flue gas fan to start. 0=100%,
255=0%

eu

Par
15
Par
16
Par
17
Par
18
Par
21

POWER UP

min

15

120

POWER DOWN min

30

15

45

UP CYCLE

min

DOWN CYCLE

min

PELLET
NORMAL

g/n

Par
22

PELLET LIGHT

g/n

Par
23

PELLET HEAVY g/n

Par
24

LOADING
FEED

rot

PV350
PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0
PV350

Par
25
Par
26

LOADING 2
FEED
BURN END
FEED

rot

PV500
PV700
PV100
0

80
160
160
160
75
150
150
150
85
170
170
170
35
35
40
40
5

50
120
120
120
50
120
120
120
50
120
120
120
20
20
20
20
1

100
250
250
250
100
250
250
250
100
250
250
250
80
80
80
80
15

50
65
70
80

20
30
40
20

80
120
120
120

Par
27
Par
30
Par
31

END BLOW
TIME
FAN 2 ON

min

15

AUTO

ON/OFF/AUTO

FAN 2 @level
1

rps

PV350

15

80

Par
32

FAN 2 @level
3

rps

Par
33

FAN 2 @level
5

rps

Par
34

FAN 2 @level
7

rps

PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0
PV350
PV500
PV700
PV100
0
PV350

15
13
16
20
20
23
22
30
30
32
30
36
36
39

5
5
5
5
5
5
5
5
5
5
5
5
5
5

80
80
40
80
80
80
50
80
80
80
55
80
80
80

rot

PV350
PV500
PV700
PV100
0

PV500
PV700

DK9601
B1

AUTO for normal operation

eu

PV350 pellet burner

Annex A Parameters

p 34/

40

PV100
0
PV350
PV500
PV700

38
40
40
41

5
5
5
5

55
80
80
80

rps

PV100
0
PV350

FAN 2 BASE

PV500
PV700
PV100
0

42
46
46
43
46
100

5
5
5
5
5
65

55
80
80
80
55
140

FAN 2 MIN

rps

20

PHOTOCELL
LEVEL

90

50

100

Par
41
Par
42
Par
46

PRE-BURN
TIME
PRE-BURN
CYCLE
FEED
CURRENT

25

15

80

10

PV350

3,0

1,0

9,9

Feeder max. Current.

Par
47
Par
48
Par
50

GRATE
A
CURRENT
CLEANING
min
CYCLE
ERROR RELAY

PV500
PV700
PV100
0

6,0
6,0
6,0
2,0

1,0
1,0
1,0
0,2

9,9
9,9
9,9
6,0

Grates actuator max. Current

30

250

Cleaning cycle delay.

1 NO 2- NC 3 Pump control 4
not used
5 used for cleaning air control

Par
52
Par
53

SMS COUNT

Temp. Sensor action type: 0-no

sensor, 1- overheat sensor, 2temp. holding sensor

Par
54
Par
55
Par
58

TEMP LEVEL

70

30

105

Temp. Holding setpoint

TEMP HYST

10

Temp. Holding hysteresis

BASE
FREQUENCY

Hz

50

45

63

Par
60

FLUEGAS TYPE

Par
61
Par
62
Par
63

DRAFT SET

250

Power grid frequency (for triac

operated
fans)
Flue gas fan/ underpressure control
type: 0
- no-fan, no-control, 1 - no-fan but
controlled underpressure, 2 inverter, 3 Draft setpoint

DRAFT ERROR +Pa

10

20

Draft error level

DRAFT BASE

110

50

150

Draft sensor calibration value

Par
35

FAN 2 @level
9

rps

Par
36

FAN 2 @level
11

Par
38
Par
39
Par
40

TEMP TYPE

-Pa

Photocell sensitivity 100% = infinity

fame

Par
70
Par
71

HEAT UP TIME min

20

60

Max. Time for HEAT UP cycle.

30
40
50
70

10
10
10
10

100
100
100
150

Power at HEAT UP

Par
72

HEAT UP TEMP C

500

250

900

Stone temperature to reach at

HEAT UP

Par
73
Par
99

TEMP BASE

20

100

HEAT UP
POWER

BURNER TYPE

kW

PV350
PV500
PV700
PV1M

PV350 PV350/PV500/PV700/PV1M

PV350 pellet burner

p 36/

40

Annex B Burner status change logic

7 Annex B Burner status change logic

Status

Next Status

Change conditions

Waiting

Testing

Signal from boiler thermostat

Testing

Loading

All tests are done successfully

Battery error

Battery voltage is too low

Fan error

Fan does not reach 40* rps at pre-burn

Level error

The level sensor recognizes pellets in the feeder

Ignition

Loading (22* rot.) made by feeder

No pellets

Maximum loading time (5 or 20 min.**) is reached

Burn end

Flame detected and unknown start conditions

Loading

Loading 2 Ignition
Pre-burn
Ignition

Pre-burn

Previous state was ignition and rotations (3* rot.) made by

feeder
Previous state was hold fame and rotations (3* rot.) made
by feeder
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

Hold fame

Pre-burn cycles (3*x40*sec.) is done and continuous flame

is
recognized more than 10 seconds
Pre-burn cycles is done and fame is NOT recognized and
load 2 is NOT
done
Pre-burn cycles is done and fame is NOT recognized and
load 2 is done
NO Signal from boiler thermostat (hold fame is NOT
allowed)
NO Signal from boiler thermostat (hold fame is allowed)

Burn end

Maximum burning time (4 hours) is reached

Burn end ->

End
blow
->Level
Burn end ->
End
blow
->No
No fame

Fuel level is continuously detected in time of 8 feeder

rotations

Loading 2

Signal from boiler thermostat

Burn end

Max keep fame time (1 hour) is reached

Loading 2
No fame
Burning

Hold
fame

Burn end

Fuel level is not detected in 4 min.

No Flame more than 2 minutes

Burn end End blow

Burning
End Blow Waiting

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

Signal from boiler Thermostat, feeder made less
than 8 rot and previous state was BURN
No Flame 1 min. and RUN command is active

Stopped

No Flame 1 min. and RUN command is NOT active

No fame

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 Flame 1 min. and error is set From: Burn-> Burn end\->
End blow>No pellets
Power exist and RUN command is active

No pellets
No Power Wait
Stopped

Power exist and RUN command is NOT active

Burning

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

Power
RUN command is activated

Any other Waiting

PV350 pellet burner

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40

Annex C Controller board description

8 Annex C Controller board description

X1

ERR

X2

UAR
T

TMP1
FAN
TMP
2
TMP3
BU
T

PRO
G

FD
R
CONTR

BUT User interface buttons

CONTR LCD contrast and viewing angle adjustment
FAN Primary air fan speed feedback sensor
FDR Secondary air fan speed feedback sensor
TRS Fuel level sensor transmitter
(black marking) RSV Fuel level sensor
receiver (white marking) TMP1
External boiler temperature sensor

TRS

RSV

TMP2 Pressure sensor (via

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

GN
D
T
x
R
x
+5
V

Figure 20 Modem connector

Table 17 Controller board fuses

Fus
eF1
F2
F3
F4
F5

Rating
1A
1A
1A
3A quick
3A quick

Function
External
auger
Fan
Flue gas
fan
Igniter
Controller and feeder motor

Table 18 Controller connectors X1 and X2

X1
1
2
3
4
5
6
7
8
9
10

Description
Igniter
Igniter
N
Flue gas fan
Mains
transformer
Mains
transformer
Fan
L
Thermostat
External auger

X2
1
2
3
4
5
6
7
8
9
10

Description
Ash removal Ash removal +
Battery positive
terminalnegative
Battery
terminal
Flame
sensor
Flame sensor
Feed screw - (black)
Feed screw + (red)
Mains transformer
Mains transformer
DK9601
B1

eu

Table 19 Extension board X1

X1
1
2

3
+27.2V
4
Ground
5
Inverter F
6
7
Inverter CC
8
Inverter VIA
9
10
-

1
board

Figure 21 Extension board

Description
Lambda +
Lambda -

TMP1 not connected

TMP2 connected to TMP2 on main board
TMP3 connected to TMP3 on main