ZMM Haskovo PYROTHERM Series, User Manual

Page 1: ...User manual Green ECO Therm for installation and exploitation of wood gasification hot water boiler of series PYROTHERM http www greenecotherm eu...

Page 2: ...ining center and get certified as well ATTENTION In interest of your personal security it is obligatory to read thoroughly and carefully this instruction manual before proceeding with any actions with...

Page 3: ...therm considering it s easy maintenance and servicing 19 5 1 Basic fuel requirements 26 5 2 Basic requirements for exploitation of the hot water boiler connected to a heating system 26 5 3 Starting wo...

Page 4: ...ut the maintenance and adjustment procedures of the boiler 59 5 9 Safety and unexpected risks 60 5 10 Operation faults and their repairing 61 5 11 Hot water boiler warranty form completion 64 5 12 Act...

Page 5: ...r The set of the hot water wood gasification boiler of series Pyrotherm consists of the following Hot water boiler of series Pyrotherm 1 sp Combustion chamber ceramic directing element 1 sp Thermovalv...

Page 6: ...It is possible along with the wood logs to utilize other wood based fuel like saw dust shavings and other small fuel particles but their quantity should be less than 20 of the total charged fuel in t...

Page 7: ...and environmentally friendly and its operation does not contribute to the global warming of the Earth The price of the thermal energy derived by utilizing the boiler like local energy source is less...

Page 8: ...25 16 32 26 52 Utilized fuel Wood logs for heating purposes water content up to 20 Wood logs consumption rate at nominal thermal capacity kg h 7 9 10 2 16 5 kg h 93 120 195 Fresh air flow rate require...

Page 9: ...ating water at nominal thermal capacity hPa 3 54 5 27 8 37 Heating system expansion vessel type opened or closed Factory tested overpressure MPa 0 4 Recommended circulating water temperature in the bo...

Page 10: ...lized by natural drying of the material at ambient conditions for a relatively long period of time at least for a year during the summer period the drying is high intensified The fuel should be protec...

Page 11: ...eating value Wr LHV MJ kg kWh kg 0 18 000 5 000 5 16 978 4 716 10 15 956 4 432 15 14 934 4 148 20 13 912 3 864 25 12 890 3 581 30 11 868 3 297 35 10 846 3 013 40 9 824 2 729 45 8 802 2 445 50 7 780 2...

Page 12: ...er section of the fuel hopper which ensures optimal conditions for efficient combustion process Ceramic directing element which is positioned in the combustion chamber of the boiler allowing high temp...

Page 13: ...ich allows lower heat loses to the surrounding atmosphere The doors of the fuel hopper and the combustion chamber are fabricated from cast iron which allow high thermal resistance and air tightness of...

Page 14: ...gasification hot water boiler of series Pyrotherm front view Figure 3 3 View of the wood gasification hot water boiler of series Pyrotherm side view EXPLANATION the value of the dimensions marked with...

Page 15: ...p 15 69 Figure 3 4 View of the wood gasification hot water boiler of series Pyrotherm back side view Figure 3 5 View of the wood gasification hot water boiler of series Pyrotherm top view D W W...

Page 16: ...ies Pyrotherm Fuel hopper Orifice for extracting the gasses of the fuel chamber at ignition Combustion nozzle Combustion chamber Flue gas directing profiled ceramic in the combustion chamber Primary a...

Page 17: ...ght to make any changes of the design and construction of the boiler without obligation to inform the end user Flue gas exit duct Control box of the boiler Combustion nozzle Flue gas fan Flue gases di...

Page 18: ...for the water capacity of the entire heating system its capacity is calcutated at the step of heating system project development Both the entire heating system and the hot water boiler should be tota...

Page 19: ...400 mm o The minimal distance from the boiler s side and a wall should be 500 mm in order to allow easy maintenance and servicing procedures of the boiler s convective heat exchanger and back side of...

Page 20: ...ber of the boiler ATTENTION at the mounting and installation of the ceramic element should be done with care and preventive measures should be taken in order to keep this element s integrity After the...

Page 21: ...y cooling coil of the boiler thus decreasing the circulating water temperature See the user manual of valve for more details EXPLANATION the sensing section of the thermovalve should be screwed in an...

Page 22: ...for emergency cooling coil with tap water should be screwed in Figure 4 5 View of the back side of the boiler the ends of the emergency cooling coil are pointed Inflow outflow of the emergency cooling...

Page 23: ...n the warranty list filling all the data fields is obligatory The heating system and the boiler should be filled up with circulating water most commonly tap water is utilized However the water used fo...

Page 24: ...4 1 Parameters of the water allowable to be used as circulating fluid in a heating system In case the heating system contains copper elements and the circulating water id in direct contact with them t...

Page 25: ...re 4 7 EXPLANATION According to EN 303 5 the heat accumulator tank is obligatory module of a local heating system operating with solid fuel hot water boiler The heat accumulator capacity calculation i...

Page 26: ...nts for exploitation of the hot water boiler connected to a heating system In principle heating systems which are hydraulically opened to the atmosphere allow direct contact between the circulating fl...

Page 27: ...lly loaded elements which will lead to intensive corrosion That s why during the heating period it is necessary to check the circulating water pressure periodically and drain or fill if needed Please...

Page 28: ...erform any interventions repairs etc of the unit In case that warning and failures arise check the failures table applied at the end of this manual and call the service support if the case is not desc...

Page 29: ...d lower heat exchanging rates It should be considered that the raw wood material which has high moisture content have low heating value and will lead to high fuel consumption rates and low boiler s ef...

Page 30: ...of the volatile gases release of the wood logs in the fuel hopper and efficient combustion process 5 3 1 Interface control board of wood gasification hot water boiler of series Pyrotherm The front pa...

Page 31: ...ergency thermostat In case of activation cool down the unit and check and repair the reason for the emergency situation finally reset the emergency thermostat Alarm 2 indicator option indicates the st...

Page 32: ...ng system efficiency and functionality Flue gas fan Ignition flap Position and condition of the ceramic element in the combustion chamber of the boiler Thermovalve which controls the air flow rate as...

Page 33: ...ff position the START switch The status of the operating mode of the flue gas fan is indicated with the lamp mounted above this switch The ignition of the fuel as well as the boiler s heating up is pe...

Page 34: ...y by using a match or a lighter for example take care and cover the fire safety requirements After the initial fuel has been fired up half close the door not allowing any flue gases getting out of thi...

Page 35: ...ting parameters have been reached it is necessary to make appropriate adjustment of this thermovalve functionality see the description below EXPLANATION the heated up circulating water due to the grav...

Page 36: ...duces the thermal capacity of the boiler This thermovalve is functioning without any energy sources it is proportionally driven and its lever turns linearly by changing the temperature The position of...

Page 37: ...tate mode as well as the hot water boiler The adjustment of the combustion process should be performed in this nominal operating mode only The operation of other control valves as well as other contro...

Page 38: ...onsidering the requirements and legislations NOTES In case that the heating system is equipped with circulating pump which transfers the heat energy from the boiler to the heating system the return fl...

Page 39: ...n on the figure above o Wait for 5 10 seconds open the door of the fuel hopper chamber The opening process of the door should be performed in steps first half open the door so the ambient air will pen...

Page 40: ...ating parameters Figure 5 7 View of the fuel hopper chamber and the status of the fuel after approximately 30 minutes of its charging The figure above shows that the wood logs has already been dried o...

Page 41: ...our from the fuel hopper with wood logs the nominal operating parameters of the boiler are reached as well as the boiler s thermal capacity After this period the boiler will operate at nominal paramet...

Page 42: ...reated as gas combustion because most of the fuel is gasified and combusted in the oxidation chamber of the boiler The design of the boiler allows optimal conditions for the combustion process and hig...

Page 43: ...That s why any change of the adjustment of the boiler s air distribution should be followed with appropriate period of time in order get effect The practice shows that utilization of wood logs which...

Page 44: ...d with the position of the primary air control flap is required in order to sustain the pyrolisis process organized in the fuel hopper chamber of the boiler By changing the position of this flap it is...

Page 45: ...ment will be required because a lot of operating parameters could be changed for example the fuel has been changed changing the thermal capacity of the boiler and or heating system chimney s operating...

Page 46: ...The effect of this adjustment will be seen in a period of at least 15 minutes so one has to be patient and wait The change of the axis position should be done in small steps as this adjustment is high...

Page 47: ...lculate the instant fuel flow rate by dividing the averaged mass of the fuel by 3600 1 hour 3600 seconds and get the result m wood_logs 0 002972 kg s o Estimate the heating value of the fuel Hwood_log...

Page 48: ...wo fuel charging with wood logs In case the boiler should run at lower that nominal thermal capacity then it is highly recommended to install a heat accumulator tank in the heating system see the desc...

Page 49: ...s higher than the heat demand the temperature of the circulating water will be increased and will be reached the set point of the operating thermostat of the boiler in such a case the flue gas fan wil...

Page 50: ...at demand This is the main argument to install a heat accumulator tank in the heating system Figure 5 11 Instant thermal capacity of a typical heating system at ambient temperature of 0o C the left fi...

Page 51: ...he fuel chamber of the boiler and wait the combustion process get quenched then changing the START switch into OFF position After the boiler has cooled down to ambient temperature the boiler should be...

Page 52: ...natural cooling down to the ambient temperatures and after that to perform thorough investigation of the boiler and the control modules of the system this should be performed by authorized and trained...

Page 53: ...should be cooled down but still operating and special measures for self protection should be taken in order to prevent any skin injuries It should be considered that hot flue gases will be emitted in...

Page 54: ...content of the fuel is transported by the flue gases to the convective heat exchanger section of the boiler which leads to sensible decrease of the heat transfer rate of the flue gases to the circulat...

Page 55: ...adhered to the plates of the convective section which will to difficult detachment of the lids take care no to damage the gasket rope eventually it has to be replaced Figure 5 14 Convective lid which...

Page 56: ...nd downwards After the ash has been brushed away the collected ash residue should be cleaned by opening the lower lid and to scrape out the ash out of the lower section of the convective heat exchange...

Page 57: ...ne where should be positioned one of these elements has shorter curved elements practically the place of the elements could not be mistaken due to special feature of the design of the boiler The ash c...

Page 58: ...hly recommended to detach the flue gas fan and to clean it thoroughly next it should be carefully installed back on the boiler considering the gasket and the its tightness The flue gas ash cleaning pr...

Page 59: ...he procedure for boiler s maintenance the procedure for ash cleaning from the combustion chamber of the boiler the procedure for cleaning the ash residue of the convective duct of the boiler the proce...

Page 60: ...orms However in spite of that possible risks are considered as a result of the operating process of the boiler it is possible to arise risks as follows Cauterization risks caused by high temperatures...

Page 61: ...rature of the boiler s operating thermostat It is necessary to increase the set point of the boiler s operating thermostat up to 90o C 1 Low temperatures in the heat supplied rooms Low set point tempe...

Page 62: ...e main POWER switch is turned OFF and back ON afterwards and the boiler should be started Low quality wood logs in most cases the moisture content is higher than 20 Fuel replacement is recommended use...

Page 63: ...and to check if any changes are required the height the cross section insulation etc performed by expert Ash deposited or clogged chimney It is necessary to clean the ash deposited in the chimney Ash...

Page 64: ...DATE the WARRANY FORM of the unit 5 12 Actions after the unit is not in exploitation anymore After the lifetime period of the unit has been completed then it should be treated properly in order to pre...

Page 65: ...emove the bridge and connect the room thermostat to this connector Figure 6 1 Electrical scheme of the boiler control board of series Pyrotherm START indicator Alarm cleaning L N PE 220 V N 10A FS1 1...

Page 66: ...p 66 69 QUALITY CERTIFICATE Product type Hot water wood gasification boiler Pyrotherm Model Boiler s serial number Date of production of the boiler Operation test check of the boiler Technical control...

Page 67: ...Failures caused by natural disasters Earth quakes fires floods etc Unsatisfied installation maintenance and service requirements which are described in this manual Repairing of any failure of the unit...

Page 68: ...h the unit is warranty serviced by authorized technicians the period between failure notification and its repairing The warranty period of the unit is 24 months The warranty of the unit is valid when...

Page 69: ...p 69 69 WARRANTY SERVICE PROCEDURES LIST Entry date of unit in the service company Description of the failure Date of delivery back to the end user Signature of the technician which repaired the unit...