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Operation
and
Maintenance
Manual
Operation and Maintenance Manual - EN
www.atmos.cz
Operation and Maintenance Manual - EN
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-3
CONTENTS
1. General information 4
Introduction 4
Application 4
Technical specifications 4
2. Design 5
Description 5
3. Burner accessories 9
4. Safety, burner installation and commissioning 10
Safety and connection of the burner to the boiler 10
Design and technical measures for increasing safety 10
Basic measures of the opening for installation of the burner into a boiler 11
5. Type of environment and location of the boiler with the burner in the boiler room 12
6. Chimney 12
7. Flue gas duct of the boiler 13
8. Fire protection within the installation and use of heat appliances 13
9.
Connection of DC40SPT, DC40GSP boilers with two accumulation tanks (connected in series)
for burner control on the basis of TS and TV sensors, control of the boiler, burner and
boiler pump based on TSV and TK sensors 15
Function for automatically starting the burner after the wood burns out 15
10.
Connection of DC40SPT, DC40GSP boiler with two accumulation tanks (connected in parallel)
Boiler, burner and heating system operation is controlled from the ACD 03 (04) controller.
Function for automatically starting the burner after the wood burns out. 16
11.
Connection of DC40SPT, DC40GSP boiler with accumulation tank for burner control
on the basis of TS and TV sensors, control of the boiler, burner and boiler pump based
on TSV and TK sensors
Automatic burner start function after the wood has burned out. 17
12. Connection of the boiler and burner to the electric mains 18
13.
Connection diagram of the electronic unit AC07X with AC07X-C additional module
for DC40SPT, DC40GSP boilers 19
14.
Electric wiring diagram connection of the DC40SPT boiler, model AC07X with 6-pin connector
on the boiler and the AD03 module for controlling the boiler exhaust fan and the pump
in the boiler circuit, with control of the servo damper for the combustion air supply (R3 and R4)
20
15.
Electric wiring diagram connection of the DC40GSP boiler, model AC07X with 6-pin connector
on the boiler and the AD08 module for controlling the boiler exhaust fan and the pump
in the boiler circuit, with control of the servo damper for the combustion air supply (R3 and R4)
22
16. Electric diagram of the burner ATMOS A45
- for DC40SPT, DC40GSP boilers
- model AC07X - (R, R2, R3, R4, sensors TV, TS, TK, TSV)
- with additional module AC07X-C - (R5, R6) and the AD04 module for controlling the servo damper
at the combustion air inlet to the burner 24
17. Commissioning 25
18. Control and setting of the burner 28
Display and control panel 28
Passwords and their functions 29
PARAMETERS menu 30
Setting the required power and combustion quality: 31
INFORMATION menu 55
TESTING menu 56
19. Information - error messages - troubleshooting 57
General troubleshooting 57
Table of error messages on the display - alarms 57
If you are not sure, proceed as follows: 62
If no problem has been found, reset the regulation AC07X by the RESTART command. 63
If the system is working, but you are not satisfied with its function, proceed as follows: 63
21. List of spare parts 66
22. Expanded view of the burner A45 for GSP and SPT boilers 67
GUARANTEE TERMS 68
RECORD OF INSTALLATION OF THE BOILER AND BURNER
69
ANNUAL INSPECTIONS RECORDS 70
RECORDS OF GUARANTEE PERIOD AND POST-GUARANTEE PERIOD REPAIRS 71
EN
www.atmos.cz
4-EN
Operation and Maintenance Manual - EN
1. General information
WA R N I NG - Before starting the burner you must get thoroughly acquainted with all provisions
of this manual. The manufacturer is not liable for damages caused by operation, maintenance
or wrong setting of the power of the burner that will cause heat overloading of the burner.
Introduction
This manual is intended for all users and contains information necessary for the installation,
start-up, maintenance and safe operation of the burner.
We recommend you to pay great attention to the safety regulations. Interventions that require
removal of some parts should be carried out carefully by qualified authorized experts. Repairs and
settings that are not described in the manual should not be carried out at all.
Application
The burner is designed for ATMOS DC40SPT, DC40GSP
Technical specifications
Name: ATMOS A45
Prescribed fuel: high-quality (white) wooden pellets with the diameter of 6 to 8 mm, length of 5 to
25 mm and calorific value of 16 - 19 MJ.kg-1
Nominal heat input of the burner: 49 kW
Minimum heat input of the burner: 8,5 kW
Maximum heating surface of the boiler that the burner may be installed in: 5 m2
Fuel bin: not part of the delivery - The recommended tank volume is 1000 l
Fuel feeding: with an external worm conveyor type DRA50
Burner control: with an
AC07X
electronic control unit that controls the operation of the external
conveyor, two ignition spirals and the fan in accordance with requirements of the boiler and the
heating system. The electronic system is protected with the safety thermostat of the boiler, safety
thermostat at the pellet supply to the burner, the fan speed transducer and the flame sensing photocell.
The operation of the burner is indicated on the electronic control display.
Power supply: 230 V / 50 Hz
Maximum power input at the start with one ignition element: 480 W - normal setting
Maximum power input at the start with two ignition elements: 1042 W - special functions
Average power input at the nominal heat input operation: 47 W
Average power input at the minimum heat input operation: 29 W
Average heat input in the standby mode: 3.3 W
Prescribed fuse protection of the burner with the boiler: 6.3 A
Acoustic pressure level (noisiness): 47 dB
Burner weight: 26 kg
Burner dimensions, WxHxD: 31 x 52 x 76 cm
Minimum dimensions of the combustion chamber: diameter / width = 400 mm, length / depth = 400 mm
Minimum ashpan space of the boiler: must correspond to operation at the nominal output for at
least one week (min. 4 l)
Minimum vacuum in the combustion chamber of the boiler: 2 Pa
Min. protection against inadvertent opening of the boiler chamber (door): with a safety screw
(except DxxP)
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-5
2. Design
Description
Heating with pellets with the use of the ATMOS A45 pellet burner has a lot in common with
natural gas or oil heating. However, there is a difference that burning of pellets produces a certain
quantity of ashes that must be removed from the burner and boiler in an interval to avoid impairment
of efficiency or affecting the functionality of the burner.
The ATMOS A45 pellet burner is supplied with automatic fuel ignition as standard. The assembly
of the burner, external conveyor and fuel bin work completely automatically during operation and
is controlled by an electronic control unit with the use of a flame sensor (photocell). In the burner
body the fuel and combustion air are supplied in such a way to ensure maximum efficiency and
environment-friendliness of fuel burning.
Only high-quality pellets with the diameter of 6 to 8 mm and length of 5 to 25 mm should be fed
into the burner. Pellets made of soft wood without bark, called white pellets, are considered as
high quality pellets.
Ashes are normally removed from the burner through the open door once every 7 to 30 days as
necessary. It is recommended to thoroughly clean the inner parts of the burner once a year; for this
operation the burner should be removed from the boiler. For ideal cleaning of the combustion chamber
(pot) of the burner you can use a special vacuum cleaner or a poker.
The burner consists of the following parts:
CAUTION -
For the A45 burner DRA50 external shaft conveyors with the length of 1,7,
2,5, 4 and 5m with the diameter of 80 mm
are designed
or compact set of AZPD tank with
DRA25 conveyor
.
1 - End switch
2 - Safety thermostat 95 °C
3 - Display of the electronic unit of the
burner
4 - Combustion chamber (mouth) of the
burner
5 - Socket for the external conveyor
6 - connector for additional cable (R3 and R4)
7 -
connector for interconnection cable between the boiler
and the burner (power cable) (L1, L2, N, PE, R a R2)
8 - connector for connection of TS, TV, TK and
TSV sensors
3
6 5
2
4
1
7 8
EN
www.atmos.cz
6-EN
Operation and Maintenance Manual - EN
Fig. 4 - Disassembled plate with the ignition
spirals
Fig. 2 - Removable combustion chamber - must
be regularly cleaned
Fig. 3 - Uncovered combustion chamber with
openings behind which the ignition spirals are
installed
Fig. 5 - Electronic control unit with keys, bottom
terminal board (1-18), upper distribution frame
for connection of TS, TV, TK, TSV sensors and
photocells with AC07X-C (R5, R6) additional
module
Fig. 1 - Combustion mouth of the burner
Fig. 6 - Photocell - be careful about its proper
orientation - we recommend you to clean it at
least once a year new fotocell / old fotocell
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-7
Fig. 7 - Burner fan with an air ap
Fig. 9 - Fan speed transducer
Fig. 8 - End switch with a special stop
Fig. 10 - Safety thermostat on the pellet supply
pipe, 95 °C
Fig. 11 - special servo controlled ap Fig. 12 - burner – two 6-pin connectors: left for
power, right for sensors, a 2-pin connector for
additional cable (R3 and R4) and a socket for
conveyor
EN
www.atmos.cz
8-EN
Operation and Maintenance Manual - EN
Fig. 13 – View of the AD04 module for special
functions of the burner
Fig. 15 a view of the ue gas temperature sensor
TSV at the side of the ue gas duct of a
DC40SPT,
DC40GSP
boiler
Fig. 14 – View of the water temperature sensor in
the pocket of the accumulation tank (TV and TS)
Fig. 16 – View of the water temperature sensor
TK in the boiler pocket DC40SPT, DC40GSP ty-
pes
Fig. 17 – High-quality wooden pellets – white
without black dots (bark)
Fig. 18 – Poor-quality wooden pellets – dark with
bark (with black dots)
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-9
3. Burner accessories
Accessory - burner part
Stop for the end switch 1 piece
Bushing for various applications – formerly for TS and TV sensors 2 pieces
Interconnection cable between the boiler and the burner with a connector (6x1.5 mm)
1 piece
Operation and Maintenance Manual 1 piece
Fuse - type F 3.15A/1500A/5x20mm (ignition spirals) 2 pieces
Fuse - type F 0.8A/1500A/5x20mm (conveyor) 1 piece
Fuse - type F 1.0A/1500A/5x20mm (ventilator - possible replace with F 0.8A) 1 piece
Accessories that are not part of the burner and can be purchased separately:
DRA50 pellet conveyor with the length of 1,7 m and diameter of 80 mm (40 W) - CODE: H0039
DRA50 pellet conveyor with the length of 2.5 m and diameter of 80 mm (40 W) - CODE: H0037
DRA50 pellet conveyor with the length of 4 m and diameter of 80 mm (40 W) - CODE: H0004
DRA50 pellet conveyor with the length of 5 m and diameter of 80 mm (40 W) - CODE: H0005
Water temperature sensor with a 5 m cable (range - 20 ...+ 110 °C) - type KTF 20
(2x KFT 20 – included in DC40GSP, DC40SPT boiler packing – factory setting) - CODE: P0431
Flue gas temperature sensor AGF2 (0...+400 °C) - CODE: P0413
(included with a DC40GSP, DC40SPT boiler – factory setting)
Pocket for a flue gas sensor to be positioned in the flue gas duct, 3/4“ x 70 mm - CODE: V0524
AD03 module for control of the boiler fan and the pump in the boiler circuit (solar)
- CODE: P0436
(
(included with a
DC40SPT - factory setting)
AD04 module - for special functions of the burner - CODE: P0446
(included with the burner – factory setting)
AD08 module - for special functions of the burner
- CODE: P0450
(included with a DC40GSP boiler – factory setting)
Cavity with tin for extension of conductors (sensors) - CODE: P0445
EN
www.atmos.cz
10-EN
Operation and Maintenance Manual - EN
4. Safety, burner installation and commissioning
Safety and connection of the burner to the boiler
WA R N I NG - Before starting the burner you must carefully read all the provisions of this
manual. At the same time you must observe all general safety regulations for work with
heating equipment resulting from the valid legislation.
The premises where the equipment will be installed must comply with all fire protection regulations
in accordance with valid standards and laws.
The equipment must be positioned in such a way to ensure access for cleaning and removal of
ashes not only from the burner, but also from the boiler, flue gas duct and chimney.
The burner must be installed to the boiler over a sealing cord, soft Sibral sealing or another
insulation and sealing material to prevent flue gas from escaping along the burner to the boiler
room. Under one of the nuts with the use of which the burner is attached to the boiler a SPECIAL
SHEET-METAL PART - END SWITCH STOP must be positioned. It is used to compress the
end switch that monitors the proper position of the burner on the boiler. This protective device
must not be omitted in any case as it is directly related to fire safety.
The connection between the burner and the boiler must be properly tightened to prevent flue gas
from escaping to the boiler room.
During the installation you must make sure that the pellets can freely fall through the hose to the
burner. The connections between the hose, burner and conveyor must also be properly tightened.
Design and technical measures for increasing safety
The ignition and combustion process is controlled by the electronic control unit by means of the
flame sensor - photocell. If the sensor does not sufficiently see the flame during operation, it will
automatically put the burner out of operation.
The electronic control unit senses the speed of the burner fan and at any problems of the fan it
automatically puts the burner out of operation.
On the burner frame there is an end switch and end switch stop that does not make it possible to
start to burner if the burner is not properly fixed to the boiler (e.g. after cleaning of the burner).
If during normal operation of the burner the end switch gets disconnected, the burner will be
automatically put out of operation. If at the start after two attempts with the fuel supply and one
attempt without the fuel supply the pellets are not ignited, the burner will be automatically put out
of operation.
If during normal operation of the burner the fuel bin runs out of pellets, the burner will try a new
start and subsequently will be put out of operation. After replenishing pellets in the fuel bin and
drawing pellets to the conveyor you can start the burner by merely turning off and on the burner
switch on the boiler panel.
The flexible transparent hose between the burner and external conveyor is made of special material
that melts at high temperatures and the hose will change to a spring that will separate the burner
from the fuel bin.
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-11
The safety thermostat - located on the fuel supply pipe of the burner, will shut down the burner
if its temperature is higher than 95 °C. Thus, it protects the burner from return ignition of pellets
in the conveyor and at the same time from operation with clogged flue gas exhaust from the boiler
(e.g. in case of a failure to remove dust from the boiler, flue gas duct and chimney). The safety
thermostat will also put the burner out of operation in case the hose between the burner and
conveyor gets perforated to prevent flue gas from escaping to the boiler room.
Servo (actuator) controlled special flap of the burner – situated between the body and the fan
of the burner. It prevents false air suction into DC40SPT, DC40GSP boiler through the pellet
burner while burning wood.
INFO - After any shutdown of the burner when an error message (ALARM) appears on
the display it is necessary to immediately find the cause and remove it. After removing the
cause of the error you can start the burner by merely turning off and on the burner switch,
which is located on the boiler panel.
Basic measures of the opening for installation of the burner into a boiler
In DC40SPT, DC40GSP boilers Sibral mineral wool sealing is used under the burner (code: S0140).
Explanatory notes:
1. A45 burner
2. Decorative nut M10
3. End switch stop
4. Sealing
5. Lid
A25 - M8
A45 - M10
A25 - 220 mm
A45 - 277 mm
A25 - 168 mm
A45 - 207 mm
A25 - 185 mm
A45 - 209 mm
A25 - 80 mm
A45 - 101 mm
A25 - 105 mm
A45 - 108 mm
4
32
1
EN
www.atmos.cz
12-EN
Operation and Maintenance Manual - EN
5. Type of environment and location of the boiler with the
burner in the boiler room
Boilers with a pellet burner
may be used in the AA5/AB5 basic
environment in accordance with
the ČSN3320001 standard. Boilers
must be installed in a boiler room
with guaranteed sufficient supply of
combustion air. It is unacceptable to
locate boilers on residential premises
(incl. corridors). The cross-section of
the opening for supply of combustion
air to the boiler room must be at least
350 cm2 for boilers with an output of
5 - 45 kW.
6. Chimney
A boiler with a burner must always be connected to the chimney vent with consent of the
responsible chimney maintenance company. The chimney vent must always produce sufficient draught
and exhaust flue gas to the free atmosphere in virtually all operation conditions. For proper function of
boiler the separate chimney vent must be properly dimensioned as the combustion, output and service
life of the boiler depends on its draught. The draught of a boiler directly depends on its cross-section,
height and roughness of the inner wall. No other device may be connected to the chimney to which a
boiler is connected. The diameter of the chimney must not be smaller than the outlet on the boiler
(min. 150 mm). The chimney draught must achieve prescribed values (see the technical specifications
in the boiler manual). However, the boiler must not be excessively high so as not to reduce the efficiency
of the boiler and not to disturb its combustion (tear the flame). In case of too strong draught install a
throttling flap or draught reducer in the flue gas duct between the boiler and the chimney.
Guideline values of dimensions of the chimney cross-section:
20 x 20 cm height 7 m
Ø 20 cm height 8 m
15 x15cm height 11 m
Ø 16 cm height 12 m
The exact determination of chimney dimensions is defined by the ČSN 73 4201 standard.
The prescribed chimney draught is specified in the “Technical data” chapter of the manual
of the particular boiler.
CAUTION - The draught of the chimney during operation must ensure the minimum
vacuum of 2 Pa in the combustion chamber of the boiler.
1. Chimney
2. Flue gas duct
3. Boiler
4. A25 burner
5. External conveyor
6. Bin (500 l)
Operation and Maintenance Manual - EN
EN
www.atmos.cz EN-29
MAIN menu
PARAMETERS
this is a separate menu where individual parameters and functions can be set
depending on the type of the boiler and heating system and the authorization level.
INFORMATION – this is a separate menu where you can view the current status of individual
devices and elements on the A45 burner.
PASSWORD – this is a very important parameter, designed only for service engineers. After entering
the required password the service engineer is allowed to change some parameters
depending on the authorization level.
Basic authorization levels: User, service engineer (installer), manufacturer
Accessible parameters depending on authorization:
Customer: T1, T4, T6, S16, S17, S18, S19, Restart, Language
Service engineer:
T1,T2, T4, T5, T6, T7, T8, T10, S1, S2, S3, S6, S11, S12, S13, S14,
S15, S16, S17, S18, S19, S24, S26, S27, S28, S29, S30, S31, S32, S33, S34, S35, S36, S37,
S38, S39, S40, S41, S42, S43, S44, S45, S48, S49, S50, S51, S52, S53, S54, S55, S56, S57,
S58, S59, S60, S61, S62, S63, S64, S65, S66, S67, S68,
OffsetTS, OffsetTV, OffsetTK,
OffsetTSV, Reset, Restart, Language
Manufacturer: all
CAUTION - The customer is expressly prohibited to change parameters
or functions of the burner without consent of the manufacturer or service
engineer although some of them are not directly protected with a password.
Otherwise the manufacturer reserves the right to decline the guarantee due to an
inexpert intervention into the burner.
Particular passwords are production secret of the ATMOS Company and
the service engineer (installer) is not authorized to provide them to anybody
without the manufacturer’s consent.
INFO - After replacement of any ignition spiral the service engineer must enter
the password: 1234, which will reset the check algorithms for the ignition
spirals. Without entering of this password the ignition spirals will never be started
(activated).
Passwords and their functions
Password Authorization / function
Service engineer
Manufacturer
8118 Switching o and on the fan speed control
Locking and unlocking all parameters
1234 Reset of check algorithms for the ignition spirals
29


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