Trianco GREENFLAME 55 Benutzerhandbuch

GREENFLAME 55/85/100/125/199 kW

Commercial Wood Pellet Boiler System

INSTALLATION, OPERATION AND

SERVICING INSTRUCTIONS

Please read these instructions carefully before installing

and operating this appliance.

TO BE RETAINED BY THE HOUSEHOLDER

TR Engineering Ltd

TR Engineering Ltd operates a policy of continuous development and improvement of our

products and welcome any feedback from our Customers. Please forward your comments

to :

TR Engineering Ltd

Unit 7 Newton Chambers Way

Thorncliffe Industrial Estate

Chapeltown

Sheffield

S35 2PH

United Kingdom

Tel: 0114 2572300

Fax: 0114 2571419

E-mail: info@trianco.co.uk

Web: www.trianco.co.uk

This symbol is used to

highlight important

information

SAFETY NOTICE

PLEASE READ THIS ENTIRE MANUAL BEFORE YOU INSTALL AND USE YOUR

NEW BOILER.

THIS APPLIANCE MUST BE INSTALLED BY APPROVED AND COMPETANT

PERSONNEL ONLY. FAILURE TO INSTALL THE APPLIANCE IN ACCORDANCE

WITH THE MANUFACTURERS INSTRUCTIONS AND LOCAL BUILDING

REGULATIONS AND BY-LAWS WILL INVALIDATE THE WARRANTY.

Manual Edition : GREENFLAME Commercial Series May 2012

Table of Contents

1General Information 5

1.1 Important note for efficient and low-emission operation

of your Greenflame biomass heating system. 6

2 Safety Information 7

2.1 Greenflame Safety Guidelines 7

3 Greenflame System Features 9

3.1 Greenflame Boiler Features 10

3.2 Fillomatic Pellet Transport Features 11

3.3 Self Cleaning Burner Features 12

3.4 Control System 13

4 Installation 14

4.1 Setting out the boiler location 14

4.2 Unpacking 15

4.3 Assembly 16

4.4 Flues 17

4.5 Flue Pipe 17

4.6 Flue Requirements 19

4.7 Air Supply 22

4.8 Water Connections 24

4.9 Electrical Connections 28

4.10 Self Cleaning Burner Electrical Schematic 29

4.11 Boiler Control Panel Electrical Schematic 30

5 Digital Control System 31

5.1 Buttons 31

5.2 LED’s 32

5.3 LCD Display 32

5.4 Power Display 34

5.5 Error Messages 34

5.6 Menus 35

5.6.1 User Menu 35

5.6.1.1 Power Menu 37

5.6.1.2 Boiler Thermostat Menu 37

5.6.1.3 Chrono Menu 37

5.6.1.4 Time & Date 37

5.6.1.5 Monitor 38

5.6.1.6 Load Menu 38

5.6.1.7 Language Menu 38

5.6.2 Keyboard Menu 39

5.6.3 Secret Menu 39

6 Troubleshooting 40

7 How Does My Wood Pellet System Work 43

7.1 Sensors 43

7.2 Combustion Process 43

7.3 What Happens When I Turn On My Boiler 45

7.3.1 Check-Up 45

7.3.2 Pre-Heating 45

7.3.3 Pre-Load 45

7.3.4 Variable Ignition 46

7.3.5 Stabilisation 46

7.3.6 Run Mode 47

7.3.7 Modulation Mode 47

7.3.8 Standby / Extinguishing / OFF 48

7.3.9 Pump Management 48

7.3.10 Extinguishing When Boiler Is In The OFF State 48

8 Operation 50

9 Maintenance 51

10 Commissioning 52

11 Warranty Information 55

12 Fuel 56

13 Technical Data 57

13.1 Boiler Dimensions 58

13.2 Boiler Section 59

Table of Contents

1. General Information

Dear Customer,

We would like to congratulate you on choosing this high-quality product from TR

Engineering Ltd. The Greenflame range of wood pellet boilers for commercial / light

industrial applications are designed specially with aim of maximising efficiency, reduced

CO2 emissions, compact design for installation in the smallest of plant rooms and cutting

edge system management features with remote access through the cellular network for

remote routine maintenance, as standard. Due to the low-emissions and CO2-neutral heat

produced by renewable fuels, you are making a considerable contribution to the protection

of the environment and its resources.

You have also chosen a product with an elegant line, a refreshing design and perfect

workmanship. The outer surfaces require minimum care in day-to-day life and are easy to

clean. On the inside, however, is a carefully designed and ultra efficient heat exchanger

which has been developed from TR Engineering Ltd’s 40 years of boiler manufacturing

experience.At the centrepiece of the system is a self cleaning pellet burner which is at the

cutting edge of combustion technology and innovation which guarantees low emissions and

high efficiency by maintaining the combustion area in a clean condition. The mastermind of

the system is the TR Engineering Ltd Boiler Management System (BMS) control which sets

the standard in control engineering. The LCD display with generous graphics and clear-text

user management provides brilliantly simple and easy-to-use operation.

This new-generation control system together with the self-cleaning mechanism and the

automatic de-ash system makes sure that under normal operating conditions (except for

boiler maintenance) only occasional emptying of the ash box is necessary –no other tasks

are required. This instruction and maintenance manual contains all the information required

for trouble-free operation and handling of the system. Please read it carefully.And if you

still have any questions, please contact your sales partner. No claims for damages incurred

as a result of misuse of the safety, operating or maintenance notes can be accepted.

We wish you many years of heating pleasure with your new TR Engineering Ltd

Greenflame biomass heating system.

Best regards from your TR Engineering Ltd team,

We provide heating with a clear conscience!

1.1 Important note for efficient and low-emission

operation of your TR Engineering Ltd biomass heating

system.

For efficient and low-emission operation of your TR Engineering Ltd heating system,

please follow these instructions:

• Only use the fuels specified in this TR Engineering Ltd instruction manual. Only then can

a low-emission, economic and trouble-free operation of your heating system be

guaranteed. (Section 12)

• Carry out maintenance and cleaning work recommended by TR Engineering Ltd on your

heating system at regular intervals. Details can be found in the instruction manual in

section 9. By doing this, you will not only be ensuring the operational reliability of the

heating system but also its efficient and low-emission operation. The best way of caring for

your heating system is by taking out a TR Engineering Ltd maintenance contract. Your TR

Engineering Ltd Agent will be happy to give you information about this.

• Your TR Engineering Ltd heating boiler is adjustable within an output range of 30 to

100% of the boiler’s rated power.

A buffer tank / thermal store is recommended and should be correctly sized by your

heating engineer. This ensures efficient and low-emission operation of your TR

Engineering Ltd heating system.

2. Safety Information

In the design of the TR Engineering Ltd biomass system, special attention has been

placed on safety. However, since the system contains elements which can reach high

temperatures, it is essential that several simple, but important rules, are adhered to by

the user.

2.1 TR Engineering Ltd Safety Guidelines

Please read the instruction manual carefully before

starting the system for the first time, and pay special

attention to the safety instructions. If something is not

clear, please look it up in this operating manual.

•Ensure all maintenance doors are closed tightly.

•The boiler room should always be locked.

•When opening the boiler door make sure that no flue gases or sparks come out. Never

leave the boiler door open without supervision.

•Make sure that there is sufficient supply of fresh air to the boiler room and avoid frost.

•Carry out maintenance work regularly or call your Agent to arrange to have this done.

•Always make sure the power is isolated when carrying out maintenance work or

opening the control system.

•Combustible materials (including fuel) should not be stored in the boiler room, other

than the fuel that is required for the operation of the boiler.

•Fire extinguishing apparatus should be located near the door of the boiler room.

•The boiler may only be run on wood pellet fuel as prescribed in the fuel section of this

manual.

• Do not carry out any unplanned changes to the settings; do not modify the system in

any way without first consulting your local dealer.

• The boiler should be switched off the before refilling the fuel silo using a pump truck for

blowing pellets into the storage hopper.

• In the case of any problems contact your Agent or for Troubleshooting visit

www.trianco.co.uk .

Legislation stipulates certain devices should be used with automatic pellet boilers which

prevent back-burn along the conveying troughs into the fuel store. The following safety

precautions are implemented in TR Engineering Ltd systems:

• A cell wheel is located between the head of the conveying auger and the combustion

area thus helping to prevent back burn.

•If the temperature in the pellet feed pipe exceeds an pre-determined safety

temperature the a high temperature safety thermostat will send a signal to the controller

that a high temperature has been reached and will initiate a safety shut down sequence.

HEALTH AND SAFETY PRECAUTIONS

Special care must be taken when installing the boiler such that the requirements of the

Health and Safety at WorkAct are met.

Handling

Adequate facilities must be available for loading, unloading and site handling.

Fire Cement

Some types of fire cement are caustic and should not be allowed to come into contact with

the skin. In case of contact wash immediately with plenty of water.

Asbestos

This boiler contains no asbestos. If there is a possibility of disturbing any asbestos in the

course of installation then please seek specialist guidance and use appropriate protective

equipment.

Metal Parts

When installing or servicing this boiler care should be taken to avoid the possibility of

personal injury.

In all cases the installation must comply with current Building Regulations, LocalAuthority

Bye-laws and other specifications or regulations as they affect the installation of the boiler.

It should be noted that the Building Regulations requirements may be met by adopting the

relevant recommendations given in British Standards BS 8303, BS EN 15287-1:2007 as an

alternative means to achieve an equivalent level of performance to that obtained following

the guidance given in Approved Document J.

Please note that it is a legal requirement under

England and Wales Building Regulations that

the installation of the boiler is either carried

out under Local Authority Building Control

approval or is installed by a Competent Person

registered with a Government approved

Competent Persons Scheme. HETAS Ltd

operate such a Scheme and a listing of their

Registered Competent Persons can be found

on their website at www.hetas.co.uk.

3. Greenflame System Features

The data plate contains important information on the type designation of the

appliance. You will find this on your system mounted on the control panel cover .

The boiler is located on the left hand side of the unit with the burner located

underneath the integral storage hopper.

The fuel is loaded in the integral hopper which has a capacity of 125 kgs, the

TR Engineering Ltd Fillomatic pellet transport system which will fill the integral

hopper from a remote bulk storage silo.

RemovableAccess Panel

Vacuum Cyclone Unit

Ash Containers

3.1 Greenflame Boiler Features

The heat exchanger has been designed and developed to provide maximum efficiency

and combustion quality as well as not having to compromise on space. The compact

nature of it’s design has allowed the integral hopper to be incorporated as part of the

overall unit. The secondary heat exchanger is cleaned by mechanically operated

spirals which actuate vertically at pre-determined intervals to clean the tubes.

The drop feed burner is fitted to the side of the boiler where the flame fires in a

horizontal direction across the combustion chamber. The flue gases are then forced

to rise to the top of the chamber and are forced down behind the refractory board

which aids in the complete combustion of the flue gases. The flue gases must then

rise again through 12 vertical pipes before exiting through the flue chamber at the rear

of the boiler and are eliminated through the flue. The flue has an exhaust fan which

aids in providing the ideal draft conditions for the appliance to work efficiently and

safely. The flue fan is controlled automatically by a vacuum sensor in the combustion

chamber which will automatically adjust the exhaust fan to provide the optimum under-

pressure conditions in the combustion chamber.

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