kunzel BT 2030, Operating Manual

Page 1: ...Operating manual Wood gasifier boiler BT 2030 and BT 2050 ...

Page 2: ...June 22 2010 2 ...

Page 3: ...tents of this manual before installing and operating the boiler Be sure to also comply with the regional regulatory provisions they may differ in full or in part from the requirements named in this manual In this case the regulator requirements always have precedence The master chimney sweep responsible for your region can always provide information The company KÜNZEL would like to thank you for y...

Page 4: ...3 The KÜNZEL Wood gasifier boiler BT 10 3 1 Nameplate 10 3 2 Design of boiler 11 3 3 Design of turbo burner 12 3 4 The feeder hatch lock 12 3 5 Control panel 13 4 Heating 13 4 1 Heating with wood 13 4 2 Initial startup 15 4 3 Warming up and adding fuel 15 5 Maintenance and servicing 18 5 1 Daily cleaning 18 5 2 Monthly cleaning 18 5 3 Quarterly cleaning 20 5 3 1 Smoke ducts 20 5 3 2 Fans 20 6 What...

Page 5: ...disposal units We reserve the right to make technical changes We are not liable for functional problems resulting from the use of components other than original KÜNZEL components This applies in particular to controllers and external conveyor equipment from other manufacturers We also do not accept liability for operating problems resulting from insufficient hydraulics and or exhaust systems 1 2 G...

Page 6: ...cumstances there is a risk of explosion g During this period the boiler can continue to be operated normally 2 Installation 2 1 General The KÜNZEL Wood Combustion Water Boiler is design tested DIN K 2106 90 and complies with the German BImSchV regulations dated October 1988 Before installing the wood gasification boiler it must be ensured that all of the statutory require ments have been met and t...

Page 7: ...sed for exhaust gas extraction a further controller can also be installed on the unused side smoke duct The draught regulator and the smoke duct sections are removable to enable connection to the chimney on any of the three sides However the draught regulator can only be mounted on the two side duct sections The exhaust pipe should be short if possible without any further bends and attached at an ...

Page 8: ...hut off valves The pipe cross section should be NW 20 Figure 2 Thermal discharge safety device installation in the boiler The valve for the thermal discharge safety device 1 is installed on the connections The sensor pipe is then fed beneath the boiler jacket to the left side of the boiler Here it is routed below the mount for the side panel towards the rear of the unit and fixed in place using ca...

Page 9: ...the performance and emissions values 4 Ensure the boiler is up to operating temperature before commencing with the measurement proce dure This means that the boiler temperature must be at least 75 C and the exhaust gas temperature must have reached at least 150 C 5 Heat the boiler for about an hour before starting to take measurements The furnace chamber should only be half filled for this Lay the...

Page 10: ...ght regulation damper open However this must be noted in the test record 11 According to the boiler and wood quality the following test measurements must be achieved Boiler temperature 80oC 85oC Exhaust temperature 170oC 220oC oxygen content O2 5 9 carbon monoxide content CO 300 3000ppm 3 The KÜNZEL Wood gasifier boiler BT 3 1 Nameplate If you have any questions or complaints about your boiler ple...

Page 11: ...tch for ascending draught pipe 18 Primary air vents 6 Heating up hatch 19 Combustion air ventilator 7 Alternative smoke ducts with draught regulator 20 Ferrule for electric ignition 8 Flue gas sensor 21 Airduct flap can be opened 9 Turbo disk 22 Secondary air vents 10 Burner ring 23 Combustion chamber Ash tray 11 Pot burner 24 Ash door 12 Lower shroud ring 25 Return 11 2 13 Cover for control panel...

Page 12: ...tch lock To open the feeder hatch two levers must be lifted Firstly lift the lever on the heating up flap 1 and pull it out completely It will then latch in this position Then turn the handle on the feeder hatch and open it After a few centimetres the hatch will click into place suspended by its safety hook 2 on the right 12 ...

Page 13: ... tightly It should only be possible to latch in the heating up hatch lever if pressure is applied If the heating up hatch rods are too loose the heating up hatch will not close tightly enough and efficient operation could be considerably impaired The rods must then be re adjusted To do so the heating up hatch rods should be latched in heating up hatch closed and the rear upper casing cover removed...

Page 14: ...ogether and there are no hollow spaces between them otherwise there is a danger of cavity burning and the Wood Combustion Water Boiler cannot reach its full efficiency 2 The basic firebed must be evenly distributed and should be around 5 cm thick Kindling and thin logs are first laid on this basic firebed only then are the normal sized logs added 3 The logs are laid in the boiler with their split ...

Page 15: ...es remove the turbo disk and push the ash into the burner hole Do not force through Danger of damaging The ash should not be removed from the chamber with a vacuum cleaner as it could still contain glowing embers of wood 2 Remove the ash tray and brush along the combustion chamber bars as well as around the rear bend After this the ash can be removed In this case a vacuum cleaner can be used 3 Rep...

Page 16: ...ontrol panel To learn how to do this please read the control panel operating instructions When selecting the ignition time it should be considered that the boiler must run for about an hour before it can provide the heating system with its full output Once the ignition phase has been completed the unit switches automatically into normal heating mode 4 Start manually Light the fire over the turbo d...

Page 17: ...light more wood it is usually sufficient just to rake the embers and to clear the area around the turbo disk so that the flue gas can escape and to empty the ash tray Make sure that the upcoming heat can be fully absorbed by the buffer tank Then relight the fire using the remaining embers and small kindling wood and continue as described above Important On every occasion the furnace chamber door i...

Page 18: ...ld cause damage to the nozzle Do not use a vacuum cleaner to clean the feeding chamber as the ash could possibly still contain glowing embers To improve the heating up process we recommend you to leave some ash in the feeding chamber Then remove the ash tray from the boiler and brush the lower bars with the enclosed cleaning device Finally the ash can be disposed of If you only burn naturally grow...

Page 19: ... igniter In the event of there being considerable deposits it is a good idea to remove the igniter for cleaning This is done as follows Disconnect the mains power plug Open the plenum chamber centre black door and disconnect the plug for the igniter cable Unscrew the threaded cap and pull the igniter forwards Please note In the case of systems that have been in operation for a considerable time as...

Page 20: ...eding hatch and the ash flap can be adjusted to optimize the hatch sealings Release the counter nut on the eye bolt pull our the hinge bolts and pull these hatch carefully towards you or hang it out altogether Now adjust the eye bolt and replace the hatch door Grease all the movable parts with a drop of oil so that they can be easily moved in future 5 3 2 Fans Caution Always pull out the mains plu...

Page 21: ... the furnace chamber door hinge and clean the furnace chamber door seal The diameter of the chimney is too small The chimney is not high enough The chimney is still cold c There is no formation of wood gas flame instead there is only dense smoke The furnace chamber door lock has not engaged the fan is not running The kindling wood is too moist or too coarse in structure Too few wood chips are cove...

Page 22: ...s on and off The water flow rate through the boiler is too high set the boiler circulation pump one speed lower Check the operation of the return flow increase feature Thermomix Heat the boiler thoroughly for an extended period of time f Both fans are not running The furnace chamber door lock is not engaged The boiler temperature is higher than 90oC The fan fuse in the control panel is defective 2...

Page 23: ...e Lambda sensor fuse in the control panel is defective 4 Ampere medium time lag l If the control system is behaving unusually please read the control panel operating instruc tions Should you have any further questions about or problems relating to the KÜNZEL wood gasification boiler please feel free to contact your heating engineer or address them directly to KÜNZEL GmbH Co Ohlrattweg 5 25497 Pris...

Page 24: ...0 47 Fuel Holz Holz consumption at nominal output kg h 9 6 11 6 Air requirement m3 h 75 120 Duration of combustion beech tree h 3 5 3 8 Energy content of charge beech tree kWh 103 3 179 Duration of combustion softwood h 2 1 2 5 Energy content of charge softwood kWh 62 9 118 Duration of combustion beech low load h 4 4 4 0 Permitted boiler temp oC 95 95 Nominal boiler temp oC 90 90 Permitted positiv...

Page 25: ... Draught requirement 1 Pa 10 10 Necessary conveyance pressure Pa 18 18 Exhaust mass current 2 kg s 0 022 0 035 when heating kg s 0 045 0 070 Exhaust gas temperature nominal oC 170 180 Exhaust gas temp when heating oC 150 150 CO2 at nominal output 13 5 15 Particulate emissions 13 O2 mg m3 9 18 Total efficiency 91 92 Stand by loss Watt 55 65 Electrical connections 240V AC 10A 50Hz 240V AC 10A 50Hz 1...

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