Twin Heat COMPACT STOKER Cpi12, Instructions Manual

Page 1: ...Users manual Version 3 0 COMPACT STOKER Nørrevangen 7 DK 9631 Gedsted Tlf 45 98645222 Fax 45 98645244 Mail twinheat twinheat dk Web www twinheat dk ...

Page 2: ...Cpi 12 has been tested and approved according to DS EN303 5 by Danish Technological Institute The test institution for smaller bio heating appliances Wood pellets with app 8 water content Forrest wood chips with app 25 water content Grains with app 15 water content 1 feed chalk added Version 3 0 May 2011 ...

Page 3: ...ypass 12 Section 3 troubleshooting 13 3 1 Open lid 13 3 2 Error Hot boiler 13 3 3 Low temp 14 3 4 Stoker stop 14 3 5 High O2 14 3 6 Lambda offs 15 3 7 Power cut 15 3 8 Sprinkler system 15 Section 4 Maintenance 16 4 1 Maintenance intervals 16 4 2 Maintenance of boiler 17 4 3 Maintenance of burner tube 17 4 4 Maintenance of fuel store 18 Section 5 Various types of fuel 19 5 1 Wood pellets 19 5 2 Woo...

Page 4: ... Stoker auger 7 Fuel stirrer 8 Auger channel 9 Lid fuel store 10 Gear motor 11 Combustion fan 12 Chain connection 13 Sprinkler system 95 ºC 14 Pressure tank for sprinkler 15 Control panel 16 Lambda probe oxygen control 17 Overheating thermostat 18 Safety switch 19 Flue temperature regulation bypass 20 Handle to release fuel store Plant drawing ...

Page 5: ...ature is shown e g 70 C Press notice that the cursor change appearance to Now the temperature can be adjusted between 70 90 C by Confirm the chosen temperature by pressing Leave the menu by pressing Change type of fuel Press to setting Press to choose setting Press to Fuel type The cursor is placed by Fuel type The chosen fuel type is shown e g Pellets Press notice that the cursor change appearanc...

Page 6: ...Setting Stoker Motor menu Power setpkt 50 Error times 10 Power 0 Times 0 Settings menu Fire starter menu Ash exhale menu Blaster menu Password 0 Recall all No Buffer menu 1 3 Adjustment of temperature The temperature boiler temperature can be adjusted between 70 90 C The temperature is from factory pre set to 70 C Some situations such as an under dimensioned radiator system or hot water tank might...

Page 7: ... temperature min 180 C High boiler output min 50 High boiler temperature min 80 C 1 5 O2 regulation ore manual operation Manual operation can be an advantage if the fuel used is of bad quality or if e g the lambda probe goes defect The cursor must be placed by the line Setting Press to choose setting Press to O2 regul On off Press to choose O2 regulator menu Press Now you can choose YES or NO by p...

Page 8: ...nd Actual boiler load 65 The cursor must be placed by the line Setting Press to choose setting Press to O2 regul On off Press to choose O2 regulator menu Press to Man Fac Press Now the amount of fuel can be adjusted between 0 100 by Confirm the new setting with Leave the menu by pressing 1 6 Adjustment of the fuel program Other In the Settings menu under Other fuel you can adjust the relevant para...

Page 9: ...for the auger per period The controller calculates the actual running time from O2 and pulse chosen Stoker term Defines the pause time between each running period 1 6 3 Pause Under Pause you can adjust 3 parameters for the pause of the boiler Stoker pulse Defines the running time for the auger per period Stoker term Defines the pause time between each running period After run blower Decides how lo...

Page 10: ...be established when the probe is exposed to absolutely clean atmospheric air This is most easily done when the boiler has been stopped for a period There should not be any smoke at all in the combustion room or the flue pipe when making the test Close the bypass damper on top of the boiler and undo the top cleaning door to the flue pipes now the chimney will suck in clean air passing by the probe ...

Page 11: ...tory See enclosure 1 If you use a fuel which has a tendency to build bridges such as wood chips or the like then mount chain and stirrer wings on plate stirrer See enclosure 1 When you have finished filling up with fuel the lid must be carefully closed by means of the two rotating handles which always must be tightly closed When pressing START the boiler will continue the operation Please be aware...

Page 12: ...to limit the boiler load when starting up a cold boiler The boiler runs in soft start mode for a period of 15 minutes Should the combustion not have been correctly stated when the boiler goes into the mode Running the result can be un combusted fuel being pushed through the burner tube into the combustion room Hence you should check the stoker app 1 hour after start Normally this can be done in lo...

Page 13: ...oted The boiler has to work harder to maintain the boiler temperature The LOAD data in the display is showing how hard the boiler works 2 6 Pause mode If the heat demand is relatively small and the controller has reduced the load down 20 the boiler goes into Pause During the pause the fan is started every 10 min and runs a little to keep the glows in the burner tube alive The boiler will go into r...

Page 14: ...y 100 load when leaving the flue outlet The flue temperature is closely connected to the boiler output means lower load lower flue temp The handle on top of the boiler the bypass is used to adapt the flue temperature in relation to boiler output By fully opened damper only a part of the flue is passing the flue cooler By fully closed damper the flue is cooled to maximum see fig 4 Section 2 Start u...

Page 15: ...ck 3 2 Error Hot boiler The boiler temperature has exceeded 95 ºC and the over temperature thermostat has stopped the boiler The produced amount of heat could not be used in the heating system Causes There is no real need for heat typical for the summer There might be an air pocket in the system no water circulation The circulation pump does not function When the boiler temperature has fallen belo...

Page 16: ...ection 2 2 Taking fuel forward to the burner tube 3 4 Stoker stop The controller is keeping track on the power consumption used by the auger If the auger uses more power than calculated it is because it has jammed ore moving too slow The load on the auger is too high Causes The auger is jammed by a stone or the like Heavy coating in the burner tube see section 4 3 Maintenance of burner The fuel is...

Page 17: ... 3 7 Power cut In case of power cut the boiler will automatically restart though depending upon length of the power cut Should the boiler temperature have dropped more than 15ºC during power cut the boiler will not restart but display the error Low temp see section 3 3 Low temp 3 8 Sprinkler system Should the fuel back burn into the auger channel and the temperature exceed 95 ºC the sprinkler migh...

Page 18: ...n the doors to the combustion room are OK Clean the side walls in the combustion room Check and clean the burner tube for slag in the area close to the auger Check and clean the perforations in the side of the burner tube If a draft stabiliser is fitted check it for free movement and clean it if necessary Yearly maintenance The flue box should be totally cleaned out for ashes Check that the flue p...

Page 19: ... should clean the combustion room walls The temperature should be read a the same load as it increased with boiler load In case the plant is stopped for a longer period e g over summer it should be totally cleaned out for ashes It is important to leave the combustion room door slightly open to prevent condensation and corrosion 4 3 Maintenance of burner tube The burner tube must be cleaned if a he...

Page 20: ...he bearing behind the bigger chain wheel is greased by a grease pump Chain tightener The sprinkler valve is controlled by unscrewing the hose where after the red hut under the valve is activated It is very important to secure that the valve is tight after the test as you otherwise will have water dripping into the fuel Should the valve not be tight you must open it and clean the contact surface an...

Page 21: ...t or the like The specific weight must be OK There should not be any kind of additives in the pellets The amount of saw dust and the like should be very low How to control these preconditions Smell Put a few handfuls of pellets into a plastic bag and smell the content If the pellets smells from wood they are OK But remember that some pellets are made of beech or oak which smells different than pin...

Page 22: ...best wood chip is made from hardwood which has been dried for 2 3 years The chips should be maximum 2 x 2 x 1 cm but some few parts may be larger If the chips in general is too rough too many large parts you will increase the rubbing off on the auger and auger channel considerable as the auger has to squeeze the material through the channel In other words relatively rough chips increases the wear ...

Page 23: ...ort of grains is better than another as the heating value depends on the year the grain was grown much rain little rain and more and of the type of soil on which it was grown Further you should anticipate that grains has a tendency to create slag in the burner tube e g the ashes gets so hot that they create slag in the lower part of the burner tube This can be remedied by adding 1 2 kg of feed cha...

Page 24: ...al load Kg h 28 27 31 Flue gas amount by minimum load Kg h 11 13 15 Minimum temperature of water returning Lowest acceptable C 60 65 65 Draft necessary 10 Pa 1 mbar Diameter of flue outlet Ø 130 mm Heating area in boiler 1 8 m Amount of water in boiler 74 litres Water resistance by temp difference 10 C 5 4 mbar Water resistance by temp difference 20 C 19 6 mbar Adjustment span for boiler thermosta...

Page 25: ...hind gasket in front of burner 0103011 00 1 Gasket between burner and fuel store 2100051 00 1 Gasket between burner and boiler 6200308 00 4 Top nut 4001108 00 1 Fan 4001109 00 1 Capacitor for fan 7 2 Parts list sprinkler Parts no Pcs Description 6000435 00 1 Pressure tank 6000450 00 1 Sprinkler valve 6000410 00 1 Contra valve 6000460 00 1 Dirt strainer 6000820 00 1 Hose steel armed 6000830 00 1 Ho...

Page 26: ...0109 00 1 Chain for stirrer 84 links 7000104 00 1 Cranket chain link 7000110 00 1 Chain wheel Z40 Ø35 7000112 00 1 Flange bearing for stirrer Ø35 4000610 00 1 Electrical switch for lid 1005350 00 1 Bronze bearing 1102000 00 1 Auger 1005525 00 1 Stirrer wing short model 1005520 00 1 Stirrer wing 1101038 00 1 Stirrer plate 1101020 00 1 Stirrer axle 7000121 00 1 Flange bearing for stirrer Ø25 1100052...

Page 27: ... for boiler door 3100021 00 1 Gasket for cleaning door 3103000 00 1 Boiler door complete 3103040 00 1 Insulation for boiler door 6101115 00 1 Gasket for lambda probe 4001100 00 1 Lambda probe 4001160 00 1 Over heat thermostat 3100030 00 1 Gasket for mudhole 3104020 00 1 Insulation for cleaning door 4001125 00 1 Heat sensor ...

Page 28: ... N2 U W V N C ondensator U 1 W 1 V 1 24V AC W 1 N U 1 V 1 L1 L2 L3 T1 T2 T3 JP3 N W 5 12V AC 0V white orange rød lysrød F1 4AT F3 315mAT N U 3 W V U N A1 A2 12VD C 12V AC 12V AC 0V D C AC 1 0VAC 0V AC AC G ND 22 23 O 2 Signal O V Signal 0V AC Black G rey Hot boiler therm ostat Lid Safety Switch 25 26 28 27 29 30 32 31 41 42 44 43 45 46 Boiler tem p sensor NTC 12V D C 12VD C F2 4AT ...

Page 29: ...27 Section 7 Diagrams 7 6 Electrical Diagram 230V 1 phase ...

Page 30: ...P5 SP 9 SP 10 SP4 SP 3 F1 4AT F4 315mAT F2 4AT F3 315mAT X5 X2 X7 X8 X9 X1 X10 X3 X4 X11 X6 Control board F1 1 6AT 12VDC Control board Power board F1 4AT 230VAC Automatic filling etc F2 4AT 12VAC Power supply Controlboard Lambda probe F3 315mAT 24VAC Power supply Relays automatic filling etc F4 315mAT 230VAC Power supplyTransformer 12VAC 24VAC ...

Page 31: ... in conformity with the provisions of the Machinery Directive directive 98 37 EC and with national implementing legislation Is in conformity with the provisions of the following other EC directives 73 23 EEC 89 336 EC And furthermore declares that the following harmonized standards have been applied EN60 204 1 EN50 081 DS EN 292 1 DS EN 292 2 Gedsted the 1th may 2011 ...

Page 32: ...r fixation The chain is easiest fitted if somebody can help you holding the chain tightener Do remember to cut the power Cut power at Main Switch 1 Place the wrench a big thong or the like at arm of the chain tightener and press against the cog wheel as shown 2 When holding the chain tightener you are now able to mount the chain by means of the chain connection included shown by the arrow 3 When t...

Page 33: ...Enclosure 2 accessories included Cleaning brush Ø40 mm and handle Fire hook Stirrer wings long and short version Plus chain for the mounting of stirrer Enclosure 2 Oct 2002 ...