Topling BTA1000, User Manual

Page 1: ...er Guide Topling Prnjavor Page 1 PRIVATE COMPANY FOR PRODUCTION SERVICES AND TRADE TOPLING d o o PRNJAVOR BOSNIA AND HERZEGOVINA www topling com info topling gmail com USER GUIDE Hot Water Pellet Boil...

Page 2: ...3 4 Boiler room and the storage of fuel 4 1 Boiler room 31 4 2 The storage of fuel 34 4 3 Pellet quality requirements 36 5 Boiler installation 5 1 Boiler connection to central heating system 38 5 2 In...

Page 3: ...n in this User Guide Please comply with this User Guide and this system will always function at your pleasure KEEP THIS USER GUIDE FOR LONG TERM USE AND IN AN ACCESSIBLE PLACE FOR FURTHER REFERENCE Pl...

Page 4: ...ments When the boiler is commissioned by the authorized person in the same time the operator appointed by the buyer is trained After the training is finished the Record on successfully completed train...

Page 5: ...type BTA We keep developing and enhancing our boilers All information regarding this Guide that are related to the boiler type BTA are correct at the moment of print out Before the use all details me...

Page 6: ...Boiler intended for burning of pellet Central Unit Electric controller for managing boiler operation Pellet Type of solid fuel made of sawdust previously dried then pressed and in such manner making a...

Page 7: ...it the right way and for the purpose for which it is intended always taking care of your own safety and the safety of others and the safety of property Constantly comply with this User Guide Any defe...

Page 8: ...by the German Standard DIN 51731 or Austrian Standard ONORM 7135 Pay special attention to the quality of pellet both when ordering and admission Use pellet that meets the standards of DIN or ONORM For...

Page 9: ...arked with this symbol could result in serious injury or create serious damage Attention Possible hand injury Work in areas marked with this symbol can lead to hand injuries Attention High temperature...

Page 10: ...tion must be paid to the Chapter 2 Safety instructions This especially refers to those who only occasionally use the boiler for example only when cleaning or other tasks related to the maintenance of...

Page 11: ...h makes it suitable for widespread use Pellet is an environmentally clean fuel produced from sawdust Sawdust is initially dried and then pressed under high pressure The final product is fuel of except...

Page 12: ...2001 EN 12953 9 2007 EN 12953 10 2003 EN 12953 11 2003 EN 60204 1 2006 EN 61000 6 3 2006 And other standards EN 287 1 2011 EN 15614 1 EN 10204 2004 EN ISO 7000 2012 Applyed procedure for declaration o...

Page 13: ...om the flue gases in order to reduce environmental pollution and to prevent the release of sparks that could cause a fire Flue gas fan through the flue pipe transports flue gases to the chimney Counte...

Page 14: ...BTA User Guide Topling Prnjavor Page 14 Figure 1 Boiler room with two system units and external silo...

Page 15: ...BTA User Guide Topling Prnjavor Page 15 A F C E B Figure 2 Boiler dimensions with pellet burner...

Page 16: ...10000 10000 10000 10000 12000 12000 14000 Chimney diameter mm 400 450 500 550 600 600 600 600 Maximal working water pressure bar 2 5 2 5 2 5 2 5 2 5 2 5 2 5 2 5 Maximal water temperature 0 C 90 90 90...

Page 17: ...ater is recommended for filling the boiler from the system Circulation pump is put into operation only when the heating system is filled with water What must be taken into account is that the system i...

Page 18: ...should be placed horizontally or vertically All connections must be well sealed Risk of boiler overheating When wooden logs or coal are used as a fuel there is a risk of overheating in case of interr...

Page 19: ...connected to the boiler The power supply is single phase 220 V 50 Hz Installation must be performed by an expert because there is a danger of electrical shock Before putting into operation the work Y...

Page 20: ...660 720 840 960 1080 1200 1320 1500 1920 2160 2400 2700 3000 3300 3600 4200 4800 5400 6000 6600 7200 8400 dB A LM 28 80B 4 0 75 1375 38 40 42 44 45 47 48 52 52 50 45 40 56 LM 33 90S 4 1 1 1410 58 59 6...

Page 21: ...rotor dynamically balanced mounted directly on the electrical motor shaft forcedly cooled by self cooling rotor It is covered with the paint for high temperatures Technical characteristics type C4 62...

Page 22: ...BTA User Guide Topling Prnjavor Page 22 Silo Figure 5 According to available space silos of different dimensions and shapes are added on BTA systems...

Page 23: ...23 Gear motor GFL producer Lenze Gear motor GSS producer Lenze Figure 6 Depending on the boiler power ratings geometric characteristics of boiler room and the customer s requirements different types...

Page 24: ...BTA User Guide Topling Prnjavor Page 24 helical shaft mounted gear motors tip 112 N screw feeder and inter screws Figure 7 Dimensions of helical shaft mounted gear motors Output shaft Carrier Motor...

Page 25: ...tion Supporter is connected with gear motor via rubber elements the shock absorber Figure 8 Shock absorber Table 5 Dimensions of shock absorber type dimensions Torque Tmax Nm compressive force Fp N sc...

Page 26: ...BTA User Guide Topling Prnjavor Page 26 Figure 9 Bearings SKF 722509 DA screw feeder rotary feeder Table 6 Dimensions and marks of bearings...

Page 27: ...BTA User Guide Topling Prnjavor Page 27 The system includes rotary feeder which gradually separates two screw feeders and prevents the return of fire into the main silo Figure 10 Rotary feeder...

Page 28: ...r Page 28 The system must not be put into operation without protective chain cover The chain cover must not be removed during the operation of the system Figure 11 Power transmision by sprockets and r...

Page 29: ...ey pipes should be insulated with mineral wool against the fire The connections between multi cyclone and boiler multi cyclone and chimney are done by clamp with thermo resistant pads Flue gas pipe be...

Page 30: ...g 450 kW 1000 mm for systems above 450 kW On the prepared basis anchor plates positioned together with chimney Anchor plate has dimensions N x N with openings which are suitable to axial distance of a...

Page 31: ...any must be secured by a fence of min 800 mm height Boiler room must be so high that between the ceiling or the beams of the roof structure and the boiler is at least 1 80 m The boiler room should be...

Page 32: ...lammable building materials and built in furniture so that temperatures of mentioned boiler heating capacity over 80 C cannot occur Otherwise you must maintain a distance of at least 80 cm Mouth for t...

Page 33: ...9 Recommended boiler room dimensions according to boiler power BTA 350 450 550 750 1000 1200 1500 2000 A mm 9500 10000 11000 11000 11000 11500 11500 12000 B mm 6000 6000 6000 6000 6000 6000 6000 6000...

Page 34: ...lls for fuel storage must have a fireproof walls that meet the requirements for fire protection In this event it means that chambers or tank are built of bricks blocks reinforced concrete and other in...

Page 35: ...ed and be visible Chambers tank and other equipment for the storage filtration chambers and separators must be equipped with fire extinguishers resistant to frost which provides fire suppression witho...

Page 36: ...e protection 4 3 Requirements for pellet quality GERMAN STANDARD DIN51731 Pellet in group of size HP5 is made of pressed wood chips of intact wood including bark with no additional bonding materials T...

Page 37: ...der to ensure the required quality of pellet PELLET CHARACTERISTICS Table 10 Pellet characteristic Standard DIN 51731 NORMM7135 DINplus AS NZS4014 6 Length max 50 mm max 5 x max 5 x max 38 mm Diameter...

Page 38: ...ns of initial and backflow route Do not attach to the safety cables or other accessories It is recommended to install a shut off parts so that water does not have to be discharged from the entire inst...

Page 39: ...vessel is usually placed vertically above the boiler If this is not possible because of the construction then the total extension of the safety lines shall not exceed ten times the value of verticall...

Page 40: ...A J J 1 1 Boiler BTA 2 Pellet burner 3 Dosing screw 4 Vented expansion vessel 5 Water softener 6 Collector 7 Boiler controller 4 7 2 3 6 5 water supply Figure 16 Connecting hot water boiler BTA to hea...

Page 41: ...1 Boiler BTA 2 Pellet burner 3 Dozin screw 4 Expansion module EM 2A 5 10K 5 Water softener 6 Collector 7 Boiler controller 8 Safety valve 8 6 2 7 3 4 5 Water supply Figure 17 Connecting hot water boil...

Page 42: ...iler BTA 2 3 Pellet burner 1 4 Pellet burner 2 5 Dosing screw 1 6 Dosing screw 2 7 Expansion module EM 2A 5 10K 8 Water softener 9 Salt vessel 10 Collector 11 Safety valve 1 3 5 10 2 4 6 Danfoss ECL30...

Page 43: ...in order to avoid the corrosion of metal parts with the goal of extending life Softened water is recommended for filling the boiler in the system Circulation pump is put into operation only when the h...

Page 44: ...e with opening pressure of 2 5 bars is required and installation of expansion vessel Locking element must not be installed between the safety valve and expansion vessel Water temperature in boiler may...

Page 45: ...s also illuminated light that flashes when an alarm is activated To reset the automated control it is necessary to press the RESET button for 5 seconds Black button START VREM PROG Is used to start an...

Page 46: ...re is given The main menu has ten items which are listed by keys and By pressing the appropriate number the one enter in the selected menu item On the right side of the display the current temperature...

Page 47: ...urner pressing the button 1 you are take to the submenu TEMPERATURE SETTINGS with three displays and moving from one to other is done by buttons and On the first display of the submenu TEMPERATURE SET...

Page 48: ...h START VREM PROG is in neutral position or is set to work by the time program and the current time is not such that the boiler should work At the last display under the submenu TEMPERATURE SETTINGS t...

Page 49: ...coder is adjusted The values of these times are given in seconds and the first digit refers to the operating time and the second digit refers to the break work pause Number of rotations of this screw...

Page 50: ...displays AIR SUPPLY 1 2 and AIR SUPPLY 2 2 the speed of the fan which injects air into the burner at various temperature intervals of the burner is adjusted Values are given in percentages and the fan...

Page 51: ...f flue gases through the frequency converter At various stages of the work the different subpressures in the boiler are required At the first of two displays under VACCUM there are information about t...

Page 52: ...4 DISPLAY LIGHTNING 5 By pressing the suitable number you enter into the desired menu Real time and date are set on the following display In submenu OPERATION TIME VRIJEME RADA time intervals of boile...

Page 53: ...or the following day will appear with previously entered values HOURS OF SYSTEM OPERATION BROJ SATI RADA SISTEMA is the information about total number of boiler operation hours On DISPLY LIGHTING OSVJ...

Page 54: ...re of 80 C In the lower left corner the information about the solenoid valve open7closed is shown PHOTOCELLS The photocell is located in a hole in the back of the burner Photocell serves as a flame de...

Page 55: ...isters the flame at the burner in the process of firing the boiler starts regular operation and doses pellets and air as it is set for current temperature of the burner On the last display of this ser...

Page 56: ...screw feeder is overloaded when bimetallic protection reacts 4 Flue gas fan it is shown when flue gas fan is overloaded or in the case if some other fault on frequency regulator 5 Fan of the burner i...

Page 57: ...for cleaning of tubes pass through the tube several times Soot which felt into the multi cyclone when cleaning of tubes should be removed through the inspection opening on multicyclone A week Clean t...

Page 58: ...he impeller is dirty Then at the first stop of the system the bolts on the flange of the flue gases fan should be unfastened on the top of multicyclone and then the cleaning of fan circuit and the fan...

Page 59: ...of this surface may have a temperature up to 200 C in the operating mode It is necessary to cool them down In all of the cleaning works there is the danger of suffocation with carbon monoxide if the b...

Page 60: ...ufacturers should not be mixed Oil change is done when the gear is idle gear in warm operating condition After the release of old oil and flushing the body the new oil is poured through the vent openi...

Page 61: ...er opening is sealed with safety cap The gaskets one on the front and one to the back of the case in envisaged grooves are installed in the case Such case with no cover is to be pulled to the shaft an...

Page 62: ...flange is not at the right angle etc At the end the housing cover is set and tighten to the body by three screws After assembling the shaft is lubricated with the amount of lubricant according to tab...

Page 63: ...BTA User Guide Topling Prnjavor Page 63 Seal on the bottom of the shaft housing Inspection of mouth position on overlapping surpfaces Tightening the housing cover Tightening housing to the flange...

Page 64: ...unt for certain housings On screw conveyors and rotating dispensers the housings of type FNL 509 DB are used where D denotes the triangular base housing and B a housing through which the shaft entirel...

Page 65: ...BTA User Guide Topling Prnjavor Page 65 Housing type DB Housing type DA Figure 28 Type of housing...

Page 66: ...guide The quality of pellet must comply with recommendations stated in this user guide 7 3 The warranty does not apply to cases The guarantee does not apply if the damage resulted from improper use o...

Page 67: ...water in certain containers and the re condensation of water vapour in coolers Impurities in the water may include mechanical colloidal and dissolved Mechanical admixtures can float and deposit depend...

Page 68: ...in contact with iron oxide produces and the effects of salt contained in the water Boiler scale at a temperature of 600 C decomposes and causes damaging of boiler sheet metals The process of corrosio...

Page 69: ...BTA User Guide Topling Prnjavor Page 69 9 Addendum 2 9 1 Wiring diagram Wiring diagram of the control cabinet is shown in several figures in this Section...

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Page 81: ...red during standard use of the product i e those which are included into Warranty Sheet Deadline for providing the service is 7 days after the investigation of malfunction 3 We guarantee service maint...