PYROTEC Grate combustion 390 to 1250 kW Technical guide PYROTEC GRATE COMBUSTION Fully automatic wood boiler for the combustion of woodchips, pellets, shavings and mixed wood 5822 511 GB 05/2010 Downloaded from www.Manualslib.com manuals search engine Index 1. Principles of wood combustion 1. 1 Principles of pellet combustion for generating heat .................................................... ■ What are wood pellets? .......................................................................................... ■ Fuel requirements ................................................................................................... ■ Forms of delivery .................................................................................................... 1. 2 Principles of woodchip combustion for generating heat ............................................. ■ What are woodchips? ............................................................................................. ■ Fuel requirements ................................................................................................... 1. 3 Minimum wood fuel requirements ............................................................................... ■ Content ................................................................................................................... ■ Non-wood biomass fuels ......................................................................................... ■ Wood fuel regulations and standards ..................................................................... 5 5 5 5 5 5 5 6 6 6 6 2. PYROTEC 2. 1 Product description ..................................................................................................... ■ Benefits at a glance ................................................................................................ ■ Delivered condition ................................................................................................. 2. 2 Specification ............................................................................................................... ■ Specification ............................................................................................................ 7 7 7 8 8 3. Control unit 3. 1 Specification for Pyrocontrol ....................................................................................... ■ Functions ................................................................................................................ ■ Operation: ............................................................................................................... ■ Standard delivery: ................................................................................................... 3. 2 Accessories for Pyrocontrol ........................................................................................ ■ External drive control .............................................................................................. ■ Control of external drive with light barrier ............................................................... 3. 3 Accessories for Pyrocontrol output management ....................................................... ■ Cylinder management 5 sensors (QM) ................................................................... ■ External requirement on/off ..................................................................................... ■ Operating message zero volt .................................................................................. ■ Output signals 0-10 V ............................................................................................. ■ Requirement, additional heat source KP0 .............................................................. ■ Requirement, additional heat source KP1 .............................................................. 3. 4 Accessories for Pyrocontrol remote transfer ............................................................... ■ Fault message device, analogue with battery ......................................................... ■ Export of operating data .......................................................................................... ■ Visualisation, externally via modem (connected with cable) ................................... ■ Visualisation, internal .............................................................................................. ■ Data line to internal visualisation ............................................................................ 3. 5 Mastercontrol for two-boiler systems .......................................................................... ■ Information on the Mastercontrol ............................................................................ 3. 6 Accessories for Mastercontrol .................................................................................... ■ Heat meter signal .................................................................................................... ■ Requirement, additional heat source KP0 .............................................................. ■ Requirement, additional heat source KP1 .............................................................. ■ Fault message device, analogue with battery ......................................................... ■ Export of operating data .......................................................................................... 13 13 13 14 15 15 15 16 16 16 16 16 16 17 18 18 18 18 18 18 19 19 21 21 21 21 22 22 4. Heating water buffer cylinder 4. 1 Specification, buffer cylinder ....................................................................................... 23 5. Installation accessories 5. 1 Boiler accessories ....................................................................................................... ■ Flue gas recirculation .............................................................................................. ■ Insulation, flue gas recirculation line ....................................................................... ■ Displacer rods ......................................................................................................... ■ Automatic ignition system ....................................................................................... 5. 2 Boiler safety equipment .............................................................................................. ■ Thermally activated safety valve 100 °C ................................................................. ■ Thermally activated safety valve 50-120 °C ........................................................... ■ Thermally activated extinguishing valve ½”, 50-90 °C ............................................ ■ Supply screw conveyor two-level ............................................................................ 5. 3 Accessories, heat distribution ..................................................................................... ■ Motor three-way valve ............................................................................................ ■ Pumps ..................................................................................................................... 5. 4 Accessories, flue system ............................................................................................ ■ Flue gas dust extractor 240/800 ............................................................................. ■ Accessories, cleaning pneumatic ............................................................................ ■ Price reduction net compressed air on site ............................................................ 2 Downloaded from www.Manualslib.com manuals search engine 24 24 24 24 24 25 25 25 25 25 26 26 26 27 27 29 30 PYROTEC 5822 511 GB Index Index (cont.) Design information 5822 511 GB 6. PYROTEC Downloaded from www.Manualslib.com manuals search engine 5. 5 Accessories, ash removal ........................................................................................... ■ External container ................................................................................................... ■ Extension of ascending screw conveyor ................................................................. ■ Extension of combustion chamber screw conveyor ................................................ 31 31 32 33 6. 1 System design ............................................................................................................ ■ Selection of rated output ......................................................................................... ■ Flow temperatures .................................................................................................. ■ Safety temperatures ................................................................................................ 6. 2 Delivery ....................................................................................................................... 6. 3 Handling ...................................................................................................................... 6. 4 Installation ................................................................................................................... ■ Requirements for boiler room ................................................................................. ■ Requirements of Sample Combustion Order .......................................................... ■ Combustion air supply ............................................................................................ ■ Minimum clearances ............................................................................................... 6. 5 Water connection ........................................................................................................ ■ Heating connections ............................................................................................... ■ Boiler circuit and shunt pumps ................................................................................ ■ Safety equipment to DIN EN 12828 ........................................................................ ■ System examples .................................................................................................... 6. 6 Electrical installation ................................................................................................... ■ Positioning of the programming module and control panel ..................................... 6. 7 Safety equipment ........................................................................................................ ■ Expansion ............................................................................................................... ■ Extinguishing facilities ............................................................................................. ■ Extinguishing water container ................................................................................. ■ Extinguishing facility with cold water supply ........................................................... ■ Back burning protection, boiler system ................................................................... ■ Prevention of combustion chamber overfilling ........................................................ ■ Reignition protection ............................................................................................... ■ Back burning protection, fuel supply (RSE) ............................................................ ■ Shut-off gate valve .................................................................................................. ■ Rotary lock valve ..................................................................................................... ■ Dual rotary lock valve with pressure compensation ................................................ ■ Low water indicator ................................................................................................. ■ Maximum pressure limiter ....................................................................................... ■ Minimum pressure limiter ........................................................................................ ■ Safety valve ............................................................................................................ ■ Expansion vessel .................................................................................................... 6. 8 Fire protection ............................................................................................................. ■ Fire protection, fuel store ........................................................................................ 6. 9 Commissioning ........................................................................................................... ■ Fuel for commissioning ........................................................................................... ■ Filling the heating system ....................................................................................... 6.10 Fuel ............................................................................................................................. ■ Suitable fuels .......................................................................................................... 6.11 Fuel discharge by means of screw conveyor .............................................................. ■ Discharge conveyor, pellet, D = 120 mm ................................................................ ■ Drive, discharge conveyor, pellets .......................................................................... 6.12 Fuel discharge by means of agitators ......................................................................... ■ Spring core discharge AF ....................................................................................... ■ Discharge screw AF to spring core discharge ........................................................ ■ Horizontal discharge AH ......................................................................................... ■ Discharge screw AH for horizontal discharge ......................................................... ■ Protective panel AH for bunker ............................................................................... ■ Cover panel AH for pellets ...................................................................................... 6.13 Fuel discharge by means of funnel discharge ............................................................ ■ Funnel discharge .................................................................................................... ■ Additional outlet flange ............................................................................................ ■ Funnel, large .......................................................................................................... 6.14 Fuel discharge by means of a push floor (sizing) ....................................................... ■ Number and length of the pushrods with a maximum dumping height ................... ■ Specification for the pushrod drives ........................................................................ ■ Forces on the building ............................................................................................. ■ Slot discharge, for pulling ........................................................................................ ■ Centre discharge ..................................................................................................... ■ Slot discharge with fill function ................................................................................ 33 33 33 33 33 33 34 34 35 35 36 36 36 37 37 37 39 39 39 39 39 40 40 40 41 41 41 41 41 41 41 41 42 42 42 42 42 42 42 42 43 43 43 43 44 45 45 47 47 50 50 50 51 51 52 52 52 52 53 53 54 55 57 3 Index (cont.) 8. Appendix Keyword index 4 Downloaded from www.Manualslib.com manuals search engine 59 59 59 59 59 59 60 60 61 61 61 62 62 62 62 62 63 63 65 66 66 66 66 67 68 68 68 71 71 71 71 72 72 72 72 73 75 75 75 77 77 77 77 78 78 78 79 79 80 80 80 81 81 81 82 82 7. 1 Sizing the expansion vessel ....................................................................................... ■ Selection example ................................................................................................... 7. 2 General information regarding low pressure hot water boilers with safety temperatures of up to 110 ºC ............................................................................................................ 7. 3 Pipe connections ........................................................................................................ 7. 4 Electrical installation ................................................................................................... 7. 5 Operating instructions ................................................................................................. 7. 6 Flue system ................................................................................................................ 7. 7 Checks as part of the Building Regulations approval process .................................... 82 82 83 83 83 83 84 84 .............................................................................................................................................. 85 PYROTEC 5822 511 GB 7. 6.15 Fuel discharge by means of push floor (accessory) ................................................... ■ Pushrod drive, individual ......................................................................................... ■ Weld base, pushrod drive, individual ...................................................................... ■ Pushrod drive, twin ................................................................................................ ■ Weld base, pushrod drive, twin ............................................................................... ■ Weld base, bunker .................................................................................................. ■ Pushrod ................................................................................................................... ■ Hydraulic drive, AS individual ................................................................................. ■ Hydraulic drive, AS twin .......................................................................................... ■ Push floor screw conveyor D = 190 mm ................................................................. ■ Push floor screw conveyor D = 250 mm ................................................................. ■ Drive, push floor screw conveyor, standard ............................................................ ■ Drive, push floor screw conveyor, higher-power ..................................................... ■ Cover, push floor screw conveyor ........................................................................... 6.16 Charging the boiler with fuel ....................................................................................... ■ Trough screw conveyor ........................................................................................... ■ Drive, trough screw conveyor, standard ................................................................. ■ Pipe screw conveyor ............................................................................................... ■ Drive, pipe screw conveyor, pellets ........................................................................ ■ Drive, pipe screw conveyor, standard ..................................................................... ■ Drive, pipe screw conveyor, high-power ................................................................. 6.17 Fuel storage in on-site pellet store (sizing) ................................................................. ■ Sizing the pellet storage room ................................................................................ ■ Pellet storage room design and required system components ............................... ■ Additional safety instructions for pellet stores ......................................................... ■ Protective boards with Z profiles ............................................................................. ■ Fill connector and return air connector ................................................................... 6.18 Fuel storage in on-site pellet store (accessories) ....................................................... ■ Deflector 1.42 x 1.25 m ........................................................................................... ■ Blast pipe, straight .................................................................................................. ■ Blast pipe with 45° bend ........................................................................................ ■ Extension, blast pipe, straight ................................................................................. ■ 45° bend for blow line ............................................................................................. 6.19 Fuel storage in on-site bunker (accessories) .............................................................. ■ Silo cover, manual FDM 2.9/1.3 m .......................................................................... ■ Bunker cover hydraulic FDH ................................................................................... ■ Fall protection grille 120 for FDH ........................................................................... ■ Fall protection grille 200 for FDH ........................................................................... ■ Bunker cover, movable FDB ................................................................................... ■ Fall protection grille, 120 for FDB ........................................................................... ■ Fall protection grille, 200 for FDB .......................................................................... ■ Shaker motor for fall protection grille ...................................................................... ■ Hydraulic drive, bunker charging cover, ASH ......................................................... ■ Cover drives for hydraulic drive, ASH .................................................................... ■ Silo filling screw conveyor FS 300 .......................................................................... ■ Drive, silo filling screw conveyor ............................................................................ 6.20 Back burning protection .............................................................................................. ■ Rotary lock valve ..................................................................................................... ■ Shut-off gate valve MA 220 ..................................................................................... ■ Downpipe L = 1.0 m ................................................................................................ ■ Special adaptor ....................................................................................................... 6.21 Connection on the flue gas side ................................................................................. ■ Chimney .................................................................................................................. ■ Flue pipe ................................................................................................................. 6.22 Sound insulation ......................................................................................................... ■ Braces ..................................................................................................................... Principles of wood combustion 1.1 Principles of pellet combustion for generating heat What are wood pellets? Wood pellets are made from 100% natural wood residues. This raw material is waste matter created by the wood industry in large volumes through planing or sawing. Wood remnants are compressed under high pressure and formed into pellets, i.e. pressed into a cylindrical shape. The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage conditions. Perfect and effective combustion can only be ensured under these conditions. Fuel requirements For combustion in the PYROTEC, use pellets with a diameter of 6 mm, a length from 5 to 30 mm (20 % up to 45 mm) with a maximum residual moisture content of 10 %. The wood pellets used for combustion in the PYROTEC must comply with the requirements of DINplus or ÖNORM M 7135. Demand Abrasion resistance Raw density Water content Ash content Net calorific value Sulphur content Chlorine content Nitrogen content Compression additive Ext. production control DINplus % kg/dm3 % % MJ/kg kWh/kg % % % % ≤ 2.3 ≥ 1.12 ≤ 10 ≤ 0.5 ≥ 18 ≥5 ≤ 0.04 ≤ 0.02 ≤ 0.3 ≤2 yes Ö-NORM M 7135 ≤ 2.3 ≥ 1.12 ≤ 10 ≤ 0.5 ≥ 18 ≥5 ≤ 0.04 ≤ 0.02 ≤ 0.3 ≤2 – Quality characteristics High quality pellets: ■ smooth shiny surface ■ uniform length ■ low proportion of dust ■ sink in water Low quality pellets: ■ cracked rough surface ■ severely varying length ■ high proportion of dust ■ float in water Forms of delivery In their loose form, pellets are transported by silo tanker and blown into the storage room via a hose system. Careful handling of pellets enables a low proportion of dust, perfect boiler charging and a constant wood boiler output. 1.2 Principles of woodchip combustion for generating heat What are woodchips? Woodchips are made from 100% natural wood from forests and plantations. This raw material comes in the form of trunks or branches. The wood is then processed with high speed cutting tools in accordance with ÖNORM M 7133. The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage conditions. Perfect and effective combustion can only be ensured under these conditions. Fuel requirements For combustion in the PYROTEC, use woodchips with a maximum percentage of coarse chippings of 20%, a maximum cross-section of 5 cm² and a maximum length of 12 cm (5 % with max. 16 cm). The water content of the woodchips may be max. 50 % (W50). Bulk density S (kg/m³, water content W (%), size G (mm) as per ÖNORM M 7133 S 200 W20 G30/50 Soft natural woodchips from forest thinnings S 250 W20 to W35 G30/50 Soft natural woodchips from forest thinnings S 300 W20 to W35 G30/50 Soft/hard natural woodchips from forest thinnings S 300 W35 to W50 G30/50 Soft natural woodchips from forest thinnings S 350 W20 to W35 G30/50 Hard natural woodchips from forest thinnings S 350 W35 to W50 G30/50 Soft/hard natural woodchips from forest thinnings S 350 W50 to W60 G30/50 Soft natural woodchips from forest thinnings S 400 W35 to W50 G30/50 Hard natural woodchips from forest thinnings S 400 W50 to W60 G30/50 Soft/hard natural woodchips from forest thinnings 5822 511 GB Quality characteristics ■ Max. 5 % outliers ■ Smooth surfaces Good woodchips: ■ As per ÖNORM M 7133 ■ Size up to G30 or G50 PYROTEC Downloaded from www.Manualslib.com manuals search engine 5 1 Principles of wood combustion (cont.) Poor woodchips: ■ Frayed surface ■ More than 5 % outliers ■ Coarse percentage higher than 20 % ■ Greater than G50 1 1.3 Minimum wood fuel requirements Content When procuring wood for combustion, it is important to ensure that foreign matter (e.g. stones, metal parts, brick fragments, plastics, etc.) is avoided. These change the composition of the charge and therefore the critical parameters of the combustion process. The values must not exceed or fall below the following limits (per kg of dry fuel) for the non-combustible contents (ash at an analysis temperature of 815 °C): Limit Chlorine Cl Sulphur S Total Cl, S Ash content total Alkali oxides in the ash (K2O and Na2O) SB starting of ash sintering mg/kg mg/kg mg/kg g/kg g/kg °C A consequence of exceeding the above limits is a shortened combustion chamber and wood boiler service life. This also means that the maintenance work is increased and the servicing intervals are shortened. max. 300 max. 1000 max. 1000 max. 15.0 max. 1.0 min. 1000 Comparison with natural wood from forest thinnings 10 120 130 5.0 0.35 approx. 1200 The proportion of dust-like and fine-grain materials should also be minimised (in accordance with ÖNORM M 7133). Non-wood biomass fuels Non-wood biomass fuels, such as needles, leaves, grain, straw, husks, fruit kernels, etc., are generally unsuitable as a fuel for trouble-free operation and therefore not permissible. In some cases, the fuel properties (essential composition, ash sintering point, etc.) differ considerably from those of wood. Combustion in a PYROTEC can lead to impairment of the combustion characteristics and to greater stress on the fireclay lining and the heat exchanger surfaces. Warranty claims can therefore only be asserted when using permissible fuels. Wood fuel regulations and standards 1.BImSchV in the revised version dated 22.03.2010 FAV dated 18.11.1997 "Ordinance for Combustion Systems" § 3.(1) 3. Solid fuels Clean air regulations LRV dated 16.12.1985 (as at 28.03.2000) Woodchips for energy purposes (1998) Boilers for solid fuels, table 8 "Test fuels" Solid biofuels 5822 511 GB Germany Austria Switzerland ÖNORM M 7133 EN 303-5 CEN/TS 14961 6 Downloaded from www.Manualslib.com manuals search engine PYROTEC PYROTEC 2.1 Product description A B C D E F G H K L M The PYROTEC grate combustion has been specially developed for the automatic combustion of dry and moist wood fuels (waste wood, wood pellets or woodchips from forest thinnings up to max. W50). It combines the benefits of underfeed combustion with the advantages of grate combustion to optimum effect. The PYROTEC grate combustion is particularly impressive thanks to its maximum efficiency and perfect combustion in all load stages. The horizontal heat exchanger with pneumatic cleaning is ideal for the use of fuels with a high fine percentage. 3-pass boiler (3 bar or 6 bar) External grate with primary air 2 Safety heat exchanger Secondary air Ignition fan Supply screw conveyor with separating barrier Combustion retort with internal grate and primary air 1 Removal of ash Combustion chamber door Moving infeed grate Pneumatic heat exchanger cleaning 2 The ash is removed automatically from the combustion base and transported into a standard container. Efficiency of over 90 % enables maximum seasonal efficiency in modulating operating mode. The use of a PYROTEC grate combustion as a base load boiler is practical in terms of a building heat load of 300 kW. Combination with a solar thermal system is also easily possible. The PYROTEC grate combustion is tested and permissible to EN 303-5. It is produced in accordance with the Machinery Directive and has a CE designation. It is also subject to ongoing monitoring by the TÜV. Benefits at a glance ■ High efficiency thanks to proven combustion technology, 3-pass heat exchanger, modulating output control and regulated primary and secondary air supply ■ Easy service thanks to fully automatic ash removal and optional pneumatic cleaning system ■ Highly developed safety devices ensure a safe and reliable operation ■ Optimum system output is the result of manufacture and delivery of all system components from a single source ■ Automatic ignition device prevents having to maintain the incandescent bed and saves fuel (option – only for fuels with water content below 40 %) ■ Individual planning of your system by our team of experts ■ Excellent output control from 30 to 100 % Delivered condition Preassembled steel boiler for wood pellets and woodchips according to DINplus and ÖNORM M7135. With integral return temperature raising facility, combustion chamber door, ash doors, ash boxes, cleaning device. 1 supply screw conveyor with separating barrier, incl. extinguishing valve with dirt trap 1 Pyrocontrol programming unit 1 flue gas fan 1 extinguishing water container with holder 1 automatic ignition system 1 secondary air device (draught stabiliser); for the installation in the flue pipe 5822 511 GB Pyrocontrol ■ Programming unit ■ Update-compatible software ■ Data line 10 m ■ Control panel ■ Infrared light barrier for level monitoring, separating barrier, supply screw conveyor ■ Safety limit switch on inspection cover of supply screw conveyor ■ Contact sensor PT-100 at the supply screw conveyor ■ Infrared light barriers for level monitoring of the fuel in the combustion chamber ■ Zirconium dioxide probe with measured value transducer ■ Flue gas temperature sensor PT-100 ■ Return temperature sensor KTY ■ Boiler water temperature sensor KTY ■ High limit safety cut-out ■ Underpressure sensor ■ Sensor KTY with sensor well ■ Overpressure limiter ■ Light barrier ash removal ■ Limit switch, combustion chamber door PYROTEC Downloaded from www.Manualslib.com manuals search engine 7 PYROTEC (cont.) 2.2 Specification Specification Output with woodchips W 45*3 Heating data Content on hot gas side Permissible shutdown temperature of the high limit safety cut-out Minimum return temperature Grate ash container capacity Ash container capacity, flue gas dust extractor Boiler water content Water-side pressure drop (diff. 15 K) Permiss. operating pressure Test pressure Maximum operating pressure Heating surface CE designation Boiler class to DIN EN 303-5 Overall dimensions Total length Total width (boiler) Total width (boiler with supply screw conveyor) Total height (boiler) Total height (boiler with induced draught fan) Weight Boiler Combustion block Displacer rods Flue gas fan Supply screw conveyor Total dry weight Total wet weight Max. power consumption Ignition unit Electrical connections (total) During heating operation Supply screw conveyor Primary air fan 1 Primary air fan 2 Secondary air fan Flue gas fan Grate drive Electrical power consumption with QN Electrical power consumption with Qmin Boiler connections Boiler flow and return Extinguishing water connection Boiler drain and fill valve Safety heat exchanger Sensor well for TS PYROTEC grate combustion 530 720 950 7423 675 7423 676 7423 677 390 7423 674 1250 7423 678 kW kW kW 390 390 97 530 530 132 720 720 180 950 950 238 1250 1250 312 kW 380 515 700 920 1210 l °C 1540 100 2280 100 2830 100 4050 100 5210 100 °C l l l mbar 65 240 240 1150 13 65 240 240 1444 23 65 240 240 1861 43 65 240 240 1943 26 65 240 240 2482 45 7.8 6 42.50 7.8 6 55.50 7.8 6 74.80 7.8 6 91.00 bar bar m2 7.8 6 26.32 CE CE 3 CE CE CE 3 3 3 3 mm mm mm mm mm 4370 1274 2382 2378 3186 4870 1247 2382 2536 3186 5257 1380 2488 2834 3378 5447 1612 2852 3035 3452 5992 1612 2852 3230 3717 kg kg kg kg kg kg kg 1680 2970 394 60 153 5230 6380 2707 4238 394 62 153 7554 8998 3291 4953 394 78 153 8869 10730 4874 5779 538 82 190 11463 13406 5563 6520 538 107 190 12919 15400 W W W W W W W W W W W 1600 5410 2880 1100 140 1600 7020 3570 1500 300 1600 8120 4560 1500 300 1600 9350 5170 2200 480 1600 11150 6790 2200 480 DN R R R R 900 900 900 900 900 900 1100 120 2880 2340 1500 1100 120 3570 2900 1500 2200 120 4560 3710 1850 2200 120 5170 4150 1850 4000 120 6790 5470 100 ¾ 1½ 4x½ ½ 100 ¾ 1½ 4x½ ½ 100 ¾ 1½ 8 x½ 2x½ 125 ¾ 1½ 8x½ 2x½ 125 ¾ 1½ 8x½ 2x½ 5822 511 GB 2 Trade name Rated output Part no.: Output data Rated output Continuous output*1 Minimum output Qmin*2 Levelled output as base load boiler in continuous operation with pneumatic cleaning Q ≥ Qmin: Output operation modulating control (variable output control) Q ≤ Qmin: Low load with ON Qmin/ OFF (Stop and Go operation) *3 Wet fuels: > W45 further limitation-related output, efficiency and control characteristics *1 *2 8 Downloaded from www.Manualslib.com manuals search engine PYROTEC PYROTEC (cont.) 5822 511 GB Trade name Rated output Part no.: Flue gas*4 Average temperature (gross*5) Mean flue gas temperature with QN*6 Mean flue gas temperature with Qmin Mass flow rate QN; W5; O2 8 % QW35; W45; O2 10 % Flow rate QN; W5; O2 8 %; 150 °C QW35; W45; O2 10 %; 150 °C CO2 content in the flue gas Flue outlet Required draught (at full load) Efficiency At full load*7 At partial load 390 7423 674 PYROTEC grate combustion 530 720 950 7423 675 7423 676 7423 677 1250 7423 678 °C 160 160 160 160 160 °C 120 120 120 120 120 g/s g/s 219 303 297 412 404 560 532 736 700 968 m3/s m3/s % 7 mm Pa 0.26 0.37 14.7 350 0 0.36 0.50 14.7 350 0 0.48 0.67 14.7 350 0 0.63 0.88 14.7 400 0 0.83 1.15 14.7 450 0 91 90 91 90 91 90 91 90 91 90 % % Values for calculating the size of the flue system to DIN EN 13384, based on 12.0% CO2. Actual flue gas temperature as average gross value as per EN 304 at 20 °C combustion air temperature. *6 Flue gas temperature: Reduction possible by inserting displacer rods (QN-20 °C; Qmin - 10 °C). *7 For dry fuels (W5-W20) without recirculation, lower. For PYROTEC 720–1250 without displacer rods, lower. *4 *5 PYROTEC Downloaded from www.Manualslib.com manuals search engine 9 2 PYROTEC (cont.) c 678 d KR KV l k m a b 2 f h e n 800 470 g q. p 940 o KR Boiler return KV Boiler flow kW mm mm mm mm mm mm mm mm mm mm mm mm mm mm 390 2378 2328 4370 2060 577 1200 2405 1086 803 453 2077 308 1274 1263 530 2536 2486 4870 2560 577 1200 2905 1086 803 453 2331 308 1274 1417 720 2834 2784 5257 2562 577 1200 2993 1380 803 453 2491 308 1380 1413 950 3035 2981 5447 2562 657 1275 2861 1612 929 479 2444 440 1612 1317 1250 3230 3176 5992 3107 657 1275 3406 1612 929 479 2639 440 1612 1566 5822 511 GB Dimensions Rated output a b c d e f g h k l m n o p 10 Downloaded from www.Manualslib.com manuals search engine PYROTEC PYROTEC (cont.) D B C E H K G 960 A F 2 L 220 M a b A B C D E F G H K L M Boiler drain and fill valve Boiler return Return temperature sensor Drive, ash removal High limit safety cut-out Safety heat exchanger Dimensions Rated output a b kW mm mm Primary air fan 1 Boiler water temperature sensor Boiler flow Secondary air fan Supply screw conveyor 390 3282 3800 KR 530 3782 4300 720 3877 4434 950 3835 4392 1250 4380 4937 KV B C A D E F K H G L M N V U T O 5822 511 GB S KV Boiler flow KR Boiler return A Removal of ash PYROTEC Downloaded from www.Manualslib.com manuals search engine R Q P B Cleaning cover, heat exchanger C Combustion chamber temperature sensor D Overpressure limiter 11 PYROTEC (cont.) E F G H K L M N Light barrier, incandescence Ignition unit Cleaning cover, combustion retort Cleaning cover, external grate Light barrier ash removal Boiler door Cleaning, pneumatic Combustion chamber door O P Q R S T U V Limit switch, combustion chamber door Primary air fan 2 Drive, infeed grate Contact sensor, supply screw conveyor Limit switch, maintenance cover Light barrier, supply screw conveyor Extinguishing water connection Boiler drain and fill valve 5822 511 GB 2 12 Downloaded from www.Manualslib.com manuals search engine PYROTEC Control unit 3.1 Specification for Pyrocontrol Programmable logic control (PLC) for the PYROTEC boiler system incl. the control of equipment for fuel charging according to the articles listed separately. Modulating matching of the boiler output to heat consumption is carried out. Rated output range Part no. kW The control circuit of combustion optimisation with a Lambda probe overlaps the output control circuit. With regard to fire protection and personal safety, the highest possible quality criteria are fulfilled. 390 7423 692 530 7423 693 720 7423 694 950 7423 695 1250 7423 696 Functions ■ Output control circuit with modulating output operation (25-100 %) ■ Air-controlled by means of variable speed ventilation fan subject to flow temperature ■ Exact fuel supply via the supply screw conveyor from dosing container with separating barrier ■ Level monitored top up of dosing container ■ Limitation and distribution of the fuel in the combustion chamber ■ Emissions optimised control circuit with fine tuning of the fuel/air mixture using the Lambda probe ■ The pressure control unit ensures a constant underpressure in the combustion chamber. ■ Limitation of the combustion chamber temperature with corresponding variation of air ratio for protection of the fireproof lining ■ Keeping up the return temperature through the boiler ensures a long boiler service life ■ Protection to avoid: – Excessive temperature – Burn-back – Opening of the combustion chamber door – Opening of a charging cover – Pressure in the combustion chamber ■ Zero volt output (fault message) Operation: Operation is carried out via a 8” touch-screen module. All operating data can be shown on the display. The set values of all important parameters can be entered easily. Fault messages are displayed in plain text and output in the sequence of occurrence. Programming module: For operating the heating system. The 8” touch-screen module integrated in the control panel door enables visualisation and graphical evaluation via the system. Übersicht Status: Level 0 Zeit: 05.10.07 10:45:01 Text: Warnung Feuerrauntüre offen Aus 26,4 °C 25,9 °C 21,0 % 27,0 °C 30,0 °C 26,6 °C 26,2 °C KOB PYROTEC 0,0 °C 0,0 °C 26,4 °C 27,0 °C Analyse Archiv Kessel Ein Kessel Aus Sperren 5822 511 GB Einstellungen PYROTEC Downloaded from www.Manualslib.com manuals search engine 13 3 Control unit (cont.) Standard delivery: ■ Sensors and switches at the combustion block and in the flue outlet (installation on site): – Combustion chamber temperature sensor NiCrNi – Infrared light barriers, level monitoring, fuel in combustion chamber – Zirconium dioxide probe with measured value transducer (Lambda probe) – Flue gas temperature sensor PT-100 – Underpressure sensor – Overpressure limiter ■ Sensors and switches installed at top of boiler: – Boiler water temperature sensor PT-1000 in connector flow – Return temperature sensor PT-1000 in connector return – High limit safety cut-out 5822 511 GB 3 ■ Control panel loose; surface powder-coated. Version as per ÖVE/ VDE directives fully wired to terminal strips, fed 3 x 400 V 50 Hz; control voltage 230 V or 24 V; – Freely programmable control unit, CE tested – Motor overload relay for all drives according to the separate price item – Inverter for fan motors – Motor overload relay for boiler pump ■ In the control panel door: – 4-pole main isolator – 8” touch-screen, 640 x 480 mm – Documentation incl. fixed wiring diagram, terminal connection diagram with cable designation, operating and maintenance instructions, and installation instructions in a plan wallet ■ Sensors and switches installed at the supply screw conveyor: – Infrared light barrier, level monitoring, separating barrier, supply screw conveyor – Safety limit switch on inspection cover of supply screw conveyor – Contact sensor PT-100 at the supply screw conveyor 14 Downloaded from www.Manualslib.com manuals search engine PYROTEC Control unit (cont.) 3.2 Accessories for Pyrocontrol External drive control Part no. 7387 802 Control of an external conveyor drive or a rotary lock valve without reversing. The motors are protected against overload and switched off early in the case of a pressing risk. Standard delivery ■ Motor overload relay/contactor combination for drive motor fully integrated in control panel. ■ Input in control panel for safety limit switch at maintenance cover ■ Output in control panel for external conveyor drive Note The customer is resopnsible for the delivery and installation of the safety switch of the external conveyor drive. Note Only with defined limited material supply (upstream supply screw conveyor). The electrical output data of the existing conveyor device (kW, Ampere, Volts) must be given. Control of external drive with light barrier Part no. 7387 816 Control of an external conveyor drive without reversing, with interruption of the upstream charging where there is a risk of overfilling in the inlet by means of an integral light barrier. The motors are protected against overload and switched off early in the case of a pressing risk. ■ Output in control panel for external conveyor drive ■ Infrared light barrier installed at the supply screw conveyor inlet Standard delivery ■ Motor overload relay/contactor combination for drive motor fully integrated in control panel. ■ Input in control panel for safety limit switch at maintenance cover Note The electrical output data of the existing conveyor device (kW, Ampere, Volts) must be given. 5822 511 GB Note For the control of a supply screw conveyor with external motor downstream of the external discharge. PYROTEC Downloaded from www.Manualslib.com manuals search engine 15 3 Control unit (cont.) 3.3 Accessories for Pyrocontrol output management Cylinder management 5 sensors (QM) Part no. 7387 809 Modulating output operation is optimised with the use of a DHW cylinder. Short term heat demand peaks are also covered. The temperature sensors record the heating of the cylinder. The specification for the charging level of the cylinder is weather-compensated and carried out via the external sensor. The combustion output is matched to the charging level of the cylinder. Standard delivery: ■ 5 additional sensors PT-1000 with sensor well 1/2" x 280 mm ■ 1 weather sensor PT-1000 External requirement on/off Part no. 7387 986 Input for automatic switching on/off of the system via external zero volt N/O contact. 3 Note For external requirement, an automatic ignition system is necessary Operating message zero volt Part no. 7387 987 Issue of the operating condition "Load operation" (zero volt output) to higher control technology. Output signals 0-10 V Part no. 7387 835 Issue of boiler output as voltage signal and connection preparation to receive a maximum limit of the boiler output included in standard delivery. ■ Issue of the output signals. ■ Receipt and processing of an external output restriction. ■ Receipt and processing of an external output restriction. – Incandescent bed – Output operation Note Note: The installation of "Output signals 0 – 10 V" downstream of QM wood heating plants is possible irrespective of additional control modules to be used. Requirement, additional heat source KP0 Part no. 7387 973 Function The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder, which is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the motorised shut-off device is open. Standard delivery: ■ Sub-menu on touch-screen ■ Motor protection, boiler circuit pump, additional heat source ■ Control of motor, shut-off device ■ Zero volt contact for the control of the burner ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor) 5822 511 GB Note The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given. 16 Downloaded from www.Manualslib.com manuals search engine PYROTEC Control unit (cont.) Requirement, additional heat source KP1 Part no. 7387 905 Function The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder. This is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the control unit of the boiler mixer is enabled. Standard delivery: ■ Sub-menu on touch-screen ■ Motor protection, boiler circuit pump, additional heat source ■ Control of motor, shut-off device ■ Zero volt contact for the control of the burner ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return of additional heat source) ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor) 3 Pt1000 5822 511 GB Note The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given. PYROTEC Downloaded from www.Manualslib.com manuals search engine 17 Control unit (cont.) 3.4 Accessories for Pyrocontrol remote transfer Fault message device, analogue with battery Part no. 7387 840 Transmission of fault messages of boiler system either as SMS on a mobile or as a fax. Four different text messages are possible, as the fault message modem has four independent digital inputs. To be carried out on the customer side: ■ Electrical connection of the phone line to the modem ■ Configuration in accordance with the documentation Standard delivery: ■ Analogue modem in control panel ■ Battery station (also works in the event of a power failure) Export of operating data 3 Part no. 7387 890 Issue of relevant boiler system operating data and fault messages as ASCII dataset via serial interface to higher control technology on the customer side. All selectable parameters can be changed by higher control technology if this is planned by control technology. Standard delivery: ■ Interface at the control panel ■ Software module ■ MOD BUS report (Baud rate 9600) Note Additional fault message device, analogue with battery station [ECO-SME / 7387994] possible Additional visualisation, wired [ECO-SVD] or wireless [ECO-SVG / 7388003], not possible Visualisation, externally via modem (connected with cable) Part no. 7387 997 Package for the transmission of relevant data to an EDP workstation (internal and/or external) for the visualisation, remote maintenance and operating data archiving of the PYROTEC boiler system. Hardware and software are integrated into the Pyrocontrol control unit. All selectable parameters can be changed from the EDP workstation. Standard delivery: ■ Industrial PC with interfaces for screen, keyboard and PC mouse for EDP – workstation close to boiler room ■ Analogue modem in control panel ■ Windows operating system, remote maintenance software pcAnywhere and visualisation/archiving software installed and tested on the industrial PC. Images on the screen: ■ Cross-section image of boiler, 3D with display fields ■ Installation scheme for heat source with display fields ■ Table of parameters (with change option) To be carried out by customer: ■ It is the responsibility of the customer to organise the EDP workstation for remote maintenance together with modem, and installation of pcAnywhere and modem independently. Note Additional fault message device, analogue with battery station [ECOSME / 7387994] possible Also, export of operating data [ECO-SED / 7388038] not possible Visualisation, internal Part no. 7387 902 With a data line (max. 30 m) to the PC, all data is fed via the serial interface RS 232 at the programming module to the PC. The current operating data for the boiler system is shown visually on a function screen with all options for inputting values and functions and reading out the operating conditions (exception "Start boiler"). All operating data is archived cyclically and can be evaluated graphically in an extremely simple way. PC and data line are not included in the price. Standard delivery: ■ CD with visualisation software and installation instructions Note Requirements for on-site PC: Operating system Windows 98 / 2000 / XP Free hard disk memory at least 50 MB At least 128 MB RAM Per boiler 1 free serial interface Note The PC and data line are not included in the price. Part no. 7379 404 Data line comprising: 18 Downloaded from www.Manualslib.com manuals search engine ■ D-SUB connector for connection between programming module and data line, soldered ■ 30 m data line 3–pole (cut to length as required on site) ■ D-SUB connector with threaded fittings 9–pole for connection to the PC PYROTEC 5822 511 GB Data line to internal visualisation Control unit (cont.) 3.5 Mastercontrol for two-boiler systems The Mastercontrol optimises the entire heat generation of two biomass boilers (PYROTEC dual system) incl. control of an oil, gas or electric boiler as a redundancy and/or as a peak load boiler. Trade name Boiler combination Boiler Part no.: Mastercontrol for A Boiler 1 Pyrotec 7387 863 Boiler 2 Pyrotec B Boiler 1 Pyrotec 7387 848 Boiler 2 Pyrotec Information on the Mastercontrol Function ■ Heat management: Optimum division of the required heating output between the two biomass boilers with the main load on the lead boiler and the remainder load on the lag boiler via a defaulted output value. The defaulted output is calculated in accordance with QM wood heating stations in line with the required set temperature in the common low loss header. Automatic switchover of the two boilers between the lead boiler and the lag boiler is possible. This ensures an even boiler load over a long operating time (e.g. weekly changeover). ■ Charging: If fuel for the two biomass boilers is taken from a common fuel store, charging is controlled up to fuel distribution by the Mastercontrol. ■ Operating data archiving: Relevant operating data of the past 31 days is stored in a ring buffer and can easily be displayed in graph form on the Mastercontrol touch-screen. ■ Contactor/overload relay combinations for all common charging drives (3 x 400 V) according to separate price items ■ Ethernet interface (network connection) on touch panel ■ Zero volt output (fault message) ■ 10“ touch-screen ■ 4-pole main isolator ■ Documentation incl. fixed wiring diagram ■ Terminal connection diagram with cable designation in plan wallet ■ Cylinder management 5 sensors (QM) ■ 5 sensors PT-1000 with sensor well 1/2" x 280 mm ■ 1 weather sensor PT-1000 ■ Defaulted output value for both biomass boilers for further processing in the subordinate boiler control units via CAN-BUS Operation: Operation is carried out via a 10“ touch-screen integrated in the control panel. Visualisation with the touch-screen ■ Operating data archive ■ Display and archiving of the relevant ■ operating data of both wood boiler systems and the Mastercontrol ■ Easy operation of the wood boiler systems at the touch-screen of the Mastercontrol ■ Installation scheme for heat source with display fields ■ Table of parameters (with parameter setting options) ■ Fault history 5822 511 GB Standard delivery: ■ Control panel: Surface powder coated in RAL 7035 (grey) texture. Version as per ÖVE/VDE directives fully wired to terminal strips, fed 3 x 400 V 50 Hz; control voltage 230 V or 24 V ■ Freely programmable control unit, CE-tested, program and real time clock are battery backed Note Remote maintenance with PC or network, water-side and electrical installation is the responsibility of the customer. PYROTEC Downloaded from www.Manualslib.com manuals search engine 19 3 Control unit (cont.) Schematic diagram A T M B M M PYROCONTROL PYROCONTROL 2 1 PYROTEC 1 T B28.1 PYROTEC 2 MASTERCONTROL T B28.2 C T B28.3 T B28.4 3 T B28.5 D PYROCONTROL PYROCONTROL 1 2 1 (ECOTRONIC) 2 G E MASTERCONTROL F Additional heat source Flow consumers Cylinder as low loss header Return consumers E Charging exclusively boiler 1 in control unit boiler 1 F Charging exclusively boiler 2 in control unit boiler 2 G Common charging, control unit modules 5822 511 GB A B C D 20 Downloaded from www.Manualslib.com manuals search engine PYROTEC Control unit (cont.) 3.6 Accessories for Mastercontrol Heat meter signal Part no. 7387 975 Function With this analogue input (0-10 V signal), the external heat meter can be read into the Mastercontrol. The current values can be displayed. The heat meter data is archived in the visualisation. Requirement, additional heat source KP0 Part no. 7387 973 Function The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder, which is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the motorised shut-off device is open. It is generally used when integrating an electric boiler. 3 Standard delivery: ■ Sub-menu on touch-screen ■ Contactor and overload relay, boiler circuit pump, additional heat source ■ Control of motor, shut-off device ■ Zero volt contact for the control of the burner ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor) Note The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given. Requirement, additional heat source KP1 Part no. 7387 905 Function The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder. This is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the control unit of the boiler mixer is enabled. It is generally used when integrating oil or gas boilers. 5822 511 GB Standard delivery: ■ Sub-menu on touch-screen ■ Contactor and overload relay, boiler circuit pump, additional heat source ■ Control of motor, shut-off device ■ Zero volt contact for the control of the burner ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return of additional heat source) ■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor) Pt1000 Note The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given. PYROTEC Downloaded from www.Manualslib.com manuals search engine 21 Control unit (cont.) Fault message device, analogue with battery Part no. 7387 840 Transmits the boiler system fault messages as a phone message. The fault message must be acknowledged. Four different text messages are possible, as the fault modem has four independent digital inputs. To be carried out on the customer side: ■ Electrical connection of the phone line to the modem ■ Configuration in accordance with the documentation Standard delivery: ■ Analogue modem in control panel ■ Battery station (also works in event of a power failure) Export of operating data Part no. 7387 890 Issue of relevant operating data and fault messages of the boiler system via MOD-BUS as ASCII dataset via a serial interface to higher control technology on the customer side. All selectable parameters can be changed by higher control technology if this is planned by control technology. Standard delivery: ■ Interface at the control panel ■ Software module ■ MOD BUS report (Baud rate 9600) 5822 511 GB 3 Note ■ Additional fault message device, analogue with battery station possible, part no. 7387 840 ■ Additional visualisation, wired (part no. 7387 997) or wireless (7387 874) possible 22 Downloaded from www.Manualslib.com manuals search engine PYROTEC Heating water buffer cylinder 4.1 Specification, buffer cylinder Note Specification and information on request. 5822 511 GB 4 PYROTEC Downloaded from www.Manualslib.com manuals search engine 23 Installation accessories 5.1 Boiler accessories Flue gas recirculation Standard delivery: ■ Inlet line made from heat-resistant steel, from flue outlet to inlet adaptor ■ Inlet adaptor, supply air, with motorised cover ■ Recirculation fan in heat-resistant version ■ Supply line for gas mixture incl. covers for the combustion block (internal and external grates) ■ Software module in the control unit Note The primary air fans do not apply. Rated output Part no. kW 390 7388 043 530 7387 418 720 7387 982 950 7387 837 1250 7387 881 Insulation, flue gas recirculation line High temperature resistant insulation 35 mm thick made from mineral wool with aluminium lamination and side adhesive strips for straight elements of the gas recirculation line. Incl. adhesive strips made from aluminium foil for the faces. Note This is the responsibility of the customer as part of the general insulation work on flue gas and heating pipes. Displacer rods The installation of the displacer rods in the heat exchangers results in a better heat transfer and therefore a considerable reduction in flue gas temperature. Use is only recommended when particularly low flue gas temperatures are required and when used as a base load boiler. Rated output Part no. 5 kW 390 - 530 - 720 7387 419 950 7387 921 1250 Note In the boilers Pyrotec 390 and Pyrotec 530, boiler pipes NW40 are used. For this reason, the flow velocity of the flue gas in these boilers is higher. No displacer rods are therefore provided for these boilers. Automatic ignition system Part no. 7387 420 The heating element is electronically protected against overload, eliminating the need for visual heating element monitoring. It reliably achieves the specified maximum temperatures. Function If the combustion chamber is filled accordingly with fuel, the ignition process is triggered. The fuel is ignited by means of hot air. If ignition is successful, the ignition system cuts out. The fan of the ignition system runs on for approx. 1 minute. This cools the heating element and supplies the combustion chamber with fresh air. Automatic ignition only functions with a water content in the fuel of max. W40. Specification Ignition system Operating voltage Pressure Weight Length Width Height Diameter, blast tube Ø Connection, pressure compensation line Max. temp. Length, connection line Connected load V / Hz Pa kg mm mm mm mm mm °C mm kW 230/50 2800 1.1 335 85 85 31.5 38 650 2000 1.4 5822 511 GB Note In conjunction with the Mastercontrol, the automatic ignition system is essential. 24 Downloaded from www.Manualslib.com manuals search engine PYROTEC Installation accessories (cont.) 5.2 Boiler safety equipment Thermally activated safety valve 100 °C Part no. 7387 405 Standard version for response temperature fixed approx. 100° C, connection R ¾ Standard delivery: ■ Thermally activated safety valve incl. sensor well Note We recommend the thermally activated safety valve. Even if there is no need to use it in accordance with the local safety regulations. Thermally activated safety valve 50-120 °C Part no. 7387 406 Special version for response temperature of 120 ° C, connection R ¾ Note Replacement for art. no. K-TS-131; only use with manufacturer declaration Standard delivery: ■ Thermally activated safety valve incl. sensor well Thermally activated extinguishing valve ½”, 50-90 °C Part no. 7387 521 Thermally opening extinguishing valve with adjustable opening temperature for on-site connection to a pressurised water line or an extinguishing water container. Standard delivery: ■ Extinguishing valve Danfoss AVTA, adjustable 50-90 °C with dirt trap Supply screw conveyor two-level Part no. 7387 804 Version with two-level supply screw conveyor for optional optimised operation for shavings/chippings (high level) on the one side and for pellets (low level) on the other Standard delivery: ■ Geared motor, supply screw conveyor, pole-changing 750/ 300 rpm ■ Starttec for geared motor, pole-changing ■ Software module in the control unit 5822 511 GB 5 PYROTEC Downloaded from www.Manualslib.com manuals search engine 25 Installation accessories (cont.) 5.3 Accessories, heat distribution Motor three-way valve Designation Motor three-way valve, VBF 21.80/SQL 33 (ZH-3-80) Motor three-way valve, VBF 21.100/SQL 33 (ZH-3-100) Motor three-way valve, VBF 21.125/SQL 33 (ZH-3-125) Rated output Type 390 and 530 kW 720 kW 950 and 1250 kW ZH-3-80 ZH-3-100 ZH-3-125 Part no. 7388 260 7388 165 7388 053 DN [mm] Kvs [m3/h] 80 100 125 Servomotor 230 V 100 SQL 33 160 SQL 33 550 SQL 33 Incl. complete fitting Mating flanges, gaskets Mating flanges, gaskets Mating flanges, gaskets Note No individual issue: delivery only as part of an overall system Pumps Rated output Designation Part no. 390 kW Wilo TOP-S 50/7 DM (ZPS-506-4) Wilo TOP-S 65/10 DM (ZPS-656-4) Wilo TOP-S 80/7 DM (ZPS-806-4) Wilo TOP-S 80/10 DM (ZPS-8012-4) Wilo IL 100/145-1,1/4 (ZPS-1060-4) 7338 271 50 7388 221 65 7388 224 80 7388 131 80 7388 202 100 530 kW 720 kW 950 kW 1250 kW DN mm Voltage V Output Output Incl. complete W fitting m3/h / mWS 400 245-625 28.0/7.0 Mating flanges, gaskets 400 400-960 42.0/9.0 Mating flanges, gaskets 400 320-880 30/4.5 Mating flanges, gaskets 400 710-1500 30/6.0 Mating flanges, gaskets 400 1100 40/5.7 Mating flanges, gaskets Note We reserve the right to select the pump manufacturers and types. Delivery only as part of an overall system. 5822 511 GB 5 26 Downloaded from www.Manualslib.com manuals search engine PYROTEC Installation accessories (cont.) 5.4 Accessories, flue system Flue gas dust extractor 240/800 The flue gas dust extractor minimises dust emissions and is designed as a multi-cyclone with axial function. The dust extractor is fully insulated and has three covers for cleaning. The crude gas space is cleaned via the side cleaning cover. The clean gas space is cleaned via the upper or back cleaning cover (unused fan connection). The ash box has a carriage and is connected to the dust extractor with quick-action fasteners. It can easily be pulled out for emptying. The fan can be installed either on the side or top. Standard delivery: ■ 1 flue gas dust extractor 240 or 800 ■ 1 ash container with a hopper volume of 240 or 800 litres Note Additional ash containers must be ordered separately. Note The flue gas dust extractor is required for fuels with an increased fine percentage. (Fine percentage > 4 %) Flue gas dust extractor 240 Rated output Volume of ash box Part no. Flue gas dust extractor 800 Rated output Volume of ash box Part no. kW kW l 390 530 720 950 1250 240 7423 679 240 7423 680 240 7423 681 240 7423 682 240 7423 683 390 800 7423 684 530 800 7423 685 720 800 7423 686 950 800 7423 687 1250 800 7423 688 Ash container 240 l, reserve Ash container 800 l, reserve Part no. 7387 993 Part no. 7387 783 5822 511 GB 5 PYROTEC Downloaded from www.Manualslib.com manuals search engine 27 < 200 Installation accessories (cont.) øa A B c h d E m f b g øa G F C e 450 g l D k 240 l n n 800 l 1200 940 19,19 mm 1200 940 1200 940 5 < 200 Positioning in 4x 90° possible. (Removal, ash container.) C Dust extractor (axial cyclone) D Ash station 5822 511 GB A Flue gas fan (with variable rotation) ■ Either top or side ■ Unused connection as cleaning cover, clean gas space B Cleaning cover (crude gas space) 28 Downloaded from www.Manualslib.com manuals search engine PYROTEC Installation accessories (cont.) Dimensions Rated output Volume Part no. Weight with flue gas fan Dimensions a b c d e f g h k l m n Dimensions Rated output Volume Part no. Weight with flue gas fan Dimensions a b c d e f g h k l m n kW l 390 240 7423 679 500 530 240 7423 680 500 720 240 7423 681 517 950 240 7423 682 535 1250 240 7423 683 559 mm mm mm mm mm mm mm mm mm mm mm mm 350 447 2359 3186 1330 1256 600 2080 1670 620 1260 1330 350 447 2359 3186 1330 1256 600 2359 1670 620 1260 1330 350 461 2491 3378 1462 1256 660 2491 1730 620 1260 1462 400 579 2444 3452 1462 1300 690 2446 2083 620 1020 1462 450 579 2639 3717 1657 1300 760 2641 2153 620 1020 1657 kW l 390 800 7423 684 641 530 800 7423 685 641 720 800 7423 686 691 950 800 7423 687 709 1250 800 7423 688 749 350 447 2359 3186 1330 1256 600 2080 1670 620 1260 1330 350 447 2359 3186 1330 1256 600 2080 1670 620 1260 1330 350 461 2491 3378 1462 1256 660 2491 1730 620 1260 1462 400 579 2444 3452 1462 1300 690 2446 2083 620 1020 1462 450 579 2639 3717 1657 1300 760 2641 2153 620 1020 1657 kg kg mm mm mm mm mm mm mm mm mm mm mm mm Accessories, cleaning pneumatic The whole tubular heat exchanger is cleaned with periodic blasts of compressed air during operation. The process of cleaning itself is carried out in consecutive blasting of the individual sections. The ash is removed from the heat exchanger pipes by means of an extremely short but strong pressure pulse. The loosened particles are carried in the gas flow to the dust extractor, where they are largely separated out. The device is integrated in the boiler door. The compressor should preferably be installed where possible in a cool place in the boiler room. Function of the control unit: The number of cleaning processes within a unit of time (e.g. per hour) is matched according to the boiler load. An individual, complete cleaning process comprises a sequence of pressure pulses across all sections of the heat exchanger. 5822 511 GB Standard delivery: ■ Nozzle part integrated in the flue gas collector; incl. connectors with heat deflection discs ■ Compressed air distributor with container and valves; with heatresistant hoses connected to the nozzle part Specification Rated output Part no: Number of zones/valves Size of valves Max. air consumption under full load Additional weight (at the boiler) PYROTEC Downloaded from www.Manualslib.com manuals search engine kW pce l/h kg ■ Compressor (rotation compressor) for utility applications – Supply output 160 l/min – Container 90 l – Pressure max. 10 bar – Motor 1.5 kW – 1450 rpm – 3 x 400 V – Incl. pressure regulator and pressure switch – Sound power level 68 dBA ■ Compressed air hose up to max. 4.0 m length ■ Valves fully wired on terminal strip ■ Software module in the control unit To be carried out on the customer side: ■ Provision of a socket 400 V / 16A ■ Connector for compressor 400 V / 16A 390 7423 689 8 6/4” 3500 78 530 7423 689 8 6/4” 3500 78 720 7423 690 6/4” 4400 86 950 7423 691 5 6/4” 5300 104 1250 7423 691 6 6/4” 5300 104 29 5 Installation accessories (cont.) Price reduction net compressed air on site Part no. 7388 288 This eliminates the need for the compressor listed in the item "Cleaning pneumatic". The compressor provided by the customer must supply at least the specific quantity and quality of the air and has an adjustable pressure regulator and protection against the hose breaking (e.g. runtime limiter). The compressor must meet the following minimum requirements: ■ Compressor (rotation compressor) for utility applications – Supply output 160 l/min – Container 90 l – Pressure max.10 bar – Motor 1.5 kW – 1450 rpm – 3 x 400 V – incl. pressure regulator and pressure switch – Sound power level 68 dBA 5822 511 GB 5 30 Downloaded from www.Manualslib.com manuals search engine PYROTEC Installation accessories (cont.) 5.5 Accessories, ash removal External container Complete screw conveyor ash removal from the ash chamber into an external movable zinc-plated ash box. The level in the ash trough is monitored by means of the light barrier. If a certain level is exceeded, a certain quantity of ash is fed into the container. In this way, the ash can anneal in the ash trough under the combustion system and only cool, annealed ash is fed into the container in normal operation. For cleaning purposes, the ash removal can be switched to continuous operation in the event of a boiler standstill. Standard delivery: ■ Combustion chamber conveyor made from heat-resistant steel ■ Ascending ash conveyor as a pipe conveyor with direct transfer from the ash removal conveyor Drive via geared conveyor motor ■ Connection station with mobile ash container ■ Control of the conveyor drives ■ Infrared light barrier, level monitoring, ash in combustion chamber A B C D 5 5822 511 GB Connection station with mobile ash container can be installed in each case at 90°. It is possible to select the direction in which the ash container is pulled out. PYROTEC Downloaded from www.Manualslib.com manuals search engine 31 Installation accessories (cont.) 22,07 mm 30,27 mm 8,74 mm 16,14 mm 2459 1096 742 98 2106 25,93 mm 9,13 1,20mm mm 1793 9,13 mm 742 710 1311 Ash removal into an external container with a hopper volume of 240 l Ash container hopper volume Part no. l 240 7387 415 22,07 mm 16,00 mm 21,03 mm 2459 1330 16,37 mm 30,27 mm 2337 28,77 mm 1210 95 5 14,89 1,17mm mm 1793 14,77 mm 1200 1299 1708 Ash removal in external container 800 l Ash box hopper volume Part no. l 800 7387 953 Extension of ascending screw conveyor Part no. 7387 826 32 Downloaded from www.Manualslib.com manuals search engine 5822 511 GB Note Per metre Max. 2 m permissible PYROTEC Installation accessories (cont.) Extension of combustion chamber screw conveyor Part no. 7388 037 Note Per metre Design information 6.1 System design Selection of rated output Select the wood boiler according to the required heat load. The Pyrotec should be planned as a base load boiler and always operated in conjunction with a buffer cylinder (management). The correct system design point therefore does not depend on the nominal load specification (i.e. the building heat load) but rather on the required duration of use (length of the heating period, heat demand). Note In places more than 1800 metres above sea level, the project enquiry must include information about the exact geographical location (altitude and address of the location). Flow temperatures To minimise distribution losses, we recommend that you size the heat distribution system and the DHW heating to a max. flow temperature of 70 ºC. For wood boilers supplied with a boiler control unit, the max. boiler water temperature is limited to 85 ºC. The flow temperature may be increased by adjusting the control thermostat. Safety temperatures The boilers comply with EN 303 and DIN 4702, and all are CE-designated and can be used in sealed heating systems as per EN 12828. ■ Permissible flow temperatures (= safety temperatures): Up to 110 ºC To EN 12953: up to 120 ºC ■ Max. possible flow temperature: Approx. 15 K below the safety temperature ■ High limit safety cut-out of the boiler control unit: Delivered condition 110 ºC Adjustable to 100 ºC 6.2 Delivery KÖB delivers to the site. The system is unloaded on site. A special crane is required on site for unloading. The personnel carrying out transportation must be aware of any accident hazards. These hazards are to be prevented by suitable countermeasures. Only lift the boiler when it is completely empty (water, fuel, ash). To lift the combustion base, lifting eyes should be screwed to the points provided. After unloading, the lifting eyes must be removed. The heat exchanger is lifted by the lifting eyes provided for this purpose, placed on the combustion base and then secured to it with screws. 6.3 Handling Our experts can undertake the handling and installation on prepared foundations upon request (chargeable option). Recommended minimum clearances to walls for installation and maintenance work must be observed. An anti-vibration boiler support should be provided if anti-vibration measures are required. 5822 511 GB The combustion base has four eyes that must be screwed in before lifting. Lifting gear can be attached to these eyes. The heat exchanger of the PYROTEC has two lifting eyes to which lifting gear may be attached. A special crane (on site) is required to lift the combustion block and heat exchanger. PYROTEC Downloaded from www.Manualslib.com manuals search engine 33 6 Design information (cont.) A B 2°° 33,,547 20 45° B A Lifting eyes (screw in before lifting) B Lifting eyes (heat exchanger) 6.4 Installation Requirements for boiler room ■ Avoid air contamination through halogenated hydrocarbons (e.g. as in sprays, paints, solvents and cleaning agents) ■ Avoid very dusty conditions ■ Avoid high levels of humidity ■ Prevent frost damage and ensure good ventilation In rooms where air contamination through halogenated hydrocarbons can occur, install the boilers and flue gas/water heat exchangers only if adequate measures can be taken to provide a supply of uncontaminated combustion air. If these instructions are not observed, any consequential losses directly related to any of these causes are excluded from our warranty. If in doubt, please contact us. 5822 511 GB 6 A separate dry boiler room must be provided for the system. No combustible materials should be stored in the boiler room. The wood boiler may only be installed on a fire and temperature-resistant floor. No temperature-sensitive pipes or lines should be routed through the floor under the boiler. The load bearing capacity of the boiler room floor should be sized to the system weight plus the water fill volume and the fuel. Floor load bearing capacity in the area of the boiler supporting surface 2000 kg/m². The minimum clearances from walls and the ceiling according to the measurement sheet, which are required for cleaning and maintenance, must be observed. An adequate fresh air supply directly from outside into the boiler room must be ensured. If a boiler room is narrow and/or internal, forced ventilation is required. The temperature in the boiler room when operating the system must not exceed +40 °C (measurement point: in boiler proximity approx. 1 m away from boiler). The temperature in the boiler room when operating the system must not fall below +10 °C (measurement point: inner side of external wall). 34 Downloaded from www.Manualslib.com manuals search engine PYROTEC 250 d e b < 400 < 400 250 a 250 250 4,36 mm Design information (cont.) < 400 c Hatched surface Floor in heat-resistant version Surface medium grey Boiler supporting surface Foundation properties Trade name Rated output Part no: a b c d e kW mm mm mm mm mm PYROTEC grate combustion 530 720 950 7423 675 7423 767 7423 677 1026 1112 1360 1826 1912 2160 4721 4912 5096 1260 1400 1630 3061 3112 3066 390 7423 674 1026 1826 4221 1260 2561 1250 7423 678 1360 2160 5641 1630 3611 Requirements of Sample Combustion Order The installation room must meet the standards laid down by the "Fire Regulations" of the respective country. Observe the Building Regulations and Fire Regulations of the respective country of installation. Provide a sign adjacent to the emergency stop switch with the inscription "EMERGENCY STOP SWITCH - COMBUSTION". Emergency stop switch The burner, the fuel supply equipment and the burner control units must be able to be switched OFF at any time by an emergency stop switch installed outside the installation room. 6 Combustion air supply For open flue combustion equipment with a total rated output in excess of 35 kW, the fresh ventilation is deemed to have been verified if the combustion equipment is located in areas which provide an aperture or duct leading outdoors. At 35 kW rated output, the cross-section of the aperture must be at least 150 cm2. For every kilowatt rated output in excess of 35 kW, the aperture must be 2 cm2 larger than stated above. Pipes must be sized to provide equivalent flow rates. The required cross-section may be split over a maximum of 2 apertures or pipes. A 5822 511 GB A = 150 cm² + 2 cm² x (Σ²n – 35 kW) kW Σ²n = total of all rated outputs in kW PYROTEC Downloaded from www.Manualslib.com manuals search engine 35 Design information (cont.) Never close or obstruct combustion air apertures and lines. Use special safety measures to ensure that the combustion equipment can only be operated when the aperture is open. The required cross-section must not be blocked by any closure or grille. 26,39 mm > 800 Minimum clearances 10,20 mm >a > 880 12,25 mm > 500 14,68 mm 6 Dimensions and clearances Trade name Rated output Part no: a kW mm 390 7423 674 1350 PYROTEC grate combustion 530 720 950 7423 675 7423 676 7423 677 1850 1800 1600 1250 7423 678 2100 6.5 Water connection Existing systems Flush the heating system thoroughly before connecting the boiler to an existing heating system, to remove dirt and sludge residues. Otherwise, these dirt and sludge residues would be deposited in the boiler and could lead to local overheating, noise and corrosion. Boiler damage caused by such deposits is excluded from our warranty. Where necessary, install dirt traps. 36 Downloaded from www.Manualslib.com manuals search engine Connections on the heating water side it is the customer's responsibility to ensure that there is a water supply independent of the power supply. This (redundant) version guarantees that the boiler is reliably cooled in the event of a power failure via the thermally activated safety valve. We also refer to the standards and regulations listed in this document. PYROTEC 5822 511 GB Heating connections Design information (cont.) Connect all heat consumers or heating circuits to the boiler flow and return connectors. Never make any connections to the safety flow or to other connections. We recommend you install shut-off valves into the heating flow and return lines, so that the entire water content will not have to be drained, should work be required on the boiler or heating circuits. Easy installation For safety temperatures up to 110 ºC, the boiler requires no intermediate flow piece for the connection of safety equipment. All connections required for the various pieces of equipment, e.g. for water level or pressure limiters, are provided on the boiler. Boiler circuit and shunt pumps In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C. The boiler has variable output control. This requires a constant boiler flow rate of the water to be heated. The boiler circuit with boiler pump and boiler mixer should therefore be installed in accordance with the design recommendations. The sizing of the boiler circuit should be carried out in such a way that the temperature differential between the flow and return is 15 °C or smaller. The control of the boiler pump and boiler control valve is integrated in the control unit supplied. Safety equipment to DIN EN 12828 Installation of the safety equipment of the heating system should be carried out by the authorised heating installer. EN 12828 applies to the design of DHW heating systems with safety temperatures up to max. 110 ºC. This standard contains safety requirements laid down for boilers and boiler systems. ■ A low water indicator is not required, except in attic heating centres (water level limiter available as an accessory). ■ Thermometer and pressure gauge. ■ Sealed expansion vessel. ■ A safety valve at the highest point of the boiler or a pipe connected to the boiler. The pipework between the boiler and the safety valve must not be able to be shut off. Pumps, fittings or restrictions must not be present in this pipework. The blow-off line should be constructed so as to prevent the possibility of increases in pressure. Any expelled heating water must be able to be drained off safely. Arrange the outlet of the blow-off line so that any water expelled from the safety valve can be safely observed and drained off. System examples General information ■ In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C. A boiler circuit pump with boiler mixer should be provided in accordance with the system scheme. ■ The sizing of the boiler circuit should be carried out in such a way that the temperature differential between the flow and return is 15 °C or smaller. ■ Integrating heat consumers ■ The expansion vessel must be connected to the boiler without shutoff devices via the boiler flow. 5822 511 GB 6 PYROTEC Downloaded from www.Manualslib.com manuals search engine 37 Design information (cont.) --B28.4-- --B28.5---B28.5-- C G 3 --B28.2-- --B28.3-- --B28.2-- Sizing recommendation for systems with sealed expansion, cylinder circuit if required 2 --B28.5-- --B28.3-- D 2 1 2 1 2 B H --B28.1-- 3 3 --B28.1-- 1 A 3 F E --B28.1-- --M20-- 5822 511 GB KW M WW 1 L --Y20-- P 6 Example A B 38 Additional heat source 1 cylinder as low loss header (5 sensors) Downloaded from www.Manualslib.com manuals search engine C Distributor, heat consumer PYROTEC Design information (cont.) D E F G H L M Additional heat source controlled with a directional control valve for - Oil/gas boiler - Electric heater P With additional heat source, dual mode - Oil, gas, electric M20 Boiler pump Y20 Boiler mixer KW Cold water supply min. 2.5 bar, max. 3.5 bar Buffer cylinder More than 1 buffer cylinder as low loss header (5 sensors) Buffer cylinder 2 Buffer cylinder 1 Low loss header Possible with large water volume in mains TS131 (2 pce from Pyrotec 720) Sizing recommendation Trade name Rated output Boiler circuit Thermally activated safety valve TS-131 Required water flow rate at 2.5 bar Cylinder capacity Supply line ZLg Supply line ZLv Drain line ALv Safety valve type SV 68 M Safety line SL kW pce l/h l R R R R 390 NW 80 1 1637 3200 ¾ ¾ ¾ 1¼ NW 50 PYROTEC grate combustion 530 720 950 NW 80 NW 100 NW 125 1 2 2 2224 3020 3986 4300 5800 7600 ¾ 1 1 ¾ ¾ ¾ ¾ ¾ ¾ 1½ 1½ 2x 1½ NW 65 NW 80 2x NW 65 1250 NW 125 2 5246 10000 1¼ ¾ ¾ 2x 1½ 2x NW 80 6.6 Electrical installation This should be carried out in accordance with the wiring diagram. In the vicinity of hot parts (flue gas fan, flue pipe), cables must be routed in steel pipes for temperature protection with appropriate clearances. The cable entries for the motors and equipment should be dust-proof and provided with strain relief. Positioning of the programming module and control panel The programming module should be installed by the electrical company responsible for installation in a place that is easily accessible for operation. Optimal positioning of the control panel can minimise cable lengths and therefore reduce costs. The location of the programming module and control panel should be selected so that negative influence caused by thermal radiation (boiler front panel, boiler back panel with flue gas collector and flue gas fan, as well as flue pipe) and exposure to dust during cleaning is minimised. The ambient temperature of the control panel (approx. 10 cm away from the control panel) when operating the system must not exceed 40 °C. In case of doubt, the control panel should preferably be located outside the boiler room near to the boiler room door. Note The regulations of the local power supply utility must be observed. 6.7 Safety equipment Expansion The required expansion vessels should be selected according to the system-specific circumstances (pressure, water content, etc.). 6 In the case of sealed expansion, the pre-charge pressure of the expansion vessel should be equal to the max. system height plus 0.2 bar. Extinguishing facilities In accordance with TRVB 118, the container should be equipped with fill level monitoring. The boiler automatically switches off in case of a water shortage. In the case of excessive temperature, the supply screw conveyor safety is flooded, but to a limited extent. 5822 511 GB A water extinguishing facility is required on the supply screw conveyor. This facility is intended to reliably prevent burn-back in the event of a fault (e.g. power failure). For safety reasons and in order to avoid damage caused by flooding, it is not advisable to connect the extinguishing facility directly to the water mains. This extinguishing facility is equipped with an extinguishing water container 25 l with float switch and an adjustable Danfos extinguishing valve. PYROTEC Downloaded from www.Manualslib.com manuals search engine 39 Design information (cont.) Extinguishing water container Part no. 7387 785 C Material supply D Combustion A Note Part of the boiler. B < 500 C Note ■ Adjustment, valve, Danfos AVTA 15 50–90 °C 3 corresponds to 80 C°. ■ Lines should be secured in metal pipes (½“). ■ The cold water supply must not be able to be isolated without the aid of a tool. D 17,34 mm A N25 fill level monitoring B Extinguishing water container 25 l Extinguishing facility with cold water supply Part no. 7388 521 KW KW 6 A B A B A Combustion B Dosing container with separating barrier KW Cold water supply DN 15 ½“ min. 2.0 bar, max. 3.0 bar Note Alternative or additional safety equipment. A shut-off gate valve is required as standard for an unpressurised material store or a rotary lock valve for a material store with overpressure or underpressure (charging with fan, e.g. wood processing operations). 5822 511 GB Note ■ Lines should be secured in metal pipes (½“). ■ The cold water supply must not be able to be isolated without the aid of a tool. Back burning protection, boiler system The boiler system back burning protection is part of the standard delivery. 40 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Prevention of combustion chamber overfilling In accordance with TRVB 118, a fill level monitor should be installed to prevent overfilling of the combustion chamber. The boiler has two light barriers for incandescence monitoring. A sensor directly on the insert pipe is used to detect any sign of a burn-back risk and to counteract this early on by means of a short-term output increase (increasing in material feed). As a result, any prescribed protection device does not come into effect and normal operation is maintained with regard to the greatest possible heat supply reliability. Reignition protection In accordance with TRVB 118, reignition protection is prescribed for all systems over 150 kW. If a spark detection and extinguishing facility is not used, TRD 414 prescribes a constantly available separating barrier (TRD 414 relates primarily to waste wood from the preparation and distribution of wood and wood materials). There are simpler ways of achieving this for woodchips from the forestry and sawmill sector. The boiler is equipped with a separating barrier and is operated permanently with underpressure. The boiler is then equipped with reignition protection in accordance with both TRVB 118 and TRD 414. Back burning protection, fuel supply (RSE) Additional "material transportation back burning protection" depends on the relevant requirements (location, size of the fuel store, material, pressure, regulations) and is a separate item from the standard delivery ordered from KÖB Holzfeuerungen GmbH. For this boiler, we recommend installing a rotary lock valve. In addition to the back burning protection, the penetration of infiltrating air via the supply screw conveyor is also prevented. Shut-off gate valve The shut-off gate valve is permissible in all unpressurised fuel stores and is considered suitable back burning protection in accordance with TRVB 118 (test certificate BV 2979/89). Rotary lock valve If the wood remnants are introduced with fans in fuel storage rooms, due to the pressure load, at least one rotary lock valve is required to reduce pressure between the fuel store and the boiler. The rotary lock valve is suitable for reducing pressure and at the same time is considered suitable back burning protection in accordance with TRVB 118 (test certificate BV 2979/89). ■ Max. permissible overpressure in the fuel store: + 500 Pa ■ Max. permissible underpressure in the fuel store: + 0 Pa Dual rotary lock valve with pressure compensation If, due to special circumstances, mechanically generated underpressure or extremely high overpressure can be expected in the fuel store, then in accordance with the relevant project plan, two rotary lock valves with a pressure compensation to outside should be installed in the material transport path. The maximum pressures that can be expected are to be confirmed by the supplier of the chip extraction system. Leaks may occur in the rotary lock valve under the silo discharge system as a result of wearing of the sealing elements or due to larger pieces of wood that cannot be transported. Such leaks may allow the back flow of low temperature carbonisation gases from the combustion system into the silo. Between the rotary lock valve and the silo discharge system, a flue gas alarm should be installed, which, when responding, switches off the system causing the silo underpressure. ■ Max. permissible overpressure in the fuel store: + 3000 Pa ■ Max. permissible underpressure in the fuel store: - 3000 Pa 6 Low water indicator EN 12828 specifies that boilers must be equipped with a low water indicator (water level limiter). Tests have verified that the burner will be automatically switched OFF in the event of water shortage due to a leak in the heating system and oil burner operation, before the boiler or the flue system reach unacceptably high temperatures. 5822 511 GB Maximum pressure limiter If the rated output of the wood boiler is more than 300 kW, a maximum pressure limit is required for each boiler in a system. PYROTEC Downloaded from www.Manualslib.com manuals search engine For installation purposes, the wood boilers have a R½ connector on top of the boiler. 41 Design information (cont.) Minimum pressure limiter Recommended for flow temperatures in excess of 100 ºC. One required per multi boiler system. Safety valve Equip the boilers to EN 12828 with a type-tested safety valve. For all other operating conditions, this must be identified in accordance with TRD 721 with "D/G/H": The pipework between the boiler and the safety valve must not be able to be shut off. Pumps, fittings or restrictions must not be present in this pipework. Expansion vessel For boilers above 300 kW, install an expansion vessel with blow-off and drain line near the safety valve. In order to prevent a risk caused by escaping steam, the blow-off line must be routed to the outside. The blow-off line on the safety valve should be constructed so as to prevent the possibility of increases in pressure. Arrange the outlet of the drain line so that any water expelled by the safety valve can be safely observed and drained off. Replacement, expansion vessel An additional expansion vessel and blow-off line are not required if a second high limit safety cut-out and a second maximum pressure limiter are installed. 6.8 Fire protection The fire safety regulations for wood combustion systems vary depending on the country. The regulations valid for the relevant installation location must be observed. Fire protection, fuel store The measures necessary for this are not part of the standard delivery from KÖB Holzheizsysteme GmbH. Note In this regard, the conditions of the local planning office must be fulfilled by the operator. 6.9 Commissioning Initial commissioning of a newly installed system may only be carried out by KÖB Holzheizsyteme GmbH or another contractor trained and authorised by KÖB. Prior to commissioning, the system must be filled with water, fuel must be stored for the commissioning and the installation must be monitored. Fuel for commissioning 6 As the boiler system is cold and residual moisture is also extracted from the refractory concrete during commissioning, the fuel for commissioning must be at least air dry. The heat-up process should be carried out in the first three hours with low output. In order to check the function of the silo discharge system, not too much fuel should be stored so that, in the event of a fault, the discharge system can be quickly released to remedy the cause. For commissioning, dry fuel with a max. water content of 20 % (W20) should be stored. The quantity corresponds to consumption of approx. 10 – 24 full operating hours. Rated output 390 kW 530 kW 720 kW 950 kW 1250 kW Quantity of the fuel to be stored approx. 2500 kg approx. 3000 kg approx. 4000 kg approx. 5300 kg approx. 6800 kg Filling the heating system 42 Downloaded from www.Manualslib.com manuals search engine Note The fill pressure of the cold hydraulic seal should be approx. 0.1 bar higher than the pre-charge pressure of the sealed expansion vessel. However, it must not exceed a maximum of 3 bar. 5822 511 GB Usually, the system is initially filled with raw water without chemical treatment. This must be filtered and be free of suspended solids. Particular attention should be paid to careful ventilation during filling. In the case of difficult water conditions (high hardness, etc.) and/or large water volumes, VDI directive 2035 "Prevention of damage through corrosion and scaling in hot water heating systems" must be observed. Measures recommended by the directive for water treatment should be carried out. PYROTEC Design information (cont.) 6.10 Fuel The PYROTEC grate combustion has been specially developed for the automatic combustion of dry and moist wood fuels (waste wood, wood pellets or woodchips from forest thinnings up to max. W50). It combines the benefits of underfeed combustion with the advantages of grate combustion to optimum effect. Suitable fuels The Pyrotec is suitable for the following dry to moist wood fuels in accordance with ÖNORM M 7133: Note The following are unsuitable types of fuel: Fossil fuels and those containing sulphur, such as anthracite and coke, as well as plastics, grain, straw, material soaked in flammable liquids and waste wood treated with plastics or wood preservatives. Bulk density S (kg/m³) S 130 S 200 S 200 S 250 S 250 S 300 S 300 S 350 S 350 S 400 S 130 S 200 S 250 S 350 S 650 S 650 Water content W (%) W10 to W20 W20 to W35 W20 W20 to W35 W35 to W50 W20 to W35 W35 to W50 W20 to W35 W35 to W50 W35 to W50 < W15 < W15 < W15 < W15 < W10 < W10 Size G (mm) G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 G30/50 Fuel Natural sawdust Natural sawdust Soft natural woodchips from forest thinnings Soft natural woodchips from forest thinnings Natural sawdust Soft/hard natural woodchips from forest thinnings Soft natural woodchips from forest thinnings Hard natural woodchips from forest thinnings Soft/hard natural woodchips from forest thinnings Hard natural woodchips from forest thinnings Dry, mixed shavings, chippings from waste wood Dry, mixed shavings, chippings from waste wood Dry, mixed shavings, chippings from waste wood Briquettes from waste wood D 40 to 60 mm Standardised natural pellets D 6 to 10 mm Standardised natural pellets D 11 to 15 mm 6.11 Fuel discharge by means of screw conveyor Discharge conveyor, pellet, D = 120 mm Part no. 7837 954 As pellet transportation from a rectangular room with the possibility of filling from the top. The pellets trickle via a tilted intermediate floor into the conveyor channel. The supply screw conveyor found inside this channel transports the pellets to the outlet. Standard delivery: ■ Discharge conveyor for pellets according to project drawing Note Price given per m; total length in m = length of conveyor channel 6 Note For increases of 0° to 8°; exclusively for pellets; boiler output up to max. 1250 kW To be carried out on the customer side: Delivery and installation of the intermediate floor (preferably made of wood) incl. static calculation and sizing. The forces resulting from the weight of the combustion material (approx. 650 kg/m3) should be transferred to the silo floor and not through the discharge conveyor. Observe this when constructing the intermediate floor. mm mm mm D=120 mm 7837 954 < 9250 > 750 < 10000 5822 511 GB Specification Pellet discharge conveyor Part no. a b c PYROTEC Downloaded from www.Manualslib.com manuals search engine 43 Design information (cont.) 24,36 mm 7,53 mm 5,92 mm 77,60 mm a <200 b c 3,28 mm <30 0-8° 3,10 mm 8,02° 250 <110 5,15 mm c A 180x180 102,15 mm c 260 500 540 ~ 500 166 130 12,13 3,84mm mm 23,07 mm 14,79 14,03 mm 4,96 mmmm B 1,48 mm 50 C-C 2, 09 m 9,79 6,21 mm mm m D D 201 24 10,20 mm 24,31 mm 40,28 mm 115 274 454 A Possible outlet into a bunker B Optional drive left or right < 30 75 6,65 mm 58 45° 45° 6 66 24 110 8,8720,67 mm mm C C Intermediate floor D Intermediate floor with anti-vibration measure Part no. 7387 998 The system is driven via a spur geared motor and chain in a dust-proof chain guard. The geared motors are sized at the factory. 44 Downloaded from www.Manualslib.com manuals search engine Standard delivery: ■ Drive unit ■ Spur geared motor matched to boiler size and pump rate PYROTEC 5822 511 GB Drive, discharge conveyor, pellets Design information (cont.) ■ Control of spur geared motor 3 x 400 V according to boiler control unit ■ Inspection cover with safety limit switch and sealed outlet 6.12 Fuel discharge by means of agitators Spring core discharge AF Part no. 7387 964 for spring core discharge 3.5 m Part no. 7387 977 for spring core discharge 4.5 m Silo or bunker discharge with bottom agitator in lightweight version, especially for smaller bunker volumes and/or lower boiler outputs. The fuel supply is carried out via a bottom agitator with two leaf spring arms, which fills a screw channel let into the floor (or intermediate floor). If the silo is full, the leaf spring arms move to the cover disk. Drive is via a geared conveyor motor to the discharge screw and via an angular gear to the agitator. The spring core discharge is suitable for round, square and rectangular rooms. Standard delivery: Spring core discharge according to the project drawing ■ Bottom agitator with two leaf spring arms ■ Drive unit with geared conveyor motor 3 x 400 V ■ Control according to boiler control unit with enabling by the following conveyor device; speed/output: Project-related and subject to boiler output and fuel Specification Spring core discharge AF Part no. a Max. length of discharge screw b Discharge circuit c Boiler output at angle of inclination Torque at shaft Pellets S 650 Woodchips from forest S 200 Shavings Maximum fill level Pellets S 650 Woodchips from forest S 200 ■ Light barrier for monitoring the fill level at the end of the sealed screw channel ■ Outlet with inspection cover and safety limit switch To be carried out on the customer side: ■ Installation of an intermediate floor required (preferably wooden boards) Note 1. Discharge screw must be ordered for this! 2. Speed/output of the drives: Sizing by KÖB design department. m m Nm kW kW kW m m AF 3.5 m 7387 964 6 3.5 0° 450 540 300 220 AF 4.5 m 7387 977 6 4.5 15° 450 540 220 150 2.7 5.0 2.7 5.0 5822 511 GB 6 PYROTEC Downloaded from www.Manualslib.com manuals search engine 45 Design information (cont.) 11,00 mm Sizing 52,24 mm 4,14 mm 72,64 mm 11,89 mm 24,75 mm 170 ø 150 b < 6000 320 480 80 361 205 9,93 2,20mm mm 13,20 8,80 mmmm 22,00 mm 140 ø 110 500 250 øa 3,85 mm 5,42 mm 6,88 mm 13,75 mm 300 8,25 mm 385 275 700 440 C 3,03 mm 18,93 mm 10,59 mm 7,56 mm 900 160 A 400 > 42 4,40 mm 4,40 mm B > 250 8,25 1,16mm mm øa 800 m 73,85mm 47,24 m 0 E F c 160 6 4,47 mm D < 600 d G D E F G Shavings Remainder Pellets Base (height adjustable) 5822 511 GB A Second leaf spring B Installation opening (seal with fire-retardant panel) C Rotational direction 46 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Note 1. Installation position, horizontal: preferably in concrete with recess for screw conveyor and central gear 2. Installation position, angled: exclusively with intermediate floor, preferably made from wood 3. Suitable for woodchips up to G30/50; not suitable for wood briquettes and shredded matter from used or waste wood 4. Sloping installation position reduces the discharge output and the degree of emptying (by approx. 2.3% per 1 degree slope) 5. Speed/output: Project-related and subject to boiler output and fuel, sizing by KÖB design department Discharge screw AF to spring core discharge Part no. 7388 035 The fuel is moved by the spring core discharge arms into the open conveyor channel in the silo. Outside the bunker, the screw channel is sealed. Note Article price per m, always round up to whole numbers! The max. length of the discharge screw AF is 6 m. Total price = total length a in metres (max. 6 m) x individual price Standard delivery: ■ Conveyor channel with specially matched discharge screw Horizontal discharge AH Part no. 7387 979 for horizontal discharge up to D = 5.0 m Part no. 7387 854 for horizontal discharge up to D = 6.5 m Horizontal discharge with bottom agitator in heavy version, especially for larger bunker volumes and/or high boiler outputs. The two agitator arms each comprise one or two (depending on size) articulated arm(s) and an externally fitted leaf spring package. The agitator is driven subject to the fill level of the discharge screw (control via light barrier). The discharge screw itself is enabled independently of the agitator by a separate drive unit according to the boiler requirement. The result is trouble-free operation and a long service life. When using pellets, a cover panel is required over the screw channel. Maximum fill level and maximum slope must be observed. Standard delivery: Horizontal discharge according to the project drawing ■ Bottom agitator with two arms and external drive with shaft routed to inside ■ Drive for bottom agitator 3 x 400 V, with geared conveyor motor and torque support; control according to boiler control unit with enabling of discharge screw m kg Nm Nm To be carried out on the customer side: ■ Installation of an intermediate floor required (preferably made from wooden boards) Note 1. Discharge screw (part no.: 7387 603) must also be ordered! 2. Speed/output of the drives: Sizing by KÖB design department. 6 AH up to 5 m 7837 979 3.8 4.5 480 480 ~2900 ~800 ~2900 ~800 5.0 480 ~2900 ~800 AH up to 6 m 7837 854 5.0 5.5 500 500 ~2900 ~800 ~2900 ~800 6.0 500 ~2900 ~800 5822 511 GB Specification Horizontal discharge AH Part no. Discharge circuit f Weight excluding conveyor channel Torque of the drives A B ■ Drive unit for discharge screw with spur geared motor 3 x 400 V and chain drive; control according to boiler control unit with enabling of the following conveyor device; speed/output: project-related and subject to boiler output and fuel ■ Light barrier for monitoring the fill level at the end of the sealed screw channel ■ Outlet with inspection cover and safety limit switch PYROTEC Downloaded from www.Manualslib.com manuals search engine 47 Design information (cont.) 42,99 mm øg 4,33 mm 18,03 mm 410 A B 246 287 ø 1490 3,46 mm øf e 2,9629,62 mm mm a 34,54 mm37,56 mm 14,59 mm 7,29 mm D < 200 d C c b > 10000 A Axis, agitator B Screw axis 585 C Rotational direction D Centre, agitator Sizing the horizontal discharge AH with agitator and discharge screw a Min. length of protective panel for bunker walls b Sealed channel c Open conveyor channel downstream of agitator centre d Open conveyor channel upstream of agitator centre max. 2.8 m e Wall clearance to centre f Discharge circuit from 3.9 to 6.1 m depending on bunker situation g Effective scope 0.8 to 0.95 x f Depending on: fuel, installation position, compression, etc. 5822 511 GB 6 48 Downloaded from www.Manualslib.com manuals search engine PYROTEC 4,85 4,00mm mm 4,81 mm Design information (cont.) 76,25 mm A B A B > 10000 361 406 A < 330 3,65 mm B < 200 A B B A a C 0 > 1000 A < 200 A-A B-B 287 A 46 = < 300 < 170 = < 330 > 725 F < 600 E D 6 G D 1,52 mm E C 30 C-C K H < 330 1260 1360 H 0,96 mm C 13,59 mm 14,67 mm 50 33,67 mm L1 + 200 C 630 630 5822 511 GB 1260 PYROTEC Downloaded from www.Manualslib.com manuals search engine 49 Design information (cont.) A B C Installation position, horizontal (version 1) Installation position, sloping (version 2) Finished floor, concrete-lined (concrete block out for recessed installation) A Finished floor B Seal installation opening with fire-retardant panel C Height adjustable base D E F G H K Fuel-specific limits Maximum fill level Pellets S 650 Briquettes S 350 Woodchips from forest S 250 Boiler output max. Pellets S 650 Briquettes S 350 Woodchips from forest S 250 a Pellets S 650 Briquettes S 350 Woodchips from forest S 250 Note For pellets, the cover panels part no. 7387 895 are required. m m m Axis, screw conveyor Axis, agitator Sub-structure Building floor Centre, agitator Concrete block out (for recessed installation) 4.5 6.0 8.0 kW kW kW 2000 720 720 Angle of inclination max. 6° 0° 15° Discharge screw AH for horizontal discharge Part no. 7387 603 The fuel is moved by the horizontal discharge agitator arms into the conveyor channel, which is open across the entire bunker length. Outside the bunker, the screw channel is sealed. Standard delivery: ■ Conveyor channel running through the entire system with specially matched discharge screw Note Article price per m The max. length is 10 m. Total price: Total length L in m (max. 10) x individual price Protective panel AH for bunker Part no. 7387 985 Metal cover to protect against damage to the bunker wall caused by the agitator arms. Mounting on the internal wall of the silo. 6 Standard delivery: ■ Protective panel, painted Length and number matched to the project ■ Rawl plugs and screws Cover panel AH for pellets Part no. 7387 895 Metal cover of the open screw conveyor area to reduce the inlet cross section. Standard delivery: ■ Cover panel, painted Length and number matched to the project ■ Screws 5822 511 GB Note Observe the following when changing the fuel: 1. Changeover from woodchips from forest thinnings to pellets: Before filling the silo with woodchips from forest thinnings, remove the cover panels from the discharge screw. 2. Changeover from pellets to woodchips from forest thinnings: The discharge system is to be extended by means of cover panels. 50 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) 6.13 Fuel discharge by means of funnel discharge Funnel discharge Material discharge for round silos is carried out with an agitator integrated in the discharge casing. In its centre, the discharge screw is driven via a solid universal joint. When the silo is full, the screw conveyor moves into a vertical position. The funnel limits the angle of the screw conveyor when the silo is empty. Drive is via a spur geared conveyor motor to the agitator. In the case of material compression in the discharge casing, as a result of increased drive power consumption, the supply direction of the screw conveyor is changed automatically for a period set at the factory. This releases the compression, preventing a fault. Standard delivery: ■ Funnel discharge as per order data with drive unit 3 x 400 V ■ Automatic control of the drive for the spur geared conveyor motor for both rotational directions ■ Safety limit switch installed on inspection cover of discharge casing Version and drives Funnel discharge Part no. Diameter, discharge circuit, max. Boiler outputs with Pellets S 650 Woodchips from forest S 200 Shavings S 130 Torque at screw conveyor m kW kW kW Nm AP-11 7837 899 6.0 AP-12 7837 929 7.5 3000 1250 1250 ~1500 2500 2500 2500 ~3000 øa øb 95 210 c 6 11,22 mm 8,32 mm e 320 5822 511 GB < 600 d 0° 5,15 mm ° 40 40,0 17,94 mm 18,86 mm 6,69 mm 95 < 1,8 x a 2,21 mm 57,48 mm 2,26 mm PYROTEC Downloaded from www.Manualslib.com manuals search engine 51 Design information (cont.) Version and drives Funnel discharge Part no. a b c d e m mm mm mm Nm AP-11 AP-12 AP-Z02*8 7387 899 6.0 2205 708 282 431 7387 929 7.5 3005 1030 310 469 7388 042 7.5 3005 1030 - Additional outlet flange Part no. 7388 520 Additional connection option for supply equipment to discharge casing for twin-boiler system. Funnel, large Part no. 7388 042 Surcharge for a funnel diameter of 3000 mm. Note In the case of funnel discharge AP-12, a funnel diameter of 3000 mm is required. 6.14 Fuel discharge by means of a push floor (sizing) Number and length of the pushrods with a maximum dumping height Special version as individual rod with a width of up to 3.00 m possible on request. Max. permissible dumping height and length of the pushrods in S200 Trade name Type AS-2.50 Part no.: 7387 992 Dumping height with length: 12 m 3.1 10 m 3.9 8 m 5.3 6 m 7.5 6 Max. permissible dumping height and length of the pushrods in S350 Trade name Type AS-2.50 Part no.: 7387 992 Dumping height with length: 10 m 2.6 8 m 3.4 6 m 4.9 Max. permissible dumping height and length of the pushrods in S450 Trade name Type AS-2.50 Part no.: 7387 992 Dumping height with length: 10 m 2.1 8 m 2.7 6 m 3.8 *8 AS-2.25 7387 995 Pushrod AS-2.0 7387 836 AS-1.75 7387 956 AS-1.5 7387 989 3.6 4.6 6.1 8.6 4.1 5.3 7.0 9.8 4.9 6.3 8.4 12.3 5.8 7.4 9.8 14.9 AS-2.25 7387 995 Pushrod AS-2.0 7387 836 AS-1.75 7387 956 AS-1.5 7387 989 3.0 4.0 5.6 3.5 4.55 6.4 4.1 5.4 8.0 4.8 6.4 9.7 AS-2.25 7387 995 Pushrod AS-2.0 7387 836 AS-1.75 7387 956 AS-1.5 7387 989 2.4 3.1 4.4 2.7 3.6 5.0 3.2 4.2 6.2 3.8 5.0 7.5 5822 511 GB Applies to pushrods for pushrod drive (AS) individual and for the pushrod with discharge function of the AS-twin (standard version). Permissible dumping heights below are maximum values and should not be exceeded. Option for article AP-11. Required for AP- 12. 52 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Max. permissible dumping height and length of the pushrods in S650 Trade name Type AS-2.50 Part no.: 7387 992 Dumping height with length: 12 m 1.5 10 m 1.9 8 m 2.6 6 m 3.7 AS-2.25 7387 995 Pushrod AS-2.0 7387 836 AS-1.75 7387 956 AS-1.5 7387 989 1.8 2.3 3.0 4.3 2.0 2.6 3.5 4.9 2.4 3.1 4.2 6.1 2.9 3.7 4.9 7.4 Specification for the pushrod drives Trade name Type Part no.: Piston diameter Piston rod diameter Lift Test pressure Pressure force at 190 bar FZD Tensile force at 190 bar FZZ Length from centre of cylinder - piston boss mm mm mm bar kN kN mm Individual standard 7387 978 180 90 600 240 484 362 Type K 1080 Pushrod drive Twin standard 7387 915 180 90 600 240 484 362 Type L 1230 Heavy Version On request 220 110 800 240 722 542 1575 Forces on the building In the case of pushrod drives for discharge push floors with several pushrods, the hydraulic cylinders have pipes laid in opposite flow directions, i.e. the first cylinder pulls, the second cylinder pushes, the third cylinder pulls, etc. The cylinder with the lowest pressure drops generally moves first into the end position, then the next one. When all cylinders are in the end position, the oil pressure increases up to the response pressure for the pressure diverter valve (set to 190 bar at the factory) and this switches to the opposite direction. 5822 511 GB 6 FG1 Maximum tensile force on the weld base of the bunker upwards per metre length FS Total standard forces on the front panel (slot discharge) PYROTEC Downloaded from www.Manualslib.com manuals search engine FR Total standard forces on the back panel FR1 Standard force of a pushrod on the back panel FS1 Standard force of a pushrod on the front panel 53 Design information (cont.) FZD Maximum pressure force on the weld base for the pushrod drive FZZ Maximum tensile force on the weld base for the pushrod drive Number of pushrods FS FR 1 1x FS1 1x FR1 mm mm Standard version AS-001/2 Heavy version Y article 2 1x FS1 1x FR1 3 2x FS1 110 FS1 160 kN FR1 130 kN FZZ 362 kN FZD 484 kN FG1 12 kN FM1 100 kN Z 125 mm 240 kN 195 kN 542 kN 722 kN 15 kN 150 kN 150 mm Slot discharge, for pulling The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design. Specification Slot discharge, for pulling a b c d e f mm mm mm mm mm Note Only KÖB original weld bases are permissible for the pushrod drive. Screw D = 190 mm 650 380 350 For max. dumping height, see page 52 > 3200 1500-2500 Screw D = 250 mm 700 430 400 For max. dumping height, see page 52 > 3200 1500-2500 5822 511 GB 6 54 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) a 500 B 7,92 mm A 125 5,54 1,98mm mm 10,29 mm c 6,02 mm 0,89 19,48 mm 9,50 mmmm 27,72 mm 95,02 mm b 1230 50 600 > 1750 (4000 - 12000) 0,48 mm d 50 - 150 C FS1 A f > 150 A K FR1 A > 100 FZD e 49,44 mm FZZ > 100 15,84 mm E C D 1500 - 2500 D 1500 - 2500 F 1,19 mm 0,79 mm19,68 19,80 mm0,79 mm mm 42,36 mm A-A H G 5822 511 GB Required order data for the above example: Position Part no. Quantity 7387 978 2 A 7387 924 1 B 7387 952 2 C 7387 830 2 D E Corresp. to length 2 F See pricelist Corresp. to dimensions 1 G See pricelist 7387 904 1 H Corresponding boiler output 1 K See pricelist Unit pce pce pce pce 6 pce Designation Pushrod drive AS individual with hydraulic cylinder type L Cover for push floor screw conveyor (optional) Weld base, AS individual Weld base, bunker Hydraulic compartment Pushrod (incl. stop wedges) pce Push floor screw conveyor pce pce Version and drive, AQ standard Hydraulic drive, ASH individual Centre discharge The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design. PYROTEC Downloaded from www.Manualslib.com manuals search engine Note Use only KÖB original weld bases for the pushrod drive! 55 Design information (cont.) Specification Centre discharge 12,67 mm 800 500 FM1 a 5,54 mm 250 A 125 2,09 mm mm Screw D = 250 mm 400 360 For max. dumping height, see page 52 In the middle third of the silo length > 3200 8,07 mm mm mm 3,96 mm a b c d e Screw D = 190 mm 350 270 For max. dumping height, see page 52 In the middle third of the silo length > 3200 0,84 17,10 mm 9,50 mmmm 4,28 mm 33,26 mm 95,02 mm 50 1080 600 b > 2100 +10 0 C 0,43 mm 50 - 150 A-A B E 1500 - 2500 K D 1,30 mm 0,79 19,69 mm19,73 mm1,58 mm mm 43,16 mm d 15,84 mm 0,51 mm 46,86 mm 50 - 150 c (5000 - 12000) 6 H F A 5822 511 GB G 1500 - 2500 > 150 e A 56 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Required order data for the above example: Position Quantity 2 A 2 B C 1 D 4 E 1 F G 1 H 2 K Unit pce pce pce pce pce pce pce Designation Pushrod drive AS individual with hydraulic cylinder type K Weld base, bunker Cover, centre discharge Push floor screw conveyor Pushrod (incl. stop wedges) Version and drive, AQ standard Hydraulic compartment Hydraulic drive, ASH individual Weld base, AS individual Slot discharge with fill function The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design. Specification Slot discharge with fill function a b c d e f Note Use only KÖB original weld bases for the pushrod drive! mm mm mm Screw D = 190 mm 650 380 350 mm > 3200 Screw D = 250 mm 700 430 400 Charging chute For max. dumping height, see page 52 > 3200 5822 511 GB 6 PYROTEC Downloaded from www.Manualslib.com manuals search engine 57 Design information (cont.) 9,71 mm 235 500 230 5,86 mm 3,57 mm 16,78 9,32 mmmm b c 125 2,04 mm 5,44 mm 3,57 mm a 7,70 mm B A 1080 600 1,90 mm 15,53 mm >46,60 3000mm 230 d e 15,53 mm 0,50 mm 46,60 mm 46,60 mm 93,20 mm A-A 50 - 150 C < 8000 < 12000 FZZ FS1 > 100 FR1 > 150 A g 1500 - 2500 f A G FZD 3,03 0,54 mm mm 390 E 5822 511 GB F 50 - 150 > 100 49,60 mm H 1,16 mm 6 D 1500 - 2500 C 19,42 9,42 mm 0,78 mm 0,78 mm1mm 41,55 mm (< 20000) 58 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Required order data for the above example: Position Quantity 2 A 1 B 2 C 2 D 1 E 1 F 1 G 2 H Unit pce pce pce pce pce pce pce pce Designation Pushrod drive AS twin with hydraulic cylinder type K Cover for push floor screw conveyor (optional) Weld base, bunker Pushrod (incl. stop wedges) Push floor screw conveyor Version and drive, AQ standard Hydraulic drive, ASH twin Weld base, AS twin 6.15 Fuel discharge by means of push floor (accessory) Pushrod drive, individual Part no. 7387 978 With hydraulic cylinders, pushrods to which transport wedges are attached, are moved forwards and backwards. Stop wedges are fixed to the floor between the transport wedges. As a result of this movement, the wood fuel is dispensed from the bunker and fed into the trough of the push floor screw conveyor. Standard delivery: ■ Mount with hinge lug connection for the cylinder ■ Hydraulic cylinder with 2 HP ball valves and 2 hydraulic hoses ■ Pushrod up to bunker wall with hinge lug connection ■ Material for complete hydraulic pipework Weld base, pushrod drive, individual Part no. 7387 952 Solid steel structure for installation in concrete to secure the pushrod drive. The structure has been load tested and permanently withstands the dynamic stress. A prerequisite for this is the prescribed embedding in concrete. Standard delivery: ■ 1 weld base per pushrod drive To be carried out on the customer side: ■ Location, positioning and connecting of the weld base with the iron reinforcement on the customer side ■ Embedding the weld base in concrete ■ Static calculation and sizing of the iron reinforcement on the customer side Note Only KÖB original weld bases are permissible! Pushrod drive, twin Part no. 7387 915 With hydraulic cylinders, pushrods to which transport wedges are attached, are moved forwards and backwards. Stop wedges are fixed to the floor between the transport wedges. In the case of a twin pushrod drive, each longitudinal section of the bunker is moved with two pushrods working independently of one another. ■ Charging pushrod for quick removal of the fuel filled at the bunker end in the direction of the bunker centre. ■ Discharge pushrod for the dispensed discharge of the wood fuel into the trough of the push floor screw conveyor. The two pushrod drives are located one above the other and are supported by a joint mount. Standard delivery: ■ Mount for two cylinders with a hinge lug connection ■ Two hydraulic cylinders with 2 HP ball valves and 2 hydraulic hoses ■ Discharge pushrod up to bunker wall with hinge lug connection ■ Charging pushrod up to start of level charging function with hinge lug connection ■ Material for complete hydraulic pipework Weld base, pushrod drive, twin Part no. 7387 916 Solid steel structure for installation in concrete to secure the pushrod drive. The structure has been load tested. If embedding in concrete has been carried out in accordance with the regulations, the weld base permanently withstands dynamic stress. Standard delivery: ■ 1 weld base per pushrod drive To be carried out on the customer side: ■ Location, positioning and connecting of the weld base with the iron reinforcement on the customer side ■ Embedding the weld base in concrete ■ Static calculation and sizing of the iron reinforcement on the customer side Note Only KÖB original weld bases are permissible! 5822 511 GB Weld base, bunker Part no. 7387 830 Steel profiles for welding the pushrod guide elements and the trough of the push floor screw conveyor. The weld base in the bunker is also the slide rail for the pushrod. PYROTEC Downloaded from www.Manualslib.com manuals search engine Standard delivery: ■ Rolled profiles UNP 240 with anchoring irons per pushrod over the entire length ■ Angle profiles 50/50/5 with anchoring irons over the entire width (push floor screw conveyor) 59 6 Design information (cont.) To be carried out on the customer side: ■ Manufacturing the concrete floor ■ Installation of the profiles level with the concrete floor (max. deviation of 5 mm to 10 m) Note Article price per m Total price is calculated as follows: For pushrod drive, individual: (pushrod drives in pce x length of bunker in m) + (1 x width of bunker in m) x article price For pushrod drive, twin: (pushrod drives in pce x length of bunker in m) + (2 x width of bunker in m) x article price Pushrod Pushrod in solid structure with crosswise transport wedges, side connection profiles, stop wedges and guide elements. Length x width of the pushrod gives the floor area moved with the transport wedges. Note Number width transport wedge in m; article price per m; Total price: Length in m x article price (for max. length, see table 3) Standard delivery: ■ Pushrod split into rod, transport wedges and guide elements (welding during installation) ■ Stop wedges incl. fixing materials Specification Pushrod Part no. Width m B 1.50 7837 989 1.50 B 1.75 7387 956 1.75 B 2.00 7387 836 2.00 B 2.25 7387 995 2.25 B 2.50 7837 992 2.50 Hydraulic drive, AS individual 6 ■ Control: According to the boiler control unit, fuse protected with temperature and level switch in the oil container Use of the hydraulic drives for various push floors (drives plus rods)*9 Hydraulic drive, AS individual Rated output of the boiler/s kW Part no. kW Output, gear pump*10 Supply volume l/min Stage 1 Draught bar Stage 1 Supply volume l/min Stage 2 Draught bar Stage 2 Oil content l pce Max. number of pushrods*11 *9 V9 100-720 7387 912 4 9 V18 750-1250 7387 901 4 9 V40 1250-2500 7387 806 7.5 20 200 200 200 - 18 40 - 100 100 30 3 55 3(4) 80 3(4) Additional equipment for driving hydraulically controlled silo covers possible. *10 Information on function: with a 2-stage gear pump, the pump runs in standard mode at stage 2, which means that the pushrods move quickly. Only when the pressure drop is increased (e.g. in the case of a forward movement of the discharge pushrod with a high fill level) does the pump switch to stage 1. *11 Values in brackets: option only in coordination with project management at the factory. 60 Downloaded from www.Manualslib.com manuals search engine PYROTEC 5822 511 GB Hydraulic drive to actuate single pushrod drives with discharge function. When the required fill level of the push floor screw conveyor is reached, the discharge function is switched off. ■ Hydraulic drive comprising: – Gear pump 3 x 400 V – Oil container – Non-return valve – Pressure limit valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling – Hydraulic hoses – Wall mounting brackets Design information (cont.) Hydraulic drive, AS twin Hydraulic drive to activate twin pushrod drives with discharge and fill function. When the required fill level of the push floor screw conveyor is reached, the discharge function is switched off. If there is free space above the discharge push floor to accommodate top-up fuel, the top and back pushrod carries out the fill function. When the fuel is required by the heating system, the fill function is interrupted and switched to the discharge function of the bottom and front pushrod. ■ Hydraulic drive comprising: – Gear pump 3 x 400 V – Oil container – 4/2-way solenoid valve – Non-return valve – pressure limiting valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling – Hydraulic hoses – Wall mounting brackets ■ 2 infrared light barriers for level monitoring, bunker ■ Control of discharge function: according to the boiler control unit, fuse protected with temperature and level switch in the oil container ■ Control of fill function: According to the light barrier enabling in the bunker Use of the hydraulic drives for various push floors (drives plus rods)*12 Hydraulic drive, AS twin Rated output of the boiler/s Part no. Output, gear pump*13 Supply volume Stage 1 Draught Stage 1 Supply volume Stage 2 Draught Stage 2 Oil content Max. number of pushrods*14 V18 100-1250 7387 812 4 9 V40 1250-2500 7387 969 7.5 20 200 200 18 40 bar 100 100 l pce 55 3(4) 80 3(4) kW kW l/min bar l/min Push floor screw conveyor D = 190 mm Part no. 7387 811 In order to transport the discharged fuel away from the pushrods, the push floor screw conveyor extends over the entire push floor width as an open trough screw conveyor. For further transportation, the push floor screw conveyor, depending on the transfer situation, is designed in the sealed version as a trough or pipe. Standard delivery: ■ Push floor screw conveyor according to the project drawing 6 Note Article price per m Push floor screw conveyor D = 250 mm 5822 511 GB Part no. 7387 887 In order to transport the discharged fuel away from the pushrods, the push floor screw conveyor extends over the entire push floor width as an open trough screw conveyor. For further transportation, the push floor screw conveyor, depending on the transfer situation, is designed in the sealed version as a trough or pipe. *12 Additional Standard delivery: ■ Push floor screw conveyor according to the project drawing Note Article price per m equipment for driving hydraulically controlled silo covers possible. *13 Information on function: with a 2-stage gear pump, the pump runs in standard mode at stage 2, which means that the pushrods move quickly. Only when the pressure drop is increased (e.g. in the case of a forward movement of the discharge pushrod with a high fill level) does the pump switch to stage 1. *14 Values in brackets: option only in coordination with project management at the factory. PYROTEC Downloaded from www.Manualslib.com manuals search engine 61 Design information (cont.) Drive, push floor screw conveyor, standard Part no. 7387 925 Standard version for push floor screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard. Drive, push floor screw conveyor, standard Part no. Torque at screw conveyor Push floor screw conveyor Function, push floor screw conveyor Max. length, push floor screw conveyor Max. boiler output with woodchips Standard delivery: ■ Drive unit with spur geared motor 400 V and chain drive ■ Light barrier across the entire open area for monitoring the fill level (overfill protection) ■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version) Nm Type m kW ~800 AQ-L150 Pulling 10 300 7837 925 ~800 AQ-L150 Pushing 8 300 ~800 AQ-L190 Pulling 10 1250 Drive, push floor screw conveyor, higher-power Part no. 7387 880 Special, powerful version of the push floor screw conveyor for more difficult applications (high pump rate and/or pushing function). The system is driven via a more powerful version of a spur geared motor, bearing and chain in a dust-proof chain guard. Drive, push floor screw conveyor, higher-power Part no. Torque at screw conveyor Push floor screw conveyor Function, push floor screw conveyor Max. length, push floor screw conveyor Max. boiler output with chippings Standard delivery: ■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 400 V and chain drive; matching and control on project basis; ■ Light barrier across the entire open area for monitoring the fill level (overfill protection) ■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version) Nm Type m kW ~1200 AQ-L190 Pulling 10 1500 7837 880 ~1200 AQ-L250 Pushing 8 2500 ~1200 AQ-L250 Pulling 10 2500 Cover, push floor screw conveyor 6 Part no. 7387 924 Cover for the open trough of the push floor screw conveyor and the bunker slot. The cover is fitted to the front bunker panel and can be opened via a hinge. It helps to protect maintenance personnel against contact. Note Article price per m; Total price: Length A in m x article price [A = width of bunker] Standard delivery: ■ Cover of the push floor screw conveyor with wall mounting bracket and hinge according to project drawing ■ Limit switch for emergency stop of the push floor and the push floor screw conveyor when opening the cover 6.16 Charging the boiler with fuel Trough screw conveyor Part no. 7387 941 for trough screw conveyor D = 150 mm Part no. 7387 873 for trough screw conveyor D = 190 mm Part no. 7387 955 for trough screw conveyor D = 250 mm The trough screw conveyor is an extremely reliable means of transportation for all granulated wood fuels. Observe the restriction in the angle of inclination. Standard delivery: ■ Trough screw conveyor according to the project drawing 5822 511 GB Note Article price per m; total price; length L in m x article price 62 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) 2 mm 5,10 m1m4,5 176 500 mm 1,47 300 50 A-A 000 m 58,32 m < 10 m 4,53 m 166 e 5,51 mm g A f a/b 2,32 mm80 a A l 15,67 mm 3,77 mm 7,54 mm k A 7,54 mme 500 h mm 13,77 mm 4,82 14,51166 mm ~ 500 b 7,31 mm 2,32 mm80 5,80 mm 6,38 mm d c 8,30° c A 8,12 mm 1,11 mmmm > 6,40 30 8,75 mm 7,54 mm B A Drive (optionally on the l.h. or r.h. side) B Inspection clearance Trade name Type Part no: a b c (woodchips from forest thinnings) c (pellets) d e f g h k l mm mm mm mm mm mm mm mm mm Trough screw conveyor MF 150 MF 190 7387 941 7387 873 180x180 220x220 7180 7200 20° 20° 45° 45° 140 280 220 260 216 256 150 190 130 130 260 260 540 540 MF 250 7387 955 280x280 7200 20° 45° 380 352 317 250 154 350 665 Drive, trough screw conveyor, standard Proven version for the trough screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard. 5822 511 GB Trade name Part no: Torque at screw conveyor Diameter, screw conveyor Function Max. length Max. boiler output (pellets) Max. boiler output (woodchips from forest thinnings) Nm mm m kW kW Standard delivery: ■ Drive unit with spur geared motor 3 x 400 V and chain drive ■ Inlet with light barrier for monitoring the fill level (overfill protection) ■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device Drive, trough screw conveyor 7387 984 ~800 ~800 7150 7190 Pulling Pulling 10 10 2000 3200 600 1500 ~800 7250 Pulling 8 2500 Pipe screw conveyor Part no. 7387 990 for pipe screw conveyor D = 120 mm Part no. 7387 962 for pipe screw conveyor D = 190 mm Part no. 7387 928 for pipe screw conveyor D = 250 mm PYROTEC Downloaded from www.Manualslib.com manuals search engine 63 6 Design information (cont.) The pipe screw conveyor is ideal for conveying pourable wood fuels and/or in the case of steep ascending inclines. Note Article price per m Total price: Length L in m x article price Standard delivery: ■ Pipe screw conveyor according to the project drawing Trade name Part no: Diameter of the screw conveyor max. Trade name Type Part no: a b c d Angle of inclination max. with pushing screw conveyor e Angle of inclination max. with pulling screw conveyor e f g h k l mm 7387 990 120 Pipe screw conveyor 7387 962 190 7387 928 250 mm mm mm mm MR-L120 7387 990 140 150x150 140 120 Pipe screw conveyor MR-L190 7387 962 280 220x220 220 190 MR-L250 7387 928 380 280x280 324 250 mm - 90° 90° mm mm mm mm mm mm 65° 7150 140 540 130 260 65° 7200 280 540 130 260 65° 7200 380 665 154 350 5822 511 GB 6 64 Downloaded from www.Manualslib.com manuals search engine PYROTEC 3,77 mm m 12,26 4,35 12,92 mm mmmm Design information (cont.) m 13,90 mm 3,36 10,55 mm mm m m a 500 l A m m 6, 25 0 23 m 8 16 f e 4, 08 27° 46, m c k ~ 500 < d 2,58 mm b h 166 10 00 0 g 94 , 51 mm 2,56 mm 5,99 a g 4,61 mm 30 9, 10 00 92 < m 1,94 mm 7 6, m 8 72 m m 5,25 m mm m f C D E e 29 b 3, 58° 45, 16 55 c 4,60 mm 4, 5, d 0 m m 35 5 B A Drive (optionally on the l.h. or r.h. side) B Distributing container C Distributing screw conveyor 6 D Pipe screw conveyor, vertical, pushing E Pipe screw conveyor, horizontal, pushing Drive, pipe screw conveyor, pellets 5822 511 GB Part no. 7387 931 Simple version of the pipe screw conveyor MR 120 with pulling drive and only permissible for pellets. The system is driven via a spur geared motor and chain in a dust-proof chain guard. Trade name Type Part no: Diameter of the screw conveyor max. Torque at screw conveyor Function Length of the screw conveyor max. Boiler output max. PYROTEC Downloaded from www.Manualslib.com manuals search engine Standard delivery: ■ Drive unit with spur geared motor 3 x 400 V and chain drive ■ Inlet/discharge in simple version for pellets; incl. downpipe/adaptor for the following conveyor device mm Nm m kW Drive, pipe screw conveyor, pellets MR-11 7387 931 120 ~800 Pulling 10 1200 65 Design information (cont.) Drive, pipe screw conveyor, standard Part no. 7387 843 Standard version for pipe screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard. For MR 150 and exclusively with pellets, it is also possible as a pushing version. Trade name Type Part no: Diameter of the screw conveyor max. Torque at screw conveyor Function Length of the screw conveyor max. Boiler output max. when using: Pellets Woodchips from forest thinnings Standard delivery: ■ Drive unit with spur geared motor 3 x 400 V and chain drive ■ Inlet with light barrier for monitoring the fill level (overfill protection) ■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version) Drive, pipe screw conveyor, standard MR-12 7387 843 150 150 ~800 ~800 Pulling Pushing 10 8 mm Nm m kW kW 200 300 1200 - 190 ~800 Pulling 10 3200 1250 Drive, pipe screw conveyor, high-power Part no. 7387 963 Special, powerful version of the pipe screw conveyor for more difficult applications (high pump rate and/or pushing function). The system is driven via a more powerful version of a spur geared motor, bearing and chain in a dust-proof chain guard. Trade name Type Part no: Diameter of the screw conveyor max. Torque at screw conveyor Function Length of the screw conveyor max. Boiler output max. when using: Woodchips from forest thinnings Standard delivery: ■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 3 x 400 V and chain drive ■ Inlet with light barrier for monitoring the fill level ■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version) Drive, pipe screw conveyor, high-power MR-13 7387 963 190 250 ~1100 ~1100 Pulling Pushing 10 8 mm Nm m kW 1500 2500 250 ~1100 Pulling 10 2500 6.17 Fuel storage in on-site pellet store (sizing) Sizing the pellet storage room 6 The storage room should be more rectangular than square and should be of a size which allows an annual quantity of fuel to be stored. The size of the storage room depends on the heating load of the building. The floor area should, however, not be less than 2 x 3 m. The required size of the storage room for the annual fuel volume in m3 (incl. empty space) is calculated by multiplying the building heating load (in kW) by a factor of 0.9 (m3/kW). 5822 511 GB Example: Heating load of the building 150 kW 150 kW x 0.9 (m3/kW) = 135 m3 Available space (storage room less unusable area due to sloping floors) = 135 m3 x 2/3 +135 m3 = 225 m3 Amount of pellets = 225 m3 x 650 kg/m3 = 146250 kg/m3 ≈ 147 t Storage room size = 135 m3/ 2.3 m (room height) = 59 m2 floor area In order to store the annual fuel quantity, a room size of 7 m x 8.5 m is sufficient. Stored amount of energy = 58500 kg x 5 kWh/kg = 292 500 kWh 66 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) 200 mm A B C ≥ 500 mm D 40° G A B C D E F E Empty space F Discharge system G Available volume = ⅔ of the room Fill connector Return air connector Air space Slanted floor Pellet storage room design and required system components A B C D ≥ 100 6 K H G E < 9250 5822 511 GB F A B C D E <10000 Protective boards at the entrance to the storage room Supply area, screw supply system Deflector Discharge to supply screw conveyor Min./max. length of the discharge area PYROTEC Downloaded from www.Manualslib.com manuals search engine F G H K Max. storage room length Return air connector Fill connector Slanted panel to compensate for the lengths of the storage room/ supply area 67 Design information (cont.) ■ The pellet storage room must be dry, as pellets will swell up markedly if exposed to moisture. This leads to substantial difficulties in delivering the fuel to the boiler. ■ The pellet storage room must be of solid, leak-proof construction, as loading pellets into the room creates dust and the pellets will exert high pressure against the walls. ■ Doors or access hatches into the pellet storage room must open outwards and must be sealed against dust egress (with an all-round seal). From a pellet amount in excess of 6.5 tonnes, doors must be self-closing and fire-retardant T30. ■ Fit protective boards on the inside of the door opening, so that pellets do not push against the door (see page 68). ■ Avoid electrical installation in the pellet storage room. Essential electrical installations must be of explosion-proof type – in accordance with current regulations. ■ a In Austria, surrounding walls and separating ceilings in the storage room must be designed in accordance with fire resistance class F90, and doors or access hatches in accordance with T30. Observe the fire regulations to TRVB H118 and the respective legal requirements. ■ Avoid the installation of water pipes inside the storage room because of condensation and the risk of burst pipes. ■ Pellet storage rooms should be equipped with a delivery H and a return air connector G with a coupling 4” DW100 (fire hose connector) with extension hoses leading into the pellet storage room. Pipes should be metal (not plastic), should be connected to the brickwork and should be earthed. ■ Fit a deflector C opposite the fill connector to protect the pellets and the brickwork. ■ The pellet storage room must be free from foreign bodies (small stones, wood particles, etc.). ■ The wall outlet for the room discharge from the storage room should be fire-proofed (e.g. rendered). The screw conveyor system may be up to max. 10 m long. Additional safety instructions for pellet stores To operate the pellet store, we also recommend observing the following safety instructions: 1 Access by unauthorised persons is not permitted, and doors must be kept sealed 2 Smoking, fires and other sources of ignition are prohibited 3 Risk to life due to odourless carbon monoxide (CO) and a lack of oxygen 4 Before entering, ensure sufficient ventilation is in place - keep door open when entering 5 Entry into the storage room is only permitted with the supervision of a person standing outside the storage room 6 Risk of injury caused by moving parts 7 Ensure filling is carried out under the conditions stipulated by the heating installer and pellet supplier 8 Protect the pellets from moisture Protective boards with Z profiles A B A Z brackets are available as accessories for the installation of the protective boards. Never install Z brackets up to the ceiling, to facilitate the (future) removal or addition of protective boards. 6 C A Z profile (length 2000 mm) B Protective board (30 mm thick; on-site) C Door towards the storage room Fill connector and return air connector 68 Downloaded from www.Manualslib.com manuals search engine Earthing The connectors must be earthed in order to prevent static loads during the filling process. Generally the connection of each pipe element to the bonding of the building earth is recommended. At the very least, connect each pipe element securely to the brickwork, either by setting the pipe into the brickwork (without thermal insulation) or via pipe clips set into the brickwork. 5822 511 GB Arrange the connectors so that no overpressure is created in the pellet storage room during the filling process. Keep the return connector unrestricted, even when the maximum filling level in the storage room has been reached (see page 67). The connectors should be located as high as possible inside the storage room to enable it to be filled to its maximum. To prevent pellets hitting the ceiling, the fill connector should be at least 20 cm below the ceiling (fit protective boards if the ceiling is plastered). The connectors should be located along the narrow side of the storage room. Pellets are blown approx. 4 - 5 m with straight fill connectors. Where a 2 x 45° bend fitting is located before the entry into the storage room, fit a straight pipe of at least 0.5 m length on the other side to protrude into the storage room. This enables the pellets to reach the required filling velocity and therefore the necessary "blow-in" depth. PYROTEC Design information (cont.) Connector length and location The length of the fill connector is subject to the distance from the return air connector. Connectors may be spaced out < 500 mm if both connectors are set into a cellar window. Internal pellet storage room If the fill and return air connectors must be routed through an adjacent room, clad both with a fire-resistant material compliant with class F 90 (rockwool, or similar). Earth each extension piece via pipe clips. Plastic pipes should not be used as extension pieces. ≥ 500 ~ 100 If connectors must be located on the long side of the storage room, we recommend alternating the filling between the connectors. This ensures more efficient filling. In any case both connectors should be earthed. A deflector should be installed opposite both connectors. Connector clearance ≥500 mm A Fill connector B Return air connector A A B C D C D Connector Fire resistant cladding (F 90) Extension pipe Pipe clip < 500 ≥ 500 B ~ 100 Connector clearance < 500 mm A Fill connector B Return air connector 6 ≥200 mm B A approx. 100 mm B A 5822 511 GB Alternating filling A Deflector B Fill and return air connector PYROTEC Downloaded from www.Manualslib.com manuals search engine 69 Design information (cont.) Connector installation options Setting into brickwork The connector is bricked into the opening without thermal insulation. A Fill connector B Wall outlet Ø 150 mm Wall installation with screws The connector is secured to the outside wall with screws and is earthed via a pipe clip. C Pipe clip for earthing D Wall outlet Ø 110 mm C BA D A Fill connector B Screws 6 Window installation with screws A plate is set into the window opening. The connector is fitted through the plate, secured with screws and earthed via a pipe clip. C Pipe clip for earthing D Outlet Ø 110 mm E Window aperture C D E BA 5822 511 GB A Fill connector B Screws 70 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Installation into a lighting duct Connectors may be installed through a wall or through a window opening. The shortened fill and return connectors are inserted in a 45 º bend. The bend is inserted into an extension pipe routed through the wall or the window opening. C Extension pipe D Wall outlet Ø 110 mm or Outlet Ø 110 mm E 45º bend B A E C D A Fill connector B Pipe clip for earthing 6.18 Fuel storage in on-site pellet store (accessories) Deflector 1.42 x 1.25 m Part no. 7388 188 The deflector comprises 4.0 mm thick chipboard with a fabric lining for high strength. Install the deflector B at a clearance of at least 100 mm from the wall opposite the fill connector. This deflector protects the pellets as well as the brickwork or the rendering/plaster. Pieces of plaster/render or wall that have been prised off can hinder the pellet supply and the ash removal from the boiler combustion chamber. A B C Standard delivery ■ Deflector 1.4 x 1.25 m ■ Section anchor with snap link for fastening ≥200 mm 6 A Fill connector B Deflector (1000 x 1200 mm) C Fill width approx. 4 - 5 m Blast pipe, straight Part no. 7388 213 ■ Zinc-plated steel pipe with male thread M 107 x 2.0 ■ Dummy coupling with imprint and padlock Standard delivery: ■ Blow-in connector with Storz coupling 4” ■ Mounting flange 200 x 200 x 2 mm Blast pipe with 45° bend 5822 511 GB Part no. 7388 154 ■ Zinc-plated steel pipe with male thread M 107 x 2.0 ■ Dummy coupling with imprint and padlock Standard delivery: ■ Blow-in connector with Storz coupling 4” ■ Mounting flange 200 x 200 x 2 mm PYROTEC Downloaded from www.Manualslib.com manuals search engine 71 Design information (cont.) Extension, blast pipe, straight Part no. 7388 056 Standard delivery: ■ Extension DN 100, length 700 mm, zinc-plated ■ Union nut for fitting ■ Clip for fastening 45° bend for blow line Part no. 7388 052 Standard delivery: ■ Zinc-plated bend DN 100 ■ Union nut for fitting 6.19 Fuel storage in on-site bunker (accessories) Silo cover, manual FDM 2.9/1.3 m Part no. 7387 782 Cover for secure sealing of openings for wood fuel delivery. The cover is controlled manually with leg springs as an opening aid. The opening has a fall protection grille to prevent anyone falling in when the cover is open. Note For the filling process (opening, filling, closing), the local regulations on accident prevention must be observed (e.g. enclosure, safety of personnel) ■ Cover – Surface, aluminium button plate – Watertight, welded ■ Leg springs as opening aid To be carried out on the customer side: ■ Creating the ceiling recess with concrete collar ■ Seal between cover frame and supporting surface, concrete collar ■ Padlock to protect against incorrect operation Standard delivery: ■ Steel supporting structure – Permissible load 250 kg/m² – Sand-blasted – Primed with zinc dust and painted ■ Welded fall protection grille with rod clearance 150 mm 5822 511 GB 6 72 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) A All-round seal (not included in standard delivery) B Rod clearance, fall protection grille C Secured with 10 x screws 6 Bunker cover hydraulic FDH Cover for secure sealing of openings for wood fuel delivery. The cover is controlled manually using a hydraulic cylinder. The silo cover is prevented from falling shut in the event of a hose break. ■ Hydraulic cylinder with hinge lug connection, pipe break protection, mount, hydraulic hoses 1 m long ■ Rubber apron to deflect chippings on the hinge side Note For the filling process (opening, filling, closing), the local regulations on accident prevention must be observed (e.g. enclosure, safety of personnel). Where wind is strong (greater than 10 m/s), the cover must not be opened. To be carried out on the customer side: ■ Creating the ceiling recess with concrete collar ■ Seal between cover frame and supporting surface, concrete collar 5822 511 GB Standard delivery: ■ Supporting structure: permissible load 250 kg/m² made from steel, sand-blasted, primed with zinc dust and painted ■ Cover surface: Aluminium button plate, watertight, welded PYROTEC Downloaded from www.Manualslib.com manuals search engine 73 A h 40,55 mm Design information (cont.) B 62,77 mm C g Specification Type*15 Part no. Opening length x width a c Dimensions, concrete collar b d e Dimensions, cover, external f g h Number of hydraulic cylinders Weights, cover *15 Type FDH 4.0/2.4 7388 011 FDH 5.5/2.4 7387 903 FDH 7.0/2.4 7387 834 FDH 8.5/2.4 7387 884 mm mm 4020 2400 5520 2400 7020 2400 8520 2400 mm mm mm 4420 2800 250 5920 2800 250 7420 2800 250 8920 2800 250 mm mm mm pce kg 3025 4500 2924 1 1029 3025 6000 2924 1 1231 3025 7500 2924 1 1516 3025 9000 2924 2 1823 5822 511 GB 6 A Fall protection grille (optional) B Rubber apron C All-round seal, required, not included in standard delivery Recommendation: Kemperol combi roof seals 7.0/2.4 and 8.5/2.4 with covered expansion joint for heat expansion 74 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) Fall protection grille 120 for FDH Fall protection grille for corresponding bunker cover in several elements to prevent anyone falling in when the cover is open. Each element is prepared for installation of a shaker motor (shaker motor at an additional charge). Specification Fall protection grille, type 120 for Part no. Quantity Weight per pce pce kg Standard delivery: ■ Support profile for installation in ceiling recess ■ Fall protection grille in several elements, mesh size: 200 x 120 mm FDH 4.0/2.4 7387 914 2 117 FDH 5.5/2.4 7387 817 2 161 FDH 7.0/2.4 7388 014 3 133/141 FDH 8.5/2.4 7387 922 4 124/120 Fall protection grille 200 for FDH Fall protection grille to prevent anyone falling in when the cover is open. Suitable for corresponding bunker cover in several elements. Each element is prepared for installation of a shaker motor (shaker motor at an additional charge). Specification Fall protection grille, type 200 for Part no. Number of elements Weight per pce pce kg Standard delivery: ■ Support profile for installation in ceiling recess ■ Fall protection grille in several elements, mesh size: 200 x 200 mm FDH 4.0/2.4 7387 910 2 104 FDH 5.5/2.4 7387 824 2 143 FDH 7.0/2.4 7387 930 3 118/125 FDH 8.5/2.4 7387 983 4 110/106 Bunker cover, movable FDB Cover for secure sealing of openings let into travel planes for wood fuel delivery. The surface of the cover is flush with the travel plane. The sub-structure has a drip channel. The cover is controlled manually using a hydraulic cylinder. The silo cover is prevented from falling shut in the event of a hose break. Standard delivery: ■ Supporting structure: Perm. wheel load: FDB 3.0/2.0: 7.5 to; FDB 3.8/2.4 and FDB 3.2/3.2: 10.0 to; steel, sand-blasted, primed with zinc dust and painted. ■ Cover surface: For filling with asphalt or concrete on the customer side. ■ Sub-structure: Has drip channel and two drain connectors NW 100. ■ Hydraulic cylinder: With hinge lug connection, pipe break protection, mount and hydraulic hoses 1 m long To be carried out on the customer side: ■ If the travel surface is sloping, the water flowing to the cover must be drained away upstream of the cover frame by means of a drain channel ■ Drain line for rainwater, channel heating ■ Seal between cover frame and supporting surface of cover frame ■ Filling of the cover surface with a bitumen layer and asphalt or concrete, watertight design (max. permissible own weight of the fill 2200 kg/m3) 5822 511 GB 6 PYROTEC Downloaded from www.Manualslib.com manuals search engine 75 b 8° ,0 86 31,972,26 mm mm 39,71 mm Design information (cont.) 120 ° 86 A 1,90 mm ~ 1730 ø102 C B 56,10 mm a 37,68 mm c 1,87 mm58,53 mm1,87 mm 90 (120) ±0,0 f F G 90 6 E 6,78 mm d e 290 47,31 mm 1,68 mm 5,30 mm 40,20 mm C 90 C D H < 10% Filling on customer side (concrete or asphalt) Channel for rainwater Rainwater drain (on site) Threaded fitting 76 Downloaded from www.Manualslib.com manuals search engine E F G H Filling level Fall protection grille (optional) All-round seal (required) (on site) Drain channel, running water (on site) 5822 511 GB A B C D PYROTEC Design information (cont.) Specification Bunker cover, movable FDB Part no. a b c d e f Weight, cover, FDB Max. permissible wheel load mm mm mm mm mm mm kg t FDB 3.0/2.0 m 7387 850 3000 2110 2000 3150 2530 2150 1520 7.5 FDH 3.8/2.4 m 7387 793 3800 2510 2400 3950 2930 2550 2360 10 FDH 3.2/3.2 m 7387 974 3200 3310 3200 3350 3730 3310 2680 10 Fall protection grille, 120 for FDB Fall protection grille to prevent anyone falling in when the cover is open. Suitable for corresponding bunker cover in several elements. Each element is prepared for installation of a shaker motor (shaker motor for additional charge). Specification Fall protection grille, type 120 for Part no. Number of elements Weight per pce Standard delivery: ■ Support profile for installation in ceiling recess ■ Fall protection grille in several elements ■ Mesh size: 200 x 120 mm pce kg FDB 3.0/2.0 m 7387 889 2 130 FDH 3.8/2.4 m 7388 016 2 205 FDH 3.2/3.2 m 7387 868 2 230 Fall protection grille, 200 for FDB Fall protection grille to prevent anyone falling in when the cover is open. Suitable for corresponding bunker cover in several elements. Each element is prepared for installation of a shaker motor (shaker motor for additional charge). Standard delivery: ■ Support profile for installation in ceiling recess ■ Fall protection grille in several elements ■ Mesh size: 200 x 200 mm Specification Fall protection grille, type 200 for Part no. Weight per pce pce kg FDB 3.0/2.0 m 7387 798 2 120 FDH 3.8/2.4 m 7387 801 2 180 FDH 3.2/3.2 m 7388 019 2 210 Shaker motor for fall protection grille Part no. 7387 810 The shaker motor sets the fall protection grille in an oscillating motion. This prevents the delivered fuel from bridging the fall protection grille and therefore ensures a steady material flow during filling. Standard delivery: ■ Shaker motor, 3 x 400 V incl. control, thermal protection and installation material ■ Key switch To be carried out on the customer side: ■ Electrical connection of shaker motor and key switch Note One shaker motor is required per fall protection grille element. In addition, when using shaker motors, a large control panel must be included in the plans. Hydraulic drive, bunker charging cover, ASH Standard delivery: ■ Hydraulic drive comprising: – Gear pump 4 l/min incl. motor 1.5 kW 3 x 400 V – Oil container 12 l, non-return valve – pressure limiting valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling 5822 511 GB Part no. 7388 856 The hydraulic drive is used exclusively for actuating a bunker cover, which is opened hydraulically. The cover is opened by the hydraulic cylinder when the key switch button is pressed. When the key switch button is released, the load holding valve fixes the cover in position. PYROTEC Downloaded from www.Manualslib.com manuals search engine 77 6 Design information (cont.) – Hydraulic hoses – Wall mounting brackets ■ Control: – According to the boiler control unit, fuse protected with temperature and level switch in the oil container ■ Key switch button OPEN/OFF/CLOSED for installation of a locking cylinder on the customer side (installation close to cover) Note Application in the case of silo discharge systems without hydraulic activation (AF, AG, AP, external discharge) Cover drives for hydraulic drive, ASH Type Part no. ASH 1 7388 010 ASH 2 7387 913 ASH 3 7387 897 The auxiliary equipment for the hydraulic drive ASH of the pushrod discharge for activating hydraulically opening bunker covers. The covers are opened by the hydraulic cylinder when the key switch button is pressed. When the key switch button is released, the load holding valve fixes the cover in position. Control: According to the boiler control unit One key switch button OPEN/OFF/CLOSED per cover for installation of a locking cylinder on the customer side (installation close to bunker cover so that the motion process can be monitored). Standard delivery: ■ 1 valve block per cover, each equipped with: – 2 solenoid valves – 1 load holding valve – 2 non-return throttle valves Silo filling screw conveyor FS 300 Part no. 7387 808 Supply screw conveyor in open version for filling a fuel store located inside a building from an external tipping trough. Generally, at least two silo filling screw conveyors are required. The silo filling screw conveyors are routed through the fuel store in such a way so as to maximise filling. Standard delivery: ■ Silo filling screw conveyor according to order data ■ Mounting brackets for wall mounting ■ Duct for routing through a wall Note Screw conveyor length with drive unit max. 10 m Note Price per m: Total length = wall inner up to end of screw conveyor in drop area (silo cover) Note The load bearing capacity of the walls must be verified on site by a structural engineer! Drive, silo filling screw conveyor 6 Part no. 7387 898 The drive is located inside the building but outside the fuel store. This means that the silo filling screw conveyor has a pulling effect. For safety reasons, the key switch button must be located close to the tipping trough. The operator must permanently monitor the filling process from outside. Releasing the button stops the screw conveyor immediately. 5822 511 GB Standard delivery: ■ Drive unit, silo filling screw conveyor ■ Spur geared motor with matched torque and pump rate, 3 x 400 V ■ Control of screw drive according to boiler control unit ■ Key switch button ON/OFF for installation of a locking cylinder on the customer side (installation close to cover). 78 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) 1,54 mm mm 10,19 mm 2,58 10 0, 13 ° <1 18 500 >1 mm mm 000 0 < 1500 A ø300 13,51 mm 2860 36 2,31 mm 12, 59, 22,06 mm > 10° < 800 8,72° 0° 10 A-A 200 1300 9,59 mm 350 A 6.20 Back burning protection Rotary lock valve 5822 511 GB Standard delivery: ■ Rotary lock valve according to order data ■ Control of spur geared motor for both rotational directions according to boiler control unit 6 Note Rotary lock valve 190 for supply system D 120 mm Rotary lock valve 260 for supply system D 150 mm and D 190 mm a 7,86 mm d øb 13,24 mm 10,67 mm Rotary lock valve for fire protected separation of combustion system and fuel store with overpressure or underpressure, and with simultaneous material transportation for installation in a drop section. The rotary valve is made entirely from steel and is permissible as a fire protection between the combustion system and woodchip silos in wood processing operations with overpressure or underpressure. The drive device is a spur geared motor with sprung torque support. If the woodchips are extremely coarse, briefly running the system in reverse avoids jamming. Fire protection: RSE according to TRVB and VKF Max. permissible overpressure in the fuel store: + 500 Pa Max. permissible underpressure in the fuel store: ± 0 Pa 27,93 mm 7,86 mm 14,00 mm c e f Positioning: ■ Directly above the supply screw conveyor ■ Exception for funnel discharge: directly at the casing PYROTEC Downloaded from www.Manualslib.com manuals search engine 79 Design information (cont.) Trade name Type Part no: a b c d (Di) e (Da) e (Di) e (Da) f Output, drive Drive speed Rotary lock valve MZ 190 MZ 260 7387 967 7387 422 260 330 7193 7264 662 709 150 202 200 250 150 202 200 250 274 346 0.75 0.75 252 25 mm mm mm mm mm mm mm mm kW rpm Shut-off gate valve MA 220 350 34 B 13,91 mm 287 220x220 240 12,36 mm Standard delivery: ■ Shut-off gate valve according to order data ■ Control of shut-off gate valve according to boiler control unit ■ Spring return motor (torque 30 Nm) A 158 Part no. 7388 020 Fire protected appliance for installation in a drop section, for mechanical separation of the combustion system and unpressurised fuel store. The shut-off gate valve opens automatically and closes with zero volts via a spring balancer in the event of burnout, risk of burn-back or power failure. Material: Steel/brass Drive: Spring return motor, fire protection: RSE according to TRVB and VKF 230 605 410 785 230 1015 6 A Shut-off gate valve closed B Shut-off gate valve open Downpipe L = 1.0 m Part no. 7387 942 Connection of a drop section between the discharge system or conveyor device and an onward conveyor device by means of a downpipe. Note The length of the downpipe is 1 m. Design (diameter, profile) of the downpipe is matched to the relevant project at the factory. Special adaptor Note Design (diameter, profile) of the special adaptor is matched to the relevant project at the factory. 5822 511 GB Part no. 7387 939 Connection of a drop section between the external discharge system and an onward conveyor device by means of a special adaptor. 80 Downloaded from www.Manualslib.com manuals search engine PYROTEC Design information (cont.) 6.21 Connection on the flue gas side Chimney The system is equipped with a flue gas fan and therefore combustion equipment without draught requirement. The chimney sizing should be carried out in the same way for combustion equipment with a pressurejet oil or gas burner without draught requirement (flue gas temperature at rated load 160 - 200 °C). The PYROTEC grate combustion has output control in the range of 25 - 100 % of the rated output. This results in flue gas temperatures in the range of min. 100 °C to max. 250 °C. In order to avoid a risk of soot contamination, there should be an insulated chimney. The route from the flue gas fan to the chimney should be as short as possible. 90° bends should be avoided wherever possible. Flue pipes more than 1 m long should be thermally insulated. The chimney should be connected rising at an angle of 30- 45°. The flue pipe incl. inlet to the chimney must be gas-tight. For the operation of the PYROTEC grate combustion in accordance with the regulations, a draught stabiliser (draught limiter) is required in the chimney. A chimney compliant with regulations relevant to the rated boiler output is required for efficient boiler operation. Provide verification to DIN EN 13384. Note that in its lower output range, flue gas temperatures below 90 ºC may be generated. Therefore connect the boiler to a moistureresistant chimney (thermal resistance class I to DIN 18160 T1). If the boiler is not being connected to a moisture-resistant chimney, carry out a chimney calculation or request a chimney assessment (values for a chimney calculation, see page 9). Flue pipe The induced draught fan may cause vibrations, which can lead to excessive noise. We therefore recommend connecting the connector to the chimney with a flexible flue pipe adaptor. C Lambda probe with measured value transducer D Flue gas temperature sensor E Flue gas fan Observe the following when connecting the flue: ■ Install the flue pipe rising to the chimney (with 45º if possible). ■ Never push the flue pipe too far into the chimney. ■ Ensure the full flue gas path (incl. cleaning aperture) is gas-tight. ■ Do not fit the flue pipe with mortar into the brickwork of the chimney. Instead, use a flexible flue pipe adaptor. Provide a cleaning aperture. ■ Wall liners to adapt to flue systems by third party manufacturers. ■ Provide the flue with thermal insulation of at least 30 mm thickness. A b 5,57 mm 6,90 mmc d 6,16 mm 6,64 mm 20,54 a mm > 1000 E A D C B 6 A Draught limiter B Recirculation kW mm mm mm mm 390 7423 674 447 350 450 600 PYROTEC grate combustion 530 720 950 7423 675 7423 676 7423 677 447 461 579 350 350 400 450 450 450 600 660 690 1250 7423 678 579 450 450 760 5822 511 GB Trade name Rated output Part no: a b c d PYROTEC Downloaded from www.Manualslib.com manuals search engine 81 Design information (cont.) 6.22 Sound insulation Braces To avoid the transmission of structure-borne noise during the operation of the fuel transportation equipment, the braces and the anchors of the relevant conveyor device are placed on high quality Sylomer bases (plastic anti-vibration mounts for noise attenuation) or anchored with a Sylomer support and a fixing plate in the building structure. The anchors with heavy load anchors are separated from the braces with Sylomer washers. Trade name Type Part no: Discharge conveyor 7419 991 Screw conveyor 7419 992 Standard delivery: ■ Sylomer washer ■ Sylomer support ■ Sylomer base ■ Fixing plate for the braces of the relevant equipment Sound insulation, braces Supply Spring core Horizontal discharge discharge 7419 995 7419 996 7419 997 Removal of ash 7419 998 Flue gas dust extractor 7419 999 Note ■ Depending on the means of fuel transportation, the sound insulation article should be used once, e.g. 1 AH + 1 sound insulation AH-AS ■ Installation room characteristics relating to the physical building structure largely determine the transmission of structure-borne noise in the building. It is important to note that the specified measures do not offer full sound insulation. ■ Building related measures (brick openings, fire barriers, floating screeds, etc.) must be coordinated with structural engineers and architects and are not part of standard delivery and therefore not within our area of responsibility. Appendix 7.1 Sizing the expansion vessel In accordance with EN 12828, water heating systems must be equipped with a diaphragm expansion vessel. The size of the expansion vessel is subject to the heating system specification and should be checked in each case. Vn litres 25 35 50 80 100 140 200 250 300 400 500 Selection example Datum: psv = 3 bar (response pressure of the safety valve) H = 13 m (static ceiling of the system) Q = 18 kW (rated output of the heat source) v = 8.5 l/kW (specific water capacity) panel radiators 90/70 °C VPH = 1000 l (volume of buffer cylinder) The specific water capacity v was determined as follows: ■ Radiators: 13.5 l/kW ■ Panel radiators: 8.5 l/kW ■ Underfloor heating: 20 l/kW 82 Downloaded from www.Manualslib.com manuals search engine Calculation: VA = Q x v + 1000 VA = 18 kW x 8.5 l/kW + 1000 l = 1153 l If possible, when calculating the gas pre-charge pressure, select a supplement of 0.2 bar: p0 ≥ H/10 + 0.2 bar p0 ≥ (13/10 + 0.2 bar) = 1.5 bar From the table: With psv = 3 bar, p0 = 1.5 bar, VA = 1153 l Vn = 250 l (for VA max. 1360 l) PYROTEC 5822 511 GB 7 Quick selection table for calculating the vessel size Vn Safety valve bar 3.0 psv Pre-charge bar 1.0 1.5 1.8 pressure System vollitres 220 — — ume VA 340 200 — 510 320 200 840 440 260 1050 540 330 1470 760 460 2100 1090 660 2630 1360 820 3150 1630 990 4200 2180 1320 5250 2720 1650 Appendix (cont.) Selected: 1 x diaphragm expansion vessel N 250 (from Vitoset pricelist) ■ All details relate to a flow temperature of 90 °C. ■ The tables have allowed for a hydraulic seal to DIN 4807-2. Conversion factor for flow temperatures other than 90 °C Flow temperature °C 50 55 60 65 Conversion factor 3.03 2.50 2.13 1.82 Recommendations: ■ Select a sufficiently high safety valve response pressure: psv ≥ p0 + 1.5 bar ■ For circulation pumps, due to the inlet pressure required, select at least 0.3 bar above the pre-charge pressure even for attic/roofspace installations: p0 ≥ 1.5 bar ■ Set the water side filling/starting pressure of vented systems in their cold state at least 0.3 bar above the pre-charge pressure: pF ≥ p0 + 0.3 bar 70 1.59 75 1.39 80 1.24 85 1.11 90 1.00 95 0.90 100 0.82 Divide the vessel size found in accordance with the above tables by the conversion factor. 7.2 General information regarding low pressure hot water boilers with safety temperatures of up to 110 ºC The pressure equipment (hot water boiler) has been built in accordance with TRD 702 and should be equipped in line with that Directive. Observe the operating conditions in that Directive. Subject to type, this boiler meets the following standards regarding its stated rated output and technical requirements: ■ DIN 4702 or EN 303 ■ EN 297 ■ EN 483 ■ EN 677 (See details on the type plate and the enclosed documentation). During installation and commissioning of these boilers, observe all local Building Regulations and regulations concerning combustion systems, as well as the following Standards, Regulations and Directives: ■ DIN 18160-1: Flue system (design versions). ■ DIN 1988: Technical Regulations for Drinking Water Installations (TRWI). ■ DIN 4753: DHW systems for DHW and process water. ■ EN 12828: Heating systems in buildings – Design of DHW heating systems. ■ EN 13384: Flue systems – Thermal and flow calculations. ■ TRD 702: Equipment level for steam boiler systems with hot water boilers class II ■ Also observe EN 12953 with: – Low pressure hot water boilers with safety temperatures > 110 to 120 ºC. ■ EN 12953-1: Boilers with large water chambers – General information. ■ EN 12953-6: Boilers with large water chambers – Equipment requirements. ■ EN 12953-7: Boilers with large water chambers – Requirements for combustion systems for liquid or gaseous fuels for the boiler. ■ EN 12953-8: Boilers with large water chambers – Safety valve requirements ■ EN 12953-10: Boilers with large water chambers – Feed water and boiler water requirements Use of oil combustion ■ DIN 4755: Oil combustion equipment. ■ DIN 4787-1: Atomising oil burner (in excess of 100 kg/h throughput). ■ DIN 51603-1: Liquid fuels; fuel oil EL, minimum requirements. ■ EN 230: Atomising oil burners as mono block version – equipment for safety, monitoring and control, as well as safety times. ■ EN 267: Pressure-jet oil burner. ■ TRD 411: Oil combustion for steam boilers (where applicable). Use of gas combustion ■ EN 298: Burner control units for gas burners and boilers with or without fans. ■ EN 676: Pressure-jet gas burner. ■ DVGW Code of Practice G 260/I and II: Technical rules for gas quality. ■ DVGW-TRGI 2008: Technical rules for gas installations. ■ TRD 412: Gas combustion for steam boilers (where applicable). ■ TRF 1996: Technical rules for LPG. 7.3 Pipe connections All pipe connections to the boiler should be made free from stress and torque. 7 7.4 Electrical installation Carry out the electrical connection and installation in accordance with VDE regulations (DIN VDE 0100 and DIN VDE 0116), local regulations and the technical connection requirements laid down by your electricity supply company. ■ DIN VDE 0100: Installation of HV systems with rated voltages up to 1000 V. ■ DIN VDE 0116: Electrical equipment for combustion systems. 5822 511 GB 7.5 Operating instructions According to EN 12828, section 5 and EN 12170/12171, the system installer must produce operating instructions for the whole system. PYROTEC Downloaded from www.Manualslib.com manuals search engine 83 Appendix (cont.) 7.6 Flue system Only flue pipes that meet Building Regulations may be used with condensing systems. 7.7 Checks as part of the Building Regulations approval process As part of the Building Regulations approval process, condensing combustion equipment is tested by the flue gas inspector (where applicable) for adherence to Building Regulations and any generally recognised technical rules. The State Building Regulations, their implementation orders and the combustion equipment orders, as well as the general building approvals and permits of the higher supervisory authority, in individual cases, are part of the Building Regulations requirements. 5822 511 GB 7 84 Downloaded from www.Manualslib.com manuals search engine PYROTEC Keyword index A Accessories ■ For control unit......................................................15, 16, 18, 19, 21 ■ For the boiler.................................................................................25 Agitators ■ Discharge system.........................................................................45 B Boiler circuit pump............................................................................37 Boiler room.......................................................................................34 Building Regulation approval process..............................................84 Bunker cover ■ Bunker filling.................................................................................73 ■ Movable........................................................................................75 C Chimney...........................................................................................81 Cleaning pneumatic ■ Accessories...................................................................................29 Combustion air.................................................................................35 Connection on the flue gas side.......................................................81 Content ■ Limits...............................................................................................6 Control unit ■ Accessories.................................................................15, 16, 18, 21 ■ Specification, function.............................................................13, 19 ■ Standard delivery..........................................................................14 D Delivered condition.............................................................................7 Delivery............................................................................................33 Design..............................................................................................33 Diaphragm expansion vessel...........................................................82 E Emergency stop switch....................................................................35 Expansion vessel.......................................................................42, 82 Extinguishing facilities......................................................................39 Extinguishing water container..........................................................40 F Fall protection grille ■ Bunker filling.................................................................................75 Flow temperature.............................................................................33 Flue pipe..........................................................................................81 Fuel..............................................................................................5, 43 ■ Limits...............................................................................................6 L Low water indicator..........................................................................41 M Mastercontrol.............................................................................19, 21 Maximum pressure limiter................................................................41 Minimum pressure limiter.................................................................42 Minimum wood fuel requirements......................................................6 O Output management........................................................................16 P Pellet storage room design..............................................................67 Positioning........................................................................................33 Pyrocontrol.......................................................................................13 ■ Accessories...................................................................................15 ■ Functions......................................................................................13 ■ Operation......................................................................................13 ■ Standard delivery..........................................................................14 R Requirements for boiler room...........................................................34 S Safety equipment.......................................................................37, 39 Safety temperature...........................................................................33 Shunt pump......................................................................................37 Sizing the pellet storage room..........................................................66 Sound insulation...............................................................................82 Specification, control unit.................................................................13 Specification - boiler...........................................................................8 Spring core discharge ■ AF.................................................................................................45 T Two-boiler systems....................................................................19, 21 W Woodchips.........................................................................................5 ■ Quality characteristics.....................................................................5 ■ Requirements..................................................................................5 Wood fuel ■ Regulations and standards.............................................................6 Wood pellets......................................................................................5 ■ Forms of delivery............................................................................5 ■ Quality characteristics.....................................................................5 ■ Requirements..................................................................................5 5822 511 GB H Halogenated hydrocarbons..............................................................34 Handling...........................................................................................33 Heating connections.........................................................................36 Horizontal discharge ■ AH.................................................................................................47 PYROTEC Downloaded from www.Manualslib.com manuals search engine 85 86 Downloaded from www.Manualslib.com manuals search engine PYROTEC 5822 511 GB PYROTEC Downloaded from www.Manualslib.com manuals search engine 87 Printed on environmentally friendly, chlorine-free bleached paper Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com 88 Downloaded from www.Manualslib.com manuals search engine Köb Holzheizsysteme GmbH Flotzbachstrasse 33 A-6922 Wolfurt Telefon: +43 (0)5574 6770-0 Telefax: +43 (0)5574 65707 www.koeb-holzfeuerungen.com PYROTEC 5822 511 GB Subject to technical modifications.