OPERATING INSTRUCTIONS
Contents
1. kettle HYSTERESE KETTLE TEMPERATURE pumps buffers HYSTERESE BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Kettle pump Kettle pump works if kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP Parameter pumps bufferRELEASE TEMPERATURE KETTLE PUMP Heating circle pumps Heating circle pumps do not work in this mode of operation with exception of absorption temperature Boiler charge pump Boiler charge pump switches on if boiler temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERESE BOILER TEMPERATURE and kettle temperature is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD but higher than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump switches off again if boiler temperature is higher than HOT WATER BOILER NOMINAL TEMPERATURE if kettle temperature is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if kettle temperature is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump works additionally if kettle temperature is higher than 80 C Parameter Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER pumps buffers HYSTERESE BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD pumps buffers RELEASE TEMPERATURE BOILER CHARGE PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 36 MANUAL BIOMASS HEATING INSTALLATION COM2. A P Bioenergietechnik GmbH a Traeglhof 2 Se ch KO THERM Tel 49 9608 9230128 Fax 49 9608 913319 Email info oeko therm net WW OPERATING INSTRUCTIONS SERVICING INSTRUCTIONS BIOMASS HEATING INSTALLATION COMPACT CO CT CIL WITH CONTROL AM I 2 X Com Hilltop Farms C1L Com Nr 1613 10 MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 1 1 1 2 1 3 1 5 1 6 1 7 1 8 1 9 1 10 2 3 3 1 3 2 3 3 3 4 3 5 3 6 3 3 8 3 9 3 10 4 4 1 4 2 5 5 1 5 3 A P Bioenergietechnik GmbH TABLE OF CONTENTS Description of the installation Function Installations C0 C1 C1L Setting up the installation Compactaniage CO C1 C1L Heating sided installation of the installations Compactanlagen CO C1 C1L Stoker unit with fire prevention shutter Ashes slide Section of Stoker unit installation Compactanlage CO C1 C1L Feeding conveyor Kettle cleaning and servicing of the installation Assembly tips of the control AM I Safety technical facilities Automatic return Safety shutter Sprinkler system back fire extinguishing Safety thermostat STB Door switch of boiler s door Safety switch overfilling Main switch Ashes thermostat LOW pressure supervision Safety temperature device overheating Combustion course Combustion control Automatic ignition Putting into operation of the heating installation Before first putting i
3. After fastenings of the kettle s door and pressing the OK key the Installation goes back to operation 3 6 Cover switch In case the installation is equipped with a cover switch as overfill protection it must be closed completely because it closes down the whole installation otherwise display malfunction overfill switch 3 7 Main switch The AM I control is equipped with a main switch The main switch is right in front of the switch box and interrupts the whole power supply line to the switch box 3 8 Ashes thermostat The ashes thermostat protects the installation from overfilling of the combustion bowl during heating operation The sensor is right in the area of the ashes drawer The regulator is right in the front end of the heating installation and has a control range of 0 300 C When reaching the set temperature the installation is switched off 3 9 Vacuum pressure control Vacuum in the combustion bowl is controlled by means of a pressure controller lf an overpressure is generated e g malfunction of suction draught fan both air supply fans switch off immediately If this condition is continued longer than 30 seconds installation goes over to malfunction Display malfunction vacuum 3 10 Temperature controller The temperature controller protects the kettle from overheating in addition to the STB It has a set range of 30 90 C factory setting 90 C In case of exceeding installation will be
4. second fuel line OPTION transverse screw pole socket OPTION hydraulics OPTION pendulum removable floor OPTION differential pressure transmitter huba 694 911015040 directly to connect Traeglhof 2 92242 Hirschau Seite BA 41 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 14 Guarantee The following guarantee is valid for the Compact wood chip installation 2 years however 1 year guarantee for all parts of the kettle exposed to fire and all mechanical moving parts from the day of the delivery Parts subject to wear are excluded from guarantee No guarantee is assumed for storage room and or bridging caused by fuel Guarantees and warranties are given only if instructions of operating instructions are followed The guarantee ceases particularly in case of not properly treated return flow increase General information Slight cracks in refractory lining are dry splitting and are no malfunction In case kettle is moist or wet inside check heating water temperature of kettle and back flow none of these temperatures must not have less than 65 C risk of corrosion disclaimer of warranty To fill up the installation Mixer half opened Pump to switch off Gravity brake setting on open Interruption in operation Kettle clean carefully All doors and covers close To empty perhaps in case of risk of frost In case of malfunctions by inproper operation of installation or
5. 8 BIOMASS HEATING INSTALLATION ComPAcTCO C1 C1L K I FI Fe M Boiler charqe pump to K13 This pump switches no matter whether the installation is switched on or switched off e with buffer and mode of operation buffer ON boiler temperature lt boiler nominal temperature boiler hysterese OFF boiler temperature gt boiler nominal temperature RELEASE buffer temperature on top gt release temperature boiler pump and buffer temperature on top gt boiler temperature difference temperature buffer load 3 C fixed e without buffer and mode of operation buffer ON boiler temperature lt boiler nominal temperature boiler hysterese or kettle temperature gt 80 C OFF boiler temperature gt boiler nominal temperature RELEASE kettle temperature gt release temperature boiler pump and kettle temperature gt boiler temperature difference temperature buffer load 3 C fixed e modes of operation ON OFF clock ON boiler temperature lt boiler nominal temperature boiler hysterese OFF boiler temperature gt boiler nominal temperature RELEASE kettle temperature gt release temperature boiler pump and kettle temperature gt boiler temperature difference temperature buffer load 3 C fixed Absorption temperature For safety reasons all connected pumps will be switched on and back flow mixer will be opened at a kettle temperature of 87 C A P Bioenergietechnik GmbH Traeglhof 2 92242 Hir
6. Buffers RELEASE TEMPERATURE BOILER CHARGE PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 32 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM MODE OF OPERATION BUFFER Kettle Kettle switches on if switch ON OFF is switched ON and kettle temperature is lower than NOMINAL KETTLE TEMPERATURE by more than HYSTERES KETTLE TEMPERATURE HYSTERES and temperature on top of buffer is lower than SWITCH ON TEMPERATURE ON TOP OF BUFFER Kettle switches off again if switch ON OFF is switched OFF or kettle temperature rises up higher than NOMINAL KETTLE TEMPERATURE or temperature on top of buffer is higher than SWITCH ON TEMPERATURE ON TOP OF BUFFER and temperature at button of buffer is higher than SWITCH OFF TEMPERATURE AT BUTTON OF BUFFER Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERESE KETTLE TEMPERATURE pumps buffers SWITCH ON TEMPERATURE ON TOP OF BUFFER pumps buffers SWITCH OFF TEMPERATURE AT BUTTON OF BUFFER Kettle pump Kettle pump works if kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either kettle works or kettle temperature is higher than temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Heating circle pumps Heating circle pumps work if temperature on top of buffer is higher than
7. The kettle switches on if switch ON OFF is switched ON and kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE and the temperature on top of buffer is lower than SWITCH ON TEMPERATURE ON TOP OF BUFFER The kettle switches off again if switch ON OFF is switched OFF or the kettle temperature is higher than NOMINAL TEMPERATUR KETTLE or if the temperature on top of buffer is higher than SWITCH ON TEMPERATURE ON TOP OF BUFFER and temperature at button of buffer is higher than SWITCH OFF TEMPERATURE AT BUTTON OF BUFFER Parameter Menu installation NOMINAL TEMPERATUR KETTLE kettle HYSTERES KETTLE TEMPERATURE pumps buffers SWITCH ON TEMPERATURE ON TOP OF BUFFER pumps buffers SWITCH OFF TEMPERATURE AT BUTTON OF BUFFER Kettle pump The kettle pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either the kettle works or the temperature of the kettle is higher than the temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Heating circle pumps The heating circle pumps work if the temperature on top of buffer is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS The heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS A P
8. approx 200 C in case of higher temperature kettles to be cleaned To check fire fighting valve of the thermal protection Seite BA 10 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Monthly Surface of the heat exchanger and the burn out zone are to be cleaned at least monthly The isolation of the door inside and back may be cleaned with a broom only Remove lightly adhering residues only Moreover the safety technical facility must be checked monthly back fire fighting device STB safety switch Semi annual control Check conveyor facility and mixing work for wear break tightly fittings Lubricate conveyor facility Check gearing motors for leakproofness and fixation refill if necessary oil and seal Check flue gas fan for firm seat soiling and imbalance Lubricate bearings of stoker and discharging screw Remove incrustations from combustion bowl and stoker input Check true running of the suction draught fan and clean if necessary Annual control The heating system must be completely cleaned yearly furthermore to clean the suction draught fan if available Moreover the heating installation must be checked by an expert yearly the safety technical facilities is to be controlled and the combustion setting is to be corrected if required Visual in
9. by unsuitable fuel see side BA 4 the warranty is cancelled The scope of legal warranty encloses delivery of defective parts within a m warranty Mounting times travel costs as well as necessary release are charged and are to be paid by the plant operator Spare parts Spare parts can be ordered anytime by stating Com number factory number and name of defective part Com number and factory number are to be found on the type shield Seite BA 42 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 15 Operating instructions for combustion optimization AM I Operating instruction of combustion optimization control AMI for OKO THERM Compactsystems Display Anzeige a OKO THERM AM I asr Q St rung Gebl se gt Kessel D Boiler Heizung R cklauf A Betriebs und Tastatur Storanzeiqen Seite BA 43 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L Table of contents 1 1 1 2 1 3 1 4 3 1 3 2 3 3 3 4 3 5 3 6 4 1 4 2 4 3 4 4 4 5 4 6 4 Introduction Construction overview Display Keyboard Operating and malfunction indicator Switch ON of the control Standard displays General Current operating information Mode of operation date and time Buffer temperatures Sensor values a
10. is used as dose screw conveyor a light barrier must be installed in the down shaft as filling state control 1 7 Ashes slide The ashes slide consists of heat resistant castings thrust bar sealing bush electric servomotor and ashes slide s rack The sealing bush is provided with long holes and can be adjusted in height to guarantee a horizontal run of the ashes slide linkage Seite BA 8 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL g a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM abue jmy Age S zz zz mamas zz nasnn Jang gunupap Inutgul AL EAZ Ili I m LS LETI Aki TEE MA o Buparrm Me LEE a h ri sunmuguan RT A sel ER EE Seite BA 9 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 1 9 Fuel discharger The fuel discharger consists of a geared motor to power the screw conveyor a screw channel and a intergear The mixing work is powered through the intergear The mixing work transports the fuel into the screw conveyor From there the fuel is transported to the down shaft Fuel reaches the stoker screw through fire preventing shutter back fire slide From there fuel is delivered into the combustor The material dosage can be carried out by screw conveyor according to fuel and transport system or by stoker screw When dosage shall be carried out by stoker s
11. of A P Bioenergietechnik GmbH 6 2 Security temperature limiter The security temperature limiter briefly STB exists of a combination of temperature limiter and temperature controller It is right directly beside the heating flow and should prevent overheating of installation in case of malfunction The cut out temperature of the temperature controller is adjustable and should be min 10 C higher than set installation specified temperature The cut out temperature of the temperature limiter is fixed In case of cut out a resetting is possible after cooling down the heating system lower 15 C by unscrewing the black header and by pressing the release button Seite BA 18 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Additional information about fast acting control accordinq to DIN 4751 As with biomass heating installations commonly the KO THERM Compactanlage also contains considerable amount of fire resistant ceramic components After longer full load operation these components strongly heat up and can lead to an inadmissible heating up of the kettle Overheating the kettle can be avoided by the installation of a safety heat exchanger SWT or by natural circulation in the heating net Whether a sufficient natural circulation is given depends on the heating net height differences and kind of heat consumers This can be checked by the heating co
12. ATURE HEATING CIRCLE PUMPS The heating can be switched on and off simultaneously only Parameter pumps bufferRELEASE TEMPERATURE HEATING CIRCLE PUMPS Installation variation 2 Buffer available no hot water boiler MODE OF OPERATION ON OFF Kettle The kettle switches on if switch ON OFF is switched on and the kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE The kettle switches off again if switch ON OFF is switched off or the kettle temperature rises up higher than NOMINAL TEMPERATUR KETTLE Parameter Menu Installation NOMINAL TEMPERATUR KETTLE kettle HYSTERESE KETTLE TEMPERATURE Kettle pump The kettle pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either kettle works or temperature of the kettle is higher than temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Heating circle pumps The heating circle pumps work if the temperature on top of buffer is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS The heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 28 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O
13. ATURE and the temperature on top of buffer is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD and higher than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump switches off again if boiler temperature rises up higher than HOT WATER BOILER NOMINAL TEMPERATURE if the temperature on top of buffer is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if the temperature on top of buffer is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Parameter Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER pumps buffers HYSTERES BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD pumps buffers RELEASE TEMPERATURE BOILER CHARGE PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 31 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM MODE OF OPERATION CLOCK Kettle Kettle switches on if switch ON OFF is switched ON and the kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE and at least one of 6 weekly programmes is switched on active Kettle switches off again if switch ON OFF is switched off or the kettle temperature is higher than NOMINAL TEMPERATURE KETTLES or all 6 weekly programmes are switched off inactive Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERESE KETTLE TEMPERATURE Menu weekly programme programme 1 till 6 Kettl
14. Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 30 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Installation variation 3 Buffer available hot water boiler available MODE OF OPERATION ON OFF Kettle The kettle switches on if switch ON OFF is switched ON and the kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE The kettle switches off again if switch ON OFF is switched off or the kettle temperature rises up higher than NOMINAL TEPERATURE KETTLES Parameter Menu Installation NOMINAL TEMPERATUR KETTLE kettle HYSTERESE KETTLE TEMPERATURE Kettle pump Kettle pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either the kettle works or kettle temperature is higher than the temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Heating circle pumps Heating circle pumps work if the temperature on top of buffer is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS Heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS Boiler charge pump Boiler charge pump switches on if boiler temperature is lower than the HOT WATER BOILER NOMINAL TEMPERATURE minus the HYSTERES BOILER TEMPER
15. E PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau l Seite BA 34 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM MODE OF OPERATION CLOCK Kettle Kettle switches on if switch ON OFF is switched ON and kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERESE KETTLE TEMPERATURE and at least one of 6 weekly programmes is switched on active Kettle switches off again if switch ON OFF is switched off or kettle temperature is higher than NOMINAL KETTLE TEMPERATUR or all 6 weekly programmes are switched off inactive Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERESE KETTLE TEMPERATURE Menu weekly programme programme 1 till 6 Kettle pump Kettle pump works if kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP Heating circle pumps Heating circle pumps work if kettle temperature is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS Heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS Boiler charge pump Boiler charge pump switches on if boiler temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERESE BOILER TEMPERATURE and kettle temperature is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD and higher than RELEASE TEMPERATURE B
16. F rderdruck CO 10 13 5 Metaloterm AT Offener Kamin SERS 8 EBBSESSSSSESS Seress 8 g My SuqsieeuuswuueN III TAT TI LE MT WME PALL ill h NEIL Din 5 ren H K Ki A Sie MIN iz e Mac GAL JETT USING wu U agew g BA 40 Seite Technische nderungen vorbehalten Traeglhof 2 92242 Hirschau A P Bioenergietechnik GmbH MANUAL g a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L 13 Circuit diagram 13 1 Cable numbering C0 C1 C1L switch cabinet Nr 1 Nr 2 Nr 3 Nr 4 Nr 5 Nr 6 Nr 7 Nr 8 Nr 9 Nr 10 Nr 11 Nr 12 Nr 13 Nr 14 Nr 15 Nr 16 Nr 17 Nr 18 Nr 19 A P Bioenergietechnik GmbH installation 16 pole socket primary fan secondary fan TRB STB ashes thermostat ignition induced draft fan limit switch door sensor sensors 10 pole socket lambda sensor flue gas sensor flow return sensors stoker engine pole socket discharge screw conveyor pole socket ashes transverse screw pole socket ascending screw 7 pole socket OPTION ashes slide 3 pole socket power supply control box ashes slide 3 pole plug directional control ashes slide 5 pole socket limit switch fire shutter 3 pole socket engine fire shutter 3 pole socket limit switch limit switch 3 pole socket overfill cover conveyor limit switch 3 pole socket overfill cover ascending screw OPTION low pressure measurement directly connected
17. Firma A P Bioenergietechnik GmbH Tr glhof 2 92242 Hirschau dass die nachstehend bezeichnete Maschine m ihrer Konzipierung und Bauart sowie in der von uns in Verkehr gebrachten Ausf hrung den grundlegenden Sicherheits und Gesundheitsanforderungen der EG Richtlinie Maschine entspricht Bei einer mit uns nicht abgestimmten nderung der Maschine verliert diese Erkl rung ihre G ltigkeit Bezeichnung der Maschine Compactanlage Maschinentyp CO Cl CIL Zutreffende EG Richtlinien EG Maschinenrichtlinie 98 3 7 EG in der geltender Fassun g EG Niederspannungsrichtlinie 73 23 EWG n der geltenden Fassung EG EMVYV Richtlinie 89 336 EWG in der geltenden Fassung DIN 4702 TRD 702 92242 Hirschau 01 08 2006 k SEET Herbert Fellner Gesch ftsf hrer A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 46
18. OILER CHARGE PUMP Boiler charge pump switches off again if boiler temperature is higher than HOT WATER BOILER NOMINAL TEMPERATURE if kettle temperature is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if kettle temperature is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Parameter Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER pumps buffers HYSTERESE BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD pumps buffers RELEASE TEMPERATURE BOILER CHARGE PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 35 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM MODE OF OPERATION BUFFER Kettle Kettle switches on if switch ON OFF is switched ON kettle temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE and by more than HYSTERESE KETTLE TEMPERATURE lower than KETTLE NOMINAL TEMPERATUR and the temperature in the boiler has dropped under HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERESE BOILERTEMERATUR The kettle switches off again if switch ON OFF is switched off or kettle temperature is higher than HOT WATER BOILER NOMINAL TEMPERATURE plus DIFFERENCE TEMPERATURE BUFFER LOAD or higher than KETTLE NOMINAL TEMPERATURE or if temperature in the boiler reaches HOT WATER BOILER NOMINAL TEMPERATURE Parameter Menu Installation NOMINAL TEMPERATURE KETTLE Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER
19. PACTCO C1 C1L O K O T H E RM 11 1 Pump programme AM I Compact Short circuit pump backflow booster pump to K12 This pump switches no matter whether installation is switched on or switched off ON Kettle temperature gt release temperature kettle pump and Return temperature lt Nominal return temperature OFF If switch ON conditions are not fulfilled Heating circle pump heating circle release to K14 This pump switches no matter whether installation is switched on or switched off There is no heating circle release during operation of the boiler i e the heating circle pumps are not switched on e with buffer ON Buffer temperature on top gt release temperature heating circle pumps OFF if switch ON conditions are not kept e without buffer memory ON kettle temperature gt release temperature heating circle pumps OFF If switch ON condition is not kept Buffer charge pump kettle pump to K11 This pump switches no matter whether installation is switched on or switched off e with buffer ON kettle temperature gt release temperature kettle pump and kettle temperature gt buffer temperature on top difference temperature buffer 3 C fixed or system in operation OFF If switch ON conditions are not kept e without buffer ON kettle temperature gt release temperature kettle pump OFF if switch ON condition is not kept Seite BA 37 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL e
20. RELEASE TEMPERATURE HEATING CIRCLE PUMPS Heating circle pumps can switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS Boiler charge pump Boiler charge pump switches on if the boiler temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERESE BOILER TEMPERATURE and temperature on top of buffer is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD and higher than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump switches off again if temperature is higher than HOT WATER BOILERS NOMINAL TEMPERATURE if temperature on top of buffer is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if temperature on top of buffer is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Parameter Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER pumps buffers HYSTERES BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER pumps buffers RELEASE TEMPERATURE BOILER CHARGE PUMP A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 33 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Installation variation 4 Hot water boiler available no buffer MODE OF OPERATION ON OFF Kettle Kettle switches on if switch ON OFF is switched ON and kettle temperature is lower than NOMINAL KETTLE TEMPERATURE by more than the HYSTERESE KETTLE TEMPERATURE Kettle switch
21. T H E RM MODE OF OPERATION CLOCK Kettle The kettle switches on if switch ON OFF is switched on and the kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE and at least one of the 6 weekly programmes is switched on active The kettle switches off again if switch ON OFF is switched off or the kettle temperature rises up higher than NOMINAL TEMPERATURE KETTLE or all 6 weekly programmes are switched off inactive Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERES KETTLE TEMPERATURE Menu weekly programmes programmes 1 till 6 Kettle pump The kettle pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either kettle works or temperature of the kettle is higher than temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD Heating circle pumps The heating circle pumps work if the temperature on top of buffer is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS The heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 29 MANUAL a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM MODE OF OPERATION BUFFER Kettle
22. URE Temperature absorption To avoid an overheating of the kettle an absorption temperature was set in the control If the kettle temperature rises up to more than 87 C the return flow increase mixer and kettle pump will be opened Heating circle pumps and short circuit pump are switched on so that the excessive heat can be dissipated Peak load kettle Peak load kettle Such as oil or gas is released if the on off switch is set on OFF if there is a fault at the kettle or if kettle temperature is longer than the time indicated in DELAY TIME PEAK LOAD KETTLE and lower than NOMINAL TEMPERATURE KETTLE minus HYSTERESE PEAK LOAD KETTLE pumps buffers DELAY PEAK LOAD KETTLE pumps buffers HYSTERESE PEAK LOAD KETTLE Menu installation NOMINAL TEMPERATURE KETTLE A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 26 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Installation variation 1 No buffer no hot water boiler MODE OF OPERATION ON OFF Kettle The kettle switches on if switch ON OFF is set to ON and the kettle temperature is lower than NOMINAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE The kettle switches off again if switch ON OFF is set to OFF or the kettle temperature rises up higher than NOMINAL TEMPERATURE KETTLE Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERE KETTLE TEMPERATURE Kettle pump The kettle pum
23. and Maintenance Instruction Instructions de conduite et d entretien Diese Sicherheitshinweise sind aufzubewahren These safety instructions must be kept available Ces instructions de s curit doivent tre observees Schneckengetriebe Worm Gears Reducteurs a roue et vis sans fin A Caution It is presumed that fundamental project work as weil as all work with regard to transport assembly installation starting up maintenance and repair Is performed by qualified personnei or supervised by skilled labour taking overall responsibility Make absolutely sure that no voltage is applied at all while work is being done on the ene motor Drive must also be secured against switching on A Caution Any deviation from normal operaning conditions increased power consumption temperature vibrations noise etc or warning signals by monitoring Be suggest maifunction Inform the responsible maintenance personnel at once to prevent the trouble from getting worse and causing directly or indirectly serious physical injury or material damage A In case of doubt disconnect the machine Immediately Preparing and performing installation Transport lateches on drive are designed to carry the drive weight the foundation base should be of adequate size and vibration proof install gear unit or geared motor rigid and braceless ensure sufficient ventilation make use of Lee hole DIN 332 to suit fastening to the shaft en avoid
24. bnahme Wartung und Reparaturen von qualifiziertem Personal ausgef hrt bzw durch verantwortliche Fachkr fte kontrolliert werden Bei Arbeiten am Getriebemotor mu EBENE sein da keinerlei Spannung anliegt und ieser gegen Wiedereinschaltung gesichert ist A Warnung Ver nderungen gegen ber dem Normaibetrieb h here Leistungsaufnahme Temperaturen chwingungen Ger usche usw oder Ansprechen der berwachungseinrichtungen lassen vermuten da die Funktion beeintr chtigt ist Zur Vermeidung von St rungen die ihrerseits mittelbar oder unmittelbar schwere Personen oder Sachsch den bewirken k nnten mu das zust ndige Wartungspersonal dann umgehend verst ndigt werden A im Zweifelsfall die entspechenden Betriebs mittel sofort abschalten Aufstellung Vorbereitung Transport sen am Getriebe sind f r das Gewicht des Antriebs ausgelegt Fundamente ausreichend schwingungsfrei ausf hren Getriebe oder motor fest und ohne Verspannung montieren ausreichende Bel ftung vorsehen serienm iges Innengewinde nach DIN 332 zum Aufziehen von Verbindungselementen auf die Wellen benutzen Schl ge auf die Wellen Lagerbeschadigung Maschine und Getriebe m glichst mit elastischen Kupplungen verbinden vor dem Einschalten Abtriebselemente aufziehen bzw Pa feder sichern bei Aufsteckgetrieben mit Drehmomentst tze Gummipuffer verwenden bemessen und vermeiden Betriebs und Wartungsanleitung Operating
25. crew the installation must be equipped with a filling state control mounted in down shaft Montage of fuel discharger of the installation Compactanlage Montage of the fuel discharger is very simple The feeding screw is delivered as one unit and has be screwed on the stoker unit at site First the intergear box has to be put on the right height by provided props The mixing work arms may not touch the silo ground at the underside The props for the intergear must be screwed on the ground Afterwards the screw canal is to be mounted on the connection flange of the back fire shutter or the hydraulic back fire slide 1 10 Kettle cleaning and servicing of the installation An optimum kettle cleaning influences the efficiency and the life span of the boiler Everyday control optical and acoustic control during operation of the installation Flame length and color height of the glow bed water temperature Weekly control According to fuel the ashes drawer of the combustion chamber is to be cleaned weekly or if required In case fuels of high dirty and or sandy portions are being used the time interval is to be shortened for ashes slide ashes screw moreover the installation must be cleaned more often To clean ignition and ignition pipe hole when using very dirty and wet fuels several times per week To check ashes discharger To empty ashes drawer if required To check flue gas temperature normally
26. dre largement les dimensions des embases et es r aliser exemptes de vibrations monter les r ducteurs et motor ducteurs solidement et sans haubanage pr voir une a ration suffisante pr voir le taraudage conforme la norme DIN 332 pour monter des accouplements sur ies arbres d entr e et de sortie viter de donner des coups sur les arbres cela pourrait d t riorer le roulement lier autant que possible la machine et le r ducteur avec des accouplements lastiques avant ia mise en service enlever i ment d accouplement ou et fixer la clavette utiliser pour l ex cution arbre creux avec bras de r action une but e en caoutchouc Seite BA 23 OKO THERM ht barrier stoker Li BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L MANUAL 9 1 ZSZ0ZZ9990 map nz Fungdipursfuy ITLIOYIOA suyo used UOSIUN31 IOA JUOSY sep ls RYO S F OO ALL usq sne sng Jose u p 1S u os os as unupiO ut 3s 1p apos Bunpaquyla a ap arg USIOTJOHUON uas Iosu s IJayyajop ua Jopo ssnyyos ZINN u oO sou uoorqr lun ura uuey Iyoy Joq Al Wd pun YIIvyd t q Inu Josuag uapuayosadsyus we 1J q34 Uouo wozra s eusis r 3guejdurT yr1 pun SpussS LIS ITITWANG e X0OPS VITVd aITva pun VIT Va Suru Sozr ATIeuossnv Jopo urg oma Is e gang Zunuuedg 2u191xq UOPISM 1u 1pa8 syyool YOLU IIM Douane 12J9WOHUSJOI SEP guu PILM JENQUSA AJ9S91 SBUNZINKUNOSISA SISYOY SUIS wam ao
27. e after rising of the flue gas temperature If no glowing rests exist though fuel is filled in a preprogrammed time and is lighted then by hot air If the flue gas temperature exceeds the specified temperature within the set time the installation is switched back to power fire Should the ignition attempt be unsuccessful within the set ignition time the ignition attempt is interrupted displayed ignition attempt unsuccessfully Seite BA 15 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 5 Commissioning of the heating installation 5 1 Before start of initial commissioning There is a so called condensed water formation in the kettles This is normal and is no malfunction it may continue up to one week Check whether a sufficient ventilation of the installation room is guaranteed Cross section at least as diameter of the fuel gas pipe Check whether enough water is in the heating system look at manometer Check whether the necessary control and safety facilities thermal process safety device and or safety temperature limiter boiler safety valve higher than 120 kW 2 pieces sprinkler system return flow increase ventilation expansion vessel exist The operativeness is be checked yearly 5 2 Notice for operating Heating up in general with dry material only so a sufficient temperature of the combustion bowl can be reach
28. e cuttings fine sawdust chaff material with long wooden pieces more than 170 mm or wooden pieces with cross section greater 4 cm Attention Follow important instruction to combustion of biomass Seite BA 6 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 1 Description of the installation 1 1 Function Fuel located in fuel dump is transported by the feeding conveyor to the combustor Through the safety shutter the fuel material reaches the screw conveyor that transports the fuel in the combustion chamber of the kettle There the directed combustion of the fuel takes place by supply of primary air and secondary air The complete installation is controlled by a central switch console with AM I processor control The installation is controlled fully automatically over capacity range between 30 and 100 in case the installation is equipped with a Lambda control module The switch console also controls all safety technical facilities 1 2 Installations C0 C1 C1L The special installations C 0 C 1L were developed especially for combustion of bio fuels The combustion chamber is formed that way that the combustion of the fuel can be carried out in a water cooled burning base and the post combustion in the burning upper part aided by heavy fire clay This way it is possible to use all bio fuels up to a water content of 35 The heat exchanger is
29. e pump Kettle pump works if kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and either kettle works or the kettle temperature is higher than the temperature on top of buffer plus DIFFERENCE TEMPERATURE BUFFER LOAD Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers RELEASE TEMPERATURE BUFFER LOAD Heating circle pumps Heating circle pumps work if the temperature on top of buffer is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS The heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS Boiler charge pump Boiler charge pump switches on if the boiler temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERES BOILER TEMPERATURE and the temperature on top of buffer is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD and higher than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump switches off again if boiler temperature is higher than HOT WATER BOILER NOMINAL TEMPERATURE if temperature on top of buffer is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if the temperature on top of buffer is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Parameter Menu Installation NOMINAL TEMPERATURE HOT WATER BOILER pumps buffers HYSTERES BOILER TEMPERATURE pumps buffers DIFFERENCE TEMPERATURE BUFFER LOAD pumps
30. ed fireclay starts to glow Temperature of kettle and return never lower than 60 C Seite BA 16 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 5 3 Heating up the installation Switch on the main switch Conveying fuel starts after opening the fire prevention shutter according to set conveying cycles power fire plug in and power fire break min In case the installation is equipped with automatic ignition fuel will be conveyed into the combustion bowl according to set plug in time ignition If there is no rising of fuel gas temperature within plug in time to be measured by fuel gas sensor ignition is started by microprocessor When fuel is lighted and the fuel gas sensor finds out a temperature rise in the flue gas ignition stops and the installation is switched over to power fire If no rise of the flue gas temperature is stated within set ignition attempt time though there is a display ignition attempt without success Food and circulation water Bad food and circulation water can lead to deposits on the water side Boiler scale The heat transfer is reduced The pipe wall temperature is increased Result overheating Damages blasting of the pipes Thermo shock High temperature cracks For this reason a preventive water treatment and an everyday check of the food water and circulation waters must be carried out The follo
31. edsny Ssq ln q spy t7 Dp 08 91 9 OF Zums3e7 meischunsdungs un Dp 0S 91D OT qaijag myeredursysSungasuyy 1 BYses Buessnv HOISIEUSIS puos te OTI qesd ot Ue 1851 Junuuedssqainag yars peudis adumyd uz we qg sun att I sI 108005 u pun S 01 519 0 3eqljalsurq 439 NO u oan Sur Sg SU Ce SOL NEJ H2ZSU011NBS2I XOra aIiT Vd I XOCH altvd ZH o zusnbaypyeyos Sr BD asaraysAL OCA Of WI 09 ANd NdN Zue sny ojsisug VS OVA0TL WS OVA0ST ON ON 2 ISUS AN I OT Id VS OVA0ZI VE OVAGSZ HONAN spam I avilvd Auedsny siejoy ZAMS muss ZEMS WS VAAH gt ISINTHISNV SUIYRUNESSUTYSIO SI H OVA GET AST AIVA SII Gelz OWA PZ SI OCA FT Sunuuedssq tnoq SAOSMHAS O3I L gt e SLOSUAS 2 ODIL in W3S ITVd Sunypajues unus psg u jsKS ITV4 Sunyspues unusrpag BA 24 Seite Traeglhof 2 92242 Hirschau A P Bioenergietechnik GmbH MANUAL e 8 BIOMASS HEATING INSTALLATION ComPAcTCO C1 C1L K I FI Fe M 10 Summary Servicing and inspection extent and intervals are to be set and recorded according to the size and importance of the respective installation Work in the area of the servicing and inspection which are prescribed by legal regulations and rules and regulations of the employers liability insurance association must be carried out and recorded accordingly regardless of the operation guaranteeing measures for reasons of
32. es off again if switch ON OFF is switched OFF or kettle temperature is higher than NOMINAL KETTLES TEMPERATUR Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERESE KETTLE TEMPERATURE Kettle pump Kettle pump works if kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP Heating circle pumps Heating circle pumps work if kettle temperature is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS Heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS Boiler charge pump Boiler charge pump switches on if boiler temperature is lower than HOT WATER BOILER NOMINAL TEMPERATURE minus HYSTERESE BOILER TEMPERATURE and kettle temperature is higher than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD and higher than RELEASE TEMPERATURE BOILER CHARGE PUMP Boiler charge pump switches off again if boiler temperature is higher than HOT WATER BOILER NOMINAL TEMPERATURE if kettle temperature is lower than boiler temperature plus DIFFERENCE TEMPERATURE BUFFER LOAD or if kettle temperature is lower than RELEASE TEMPERATURE BOILER CHARGE PUMP Parameter Menu Installation NOMINAL TEMPERATUR HOT WATER BOILER pumps buffers HYSTERESE BOILER TEMPERATURE pumps bufferDIFFERENCE TEMPERATURE BUFFER LOAD pumps bufferRELEASE TEMPERATURE BOILER CHARG
33. he installation have cooled off to ambient temperature before servicing and repair work Decontaminate environmentally hazardous lubrication coolants or cleaning agents properly Se Works on the electric equipment Repair work on electric equipment of the installation may be carried out by a qualified electric expert only Check electric equipment regularly Fasten loose joints again Exchange damaged wires cables immediately Keep switch console always shut Access is permitted to authorized people with key tools only Never splash switch consoles and other cases of electric equipment when cleaning by water hose Seite BA 4 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL 8 a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Work on hydraulic and pneumatic equipment To get servicing and repair work on hydraulic and pneumatic equipment carried out by especially for it qualified staff only Deflate the pneumatic and hydraulic equipment of the installation completely before servicing and repair work Exchange tube pipelines in preventive maintenance regularly even if no damages are to be seen Follow appropriate information of the manufacturers After servicing or repair work but before putting into operation e Tighten all screw joints e Make sure that removed container lids sieves or filters are mounted on again Guarantee that after completion of servicing or repair
34. horizontally to the installation by using sealing cord Afterwards the feeding conveyor is to be placed concentricly with the down shaft upper part in the fuel dump room and is to be screwed on to stoker unit The switch console is to be set up in suitable distance to the installation to serve easily Seite BA 7 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM The switch console is to be fixed by provided dowels The cables are numbered and must be connected with cables of installation Cable Nr 14 is to be connected directly with the pressure measuring box Transmitters and receivers are to be mounted on fixing of stoker s down shaft Test of rotation direction to be carried out right rotary field 1 5 Heating sided installation of the installation Compactanlage C0 C1 C1L The heating sided installation has to be carried out according to safety technical instruction The compliance with all rules and instructions is to be absolutely prescribed The return increase must be adjusted on 65 C The return sensor is to be fixed to the return main 1 6 Stoker unit with fire prevention shutter The stoker unit consists of down shaft base with Stoker s gear and stoker s screw conveyor The fire prevention shutter or the hydraulic back fire slide is being on down shaft base The sprinkler valve is fixed also there In case Stoker s screw conveyor
35. isplay information temperature switch insert for the heater 3 3 Sprinkler system back fire fighting A mechanical valve is installed in the front area of the plug in screw that opens the water influx in case of back fire in the stoker s screw and extinguishes the back fire The opening temperature is fixed approx 90 C Care must be taken when connecting the water pipe that the pipelines have been rinsed cleanly use water filters 3 4 Safety thermostat STB A safety thermostat is installed in the kettle By using the safety thermostat it is guaranteed that a flow temperature of max of approx 95 C is not exceeded Should this temperature be exceeded for whatever reasons though the installation will be switched off To repair this failure the small black protective cap of the safety thermostat is to be unscrewed to press the underlying red key ATTENTION Before doing this of course the kettle temperature has to be lowered again to below 80 C Afterwards the switch console has to be switched off and again switched on using the main switch Seite BA 13 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 3 5 Kettle s Door switch After opening kettle s door both supply air fans and the feeding are switched off immediately The installation switches over to malfunction door supervision after an adjustable time work setting 90 sec
36. made of strong sided sheet steel and is equipped with two flue gas outlets These flue gas outlets are easy to clean because a spaciously dimensioned cleansing door allows free access to the interior of the kettle The capacity range of the kettle is of between 30 to 110 of the rated capacity In case the kettle is operating in the lowest capacity range of 30 the flue gas temperature drops according to fuel quality under 90 C To avoid in this case chimney damages by falling short of dew point a dew point proof chimney high grade steel or ceramics is to be used for this operating phase If a dew point proof chimney could not be used the electronic stop of fuel gas temperature has to be activated by setting the minimum flue gas temperature on dew point proof flue gas data more than 100 C 1 3 Commissioning of the installation Compactanlage Installations C 0 C 1L have to be set up in the boiler room according to installation plan The installation must be aligned this way the distance is precisely followed to fuel dump room Installation will be removed from transport rack the lifting butt strap is under the upper covering see drawing The water sided connection of the boiler may be carried out after setting up only the pipes should be laid in a distance of 30 cm to the covering Afterwards the stoker unit is to be screwed on with down shaft base to the installation Doing this it must be heeded the stoker unit to be flanged
37. na uor a munuoy Hoxyorrpuydurg AAT un38 erp s q Masu puoys p stet Xoca vilva eu Fejyssuesyur WoA 19 euronu loq Wap MU WexYyopuy saszuy oNuoy L1 dug ID PIM SYUERJISNOTT Famurdg Jap sulyeugsrgogug qe oFrazuy onuog y r L Suegsnesiepy Sunuueds sqsm gt g och ya a Sle ay Sop puejsnzifeyss uap wars jeugis anye Suedsny IT 3301 sip Zungaysurg 21103 Pore eee SIIMO arp y tsi gu8rs o joHUOYs oyyopuydurg CAT ounss aq e uotmuna II H PANG D a SR gt puezsgeyjeydg Au 1955019 Uyg pueIsgeyfeyos e BunssBgzraregossny 4 ua snoq UspUayssidsyus arp srg Gallais os Den I sunuueds Sunuueds Su131xT Sumleu st qund po at uaga esq rm g e VRSHISSNTHOSNV Zursdgzisayeyssug usyfeyasus Zunuuredsgstnagg uuep us orjfonuoy BunfpgeyaA e Sunqorsurasneyqoypundiag Sunuucedssq rn g oO USY99I5 JONIOSJINS USP Ul JOYINISIOA jeudissSueSsny anye Suesny Sunspeyostaxung cl D ZunyjeyssjjoH u Jopiiq sSqe vulsyosyn yosuy wap ut am GTIITVd pun TV d wq ssnjyosuy VOD JOpO 9320S3231S UISp WW 310SU25S SIP AS G JEIpIDA oSlazursSunuuedssqauyag stponuoysiayyorpuygdurg uoyeyyddy r Inf losusg uspusysaidsjue uep sig usyeM e Sungyeyosjayung Zungjgeyssji gt fl 21 Hl DNVOSAV NOLLANNAA NOLSISNVAL ee Ee THVALSLHOTT NIV SS PUBISGUNEU gt S 198501 pussgejjey gt s 190119 HAAL UIDNVIdWH HAINAS NIY SSYIXH Y HUANYLSYVY LTYHDS e Sunuueds o e Bunuueds squa Zu
38. nd operating data Ignition current and motor current Menue Customer setting General Installation settings Test mode Manual ash removal Timer Date and time setting Startup setting load Malfunctions and repair A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau 12 12 14 20 31 32 33 34 35 Seite BA 44 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 16 Malfunctions and repair ATTENTION During work on the installation it must be guaranteed that system cannot automatically be switched on Main switch OFF If hydraulic back fire protection is activated additionally the pressure accumulator must be emptied completely Display is inoperative possible causes 1 power failure 2 main switch or heating emergency switch OFF 3 board fuse blew 1 check power supply 2 main switch and heating emergency Switch ONT 3 check fuse to replace if necessary Smoke emission in the heating room Flue or heating surface oft he kettle dusted To clean kettle or chimney or to get them clened Moist material Use chips or chippings with a max water content of 35 only see instruction page BA 4 Seite BA 45 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM EG Konformit tserkl rung Gem EG Richtlinie Maschinen 98 37 EWG Anhang IT A Hiermit erkl ren die
39. nstruction company or the responsible planning office If a sufficient natural circulation is not given a safety heat exchanger must be installed On this occasion the following points of view are to be followed Safety pipe The safety heat consumer is to be connected as stated in the tubing scheme between safety flow and one of both return necks to the kettle The tube is to be carried out with nominal diameter of the flanges Reductions and flow hindering installations are inadmissible The shut off valves in the safety pipe are to be protected against unintentional closing If the SWT is not be situated in the highest part of the tube an additional air bleed is to be provided The SWT should be mounted high as possible at least however 2 5 m higher than kettle return neck with the outlet neck Cold water connection The cold water inlet is to be carried out according to the connection to safety heat exchanger 3 4 or 1 The shut off valves of cold water pipe are to be protected against unintentional closing For opening the tube a thermal safety device with component testing e g Braukmann is to be used The back pressure of the supply pipe must be maintained at not less than 2 bar Hot water outlet The water running off from the SWT can exceed the prescribed maximum temperature for discharge into the sewers depending on flow rate In that case the water must be cooled or be mixed with cold water The outlet tube is to be mounted in
40. nto operation To pay attention for operation To heat up the installation Traeglhof 2 92242 Hirschau Seite BA 2 MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 6 Instructions to special dangers with operations of the installation 6 1 General 6 2 Safety temperature limiter 7 Electric ashes slide 8 Radial Ventilators 8 1 Automatic Pipe Cleaning Device PUTZMAUS 9 Drives 9 1 Light barrier stoker 10 Summaries 11 Installation scheme proposal to install pipesystem 11 1 Pump programme AM I Compact 12 Chimney connections 13 Switch plans 14 Guarantee services 15 Operating instructions of combustion s optimizing AM I 16 Malfunctions and repair Seite BA 3 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL T 4 8 BIOMASS HEATING INSTALLATION ComPAcTCO C1 C1L O KO T FI RM Close the access to the operating zone of the installation for unauthorized people before starting servicing or repair work Attach or put up a Signboard which draws the attention to the servicing or repair works Switch off the main switch for the electricity supply and protect it by padlock before servicing and repair work The key to this padlock has to be in hands of that person who carries out the servicing or repair work When exchanging heavy installation parts use only suitable and flawless load facilities and connecting means Make sure that all to be touched parts of t
41. p works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP Heating circle pumps The heating circle pumps work if the kettle temperature is higher than RELEASE TEMPERATURE HEATING CIRCLE PUMPS The heating circle pumps can be switched on and off simultaneously only Parameter pumps buffers RELEASE TEMPERATURE HEATING CIRCLE PUMPS MODE OF OPERATION CLOCK Kettle The kettle switches on if switch ON OFF is set to ON and the kettle temperature is lower than NOMUNAL TEMPERATURE KETTLE by more than HYSTERES KETTLE TEMPERATURE and at least one of the 6 weekly programmes is switched on active The kettle switches off again if switch ON OFF is switched off or the kettle temperature rises up higher than NOMINAL TEMPERATURE KETTLE or all 6 weekly programmes are switched off inactive Parameter Menu Installation NOMINAL TEMPERATURE KETTLE kettle HYSTERES KETTLE TEMPERATURE Menu weekly programmes programmes 1 till 6 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 27 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM Kettle pump The kettle pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP Heating circle pumps The heating circle pumps work if the kettle temperature is higher than RELEASE TEMPER
42. schau Seite BA 38 MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 12 Chimney connection Connection of the heating installation with the chimney The right dimensioning of the chimney is a condition for a proper operation of the heating installation The dimensions are to be calculated to DIN 4702 The values relevant for the calculation are given by the manufacturer for the corresponding capacity of the kettle and type of fuel In addition the local and state regulations shall apply The selection of the chimney installation is to be tuned with the responsible chimney sweep before installation of the heating system For heating installations with power control flue gas temperatures can lead to less than 100 C at lower power range operation In this case the heating installation is to be connected to high insulated chimneys Effective thermal resistance 1 according to DIN 18160 T 1 For high or strongly fluctuating flue an installation of a flue limiter could be advisable The connection parts to the chimney are to be mounted slightly upward in flow direction and to be insolated if necessary A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau Seite BA 39 KO THERM BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L MANUAL d V dm amp Wirksame H he m Wirksame H he m F rderdruck nach DIN CO nach DIN Metaloterm AT Gas l Gebl se 160 C Unterdruck 0 Pa
43. shocks on shafts bearing damage preferably use flexible coupling between output shaft and driven machine fit output elements to shaft end or secure feather key before starting the motor use torque arm with rubber buffer on shaft mounting gearboxes Traeglhof 2 92242 Hirschau A Avertissement ll est imp ratif que les travaux fondamentaux de installation ainsi que tous les travaux de transport montage installation mise en exploitation entretien et r paration solent accomplis par du personne quale et contr les par des techniciens sp cialis s ans ce domaine Avant toute intervention sur le motor ducteur il faut s assurer que celui ci n est plus sous tension et que la remise sous tension soit interdite A Avertissement Si en utilisation normale des modifications de fonctionnement apparaissent telles que puissance absorb e trop lev e temp rature lev e vibrations fortes bruit intense ect ou en rapprt avec les contr les techniques cela laisse supposer que diff rentes fonctions de l appareil peuvent tre d t rior es Pour viter ensuite des probl mes qui pourraient entrainer de graves accidents corporels OU de graves d gats mat riels le personnei d entreten comp tent doit imm diatement tre inform A SI vous tes dans le doute coupez imm diatement l alimentation Mise n place pr paration Le mat riel utilis pour la manutention doit tenir compte du poids de l quipement pren
44. spection of the ceramics to check for strong cracking and break Return temperature on at least 62 C Filter change of the hydraulic installation if available Cleaning of the flue gas pipes Cleaning of the supply air distribution boxes Check of all safety facilities Cleaning of the lambda sensor Cleaning of the flue gas sensor To carry out functional control of safety heat consumer To be able to guarantee the greatest possible economic efficiency of the heating installation we recommend you to get your installation checked up by our skilled staff before the beginning of every heating period Dry out of the ceramics Heat the installation for a period of 1 hrs with 30 of the nominal capacity with an exhaust gas temperature of approx 90C small flame Then increase the capacity in the course of next 2 hrs slowly up to nominal capacity The capacity can be reduced by overtime of pause periods In case the flame becomes too big or the exhaust gas temperature too high switch off the installation switch Seite BA 11 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL 8 BIOMASS HEATING INSTALLATION COMPACTCO0 C1 C1L K I FI Fe M 2 Installation instructions of the control AM I 1 x 1 Care must be taken when installing the console that it is slightly accessible the electric installation must be carried out by an electric expert 2 Care mu
45. st be taken when wiring the sensors that they are not laid in one duct with the three phase current cables 3 The three phase motors must be connected with 7 fibers cable 3 phases for three phase current neutral on star point thermal motor supervision if available and ground wire Seite BA 12 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 3 Safety technical facilities 3 1 Automatic return FOR STOKERS ONLY Drive motor s polarity will be reversed automatically and motor will run return in case of blockage of plug in screw e g by a too big wooden piece The return time is adjustable infinitely variable and should not exceed 0 5 sec This automatic return is activated three times Nevertheless before the max loading capacity of the drive motor will be exceeded the whole installation will switch over to breakdown display information malfunction over current motor 3 2 Safety shutter Safety shutter is a back fire protection and is designed as 90 rotary shutter The feather mechanism will also guarantee sure fastenings of the shutter in case of power failure The Installation will be additionally equipped by a back fire thermostat optional when using strongly back fire endangered materials When responding of this thermostat in the screw pipe the fire prevention shutter is closed immediately and the installation switches off d
46. such a way that also with failure of an elevating pump power failure the water can be safely discharged into the sewers Whether a different safety heat exchanger can be used than that one offered by the manufacturer must be checked on case by case basis But if a different safety heat exchanger is applied no guarantee will be given for operativeness of the safety circle Seite BA 19 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 7 Electrical ashes slide See enclosed external operating instructions Seite BA 20 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 8 Radial Ventilators See enclosed external operating instructions Seite BA 21 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 8 1 Automatic Pipe Cleaning Device PUTZMAUS See enclosed external operating instructions Seite BA 22 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L CU R OKO THERM 9 Drives See enclosed external operating instructions A P Bioenergietechnik GmbH A Warnung Es wird vorausgesetzt da die grunds tzlichen Planungsarbeiten der Anlage sowie Transport Montage Installation Inbetrie
47. switched off and malfunction message will appear display malfunction temperature controller KTW Seite BA 14 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 4 Combustion process 4 1 Combustion control The control of the combustion process is controlled by a microprocessor This processor regulates the whole combustion process The integrated power control regulates the combustion in the capacity range of 30 100 power control is possible in case installation Is equipped with lambda sensor only The oxygen content of the flue gas is determined by lambda sensor and secondary air is regulated accordingly By this combustion regulation optimum combustion values will be reached in the whole capacity range For installations version 1 24a 2nd fuel line the fuel is ignited with line 1 e g pellets when reaching the set flue gas temperature range from 100 C 300 C it is switch over to line 2 e g grains 4 2 Automatic ignition The automatic ignition allows a fully automatic operation of the installation and a starting and shutoff of the installation by an integrated timer After release of the heating operation the installation starts conveying fuel sequentially into combustion bowl In case ignitable glowing rests are still available they light the filled fuel this way the operation is switched over from ignition to power fir
48. the safety for the service staff and of preventing of possible material damages For the repair of installations all necessary documentation components and most important measurement devices are to be stored best on site to make fault finding as successful and short as possible Seite BA 25 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL D a BIOMASS HEATING INSTALLATION COMPACTCO C1 C1L O K O T H E RM 11 Installation scheme proposal of pipin Installation variations and modes of operation of Control AM 1 for Compakt installations This applies to all installation variations and modes of operation Mixer return flow increase The return flow increase mixer adds hot flow water to water coming back from heating net or buffer to ensure that return temperature is only as little as possible lower than MINIMUM RETURN TEMPERATURE With RETURN FLOW MIXER REGULATION BREAK TIME the control speed of the mixer can be set to existing piping The longer the break time the slower mixer regulates Parameter pumps buffers MINIMUM RETURN FLOW TEMPERATURE pumps buffers RETURN FLOW REGULATION BREAK TIME Short circuit pump The short circuit pump works if the kettle temperature is higher than RELEASE TEMPERATURE KETTLE PUMP and return temperature is lower than the MINIMUM RETURN FLOW TEMPERATURE Parameter pumps buffers RELEASE TEMPERATURE KETTLE PUMP pumps buffers MINIMUM RETURN FLOW TEMPERAT
49. wing standards must be kept Max hardness 0 2 dH pH range 9 5 10 fenolftalein value P value 2 4 phosphate concentration 20 50 mg l The oxygen concentration had to go less than 0 02 mg l or however at least balance of sodium sulfate must be due to oxygen abrasions Seite BA 17 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL T 4 8 BIOMASS HEATING INSTALLATION ComPAcTCO C1 C1L O KO T FI RM 6 Indications of special dangers when operating the system 6 1 Universal During servicing work on the heating installation it must be guaranteed that heating installation cannot switch on itself automatically Switch construction sided heating emergency OFF or main switch OFF When using a hydraulic burn back protection the pressure accumulator is to be emptied additionally The installation of the heating system is carried out by the manufacturing firm If the installation Is carried out by other people installation instructions can be requested any time The heating tubing and equipment must be carried out according to DIN and TRD A tubing scheme is added to the manual The cross section and the length for the chimney device has to be agreed upon with the local sweeper authorities The requirements of the local fire prevention are to be followed on site Special sound preventive measures and dust preventive measures both within and beyond the whole installation do not belong to the scope of supply
50. work but before resumption of the production All material tools and other equipment required for carrying out servicing or repair work have been removed from the operating zone of the installation Remove all possibly leaked out liquids All safety facilities of the installation work perfectly Follow environment protection regulations Meet legal liabilities in regard to waste avoidance and proper utilization removal with all works in and with the installation Above all water harmful material as Greases and lubricating oils Hydraulic oils Coolant solvent containing cleansing liquids may not impact the ground and may not reach sewerage These materials must be kept in suitable containers then be moved then caught up and finally decontaminated Seite BA 5 A P Bioenergietechnik GmbH Traeglhof 2 92242 Hirschau MANUAL 8 BIOMASS HEATING INSTALLATION ComPAcTCO C1 C1L K I FI Fe M Co Capacity range 16 49 kW C 1 Capacity range 29 88 kW C 1L capacity range 40 120 kW suitable for according to size of means of transport agropellets e g triticale rape etc fine chaff material forest caff material saw chaff material up to max 35 of water content industrial chaff material up to max 35 of water content max size of chaff material length 60 mm cross section 2 cm max dust content 5 not suitably for dust abrad
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