TABLE OF CONTENTS

1. General information ........................................................................................... 3

1.1. Transportation ............................................................................................. 3
1.2. Storage ...................................................................................................... 3
1.3. Control of burner's delivery ........................................................................... 4
1.4. Free space around burner ............................................................................. 4
2. Product description ............................................................................................ 5
2.1. Construction of burner .............................................................................. 5
2.1.1. REVO Mini and REVO Mini 35 models ........................................................... 6
2.1.2. REVO 44 to REVO 150 models .................................................................... 6
2.2. Quality requirements for pellets fuel .............................................................. 8
2.3. The pattern of the burner nameplate .............................................................. 9
2.4. Technical data of burner................................................................................ 9
2.5. Safety systems of burner .............................................................................13
2.6. Technical data of controller, description of functions and burner settings .............13
3. Installation ......................................................................................................14
3.1. Chimney ....................................................................................................14
3.2. Boiler / oven ..............................................................................................14
3.3. Fuel hopper ...............................................................................................17
3.4. External feeder...........................................................................................17
3.5. STB protection ...........................................................................................18
3.6. Boiler temperature sensor............................................................................18
4. Burner and feeder assembly ...............................................................................19
5. Additional connections and first start-up ..............................................................23
6. Exploitation and safety regulations ......................................................................23
6.1. Exploitation ................................................................................................23
6.2. Specification of the inspection intervals .........................................................25
6.3. Safety regulations referring to installation and exploitation of burner ...............25
6.4. Guarantee .................................................................................................26
7. Service of devices .............................................................................................27
7.1. Photosensor ...............................................................................................27
7.2. Electrical igniter replacement........................................................................28
7.3. Feeder pipe cleaning ...................................................................................28
7.4. Burner cleaning ..........................................................................................28
8. Reasons of improper operation ...........................................................................29
9. Electrical schemes ............................................................................................30
10. Reports ..........................................................................................................31
10.1. First start-up report ..................................................................................31
10.2. Inspection report ......................................................................................32
11. List of pictures and tables .................................................................................33
12. Notes ............................................................................................................34
 The author of this Manual is the company PELLASX Sp. z o.o. Sp.k.
The use of part or all of this manual in other publications is possible only with the
written permission of the author.

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 1. GENERAL INFORMATION

Read carefully the user’s manual before activating burner.

PellasX burner requires installation according to this user’s manual. Following advice included
in this USER’S MANUAL will guarantee safe functioning and installation of the device. All
doubts and ambiguities as to condition of equipment or given functions of parts of burner
should be reported to the seller in order to get explanations.

Installation of burner should be carried out by a service person who is authorized and
trained by the producer.

Improper installation may lead to loss of guarantee.

Every user of heating boiler devices should know and comply to all local rules of law.
Particularly before activating a heating installation in accordance with construction
law.
The seller does not bear any responsibility for burner installation which is not in
accordance to valid local regulations and for lack of required protocols and permissions.

1. Transportation

PellasX burner is packed in a carton with a divider (burner with a controller, mounting flange
and a feeder). The device must be carried in packaging, according to markings on the parcels.
During transportation it should be protected against unfavorable environmental conditions (snow,
rain, dust) and it should not be exposed to shocks, hits and the packaging should be protected
against damages.

Loading and unloading must be carried out in a way which does not expose the devices to shocks.
Improper loading, unloading and transportation (throwing, rapture sliding, crushing with other
heavy goods) can be a cause of damage to the product.

In case of damage of the packaging or product, the device should be subjected to control in
operation. In case when improper work of a fan or feeder motor is observed (loud work,
rubbing), possibly other faults, e.g. electronics (vanishing of characters on display of LCD display)
the burner should be sent to the service team in order to carry a reparation. Consignments
delivered by forwarding companies should be checked in presence of the courier when
the goods are delivered. In case of any incompatibilities a protocol should be prepared.

1.2. Storage

PellasX burner should be stored in environmental conditions in accordance to following

guidelines:
• Dry and draughty rooms, free from substances like gases, corrosive liquids and fumes,
which are harmful to burner. Burner and feeder can not be stored in rooms where artificial
fertilizers, chlorinated lime, acids, chemicals etc. are kept.

• Best storage temperature +5OC to +40OC. Relative humidity should not exceed 70%.
 • During storage, the device can not have direct contact with the floor. PellasX
burner until final assembly should be kept in carton and on a pallet. Burners can be
stored and transported in three layers maximum.
• In case when a burner is stored for over 2 years from its production date or in
environmental conditions not similar to above description, before installing it should
be subject to activating - test by an authorized service person. To testify proper quality
and safety of a burner, the above inspection will be documented by service person in the
guarantee card.

1.3. Control of burner’s delivery

Before commencing assembly activities check the following: condition of packaging, make
sure that there are no visible damages and if delivery is complete and not damaged.
Possible reservations and problems should be reported to the supplier immediately. He is
responsible for insuring the merchandise.

1.4. Free space around burner

According to local safety regulations referring to heating devices, provide free space around
burner, at least 1 m around boiler and space for service of burner.

The boiler room should be clean, dry and well aired. Airflow to the boiler should be at
least equal to exhaust of fumes through the chimney.

ATTENTION!
In order to minimize the risk
of fire is not allowed to store
flammable materials
near the burner
(minimal length 1m).

ATTENTION!

Controller and all devices cooperating with it should be installed on the boiler or its
area, in places where the temperature is the lowest (below 50⁰C). Electronic devices
operating at high temperature may be damaged or not work properly.

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 2. PRODUCT DESCRIPTION

PellasX is a brand under which since 2001 burners for biomass have been produced. These
products are characterized with stepless regulation of settings allowing for usage in all types
of ovens or heating boilers. In case when exchange of burner is done in an old boiler, then
it is not necessary to make changes in existing installation. Firing up, sustaining fire after
reaching preset temperature and feeding fuel is automatic.

The uniqueness of the REVO solution is the number of the design improvements used as compared
to the burners available previously with the rotary combustion chamber. This makes the operation
of PellasX REVO burners reliable and free of technical problems. Significant changes in the
technological parameters and the components used have been introduced which makes the
economic attractiveness and the environmental usability of the technology considerably better with
the burner being one of the most modern solutions in the world. The rotary combustion chamber
allows the automatic and constant removal of ash being the residue of the combustion process to
ensure high stability of the combustion itself. With such a solution not just the pellets, but also oat*
or fruit stones are high-efficiency fuels. The chamber structure ensures higher durability of the
bearings and facilitates the quick bearings replacement.

The unique solutions employed in the REVO line burners include:

• Hybrid Drive System. Fuel and air are supplied in a synchronized manner i.e. the fuel is supplied
according to the air supply rate and vice versa;
• Air Vane System ensures precise supply of air into the combustion chamber to improve the
chamber durability.
• Floating Pipe System- eliminates jams, seizures or locking caused by thermal stresses.
• Overpressure Combustion System. Air is supplied into the combustion chamber at the central
point to increase the flame spin and reduce the backfire.
• Wide range Lambda probe available for all units to improve the combustion process and reduce
the fuel consumption.

PellasX burners are used in households, bakeries, hotels, public utilities, schools and production
halls or warehouses. They are made of acid-proof steel and they are equipped in best quality parts
available on the market. The product which you have at your disposal is the highest quality,
most technologically advanced burner available on the market.

*Oat combustion reduces burner’s maximum power, yield in increasing fuel consumption (up to
50% more) and creates large amounts of ash.

2.1. Construction of burner

REVO line burners are divided into 2 groups:

1. REVO Mini and REVO Mini35 models
2. REVO 44 to REVO 150 models

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 2.1.1. REVO Mini and REVO Mini 35 models

Pic. 1. Construction of REVO Mini and REVO Mini 35 burners.

The burner is composed of the following subassemblies:

• Combustion chamber including: furnace (1) made of the highest quality steel heat-resisting
steel and a covering pipe (2),
• Blowing assembly including a cover made of non-combustible ABS V0 (3), X.PLUG socket
(4) located to the right of the burner where the controller plug is to be connected,
• Blowing system (5) located between the blowing assembly and the combustion chamber
with a quick-coupling in the upper part (6) to be attached to the feeding pipe by turning it
clockwise (detaching is carried out in the reverse direction). Afterwards the pipe which
connects the burner with the fuel feeder is connected to the quick coupling.

The cover of burner does not have any protruding nor sharp parts. It does not threat one’s health.
The temperature of burner’s cover during operation should not exceed 60ºC with exception of places
of raised temperature, i.e. bakery.

2.1.2. REVO 44 to REVO 150 models

Pic. 2. Construction of REVO 44 to REVO 150 burners.

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The burner is composed of the following subassemblies:

• Combustion chamber including: furnace (1) made of the highest quality steel heat-resisting
steel and a covering pipe (2),

• Burner’s cover – made by stainless steel;

• Blowing assembly- located under the cover, it consists: fan, gear-motor driving the fuel-
feeding "finger", gear-motor driving the gears of the rotary chamber and a multi-coupler (4)
where the controller plug is to be connected.

• Blowing system- is located underneath the cover and it is a connector between the blowing
assembly and the combustion chamber. The upper part of the chamber houses the feeding
pipe and a chimney with a barrier (3) where the pipe connecting the burner to the fuel
feeder is attached. The chimney is mounted to the rectangular opening in the upper part of
the burner chamber. A steel barrier with a counterbalance is installed inside the chimney.
The barrier prevents backfire that would result in the fire entering the feeder. It is
important that the counterbalance is not locked.

The cover of burner does not have any protruding nor sharp parts. It does not threat one’s health.
The temperature of burner’s cover during operation should not exceed 60ºC with exception of places
of raised temperature, i.e. bakery.

ATTENTION!
The producer reserves the only right
to implement from any changes in
construction of burner and feeder,
its software and wiring, otherwise he is
freed responsibilities to the buyer.

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 2.2. Quality requirements for pellets fuel

In table below given requirements as to quality of pellet fuel are shown. Using fuel which complies
to DIN 51731 or DIN PLUS certification or meet the rules of EN-14961-2 norm, extends longevity
of burner. The pellet storage location should be dry and well-ventilated. It is important that before
the hopper filling the pellet temperature is equal to the boiler room temperature.

Table 1. Quality requirements of pellet fuel.

Wooden pellet NORM

Units
Quality criteria DIN plus DIN 51731

Diameter mm 4≤d<10(6) 4≤d<10(6)

Length mm 5 x D(3) <50

Density kg/dm³ 1,12 1,0< Density <1,4>

Ash % <0,5(1);(7) <1,50

Humidity % <10 <12

Humidity when delivered % Not specified Not specified

Caloric value MJ/kg >18(1) 17,5<HW<19,5(2)

Sulphur % <0,04(1) <0,08

Nitrogen % <0,3(1) <0,3

Chlorine % <0,02(1) <0,03

Dust collected % <2,3 -

Additives facilitating
% <2(8) (4)
pressing
Temperature of melting
- Not specified Not specified
ash
Arsenic mg/kg <0,08 <0,08

Lead mg/kg <10 <10

Cadmium mg/kg <0,5 <0,5

Chrome mg/kg <8 <8

Copper mg/kg <5 <5

Quicksilver mg/kg <0,05 <0,05

Zink mg/kg <100 <100

Halogens mg/kg <3 <3

(1) Dry weight

(2) Free from water and ash

(3) No more than 20% of pellets can be as long as 7,5 x diameter

(4) DIN forbids to use additives. This ban is not valid to small heating systems.

(5) In warehouse of the producer

(6) Tolerance in differences in diameter 10 %

(7) Allowed content of dust up to 0,8%, if it is naturally higher, specific for given sort of wood

(8) Only natural additives from biomass are allowed

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 ATTENTION!
Change of pellets diameter during
using of burner (e.g. from 6mm to 8mm)
requires resetting the controller
by a qualified installer.

2.3. The pattern of the burner nameplate

Pic. 3. The pattern of the burner nameplate.

2.4. Technical data of burner

Main properties of PellasX burners from Revo line:

Safety
• Technology of overpressured burning and the built-in firewall with counterweight – no risk of
backfiring
• Burner temperature sensor
• Flexible pellet feeding pipe – is melted when backfire occurs and fuel is not fed to the burner

Reliability
• Hybrid Drive System – lower electricity consumption costs and full synchronization of fuel
feeding into the air.
• Air Vane System - precise air supply to the combustion chamber and extended chamber
durability.
• Automatic start after voltage failure – memory of recent settings
• Furnace made of highest quality heat-resistant steel

Modern controlling system

• Automatic operation: firing up, cleaning, flame control
• Stepless (electronical) power regulation
• Possibility of control over burning process by broadband lambda probe (optional)
• Low emission of CO and CO₂
• Low consumption of electricity
• Low heat inertia
• High burning efficiency – up to 99 %
• Very precise flame sensor
• Fully compatible with automatics of oil and gas boiler and with bakery oven
• Possibility of handling the chimney exhaust fan (the fan works periodically and does
not ventilate the boiler)

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 Table 2. Technical data.

Type REVO Mini REVO Mini 35 REVO 44 REVO 70 REVO 100 REVO 120 REVO 150

Power 5 - 26 kW 8 - 35 kW 10 - 44 kW 15 - 70 kW 30 - 100 kW 40 - 120 kW 50 - 150 kW

230 V AC / 230 V AC / 230 V AC / 230 V AC / 230 V AC / 230 V AC / 230 V AC /

Currency
50Hz 50Hz 50Hz 50Hz 50Hz 50Hz 50Hz
Average
consumption 50 W 50 W 70 W 85 W 85 W 85 W 85 W
of electricity

Weight 15 kg 17 kg 24 kg 27 kg 29,5 kg 33,5 kg 41 kg

Noise
63 dB 63 dB 63 dB 72 dB 72 dB 72 dB 72 dB
emission
Feeder’s
2m 2m 2m 2m 2m 2m 2m
length

pellet 6-8mm pellet 6-8mm pellet 6-8mm pellet 6-8mm pellet 6-8mm pellet 6-8mm pellet 6-8mm
oat* oat* oat* oat* oat* oat* oat*
Fuels
(see page 5th) (see page 5th) (see page 5th) (see page 5th) (see page 5th) (see page 5th) (see page 5th)
dry pit dry pit dry pit dry pit dry pit dry pit dry pit

Burning
to 99 % to 99 % to 99 % to 99 % to 99 % to 99 % to 99 %
efficiency
Efficiency
to 96 % to 96 % to 96 % to 96 % to 96 % to 96 % to 96 %
in boiler
Power
YES YES YES YES YES YES YES
modulation
Lambda
YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
probe
CH pump
YES YES YES YES YES YES YES
service
HUW pump
YES YES YES YES YES YES YES
service
Mixer
YES YES YES YES YES YES YES
service
Buffer
YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
service
Additional
feeder YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
service (silo)
Room
temperature YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
sensor
Return
temperature YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
sensor
Fumes
temperature YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
sensor
Weather
YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional) YES (optional)
automatics

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PellasX burner has simple and compact construction, which allows for easy assembly in boiler’s
door. Below in the table: the dimensions and drawings of mounting holes for given types of
burners.

There are 2 groups of burners from REVO line:

Group 1
• REVO Mini
• REVO Mini 35
Group 2
• REVO 44
• REVO 70
• REVO 100
• REVO 120
• REVO 150

Table 3. Dimensions of burners.

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 2.5. Safety systems of burner

PellasX burner is equipped with following safety systems, which effectively protect the user
against backburning:

1. Burner temperature sensor

The sensor, once it detects temperature over 90OC (setting: alarm temperatures may
be modified depending on the conditions in which the device operates i.e. bakery
ovens or dryers; please note that such changes can only be done by an authorized
service person) goes from work mode into burning off mode, at the same time it
switches off the external feeder and sets the fan for 100% power.

2. Technology of burning in overpressure

Burning in overpressure is founded on physical phenomenon which takes place in inner feeder
of burner.

3. Chimney for pouring fuel

In upper part of the burner there is a chimney for pouring fuel. It is equipped with a barring
hatch with a counterweight. In case of backfire the hatch closes inlet and also prevents
fire against reaching the fuel hopper.

4. Flexible pouring pipe

Flexible pouring pipe is an elastic connection between external feeder and burner. Its main
function is delivering fuel to burner, additionally it also protects against backfiring. Under
influence of high temperature pipe starts to deform and extend which makes fuel delivering
impossible.

Safety systems control- see chapter 6.2: Specification of the inspection intervals

2.6. Technical data of controller, description of functions and burner settings

See User’s manual of controller.

13 | S t r o n a
 3. INSTALLATION

3.1. Chimney

The parameters of chimney should be adjusted to requirements of heating device, of which

fumes are led away to chimney. The chimney can be made of ceramics or steel. Chimney
should be clean, and its draft sufficient for PellasX burner operating with heating device in
scope of preset power output. In case when chimney draft is not sufficient, it is possible to
install a mechanical fumes exhaust. Before operation chimney should be checked and approved by
a qualified chimney-sweeper.

It should be remembered that a high chimney with big capacity of fumes needs more heat
and temperature of inner part of it should not be lower than 80ºC, 1m below the top to avoid
condensation on top of the chimney. To reduce the inner profile of the chimney, a steel pipe with
proper diameter can be installed. All advice referring to chimney duct should be taken from
a professional company. Strong wind, too high or too low chimney have influence on efficiency
of burner and its settings. In such cases it is advised to install a stabilizer of chimney draft
which will ventilate chimney and help in maintaining stable draft. If chimney is too small, then
burner may not work correctly, in such case it is necessary to install a mechanical fumes exhaust.

Table 4. Minimum chimney draft.

TYPE OF BURNER MINIMUM CHIMNEY DRAFT [Pa]

REVO Mini 15

REVO Mini 35 15

REVO 44 20

REVO 70 25

REVO 100 30

REVO 120 30

REVO 150 35

3.2. Boiler / oven

PellasX burner can be installed in majority of boilers. The power of burner in relation to boiler or
oven power must be adjusted by installer. It is the best to mount the burner in boiler’s door,
just above grate or in side wall if it is possible. The diameters of mounting holes of PellasX burner
are given in table 3. The length of pipe in boiler is regulated by installer with usage of a connector
– mounting flange – similar as in oil boilers or directly into door of boiler with 4 M8 screws.
Thanks to connector it is possible to regulate length of furnace pipe of burner in boiler. If
boiler chamber is too small, burner may operate incorrectly.

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 Pic. 4. Positioning of burner and direction of flame.

Table 5. Minimum dimensions of furnace chamber.

MINIMUM DIMENSIONS OF FURNACE CHAMBER

TYPE OF
BURNER
MINIMUM DIMENSIONS MINIMUM LENGHT OF
OF FURNACE CHAMBER FURNACE CHAMBER [mm]

REVO Mini 0,023 400

REVO Mini 35 0,030 520

REVO 44 0,038 520

REVO 70 0,070 790

REVO 100 0,099 790

REVO 120 0,109 930

REVO 150 0,119 995

15 | S t r o n a
 Table 6. Exemplary minimum dimensions of rectangular furnace chamber.

EXEMPLARY MINIMUM DIMENSIONS OF RECTANGULAR

FURNACE CHAMBER

TYPE OF BURNER
WIDTH A [mm] HEIGHT H [mm] WIDTH A [mm]

REVO Mini 218 262 400

REVO Mini 35 218 262 520
REVO 44 273 327 520
REVO 70 273 327 790
REVO 100 324 388 790
REVO 120 324 388 930
REVO 150 324 388 995

Table 7. Exemplary minimum dimensions of cylindrical furnace chamber.

EXEMPLARY MINIMUM DIMENSIONS OF CYLINDRICAL

FURNACE CHAMBER
TYPE OF BURNER
MINIMUM DIAMETER OF MINIMUM LENGTH OF
CHAMBER [mm] FURNACE CHAMBER [mm]

REVO Mini 270 400

REVO Mini 35 270 520

REVO 44 337 520
REVO 70 337 790
REVO 100 400 790
REVO 120 400 930
REVO 150 400 995

Table 8. Pressure in burning chamber.

TYPE OF BURNER PRESSURE IN BURNING CHAMBER [Pa]

REVO Mini 10

REVO Mini 35 15

REVO 44 20

REVO 70 25

REVO 100 25

REVO 120 30

REVO 150 30

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 3.3. Fuel hopper

Fuel hopper can be made of any non-flammable material, i.e. steel. It can have any
capacity and should be located in proper distance from burner (Pic.7). In lower part of fuel
hopper a spiral feeder in covering pipe is mounted. The slope of feeder should not be
bigger than 45° in relation to the floor. Fuel hopper must be covered with a lid which
would protect rotating screw of the feeder against damage by leftovers.
It is forbidden to manipulate on the bottom of the hopper during operation of feeder. It is a threat
to body injury – particularly to fingers. It must be remembered to refill the fuel hopper
with pellets type fuel before activating the burner. Never pour the fuel hopper with damp or
disintegrating fuel. It can cause difficulties in operation of burner – burner blockade.

3.4. External feeder

Pic.5. Feeder’s construction.

Fuel feeder connects fuel hopper with burner. It is made of steel pipes, galvanized or
stainless steel with diameter 60mm or 76mm and 2m or 3m long (it is related to the size of burner).
There is a steel spiral inside the pipe driven by electrical engine 230V AC with gearbox. The motor
is connected using the power suitable socket located on the burner’s controller. The feeder lower
part is mounted in the lower part of the fuel hopper and its upper part is connected to the burner
with the flexible polypropylene pipe.

17 | S t r o n a
Feeder assembly:

1. Connect both pipes (1) and (2) with the bolt M8 (3) and nut M8 (4);
2. Insert the pin (6) in the shaft hole (8), and then screw the spiral (5) onto the pin (6)
and tighten with the nut (7);
3. Put the feeder’s cap (10) onto the motor pin (9);
4. Slide the shaft (8), including the mounted spiral, onto the motor pin (9) and secure with
the set screw (11);
5. Slide the spiral into the pipe inside so that it terminates at the half of the inlet hole
(figure below) and screw the motor (9) to the pipe flange with the bolts (12) and nuts
(13).

Pic.6. Feeder’s auger installation.

Fuel dosing is done automatically. Feeder operation is cyclic and is operated by outer controller.
Feeder should be positioned at maximum 45º angle in relation to the floor. Flexible, antistatic
polyurethane pipe must not be directed vertically above the pouring chimney of burner, but at least
30 cm away from it. In case of pipe overheating (back burning) or its melting, pellet fuel will not be
falling onto burner. Lack of fuel supply will cause burning off. It prevents against spreading fire on
fuel hopper and on the rest of boiler room.

NOTE: Before starting the burner, fill the hopper with pellets and fill the feeder until
pellets will start falling into the burner.

3.5. STB protection

In case when oven or boiler does not have its own STB protection, a thermostat with a capillary
on clips is added to the set. Capillary sensor should be permanently mounted in water coat of the
boiler. After reaching critical (95oC) temperature of boiler, fuel feeder is cut off. In case of restarting
the burner the switcher on cover should be reset, before that the cause of switching off due to
boiler overheating should be checked, assessed and right steps to solve the cause of the problem
should be taken.

3.6. Boiler temperature sensor

Burner is provided together with boiler temperature sensor. Its task is to control firing up and
burning off process in burner. It does not refer to burner version destined for bakery
ovens.

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 4. BURNER AND FEEDER ASSEMBLY

Pic. 7. Scheme of installation in boiler room.

Burner and feeder are delivered in ready-made state, ready for installing. They are packed
in cardboard boxes, which have to be unpacked with care.

ATTENTION!
Before starting dismantling
or disassembly entire power supply
must be disconnected.

19 | S t r o n a
1. Burner installation in boiler

To perform correct installation, isolate thermally the burner from the boiler door (2) [isolation pad
is not a part of the set].

Scheme of assembly Revo Mini and Mini35 burners in a boiler:

• Insert the burner’s furnace pipe in the boiler mounting hole and fix with the bolts M8 (1).

• To disassembly a burner from the boiler, remove M5 screw (3).

Pic. 8. Installation of REVO Mini and REVO Mini 35 burners.

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Scheme of assembly Revo 44-150 burners:

• Unscrew M5 screws (1) and remove the cover (2);

• Undo 4 buckles (3) and remove burner from covering pipe (4)
• Install the insulation layer between the supporting channel and the boiler door (6) [insulation
is not included in set].
• Assembly the covering pipe in boiler’s hole and screw it with 4 M8 screws (5);
• Insert the burner again into covering pipe and clasp 4 buckles (3);
• Assembly the burner cover (2) and screw the screws (1).

Pic. 9 Installation of REVO 44 to REVO 150 burners in boiler’s door.

ATTENTION!
When assembling burner in boiler which
does not have outer thermo-isolation in
place of mounting, isolation pad
should be used to protect burner against
influence of boiler temperature.

21 | S t r o n a
2. Assembling the chimney for pouring fuel

In top part of burner (models from Revo44 to Revo150), insert the chimney in vertical
position and press it until it properly fits in the socket.

3. Assembling the feeder Pic. 5

• Attach with joint flexible pouring pipe, long enough to connect with upper part of the feeder,
no less however than 30 cm from vertical pouring axis of burner. Second part of flexible
pipe insert onto vertical pipe of chimney for pouring fuel of burner and tighten it with a band.
• Insert lower part of feeder pipe in fuel hopper, remember that hole for
sucking granulate must be directed upwards.

ATTENTION!
Feeder should be positioned at angle
no bigger than 45 O in relation to the floor.

• Fill the hopper with fuel. Approval for fuel should be made available by the seller. Specification
of fuels is shown in Table 1.
• Join feeder with burner by electrical wire providing power to feeder and stick plug into proper
socket on the controller. Remember about zeroing wiring for cover of burner, it can not be
damaged and must be tightly screwed to the cover.
• In case when oven or boiler does not have its own STB protection, a capillary
thermostat with fastener should be added to the set. A capillary sensor should be installed
permanently in water coat of boiler, together with temperature sensor of boiler

4. Connecting the controller

Attach the cover of controller by screws on isolated wall of the boiler or on the wall of
the boiler-room. The wire of a multicoupler should be attached to proper socket on the right
side of burner.

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 5. ADDITIONAL CONNECTIONS AND FIRST START-UP

1. Additional connections of the burner are described in the controller manual.

2. Determination of the supplied pellet capacity
a) Before starting the balancing procedure, make sure that the feeder is filled with
pellets.
b) Put an empty bag (e.g. pellet bag) under the feeder and start the feeder for 15
minutes. The pellet amount collected in the bag must be weighed.
c) The value being the result should be used in the FEEDER EFFICIENCY PARAMETER
since the value is required by the controller during the initial start-up.
d) Enter the maximum operating power of the burner in the next step.
e) The controller will adjust the necessary pellet quantity automatically.

6. EXPLOITATION AND SAFETY REGULATIONS

6.1. Exploitation

ATTENTION!
PellasX burners can only be handled
by adults. It is mandatory to be
acquainted with user’s manual before
servicing the burner.

Before starting up burner’s operation all connections and joints with feeder should be checked.
Mounting screws, which join burner with boiler should be checked, as well as thermal seals between
burner and boiler.
Burner is started up according to user’s manual after connection to electricity by power cord with
zeroed plug. In order to ensure correct operation of burner, depending on quality of fuel, the inside
of burner should be cleaned from fouling and slag.
Depending on a group of burners, there are different ways of conducting the maintenance of furnace
plate:

a) Maintenance of furnace plate in Revo Mini and Revo Mini35 burners

Burners of the Revo Mini group are equipped with a furnace pipe (1) located inside the cover pipe
(2). With the design of the Revo burners they can be used for a long period with no need to
disassembly the furnace by detaching it from the cover pipe. The maintenance is limited to the
removal of deposits from the furnace using a wire brush every month (or after one tone of pellets
is burnt).

ATTENTION!
Maintenance of burner must always
be conducted on cold burner.

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 Pic. 10. Maintenance of REVO Mini and REVO Mini35 burners.

ATTENTION! During the service inspections (intervals: see Chapter 6.2.), the serviceman should
remove the furnace from the cover pipe, remove the ash from the cover pipe and unclog the nozzles
in the furnace pipe.

b) Maintenance of furnace plate in Revo 44 to Revo 150 burners

Group of Revo44 to Revo 150 burners are equipped with a furnace pipe (1) located inside the cover
pipe (2). With the design of the Revo burners they can be used for a long period with no need to
disassembly the furnace by detaching it from the cover pipe. The maintenance is limited to the
removal of deposits from the furnace using a wire brush every month (or after one tone of pellets
is burnt).

ATTENTION!
Maintenance of burner must always
be conducted on cold burner.

Pic. 11. Maintenance of REVO 44 to REVO 150 burners.

ATTENTION! During the service inspections (intervals: see Chapter 6.2.), the serviceman should
remove the furnace from the cover pipe, remove the ash from the cover pipe and unclog the nozzles
in the furnace pipe.

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 6.2. Specification of the inspection intervals.

Table 9. Specification of the inspection intervals.

12 months 18 months 24 months 30 months
6 months from
from from from from
Power rating installation
installation installation installation installation
date
date date date date
5 – 50 kW 1. Expanded 2. Expanded

51 – 150 kW 1. Expanded 1. Basic 2. Expanded 2. Basic

151 – 500 kW 1. Basic 1. Expanded 2. Basic 2. Expanded 3. Basic

The inspection interval date starts from the installation and start-up of device by the authorised
service company having the suitable manufacturer’s certificates. The inspections must be
performed not earlier than one month before and not later than one month after its scheduled date.

Scope of operational activities:

For basic operation inspection:

• Check of setting of the automatic

• Check of safety devices (STB, boiler and burner temperature sensors)
• Check and cleaning of the flame sensor
• Check of the firewall with counterweight condition (if any)
• Fumes analysis and chimney draught measuring
• Record of service counters status
• Cleaning of the blowing nozzles and burner furnace
• Check of the fixing mechanism and furnace condition
• Calibration of lambda probe (if any)

Additional operations when extended inspection is performed:

• Test of transmitters
• Check of the burner tightness
• Check of the electrical connections condition
• Check of the igniter condition

6.3. Safety regulations referring to installation and exploitation of burner

Before starting installation and exploitation of burner, the chimney shaft and boiler to which
burner will be connected should be thoroughly cleaned (see page 14). Check if there is enough
liquid in heating installation, and if pouring device works correctly.

• Burner can only be handled by adults who are acquainted with user’s manual.

• Children can not be allowed to be close to the burner.

• It is forbidden to put a hand inside the feeder pipe and burner pouring pipe,
this is a risk of an injury and disability.

• It is forbidden to open boiler’s door during operation of burner.

• Opening the door of the boiler is allowed only after extinguishing the burner and
disconnect of electric power.

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 • Burner is designed for burning dry biomass, i.e. “pellets” in boilers operating in central
heating system.

• Obligatorily burner must be electrically zeroed and connected to a socket with zeroing
pin 230V AC.

• Electrical installation must be done accordingly to current safety rules and regulations.
Electrical installation powering a burner must be done in TN-S system and protected by a
RCD – residual current device 6A/30mA. For making an installation a professional
electrician must be responsible.

• Installation of a burner must be executed by an authorized installer trained

by PELLASX sp. z o.o. sp. k. (The Producer) and the Acceptance Report should
be written – which is included in User’s Manual.

• Any sort of works and reparations of a burner or a feeder must be done with
disconnected powering cable from electricity.

• The room in which a burner works must be well and constantly aired.

• Exploitation can not be done in improper environmental conditions, i.e. too high
temperature, above 45ºC, in presence of aggressive compounds, dirt, bad ventilation,
etc.

• Following items must be connected to the boiler: capillary safety sensor STB and boiler
temperature sensor outgoing from a burner.

Failure in observing by the user – owner of a burner the above SAFETY

REGULATIONS releases The Producer – PELLASX sp. z o.o. sp. k. from any responsibility
for improper work of a burner and results in loss of the warranty.

If the user executes the installation of a burner not in accordance with instructions
and recommendations of the producer or when he does not have the „Collection
Report” written during first firing-up of a boiler by authorized installer and confirmed
with the signature of the user, then he or she loses the right to warranty for burner faults.
Also the guarantee is lost then.

6.4. Guarantee

Details in the GUARANTEE CARD attached to the User’s Manual.

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 7. SERVICE OF DEVICES

ATTENTION!
Servicing of devices can only be
executed by switched off electrical
powering of a burner and a boiler.
.

7.1. Photosensor

Photosensors installed inside the burner should be cleaned from time to time with a soft cloth as it
is done for oil or gas burners. To do that remove the cover by loosening four round head bolts (2)
or three round head bolts (1) in REVO Mini – REVO Mini35 models and REVO 44 to REVO 150
models, respectively. Remove the photosensor from the socket (1), clean and reinstall it. Once the
above operations are completed reinstall the burner cover in the reverse order.

Frequency of cleaning the photosensor:

• Bakeries- once a month
• Boiler rooms – every 3 months

Pic. 12. Position of photosensor in REVO burner.

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 7.2. Electrical igniter replacement.

When the igniter does not heat even though the “firing up” message is shown, it is probably
damaged. To replace the igniter, remove the burner cover. On the right side of the fan, there is a
steel sheath, where the electric igniter is located. Disconnect the igniter electric cables from the
terminal block, loosen the bolt mounting the steel sheath case and remove the igniter. Follow the
above procedure in reverse order to mount a new igniter and the burner cover.

7.3. Feeder pipe cleaning

If a string from the pellet bag or other object clogging the feeder operation gets into the feeder
pipe, then the feeder motor will overheat and circuit-breaker will be switched off by the temperature
sensor located in the motor.
In order to remove an object from the feeder pipe, the powering wire should be removed from the
socket inside the controller, unscrew the screws mounting the gear motor to feeder pipe,
remove the spring from the pipe and remove the object which was the cause of breakdown. Then
the feeder should be assembled and checked.

7.4. Burner cleaning

One of the reasons of lack of firing-up of a burner may be a slag filling in the burner chamber. The
igniter will not ignite the fire when there is a slag in its way. Slag does not burn itself.
As we are unsure as to the quality of fuel, that is why initially every day, later every now and then
we clean furnace pipe of a burner from slag and ash. After removing a burner, the remnants
of slag and ash should be cleaned with a wire-brush or a small poker. Common cause of
accumulating a slag is switching off a burner with the main switch. Too abrupt removal of air-
flow (oxygene) to the furnace causes unburning of fuel remnants. By another firing up of a
burner, without cleaning it from slag and ash, a smoke can come out from a burner as the
openings in it are blocked with slag. Burner is not aired enough. Therefore: Before switching
off the power of a burner, burning off process should be conducted.

In case of serious breakdowns an installer should be contacted.

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 8. REASONS OF IMPROPER OPERATION

Burner does not fire up the fuel:

Reasons:
• No fuel – check the fuel hopper and the feeder, if it is not blocked
• Too small startup dose – check the startup dose
• Burnt igniter – check the igniter
• Defective drive motor - check motor thermistors

Burner fires up but does not go into the first power

Reasons:
• Improper start-up dose – check the start-up dose
• Dirty or faulty photosensor – clean it or replace it
• Damaged outer thermostat in oil boilers or bakery ovens

Photosensor checking
See page 27.
Measuring readings:
• In darkness 0-5 units
• In full light 100 units

Overheating of inner feeder.

Reasons:
• Burner dirty with slag
• Weak chimney draft – chimney exhaust fan should be used

Damage of the feeder sensor– alarm can not be cancelled

Reasons:
• The most common reason of this breakdown is damage of thermo protection of a sensor,
which results in overheating of measuring part. Despite burner cooling off, the fault can not
be cancelled, in this case the measuring sensor should be replaced. In order to verify
if the sensor is faulty indeed, its resistance should be checked, it should be between 1-5 Ω.
The resistance of a damaged sensor is about 100 kΩ.

Feeder filling
The inner feeder is designed to mix and feed fuel evenly. The reason of filling the inner
feeder can be:
• Bad setting of the inner feeder in relation to outer feeder – increase capacity of inner feeder
(service menu/ burner feeder)
• Gearmotor damage – replace the gearmotor
• Badly adjusted interval of feeder work – this value should not exceed 20s. (service menu /
burner interval)

Blower damage
Reasons:
• Blockade of blower blades – unscrew the blower cover and check if they are not blocked
mechanically
• Check the voltage on blower wires
• Check the capacitor of blower motor

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 9. ELECTRICAL SCHEMES

Electrical scheme of PellasX controller

See controller’s user’s manual

Electrical scheme of PellasX REVO burners

Pic. 13. Electrical scheme of REVO Mini and REVO Mini 35 models.

Pic. 14. Electrical scheme of REVO 44 to REVO 150 models.

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 10. REPORTS
10.1. First start-up report

Table 10. The pattern of the first start-up.

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 10.2. Inspection report

Table 11. The pattern of first inspection report.

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 11. LIST OF PICTURES AND TABLES

List of pictures:
Pic. 1. Construction of REVO Mini and REVO Mini 35 burners. 6
Pic. 2. Construction of REVO 44 to REVO 150 burners. 6
Pic. 3. The pattern of the burner nameplate 9
Pic. 4. Positioning of burner and direction of flame. 15
Pic. 5. Feeder’s construction. 17
Pic. 6. Feeder’s auger installation. 18
Pic. 7. Scheme of installation of boiler room 19
Pic. 8. Installation of REVO Mini and REVO Mini35 burners. 20
Pic. 9. Installation of REVO 44 to REVO 150 burners in boiler’s door. 21
Pic. 10. Maintenance of REVO Mini and REVO Mini 35 burners. 24
Pic. 11. Maintenance of REVO 44 to REVO 150 burners. 24
Pic. 12. Position of photosensor in REVO burner. 27
Pic. 13. Electrical scheme of REVO Mini and REVO Mini 35 models. 30
Pic. 14. Electrical scheme of REVO 44 to REVO 150 models. 30

List of tables:
Table 1. Quality requirements of pellet fuel. 8
Table 2. Technical data. 10
Table 3. Dimensions of burners. 11-12
Table 4. Minimum chimney draft. 14
Table 5. Minimum dimensions of furnace chamber. 15
Table 6. Exemplary minimum dimensions of rectangular furnace chamber. 16
Table 7. Exemplary minimum dimensions of cylindrical furnace chamber. 16
Table 8. Pressure in burning chamber. 16
Table 9. Specification of the inspection intervals. 25
Table 10. The pattern of the first start-up. 31
Table 11. The pattern of first inspection report. 32

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 12. NOTES

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NOTES

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 NOTES

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