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User manual Green ECO Therm

1. p 8 69 Parameter Dimension Value Mod Weight 3350 330 330 370 450 water jacket capacity 60 59 59 7 8 89 thermal capacity after fuel hours 2 3 chamber charging Maximal wood log length __ __mm 330 330 500 700 _ Overall W width dimension of the D depth Damm mm CO ors Te er system WxDxH H height P1082 circulating water Hydraulic losses of the circulating water at nominal hPa 3 54 S27 14 23 8 37 thermal capacity Heating system expansion vessel type ne MES water temperature in the boiler water temperature in the A 0 18 0 24 Supply return P flow opened or closed Drainage Connections Emergency M a FP Flue gases duct gases duct mm Power supply Ce a L1 N PE 5 FE 230V Power supply cable oa Sm Electrical Electrical capacit ee Electric Electric protection _ _ P20 according to EN 303 5 Table 2 2 Dimensions and technical data for the wood gasification hot water boiler of series Pyrotherm p 9 69 Parameter Dimension Value Fuel type Wood logs Length of the wood logs See Table 2 2 Moisture content Low calorific value of the fuel LHV MJ kg Table 2 3 Proximate parameters of the recommended fuel predried and chopped wood logs EXPLANATION one of the most important parameters of the fuel is its calorific value its heat content The calorific value also known as heating value is function of the moisture con
2. Myood logs 10 7 kg h Calculate 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 Estimate the heating value of the fuel Hyood togs 13 9 MJ kg 13900 kJ kg In case that the moisture content is not known then it has to be estimated or assumed see figure 2 1 table 2 1 Estimate or assume the efficiency of the boiler at nominal operating conditions Nooiter S5 0 0 85 or the efficiency at the estimated thermal capacity of the boiler Calculate the thermal efficiency of the _ boiler Proiler 1 boiler x see ee ME o Tos 0 85 13900 0 002972 35 12 kW In case that the thermal capacity of the boiler should be estimated at different than the nominal operating conditions as well as other fuel is utilized the type or the moisture content could be different the same approach should be utilized EXPLANATION e At any change of the thermal capacity of the boiler for example at change of the fuel type and especially its moisture content it is recommended to make appropriate adjustment of the operating parameters of the boiler the position of the of the primary air control flap as well as the position of the flap which controls the total air flow rate drawn in the boiler p 47 69 e Incase that the thermal capacity of the boiler need to be decreased this could be achieved by increasing the periods be
3. Pyrotherm Norms and requirements 4 1 Basic requirements for installation of wood gasification hot water boiler of series Pyrotherm e The room dedicated to mount the hot water boiler should be supplied with fresh air supply duct necessary for optimal combustion process as well as room ventilation e Installation of the hot water boiler in inhabitable premises including dwelling corridors is not allowed e The hot water boiler should be connected to the heating system by authorized personal only e Installation and service procedures of the hot water boiler should be performed by authorized qualified and certified personal ONLY e The wood gasification boiler of series Pyrotherm could be attached to a heating system equipped with opened or closed expansion vessel which should be designed for the water capacity of the entire heating system its capacity is calcutated at the step of heating system project development e Both the entire heating system and the hot water boiler should be totally filled with circulating fluid water and air free before operating the boiler e Maintenance procedures of the boiler as well as the heating system should be performed by trained adult persons which have read the user manual of the unit ATTENTION at the transport of the boiler take care to preserve the ceramic element mounted in the combustion chamber of the boiler not to be cracked or damaged secure the detai
4. 5 1 Basic fuel requirements The fuel should be only chopped and dried wood logs described above The boiler producer recommends that the fuel should be stored in dry and well ventilated rooms The fuel should be protected from moisturizing and appropriate storage cares should be taken It is strongly forbidden to store the fuel in close region of the boiler the minimal safety distance between the fuel and the appliance is 500 mm The unit producer recommends an optimal distance between the boiler and the fuel storage site to be at least 1000mm It is recommended to store the fuel in room next to that where the boiler is installed At the installation procedure of the unit as well as the fuel storage one fire prevention recommendation should be considered It is also recommended to install a fire extinguisher in a safe and easy accessible place 5 2 Basic requirements for exploitation of the hot water boiler connected to a heating system e Jn principle heating systems which are hydraulically opened to the atmosphere allow direct contact between the circulating fluid in most cases it is water and the air During the heating season the water content in the expansion vessel absorbs oxygen from the atmosphere though the free surface The increased oxygen content in the water threatens the metal of the unit as well the pipes Through the free surface of the expansion vessel water evaporation is observed as well Considering these
5. ji inflow i i J Expansion J Fu 7 a j la j j d To heating n e ee aa n i H I aA system Domestic Ea Yo hot water ar outflow E mah From heating system 3 E i i H Tap water f i i i _ i i a mm m l ee oe mi7 i I i i I a a 25 oe ee near a i Ps Lal f j l i l i l i H j l j i rey OY A f f i i 1 fi Saat a l f2 6 L hb hs 40 guu Device 7 8 Figure 4 7 Recommended principal hydraulic scheme for connecting the hot water boiler of series Pyrotherm to the heating system equipped with three way valve and heat accumulator Hot water boiler Pyrotherm 12 Water filter Safety valve Thermovalve TV 4 Returnvalve Circulating pump 1 O charger E E Control valve Three way mixing valve Automatic air separator Safety valve Circulating pump 2 Table 4 2 Designation of the elements indexed on figure 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 is made according to the above mentioned norm as well as heat accumulator methodology developed by boiler s producer company p 25 69 5 Wood gasification hot water boiler of series Pyrotherm starting procedures ATTENTION The boiler should be installed adjusted and verified ONLY by trained and authorized staff
6. eventually service maintenance should be performed Table 5 1 Description of operation faults of wood gasification hot water boiler Pyrotherm causes and methods for repairing Flue gases are Insufficient chimney s emitted out in the draught bouler s room after certain period of exploitation p 63 69 5 11 Hot water boiler warranty form completion The applied WARRANTY FORM should be completed by filling the required information in the appropriate fields The assigned field for Signatures and stamp should be completed as well in order to VALIDATE 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 preserve environment contamination The unit should be dismounted and disassembled by environmentally safe methods This requirement is most commonly completed by appropriate components recycling considering separate waste disposal and utilization methods p 64 69 6 Electrical scheme of control board of wood gasification hot water boiler of series Pyrotherm Figure 6 1 shows the electrical scheme of hot water wood gasification boiler of series Pyrotherm Erste aan oc 1 _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Overheating H O lt Room thermostat 2 ee Connector WAGO WINSTA MINI 890 112
7. capacity strongly depends on the fuel properties mainly its moisture contents as well as boiler s operating mode The practice shows that efficient pyrolisis process in such type of hot water boilers is achieved at temperature levels of the circulating water above 60 C That s why one of the main requirements for the efficient operation of this type of boilers is to control the thermal capacity of the boiler and the outflow heat consumption in order to sustain such temperature levels of the water in the boiler In case that the water temperature is below the above mentioned levels this will lead to low intensity of volatile gases released from the wood in the fuel hopper as well as intensive condensation of the tars on the heat exchanging surfaces of the boiler This process is highly inefficient and decreases the overall lifetime and reliability of the boiler The condensed tars form organic acids which act highly corrosive on the heat exchanger surfaces as well finally the heat exchanger s wall will be thinned and eventually will be cracked and water leakage will be observed The practice shows that during the nominal operation p 29 69 of the boiler and not being touched no fuel charging no stirring the fuel will get bridged i e the fuel particles as well as char will be collected around the burner s orifice and eventually will make blockage This process will lead to high hydraulic resistance of the burner s orifice and wil
8. convective part of the boiler is clogged or in case that the flue gas duct is not fully tightened and gas leaks are possible it is highly recommended to use personal protective breathing mask 5 10 Operation faults and their repairing bad Operation fault Method for repairing Low temperatures Insufficient in the heat supplied capacity of the boiler 2 High temperatures in the heat supplied rooms Low temperature boiler s thermostat Low temperature remote thermostat connected High temperature boiler s thermostat High temperature remote thermostat connected High thermal capacity of the boiler set point of the operating set point of the room if set point of the operating set point of the room if It is necessary to increase the frequency of fuel charging and or increase the amount of fuel charged It is necessary to make adjustment of the thermal capacity of the boiler see 3a Check the moisture content of the wood log eventually replace the fuel with drier one It is necessary to increase the set point of the boiler s operating thermostat up to 90 C It is necessary to increase the set point of the room thermostat It is necessary to decrease the set point of the boiler s operating thermostat it is recommended to keep it above 65 C It is necessary to decrease the set point of the room thermostat It is necessary to decrease the frequency of fue
9. damages of the heat exchanger and the burner s nozzle It is highly recommended to cool down the heat exchanger by 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 technician as well 5 7 Cleaning the ash of the boiler The cleaning up of the deposited ash on the heat exchanging surfaces of the boiler should be performed regularly which allows efficient operation and high reliability of the unit The cleaning of the ash deposited on the surfaces of the combustion chamber of the boiler should be performed before any boiler s start up process before firing up the fuel or in case the boiler has not been stopped for couple of days the ash should be cleaned on a period of 2 3 days considering the thermal capacity and the fuel consumption rate as well as the properties mainly the ash content of the wood logs ATTENTION at the ash cleaning process small amount of the mineral matter will be released as fly ash diluted in the ambient air it is highly recommended to have individual protecting wear for example a mask which will protect the human from breathing the small ash particles p 52 69 Figure 5 12 Tools scrapper and a brush for cleaning the ash from the boiler s heat exchanging surfaces EXPLANATION The regular cleaning of the ash deposited on the hea
10. of the heating season Completing these requirements will ensure long exploitation duration of the boiler and its high efficiency and reliability The service check up of the boiler as well as thorough ash cleaning allows sustaining the lifetime of the heat exchanger decreasing the corrosion and eventual damages This procedure should be performed by authorized and certified technician only 5 6 Turning OFF the boiler The system is turned off by stopping any wood logs charging in the 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 switched off by turning off the main POWER switch It is recommended to clean the deposited ash thoroughly of the heat exchanging surfaces of the boiler e Emergency boiler stop In operating process of the boiler emergency situations could arise and the boiler will go into alarm failure mode Overheating situations are detected by the control board of the boiler and will go into automatic preventive regimes in order to protect the system The overheating protection thermostat the alarm thermostat will be activated and the ALARM indicator lamp of the boiler in case of overheating will indicate this state of the boiler After the cause of the alarm situation 1s clarified take adequate actions for bringing back the boiler into normal operating condit
11. operating conditions the boiler s thermal capacity will be increased as well EXPLANATION in case the wood logs placed in the fuel hopper have been consumed then the thermal capacity as well as the temperature of the flue gases of the boiler will be decreased In such a case the flue cases thermostat will be activated when the flue gases temperature is below the set point of the flue gas thermostat and the boiler will be switched into stand by mode i e the flue gas fan will be switched off and thus the char layer in the fuel hopper chamber will be preserved After the fuel hopper is charged with new quantity the boiler will go into nominal operation mode p 49 69 The following figures show the variation of the heat consumption rate of the heating system of a typical heating system in a period of 24 hours considering the ambient temperature Z Thermal capacity of the boiler Instant thermal consumption of a typical heating system 100 90 70 100 Thermal capacity of the boiler used for heating domestic hot water Hour of the daytime Figure 5 10 Instant thermal capacity of a typical heating system at ambient temperature 15 C The figure shows that the thermal consumption rate of a typical heating system varies during the day and typically the highest consumption rate is at the morning However the operation of the hot water boiler could not follow the consumption trend in order to cover the heat
12. out of the boiler e Fuel chamber e Ignition flap utilized at the initial phase of fuel ignition and boiler heating up e Ceramic insulated combustion chamber e Convective duct which also heats up the air consumed for the combustion process e Dash board for control and monitoring of the operating parameters of the boiler e Thermal insulation made of mineral wool The boiler is equipped with e Thermo manometer which indicates both the operating temperature and the operating overpressure of the circulating water e Operating thermostat which controls the flue gas fan e Thermostat which indicates the thermal condition of the boiler and indicates if the boiler needs to be cleaned of the accumulated ash option e Alarm thermostat which switches off the power supply of the boiler in alarm overheating mode of the boiler e Emergency cooling coil utilized in case of alarm overheating of the boiler Advantages of the boiler The boiler is designed to utilize wood biomass which makes it ecologically clean 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 influenced by the world prices of the other fuels and energy sources which makes it attractive and competitive compared with the common known energy sources The manual feeding of the fuel in the boiler allo
13. plug 890 702 socket _ _ _ _ _ _ _ Operating __ thermostat Flue gas thermostat alarm for cleaning FTh1 Bia de N Flue gas thermostat HL2 START indicator Flue gas fan Alarm cleaning l ATTENTION the room thermostat connector should be plugged in It has factory set electrical bridge Remove the bridge and connect the room thermostat to this connector Figure 6 1 Electrical scheme of the boiler control board of series Pyrotherm p 65 69 Instruction for cleaning pyrolitic boiler Before cleaning the utility must be turned off and cooled down It is obligatory to use safety guards La Open upper door and clean inside Open lower door and clean the ash walls with the scrapper remains in fireproof dish starting from top Clean with brush rod Install the Open lower cover at the back side turbolators back Install the cover back of the boiler Cleaning tool set Both chambers Wood log tank and combustion have to be cleaned before every start Flue gas way passages have to be cleaned once per month Remove the ash remains Install the cover back
14. shows that the primary air flow rate should be increased it is necessary to open the primary air control flap by pulling the axes of that flap e Smoke in the flame this shows that there is absence of secondary air and increased intensity of volatile gases as well as tar release rate That s why it is necessary to decrease the primary air flow rate and to increase the secondary air flow rate in order to do that one should close the primary air control flap by pushing it 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 highly sensitive The criteria for optimal combustion is the operating conditions of the ceramic element positioned in the combustion chamber of the boiler the outer surface of the ash layer should be light grey by color the quantity of the deposited ash should be relatively small no unburned charred particles should be seen chars are dark colored particles The quality of the adjustment of the combustion process could be estimated by monitoring the color of the flue gases released out of the chimney which is connected to the boiler In case that the flue gases are dark colored that is sign for deficiency of secondary air and or the fuel quality is not covering the requirements most often the moisture content 1s higher than required The flue gases emitte
15. the boiler to the heating system e Drainage orifice has internal thread for the size see table 2 2 which should be connected to a drainage valve p 12 69 e Emergency cooling coil is utilized for alarm cooling of circulating water in the boiler s heat exchanger in case that the water temperature has reached high levels This coil has connecting thread of size G2 e The flue exit duct the external diameter is described in table 2 2 is positioned in the back upper of the boiler and extracts the flue gases out of the convective section of the boiler e The heat exchanger is thermally insulated with mineral wool which allows lower heat loses to the surrounding atmosphere e The doors of the fuel hopper and the combustion chamber are fabricated from cast iron which allow high thermal resistance and air tightness of the boiler e The outer covers of the boiler are manufactured from steel plates and are finally color painted The next figures show the dimensions and the design of the wood gasification hot water boiler of series Pyrotherm Thermovalve for controlling the air flow rate Control board of the boiler Fuel hopper door Combustion chamber door Figure 3 1 Side view of wood gasification hot water boiler of series Pyrotherm the main elements of the boiler are described p 13 69 W ROGO ee EI I Figure 3 2 View of the wood cite i hot water boiler of series Pyrother
16. the circulating water this lever opens the air control flap in reverse at high temperatures of the circulating water the lever of the valve closes the air control flap and reduces the air flow rate for the combustion process thus reduces 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 the air control flap should be observed visually and adjusted manually with the applied chain ATTENTION the thermovalve should be adjusted in order to get closed the air control flap when the temperature of the circulating water has reached 90 C Adjustment of the thermovalve should be done in the following way e The boiler is heated up until the temperature of the circulating water has reached 80 C measured by the thermo manometer installed on the front plate of the control box of the boiler e Adjust the position of the handle of the thermovalve the signature of the thermovalve should be equal with the temperature of the circulating water in the boiler e Adjust the applied chain which connects the lever of the thermovalve with the air control flap by changing the position of the hook the position of the air control flap should be opened The chain should be strained e If necessary adjust the minimal position of the opening of the air control flap use the adjustment screw EXPLANATIO
17. the fuel hopper chamber and the combustion chamber as well in case the fuel has been consumed the thermal capacity of the boiler will be decreased also after the fuel hopper has been charged after approximately 30 minutes the wood logs start to release volatile gases which is highly intensive process and leads to increased thermal capacity of the boiler The efficiency of the boiler also varies along the fuel consumption and time The practice shows that the boiler and the heating system are seldom balanced in most case the thermal capacity of the boiler will be higher or lower than the heat consumption rate by the heating system In case the thermal capacity of the boiler is 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 will be switched off and the boiler will go into stand by mode the thermal capacity of the boiler will be decreased to higher extent In stand by mode the air is naturally driven in the boiler and the char oxidation in the fuel hopper chamber is sustained The measurements show that in stand by mode the thermal capacity of the boiler is approximately 10 of the nominal thermal capacity of the unit In case that the temperature of the circulating water is decreased the flue gas fan will be switched on and in a period of 3 5 minutes the combustion process will be in nominal
18. up is performed following the steps described below e Open the ignition flap the lever for ignition flap control 1s positioned on the right hand side of the upper section of the boiler its driven manually by pulling it Lever which moves the ignition flap NOTE the figure shows closed position of the ignition flap Figure 5 3 The lever for the ignition lever of the boiler is pushed backwards and the flap is closed e Open the door of the fuel hopper of the boiler arrange the igniters and make a pile above the orifice of burner make the pile scarce so the flue gases could easily pass through the burner s nozzle Open the door of the fuel hopper arrange a pile of chopped wood particles preferable dry pine p 33 69 wood above the nozzle Please pay attention that the pile should not block the nozzle orifice and should allow easy flue gases transition as well as fresh air Ignite the initial fuel preferably use old news papers but verify that these materials do not emit toxic gases as well as any other harmful gases ATTENTION any flammable liquids usage is not allowed The following figure shows arrangement of the igniter fuel particles in the fuel hopper chamber of the boiler Figure 5 4 Arrangement of the igniter fuel required to start the combustion process in the boiler e The initial fuel is arranged in the chamber of the boiler the fuel is ignited up manually by using a match or a lighte
19. 4 View of the orifice of the hot water boiler where the sensor module of the thermovalve for emergency cooling coil with tap water should be screwed in Inflow outflow of the emergency cooling coil of the hot water boiler Figure 4 5 View of the back side of the boiler the ends of the emergency cooling coil are pointed p 22 69 o Connect the inflow and outflow of the hot water boiler to the heating system use appropriate fittings etc according to the installation project Circulating water outflow to the heating system Flue gases exit to the chimney Combustion air control flap Circulating water inflow from the heating system Drainage orifice Figure 4 6 Backside view of the hot water boiler of series Pyrotherm the connections are pointed e Position the boiler considering the requirements for attaching the electrical power supply position the boiler in order to ensure easy access to the power supply plug box 230V 50Hz ATTENTION the finalization of the boiler s installation and commissioning of the boiler s operation as well as the heating systems should be notified in the warranty list filling all the data fields is obligatory e The heating system and the boiler should be filled up with circulating water most commonly tap water is utilized However the water used for filling the heating system should be transparent colorless no sediments oil contents or any othe
20. N the air control flap should not close tight the air orifice because this will lead to suffocation of the combustion process and intensive tar depositioning p 36 69 on the internal surfaces of the boiler The flap should be opened at distance 3 8 mm according to the local conditions chimney s draught thermal capacity of the boiler fuel properties etc Handle of the thermovalve which controls the air flow rate Chain which connects the thermovalve lever with the air control flap Air flow rate control flap Minimal air flow rate screw Figure 5 5 Thermovalve for controlling the air flow rate for the 3 combustion process EXPLANATION the methodology of the adjustment of the thermovalve is given in its user manual 5 3 5 Nominal operating mode of the boiler After the process of boiler s starting up i e the fuel has been ignited the additional fuel has been fired up the boiler s temperature has reached high levels the combustion process is stable and the circulating is circulating in the heating system the system should be tempered and then the system could be considered in steady state 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 control modules should be adjusted in this mode as well At nominal operating conditions the circulating water tem
21. The ash cleaning of the convective duct of the boiler should be performed as shown on the following figure F z k b p E E J A s h e i j ae f N Tar F a j n ea a Ls j 3 i oe ire i P t z F 2 a z z Figure 5 19 Brushing the ash deposited on the heat exchanger of the convective duct of the boiler MA p 57 69 After the convective duct of the boiler has been cleaned out from the deposited ash it is recommended to clean or at least check the condition the turbine of the flue gas fan of the boiler this procedure should be carefully done ATTENTION clean the deposited ash as well as other tar residues of the turbine of the flue gases fan by using a soft brush do not use any wire brush or any other stiff cleaning tool by operating through the inlet of the flue gases fan orifice Turbine of the flue gases fan rome Figure 5 20 View of the inlet orifice of the flue gases fan EXPLANATION it is highly 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 procedure should be performed at switched off electrical power supply of the boiler as well as unplugged power supply cable of the boiler this requirement is obligatory After the ash residue of the heat exchanging surfaces has been brushed and cleaned the lid of the lower
22. The design of the boiler is optimized in order to achieve high efficiency and low cost heating process as well as easy maintenance ash removal and servicing The hot water boiler of series Pyrotherm is manually fuel fed boiler The combustion process 1s organized in the combustion chamber of the boiler The set of the hot water wood gasification boiler of series Pyrotherm consists of the following e Hot water boiler of series Pyrotherm 1 sp Combustion chamber ceramic directing element sp Thermovalve for control of air flow rate 1 sp Steel ash cleaning brush sp Ash scrapper 1 sp User manual for installation and exploitation of hot water boiler of series Pyrotherm sp 1 2 Basic information for the pyrolisis process The pyrolisis process is chemical decomposition of the biomass through heating of the matter The word pyrolisis is coined of two Greek words pyro fire and lysis decomposition The wood pyrolisis process is realized at certain conditions the products of this process are volatile gases which are utilized like gas combustion process The pyrolisis gases are extracted out of the fuel chamber and are directed through a ceramic nozzle and oxidized in the combustion chamber reaching high intensity of the combustion process and high efficiency This process have many advantages the combustion process could be optimized and allows efficient utilization of the fuel
23. User manual Green ECO Therm for installation and exploitation of wood gasification hot water boiler of series PYROTHERM http www greenecotherm eu Producer ZMM Haskovo Plc Address Bulgaria Haskovo 6300 Saedinenie 67 blvd Phone 359 800 15 145 Fax 359 38 603070 e mail ereenecotherm erato bg home page www greenecotherm eu Thank You for buying the wood gasification boiler of series Pyrotherm This manual will help You to use and maintain the unit properly The user manual applies to the following types of hot water boilers Pyrotherm 25 Pyrotherm 32 Pyrotherm 42 and Pyrotherm 52 This document is intended to be used as additional information for the service team which will install and adjust the boiler as well as maintenance information which will help the end user The producer requires the service staff which will perform the above mentioned procedures to get training course at the producer s training center and get certified as well ATTENTION n interest of your personal security it is obligatory to read thoroughly and carefully this instruction manual before proceeding with any actions with the system mounting connecting etc its elements In case that requirements depicted in this manual are not satisfied failures of any element of the system could be expected or even fatal consequences for which the boiler s producer
24. and or changes of the electrical scheme of the boiler is strictly forbidden e Any usage of fuel which is not approved is strongly forbidden as this could lead to uncontrollable combustion process and flue gasses emmisions as well as direct boiler s structure threatening e Any adjustments increasing of thermal capacity higher than the nominal thermal load of the boiler are not allowed e The positioning of any flammable materials in near vicinity or on top of the boiler is strongly forbidden place the material considering the safety perimeter e The ash deposited in the combustion chamber of the boiler should be collected in fireproof containers and cooled down to ambient temperature The cooled ash should be disposed in appropriate waste containers During ash cleaning the presence of combustible materials in region of 1500mm around the boiler are not allowed Please take into account that the mineral p 28 69 ash result of wood logs combustion could be considered as soil fertilizer and dispersed for agricultural purposes for example e After the end of each heating season the boiler as well as the chimney and the other systems modules should be thoroughly cleaned from the deposited ash tars etc if necessary service maintenance should be performed as well e The duration of the boiler s operation depends on the operating mode of the unit as well the properties of the wood being chosen as fuel The practice shows t
25. appropriate water should be added through the expansion vessel it must cover the requirements of norm BDS 15207 81 During the heating season regular checking of circulating water level in the expansion vessel should be performed by the end user The water content in the circulating system should be kept constant If additional water is required then precautions should be taken not to add air in the heating system as well Practical experience shows that water level checkup should be performed regularly in a period of 14 days in order to sustain quasi constant water content In case that additional water is required the filling process should be performed carefully when the hot water p 26 69 boiler is cooled to the ambient temperature This precautions are induced due to prevent rising of thermal stress of the steel boiler s body and its damage leakage The water utilized for filling purposes of the heating system should be decontaminated and air free and is not dedicated for any other purposes but as a circulating fluid only Any heating system drainage is inadmissible except when repairing modules sections of the system In case that the heating system is equipped with closed expansion vessel then it should be known that these systems are under pressure and practically do not allow direct contact between the circulating fluid and the ambient air These systems are not threatened by oxygen absorption However these systems ar
26. ble to perform total drainage of the circulating water Please take into account that the presence of liquid in the heating system as well in the boiler will prevent oxidation process of the metal surfaces corrosion and system failures p 27 69 5 3 Starting wood gasification hot water boiler of series Pyrotherm procedure Basic requirements e Any maintenance procedures should be performed in accordance with the described in this manual e The hot water boiler of series Pyrotherm should be charged with fuel by person who has read this user manual thoroughly ATTNETION the presence of children around the operating boiler is won allowed e Any intervention in the working process of the hot water boiler which could lead to unit s failure and or dangerous and health threatening situations are strongly prohibited e In case that the boiler s room can be gasified with easy flammable vapors for example from organic paints varnishing etc the boiler should not be in operation as this environment is strongly dangerous and could lead to lethal ambient conditions e The boiler should be checked by the maintenance staff or any trained personal regularly e The end user should not perform 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 described there e Any intervention
27. boiler is installed by unauthorized unqualified personal e The safety instructions described in this manual are not followed and fulfilled Unexpected risks The boiler is designed and produced according to the requirements of the operating EU safety norms 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 o Cauterization risks caused by high temperatures as a result of the combustion process in the combustion chamber and or direct access to the front door of the combustion chamber at manual cleaning processes of the surfaces and combustion chamber or ash residue cleaning accumulated in the combustion chamber or any unburned fuel material or smoldering one o Electrical shock risks at indirect contact The boiler is connected to the power circuit and its operating elements are separated in specialized electric control box equipped with required protective and short circuit preventive fuse It is obligatory to perform system ground connection by authorized personal technician e Fingers injuring risks at opening closing the doors lids of the boiler at maintenance and cleaning process of the unit It is recommended to use appropriate individual resources for self protection e Suffocation risks due to flue gas uncontrolled emissions in the boiler s room in case when the chimney draught is insufficient in case that the p 60 69
28. by the applied chain EXPLANATION the adjustment of the chains length and the opening of the inflow air flap should be performed at operating hot water boiler reached operating thermal parameters In order to initially start the boiler the air flap should be opened and thus to allow air flow in the boiler o Install a self opening valve which opens at high levels of temperature not module of the boiler delivery The valve opens and directs tap water to the emergency 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 orifice positioned in the upper back side of the heat exchanger The water flow control module of this thermovalve should be mounted on one of the emergency coil ends no matter which end will be chosen as inflow and the other as outflow The water flow control module of this thermovalve should be connected to the tap water which will be under the pressure of the tap water of the domestic fresh water supply system or any other source of water at appropriate pressure level The outflow of the emergency cooling coil should be connected to the drainage systems in case of emergency hot water should be drained safely p 21 69 Orifice for installing the sensor section of the emergency coil thermovalve f jee 2 f Tea ee ony this P i Figure 4
29. c The fuel should be charged in a manner that it should be arranged in the chamber so the volume of the chamber to be optimally filled with wood logs Place the wood logs in longitudinal manner Before charging the chamber with new fuel it 1s recommended to make stirring of the chars at the orifice of the burner in p 39 69 order to allow easy convection of the volatile gases though the nozzle use appropriate tool applied with in the maintenance kit of the boiler o Close the fuel hopper door close the ignition flap push the level EXPLANATION the fuel charged should be heated up that s why at the initial step of fuel charging a decrease of the temperature of the circulating water could be observed The practice shows that approximately 30 minutes from the fuel hopper charging process the thermal capacity of the wood gasification hot water boiler start to rise and soon it reaches its nominal thermal capacity and the boiler gets its nominal operating 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 out and even partial carbonization is seen the wood logs look black intensive volatile gases release is observed the smoke if any combustion process is seen this is due to fresh air penetration in the chamber because the door is opened at nominal operating conditions in t
30. cted in from the distribution box to the burner s nozzle where it 1s preheated and afterwards mixed with the volatile gases at the burner s nozzle The total air flow rate drawn in is controlled by the position of the flap which is installed at the air entrance of the air distribution box of the boiler The position of this flap is controlled with the lever of the thermovalve of the boiler The adjustment of the air flow rate for achieving efficient combustion process should be done by trained and authorized technician by measuring the operating parameters of the flue gases with gas analyzer The practice shows that event if the combustion process of the boiler has been adjusted after passing some time new settings i e new adjustment 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 conditions etc considering that the following information will be helpful for not trained person to make appropriate adjustment of the operating parameters of the boiler in order to achieve high efficiency and optimal fuel utilization As primary step of the combustion process operating parameters adjustment it is necessary to perform visual inspection of the flame this is done by opening the door of the combustion chamber and seeing the shape and the color of the flame after that the door should be c
31. d in the atmosphere from the chimney could eventually change the transparency of the air thus the flue gases presence could be recognized even light refraction could be observed at high difference of the temperature of the flue gases and the temperature of the ambient atmosphere The products of the combustion process mainly water vapor H2O and carbon dioxide CO3 are not visible However at p 46 69 low temperature of the ambient air for example 10 C or even lower the water vapor in the flue gases could condense and light smoke rake will be visible above the exit orifice of the chimney EXPLANATION the flow rate of the air drawn in for the combustion process strongly influences the operating conditions of he boiler its thermal capacity as well as its efficiency in case the air flow rate is below the optimal one then the fuel will be partially oxidized i e low combustion efficiency at high air flow rate the combustion process will be cooled down and again the efficiency will be decreased 5 3 8 Estimating the thermal capacity of the boiler The estimation of the thermal capacity of the boiler in practice could be done by measuring the fuel flow rate 1 e the consumption rate and to estimate the heating value of the fuel as well as the efficiency of the boiler In the following section is described in details O Measure the average fuel flow for defined or assumed period of time for example one hour
32. demand This is the main argument to install a heat accumulator tank in the heating system 90 o0 ae 800 70 100 70G 100 60 E0 lipa i BOS 6056 60S 4055 Plage J0 a a 10 30 20 10 0 6 o 12 6 win H Figure 5 11 Instant thermal capacity of a typical heating system at ambient temperature of 0 C the left figure and at 15 C the right figure 5 5 Stopping the operation of the boiler Stopping the operation of the boiler should be performed by stopping any flue charging in its fuel hopper chamber The combustion of the fuel will cease and finally quenched this process could last for some hour however Turn OFF the START switch mounted on the interface panel of the boiler In case that p 50 69 the boiler will not operate for a relatively short period of time than it is recommended to clean the ash deposited on the easy accessed heating surfaces of the heat exchanger ATTENTION Jn case that the boiler will not operate for a long period of time then the heat exchanger should be thoroughly cleaned from the deposited ash The deposited on the metal surfaces ash acts corrosively on the carbon steel surfaces which will lead to a decrease of the lifetime of the boiler s main modules heat exchanger as well as the burner It is obligatory to perform service procedures and preventive observations of the unit by trained service personal only as well as thorough cleaning at the end
33. does not take responsibility User manual for installation and exploitation of wood gasification hot water boiler of series Pyrotherm Document version 16 11 2011 13 32 00 p 2 69 CONTENTS 1 Main properties and advantages of the wood gasification hot water boiler Of series Pyrotherm p5 55552i cs corsapsacdesheuses medeedoin san ttaweonausae nada 5 1 1 Basic information for the hot water boiler ccccecseeeeeeeeeeeeeeeeeees 5 1 2 Basic information for the pyrolisis Process ccesssececcccceeeceseeeeeeeeeees 5 Zs Technical data of wood gasification hot water boiler of series cepuata MiP VEOUNEGL MIN saina a deme E A AEN 8 3 Description of the wood gasification hot water boiler of series See VECO GML MN sasaran A E T R 12 4 Installation of the hot water boiler of series Pyrotherm 18 4 1 Basic requirements for installation of wood gasification hot water boiler of series PV POUM GNI 8 ecsew sisi seasseasidavssesuenassiecdanstecsewarvguedsanriaessmeavbadsonsts 18 4 2 Basic requirements for installation of wood gasification hot water boiler of series Pyrotherm considering it s easy maintenance and SOR VICING cnc ca ei ee ee AEE 19 5 1 Basic fuel FEQUITEMICTIUES o5 690s 4h esse ceevesssensedsseieencasseee ecawineecoeeaaierneuesase 26 5 2 Basic requirements for exploitation of the hot water boiler connected to a heating System cccccccccccssseecceeceeeeeceeeaeeeeeeesaae
34. e and adjustment procedures of the boiler cocc cc cccccccccccceceeeeeeeceeeeaeeeees 59 5 9 Safety and unexpected risks 000 000 cceeccccccceeeecceeeaeeeeceseaaeeeeees 60 5 10 Operation faults and their repairing cc cceeeeeeeeeeeeeeeeeeeees 6l 5 11 Hot water boiler warranty form completion cccccccseeeees 64 5 12 Actions after the unit is not in exploitation anymore 64 6 Electrical scheme of control board of wood gasification hot water boiler of Series Pyrother mM senorita eee 65 OQOUALITY CERTIFICA TE erecenionne 66 WARRANTY CONDITIONS srierionicsciiipnedoi idian a 67 WARRANTY SERVICE PROCEDURES LIST 0000000 ee 69 p 4 69 1 Main properties and advantages of the wood gasification hot water boiler of series Pyrotherm 1 1 Basic information for the hot water boiler The wood gasification hot water boiler of series Pyrotherm is steel plate hot water boiler which uses solid biomass fuel in shape of wood logs The boiler is designed to be connected to local hot water heating systems as well as heating up domestic hot water The boiler uses wood logs with moisture content up to 20 the parameters of the fuel are described below the resulting heat energy from thermo chemical conversion i e combustion process 1s transmitted to the circulation water in its water jacket and the heat energy is transported to the heating system consumer
35. e heat energy during nominal operation of the boiler and the p 38 69 heating system and releases energy when the boiler does not operate but there is thermal energy consumption by the heating system The heat energy contained in the heat accumulator is utilized both for heating purposes as well as heating domestic hot water see figure 4 5 5 3 6 Fuel hopper charging At nominal operation mode of the boiler it should be charged with fuel periodically The fuel charging procedure is described below o Open the ignition flap by pulling the level of the ignition flap see the figure below the flue gases in the fuel hopper will be released to the chimney through this flap Figure 5 6 Position of the lever which controls the position of the ignition flap the flap is opened at the position shown 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 penetrate the chamber do not allow flue gases to be released out of the chamber to the ambient atmosphere o Open the door of the fuel hopper chamber and charge with wood logs It s good idea to have the wood logs arranged so to make easy the fuel charging process ATTENTION have preventive measures not to get burned nor got suffocated with the flue gases released out of the fuel chamber wear self protecting clothes et
36. e pressurized and their pressure should be monitored and controlled if necessary in order to ensure safe system operation both the pressure rising could be dangerous as the mechanical loads of some of the heating system elements gets higher as well as the lower pressure levels could lead to air penetration even air suction through small invisible cracks in thermally 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 pay attention and do not allow air penetration in the heating systems at fill up process The circulating water should be utilized only for heating purposes It is not recommended to drain the circulating water out of the system except in case of repair works It is recommended to check and control the water pressure at systems heating up process as well as on a 14 days period If water fill up is needed then the fluid should cover the requirements described above It is not allowed in any cases to fill the operating boiler with cold water as this could lead to thermal stresses and could eventually damage the unit Fill the boiler with additional water only when it is cooled down to ambient temperature In case that the boiler as well as the heating installation will not be in exploitation for a long period then in order to prevent local water freezing and damages it is advisa
37. echnician in order to achieve optimal results The practice shows that any variation of the primary air control flap position influences the operating conditions of the boiler with a delay of approximately 15 to 30 minutes so in case of position changing one should wait al least 15 minutes better wait 30 minutes in order to get new steady state operating mode of the boiler and the influence of the flap position to get sensible effect on the combustion process The distribution of the air is performed with appropriate adjustment of the primary air control flap as well as adjustment of the air control flap driven by the chain hanged on the lever of the thermovalve mentioned above The following figures show details about the air control adjustment NOTE there is a manual observation orifice and one could verify the position of the primary air control flap p 42 69 Air distribution box Axes of the primary air control flap Fixing screw for the axes of the primary air control flap Figure 5 8 View of the axes of the primary air control flap The position of the flap could be easily changed by unscrewing the fixing screw manually push or pull the axes of the flap 1 e change its position It is highly recommended to change the position of the flap in small steps about 1 or 2 mm and finally fix the primary air control flap with the screw EXPLANATION small axial movement of the axes of the primary air control flap mak
38. ed and the upper lid has been detached the installed turbulizers which are positioned in the convective section of the boiler Ignition flap Turbulizers installed in order to intensify the heat exchange process Figure 5 16 Turbulizers installed in the convective section of the boiler The cleaning procedure of the ash should be performed with a specialized tool a metal brush by pushing and pulling the brush upwards and 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 exchanger of the boiler Draw out the turbulizers upwards The 4 practice shows that these elements could be stuck due to ash deposition it 1s necessary E to make careful handling and vertical lifting of these elements Figure 5 17 Lifting the turbulizers out of the convective heat exchanger duct of the boiler p 56 69 t DONA Ae 2 mia e mn yE te RD gos eS FS EERE A OP Ka TE i 1 i Figure 5 18 View of the turbulizers detached out of the boiler EXPLANATION the turbulizers of the boiler differs one from another and attention should be paid in order to remember which one 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
39. eeeees 26 5 3 Starting wood gasification hot water boiler of series Pyrotherm PrOCCUUT 0 pips cassccccetocsserant iane N EEE EE a 28 5 3 1 Interface control board of wood gasification hot water boiler OF Series F VVOUMG KIN eacee enni vas aneeatesy daeeudaion E O a 30 3 0 2 Start up initialization of the boiler cccecccceeeeeeeees 32 5 3 3 Ignition of the fuel and boiler s heating up 33 5 3 4 Adjustment of the air flow rate control thermovalve 36 33 5 Nominal operating mode of the boiler ceccceee 37 5 3 6 Fuel hopper cCharging ccccccccccccccsssecceceeseeeceeeaseeeeesaaeees 39 5 3 7 Adjustment of the operating parameters of the boiler 4 5 3 8 Estimating the thermal capacity of the boiler 47 5 3 8 1 Decreasing the thermal capacity of the boiler 48 5 3 8 2 Increasing the thermal capacity of the boiler 48 p 3 69 5 4 Operation of the boiler in stand by mode cccccceeeeeees 49 5 5 Stopping the operation of the boiler cc eseeeececeeeeeeeeees 50 5 6 Turning OFF the Dower jeiccssicicccsieeeeeec ee 51 e Emergency boiler StOps c00 cccnucdeiescorniinte ores 51 5 7 Cleaning the ash of the boiler cc cccccccssseccceeeeeeeeeeeaaeeeeees 52 5 8 Showing and teaching the end user about the maintenanc
40. es sensible effect on the operating conditions of the combustion process and the overall performance of the boiler 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 cover the requirements described above the primary air control flap should be closed pushed back inside However in case the fuel s moisture content is higher than required then the primary air control flap should be opened to some extend in order to sustain the pyrolisis process of the fuel in the hopper chamber Again change the position of the primary air control flap into small steps in order to achieve efficient raw fuel devolatilization p 43 69 Moving flap which closes the monitoring orifice for manual observation of the primary air control flap position Primary air control flap Direction for opening of the primary air control flap i e increasing the primary air flow rate Direction for closing of the primary air control flap i e decreasing the primary air flow rate Figure 5 9 View of the primary air control flap and the air distribution box EXPLANATION the moving flap is installed in order to allow visual inspection of the primary air control flap At nominal operating conditions this flap should close the orifice e Adjustment of the combustion process The adjustment of the operatin
41. f the boiler rather then being extracted directly to the chimney which will lead to intensive heating up of the circulating water in the boiler e Turn the flue gases thermostat in order to set it into operating position This position should be derived experimentally it is recommended to mark this position for convenience by observing the ignition process of the boiler e Adjust the thermovalve which controls the air flow rate At ignition this flap should be opened in order to guarantee availability of air for the combustion process After the boiler has been fired up and the operating 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 gravitational forces starts to convect circulating through the boiler s heat exchanger to the heating system i e naturally driven circulation of the heating media this is observed by increasing the temperature of the inflow and outflow pipes of the system even if the circulating pump is not functioning if any is installed The circulating pump should run when the operating temperature has been reached controlled by the operating thermostat in most of the cases and the heat energy is transported out of the boiler to the heating system NOTES e During the very first start of the operation of he boiler intensive water vapor condensation on the inte
42. fan will not run at temperature below the set point of this thermostat and flue gases will not be extracted by the flue gas fan thus the remaining char will be p 30 69 preserved from being consumed when only char remains in the fuel hopper of the boiler e Thermo manometer indicates the operating temperature of the circulating water in the heat exchanger jacket of the boiler well as water overpressure e START switch sends START STOP signal to flue gas fan of the boiler the boiler wiil operate at nominal thermal capacity ON or will go into stand by mode OFF e START indicator indicates the status START STOP signal to the flue gas fan of the boiler e Alarm 1 indicator emergency overheating indicates emergency overheating state of the boiler due to activation of the emergency thermostat In case of activation cool down the unit and check and repair the reason for the emergency situation finally reset the emergency thermostat e Alarm 2 indicator option indicates the status of the heat exchanger in case the flue gases temperature is above certain level it will lit and ash cleaning is required The back panel of the interface control board of the boiler has the following control devices Cable transition Emergency thermostat elements POWER switch Figure 5 2 Interface control board equipped with control and operating devices of hot water boiler
43. g parameters which define the thermal capacity of the hot water boiler should be performed by authorized trained and certified technician in order to achieve efficient combustion process and optimal performance of the unit It 1s recommended to make the adjustment of the combustion process by measurements with flue gas analyzer o The primary air flow rate which is adjusted 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 1s possible to control the volatile gases release rate 1 e the thermal capacity of the boiler this is possible in narrow range of the operating mode of the boiler As a rule of a thumb at higher moisture content of the fuel the position of the primary air control flap should be opened by pulling the axes of the flap out of the boiler and fixed again with the screw ATTENTION p 44 69 small change of the position of the primary air control flap leads to sensible variation of the primary air flow rate and consequently the intensity of the pyrolisis process it is highly recommended to change the position of the flap with small steps for example Imm o The secondary air flow rate is controlled by changing the position of the primary air control flap at decreasing the primary air flow rate the secondary air flow rate is increased and vice versa The air is dire
44. hat wood of type beech oak ash fraxinus sycamore fruit trees are materials which allow relatively high duration of the boiler s operation and thus longer period between two fuel charging of the boiler s hopper because their specific heating value the calorific value considered on the fuel volume ir relatively higher compared to the other types of wood fuel The next considering the calorific value wood materials which have lower specific calorific value of the fuel are chestnut tree birch pine spruce they are considered as second grade of quality considering their calorific values and combustion characteristics The materials of lime tree poplar willow elm tree has lowest quality considered as fuel because of their lowest specific volume heating value Also the contents of resin and tat in the wood material will lead to lower quality fuel as these contents lead to high degree of combustion chamber contamination and 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 efficiency These operating modes could lead to intensive chemical corrosion of the heat exchanging surfaces as well mainly due to the deposited tar particles and organic acids formation The wood gasification hot water boiler of series Pyrotherm is fuel manually charged boiler The boiler s thermal
45. hich have properties covering the requirements It is necessary to perform adjustment of the operating parameters of the boiler and achieve efficient combustion process see 5 3 7 It is necessary to perform adjustment of the air flow rate see 5 3 7 It is necessary to clean thoroughly the heat exchanger surfaces of the boiler exchanging intensity Water vapor Low temperature of It is necessary to perform condensates on the the inlet water flow adjustment of _ set point surfaces of the heat temperature which controls exchanging surfaces the circulating pump of the of the boiler heating system It is recommended to adjust the thermostat set point to minimum of 65 C It is necessary to check and eventually clean the chimney It may be required to heat up the chimney in order to allow efficient operation of the chimney It is necessary to check the parameters of the chimney and to check if any changes are required the height the cross section insulation etc performed by expert It is necessary to clean the ca chimney ash deposited in the chimney Ash deposited of It is necessary to clean the clogged convective convective duct of the boiler duct of the boiler Ineffective It is necessary to replace the performance of the gaskets of the doors gasket of the doors performed by technician and or lids Other failures not It is necessary to consult described above authorized technician and
46. his chamber no flame should be seen only intensive volatiles release At fuel hopper chamber charging process the following procedure should be performed e The fuel that is planned to be charged should be prepared it is highly recommended to arrange the fuel at convenient place in near vicinity of the boiler in order to minimize the time when the door will be opened p 40 69 and thus to decrease the chance to release volatile gases out of the chamber and to gasify the boiler s room The fuel should be arranged in the fuel hopper chamber in longitudinal way along the axis of the burner s orifice by taking care not to block the orifice of the burner and to allow easy volatile gases extraction to the combustion chamber At wood logs arrangement take care not to block the door it should be closed without any difficulty In case the fuel hopper chamber is charged with material of different type then the particles that have higher moisture content and or particles with high size should be arranged in the center of the chamber while smaller particles or even better relatively drier should be arranged at the side zone of the chamber This approach allows prevention of fuel bridging right above the burner s nozzle and consequently blockage of the nozzle which could lead do sensible decrease of the thermal capacity of the boiler EXPLANATIONS The practice shows that approximately half an hour from the fuel hop
47. ibution The air consumed at the combustion process is drawn in to the fuel hopper chamber as well as the burner s nozzle by the flue gases fan This air is distributed by an air box where it is preheated and directed to the fuel hopper chamber this air is named primary air and to the burner s nozzle this air is named secondary air The air distribution is adjusted by position of a primary air control flap which is positioned above the orifice for air inflow The primary air which is drawn in the fuel hopper chamber is utilized for sustaining the wood gasification so called pyrolisis process The secondary air is utilized for oxidation of the volatile gases which are passing the burner s nozzle These gases are mixed with the preheated secondary air mixed and oxidized in the combustion chamber of the boiler The above described process allows fuel efficient utilization and low running costs of the heating system The process could be treated 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 high thermal efficiency as well as easy control of the thermal capacity and boiler s operating mode The adjustment of the position of the primary air flow rate control flap requires knowledge of the boiler s operation combustion process and fuel properties as well as patience shown by the t
48. ions ATTENTION in case of emergency situation boiler overheating the emergency thermostat is activated In this case the boiler should be cooled down and the reason for such excessive process should be investigated and preventive measures should be performed The emergency thermostat should be manually reset by unscrewing its preventive cap and its stem should be pressed until the thermostat switches back on a click sound is p 51 69 heard in this process screw the cap back After the boiler is checked and the cause for overheating is determined and repaired turn the POWER switch ON in order to operate the boiler in normal operation mode ATTENTION the check up procedure of the boiler as well as the heating systems for finding the cause for overheating should be performed by trained authorized technician After has been started up again the entire system as well as the boiler should be heated up at moderate rate and should be monitored for any untypical situations in order to prevent any alarm mode to rise ATTENTION the stopping of the combustion process of the fuel in the hopper chamber should not be done by forced quenching by pouring water and or thoer fire extinguishing materials because this could cause BHMUMAHHUE cnupanemo ua npoueca na eopene 6 KamMepama 3a eopueo He mpa ea a cmaea upe3 npuny umenno 2aceHe upes 6OOA UU pyeu eacumennu meunocmu Mbu kamo moega Ou moeno Oa Oo6ede Oo irretrievable
49. ite side of the boiler and a wall should be 500 mm in order to ensure easy access to the heat exchanger and to allow easy cleaning of the deposited ash The minimal distance between the top side of the boiler and a wall ceiling should be 600 mm in order to ensure easy access to the control board of the unit for attachment of the emergency coil as well as for the cleaning and maintenance procedures of the heat exchanger EXPLANATION after the hot water boiler is positioned the following procedures of the installation process should be performed o The ceramic flue gas directing element should be placed in the combustion chamber of the boiler p 19 69 Figure 4 1 Ceramic flue gases directing element which should be positioned in the combustion chamber of the boiler DAS i Figure 4 2 Ceramic flue gases directing element is positioned in the combustion chamber 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 element has been installed in the combustion chamber it should be pushed backwards in order to touch the back vertical plate of the heat exchanger o Install the thermovalve which controls the air flow rate p 20 69 Figure 4 3 The thermovalve for controlling the air flow rate for the combustion process 1s installed and its rod is connected to the air flap
50. l or even transport it separately from the boiler Installation procedure of the hot water boiler requires engineering project for the heating system prepared according to the acting local norms and recommendations as follows e To the heating system EN 303 5 2000 Heating boilers Part 5 Heating boilers for solid fuels hand and automatically fired nominal heat output of up to 300 kW Terminology requirements testing and marking p 18 69 4 2 To the chimney Fire prevention requirements To the power circuit EN 60335 1 1997 Household and similar electrical appliances safety Part 1 General requirements The ambient air inflow orifice of the boiler s room should have cross section of minimum 0 04 m Basic requirements for installation of wood gasification hot water boiler of series Pyrotherm considering it s easy maintenance and Servicing O The boiler should be installed on thermally safe and noncombustible pad which should have height of 50 mm The minimal space in front of the boiler for cleaning maintenance etc should be 1000 mm The minimal distance allowed between the back side of the boiler and a wall should be 400 mm 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 the unit The minimal distance between the oppos
51. l charging and or decrease the amount of fuel charged p 61 69 Boiler s emergency overheating The flame looks opaque and smoke is observed at the exit of the chimney Presence of unburned fuel in the combustion chamber High temperature of the flue gases if flue gas thermometer IS mounted Absence of heat consumption or incorrect adjustment of the operating parameters of the boiler or poor operation of the heating system Low quality wood logs in most cases the moisture content is higher than 20 Inappropriate Operating parameters adjustment Ineffective fuel combustion process The heat exchanging surfaces of the boiler are deposited with ash presenting heat resistive layer thus It is necessary to check the correct operation process of the heating installation and eventually appropriate adjustment of the operating parameters of the boiler and or control valves of the heating system this should be performed by authorized technician After the boiler is cooled down to ambient temperature and the reason for boiler overheating is serviced solved out the protective cap of the emergency overheating thermostat should be unscrewed its rod should be pressed until the thermostat is reset and it s cap should be screwed back The main POWER switch is turned OFF and back ON afterwards and the boiler should be started Fuel replacement IS recommended use wood logs w
52. l lead to thermal capacity decrease That s why it is highly recommended to perform regularly manual stirring of the char particles oxidizing on the upper surface of the ceramic burner s orifice and eventually cleaning away the obstacles in order to ensure high thermal capacity rates covering the requirements for personal safety and fire preventive measures The fuel stirring also decreases the hydraulic resistance of the burner s orifice and thus the thermal capacity of the boiler will be increased due to high intensity 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 panel of the interface control board of the boiler has the following control devices Alarm 1 Operating Thermo thermostat manometer Alarm 2 Flue gas thermostat START indicator STARTS switch i Figure 5 1 Interface control board equipped with control and operating devices of hot water boiler of series Pyrotherm front side view e Operating thermostat assigns the set point of circulating water in the boiler The boiler s flue gases fan will run until this set point is reached and will supply heat energy to the heating system At stop of the fan the boiler will go into stand by mode e Flue gas thermostat assigns the set point of flue gases temperature The boiler s flue gas
53. losed EXPLANATION at opening the door of the combustion chamber the static pressure in this chamber will be immediately changed which will influence the combustion process practically the combustion chamber operates at pressure which is lower than the atmospheric one that s why it is necessary to make fast observation of the flame in the combustion chamber before the ambient air penetration to make influence on the thermal process The flame getting out of the burner s orifice is directed downwards and should reach the ceramic flue gases directing element positioned in the combustion chamber of the boiler The color of the flame at nominal Operating conditions and optimal combustion process i e the process is p 45 69 organized at low CO content in the flue gases as well as low air excess ratio should be saturated yellow and the edges of the flame should be blue colored In case that the colour of the flame 1s e Saturated red this shows that there is deficiency of secondary air it is required to increase the secondary air flow rate by opening the total air flow rate control flap driven by the thermovalve e Light yellow or with short length this indicates that there is excess of secondary air and the secondary air flow rate should be decreased by closing the total air control flap adjust the thermovalve which controls that flap e The flame has low intensity so called lazy flame this
54. m front view D G 12 ig Ls La ir N e E Figure 3 3 View of the wood gasification hot water boiler of series Pyrotherm side view EXPLANATION the value of the dimensions marked with W H n D are given in table 2 2 p 14 69 1091 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 p 15 69 i m Orifice for extracting the gasses of the fuel chamber at ignition Primary air inlet orifice Fuel hopper Combustion nozzle Combustion chamber Flue gas directing profiled ceramic in the combustion chamber Flue gasses outlet directed to the convective duct of the boiler Figure 3 6 Cross section view of wood gasification how water boiler of series Pyrotherm p 16 69 Control box of the boiler Upper lid of the convective duct of the boiler Flue gas fan Flue gas exit duct Combustion nozzle Flue gases directing ceramic profiled element Lower lid of the convective duct of the boiler Figure 3 7 Longitudinal section of wood gasification hot water boiler of series Pyrotherm The producer reserves the right to make any changes of the design and construction of the boiler without obligation to inform the end user p 17 69 4 Installation of the hot water boiler of series
55. material The design of the how water boiler of series Pyrotherm allows optimal conditions for the above mentioned process so they are p 5 69 named pyrolisis hot water boilers The fuel ignition as well as the fuel charging is done manually the ash deposition cleaning is also done periodically by hand this allows achieving optimal combustion process and efficient and low cost heat energy for the heating system The boiler could utilized the following fuel wood logs preferably chopped wood logs having the following properties p 6 69 o Pure wood contaminated i e painted chemically treated as well as other mineral or organic substances wood is not allowed o The length of the wood logs should correspond with the depth of the fuel chamber of the boiler see the specification of boiler o The cross section the diameter of the wood logs should be D lt 200mm o The moisture content of the raw material should be less than 20 W lt 20 o Itis 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 the chamber of the boiler The boiler consists of e Steel plate heat exchanger which transfers the heat energy from the flue gases to the heating media in most cases this is circulating water e Flue gas fan which extracts the exhausted gases
56. mber makes optimal conditions for fuel pyrolisis process and the volatile gases are directed to the lower section of the boiler where they are oxidized in the combustion chamber In the combustion chamber is positioned ceramic lining a nozzle and a flue gas directing element which allow efficient combustion process e Combustion nozzle produced from ceramic material placed in the lower section of the fuel hopper which ensures optimal conditions for efficient combustion process e Ceramic directing element which is positioned in the combustion chamber of the boiler allowing high temperature levels and ensures optimal fuel oxidation e Flue gases fan is installed in the back side of the boiler it transports the exhausted flue gases out of the boiler and controls the operation of the boiler e Air distribution box which has primary air control valve This box also serves as heat exchanger and preheats the ambient air before being consumed in the combustion chamber of the boiler The inlet of this box has inflow control flap which is driven by thermovalve and controls the total mass flow rate of the air sucked in the boiler e Inflow orifice has internal thread for the size see table 2 2 and is positioned on the back left lower side of the heat exchanger the outflow orifice has internal thread as well for the size see table 2 2 and is positioned in the back left upper side of the boiler Use this orifices in order to connect
57. n appropriate containers or use it as fertilizer for example p 53 69 Figure 5 13 Cleaning the ash residue deposited in the combustion chamber use the scrapper to clean the ash layer as well as the char particles RECOMMENDATION in order to minimize the risk it is recommended to place a metal shovel or an appropriate container where the ash will be collected taking care not to spill the material away The collected ash and char residues should be kept in a lid closed container or any appropriate vessel and to be cooled down to ambient temperature level please consider the safety first The cleaning procedure of the convective heat exchanger of the boiler should be performed at least once per month but in practice the operating mode and mainly the total amount of the fuel consumed should be considered The practice show that about 30 to 40 of the ash 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 circulating media 1 e the total efficiency of the boiler will be decreased However the fly ash particles will be transported by the flue gases from the boiler out to the chimney so the chimney also collects considerable amount of ash which should be cleaned as well The turbine of the flue gas fan will be deposited with fly ash and char particles as well Please note that the fly a
58. of series Pyrotherm back side view e Main POWER switch switches ON and OFF the main power supply of the boiler e Operation mode switch changes the operation mode of the control module Keep it in wood gasification pyrolisis position p 31 69 e Emergency thermostat protects the boiler from exceeding emergency temperature level and boiler overheating This thermostat is factory preset to switch off the power supply of the unit at water temperature in the boiler above 95 C 3 3 2 Start up initialization of the boiler The hot water boiler of series Pyrotherm should be connected to the electrical power supply system covering the safety requirements The hot water boiler of series Pyrotherm 1s switched on by changing the POWER switch into ON position Before manual fuel ignition of the fuel in the upper chamber of the boiler it is necessary to check the functionality of separate elements modules of the boiler which sustain its reliability as well as the heating system efficiency and functionality e Flue gas fan e Ignition flap e Position and condition of the ceramic element in the combustion chamber of the boiler e Thermovalve which controls the air flow rate as well as its adjustment e Functionality of the control and measuring elements thermostats thermo manometer e Gasket rope of the doors e Circulating pump in case that such pump is installed in the heating s
59. orifice of the convective duct should be opened the ash particles are collected in the volume of this section of the boiler see the following figure Figure 5 21 View of the orifice for ash removal from the lower section of the convective section of the boiler p 58 69 After the ash cleaning procedure has been finished the elements turbulizers flue duct lids are installed and tightened in a reverse manner 5 8 Showing and teaching the end user about the maintenance and adjustment procedures of the boiler It is necessary to show and teach the end user the maintenance procedures for operating the boiler efficiently and keep its reliability in high degree order Also the installer should demonstrate and teach the end user how to change the operative parameters of the control board of the boiler in order to operate the unit according to the local heat consumption The end user should be introduced with the following e this instruction manual the operation of the boiler the method for adjustment of the thermal capacity and the operation mode control of the boiler e the procedure for boiler s maintenance the procedure for ash cleaning from the combustion chamber of the boiler e the procedure for cleaning the ash residue of the convective duct of the boiler e the procedure for charging the fuel hopper with wood logs the logs are arranged in the fuel hopper in the chamber in order to allow easy fl
60. ow rate of volatile flue gases to the burner s nozzle of the boiler It is strongly required to utilize chopped wood logs which have moisture content according to the requirements for the fuel e ignition procedure the ignition process is described in details in ID e procedure for ash cleaning the end user should clean the deposited ash on the combustion chamber surfaces as well as the ash deposited on the other surfaces of the boiler The detailed description is shown in ee e cleaning the ash as well as other residues from the turbine of the flue gases fan it is highly recommended to perform regular ash cleaning It is required to stop the boiler and clean the turbine in case p 59 69 that non typical noise is heard from the fan Clean of the deposited ash tars and other depositions from the turbine of the boiler ATTENTION regular cleaning of the ash residue deposited on the heat exchanging surfaces of the boiler will ensure long life reliable exploitation period economic and efficient performance of the unit 5 9 Safety and unexpected risks Risks could arise at the exploitation of the boiler The wood gasification hot water boiler of series Pyrotherm is designed according to the safety requirements of the operating European standards and norms However safety and unexpected risks could arise in situations like following e Hot water boiler of series Pyrotherm is operating incorrectly e The
61. per 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 parameters for a long period of time the range is hours see the table for the operating parameters of the boiler this period greatly depends on the energy consumption and the parameters of the raw fuel When the set point of the temperature of the circulating water is reached the fuel gas fan will be switched off and the boiler soon will go into stand by mode In this mode the fuel consumption rate is decreased as well as the thermal capacity of the boiler The practice shows that the typical thermal capacity of the boiler in stand by mode is approximately 10 of the nominal thermal load of the boiler In this mode small amount of air is entering the boiler and sustains the char oxidation in order to keep the boiler in so called ready to operate mode IIT Adjustment of the operating parameters of the boiler The combustion process should be adjusted at nominal operating conditions in order to achieve efficient and optimal fuel utilization It is highly recommended to make the adjustment of the combustion process by flue gas p 41 69 measurements use gas analyzer the adjustment should be performed by trained technician The adjustment of the combustion process is performed by regulation of the air flow rate as well as the its distr
62. perature should be in the range of 65 85 C The practice shows that this mode is achieved after 1 to 2 hours after the boiler has been started up however the local conditions and the heat consumption should be accounted as well In this mode the operating parameters the boiler should be p 37 69 constant or small deviations could be observed the flue gas temperature the thermal capacity the flue gas emissions However the boiler is manually fuel fed boiler so small deviations could be observed according to the frequency of fuel charging rate as well as the fuel quality and quantity EXPLANATION the optimal condition of the boiler s operation is achieved at temperature of the circulating water in the range of 65 85 C In this temperature range the boiler operates in optimal thermal condition and the wood gasification process is easy controlled as well as high efficiency of the combustion process In case the heating system is equipped with circulating pump the operation of this pump should follow the above mentioned requirement i e it should operate at temperature of the circulating water above 65 C In case the boiler operates at temperature levels below this point 65 C the operation will lead to intensive tar deposition and decreased heat transfer rates as well as chemical corrosion which both decreases the efficiency and the reliability of the unit In nominal operation mode the boiler as well as the heating s
63. r aggressive chemical components The hardness as well as other properties of the water should cover the requirements described in the table below In case the water does not cover these requirements it should not in any case being used the water should be chemically treated or other water should be used instead p 23 69 The water utilized to fill the heating system as well as the hot water boiler should cover the following requirements according to BDS 15207 81 Parameter Dimension Value Total hardness mg kg Salt contents mg kg mg kg Total alkalescency mg kg pH mg kg Table 4 1 Parameters of the water allowable to be used as circulating fluid in a heating system 8 0 9 5 In case the heating system contains copper elements and the circulating water id in direct contact with them the pH of the circulating water should not exceed 10 ATTENTION The finalization of the system installation and performing the commissioning tests should be filled in the appropriate documents of the boiler where the required data fields should be filled in this is obligatory The boiler s producer recommends a principal hydraulic scheme for attaching the hot water boiler to the heating system equipped with three way valve and a heat accumulator as shown on figure 4 7 p 24 69 8 4 5 6 222 7 16 9 10 E A f f fy poof ri j i i i F i f i Cold tap i je f gt i i water A j CI j
64. r 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 this chamber The flue gases product of the combustion process are passing through the opened ignition flap and transported by the flue gas fan to the chimney EXPLANATION e According to the local conditions the properties of the chimney as well as the atmosphere the velocity of ignition could vary it is necessary to make personal observation of this process and achieve practical experience for the firing up process e At ignition as well as at nominal operation of the boiler it is highly recommended to take care and to prevent any intensive combustion process in the fuel hopper chamber of boiler because this could lead to excessive temperature levels of the flue p 34 69 gases convected to the chimney and could lead to flue gas fan failures and or any other elements of the boiler at this duct of the boiler e After the initial fuel has been fired up the flue gas fan should be switched on turn the START switch into on position close the door of the fuel hopper and close the ignition flap by pushing the lever for driving the ignition flap backwards see figure 5 3 This will result in change of the direction of the flue gases they will go through the burner s nozzle and will pass through the combustion chamber and the convective duct section o
65. rnal surfaces of the boiler could be observed even water leakage could be see out of the door of the combustion chamber of the boiler as well as the flue gases duct flap positioned on the lower back side of the boiler This 1s a single process and will not influence the operation and functionality of the boiler e tis not recommended to open the door of the fuel hopper chamber of the boiler when the flue gas fan is not functioning and ignition flap closed because volatile gases could be emitted out of this chamber to p 35 69 the surrounding atmosphere and the boiler s room could be contaminated with gases as well 5 3 4 Adjustment of the air flow rate control thermovalve The thermovalve which controls the air flow rate required for efficient combustion process should be adjusted in order to allow optimal operation of the boiler EXPLANATION until the nominal thermal capacity of the boiler is reached the flap driven by that thermovalve should be opened in order to ensure sufficient air flow for the ignition process This thermovalve controls the air flow rate required for achieving efficient combustion process This valve closes the air control flap in case the temperature of the circulating water has reached high levels and thus preserves the boiler from overheating This valve senses the temperature of the circulating water and actuates a lever which controls the position of the air control flap at low temperatures of
66. sh accumulates in elbows and other elements of the chimney as well as the convective duct section of the boiler will result to increased hydraulic loses of the convecting flue gases eventually the duct could be stacked and blocked which will result in sensible decrease of the draught of the chimney and even the boiler could emit flue gases out of the door gaskets as well as other lids It is highly recommended to clean p 54 69 the deposited ash in the convective section of the boiler as well as the chimney regularly Cleaning the convective duct of the boiler is performed in the following way Unscrew the specialized fixing nuts which are used to tighten the lid of the convective duct of the boiler and carefully detach the covering lid Practice shows that in some cases the gasket could be 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 Fixing nuts used to fix the upper convective duct lid Figure 5 14 Convective lid which covers the upper orifice for cleaning the deposited ash on the heat exchanging surfaces of the boiler Fixing nuts used to fix the lower convective duct lid Figure 5 15 Convective lid which covers the lower orifice for cleaning out the ash collected after the cleaning process on the heat exchanging surfaces of the boiler p 55 69 After the fixing nuts have been unscrew
67. t exchanging surfaces of the boiler allow achieving high reliability and efficient operation of the boiler as well as high durability of the heat exchanger Another criteria for efficient combustion process and optimal operation of the boiler is the color of the ash as well as the presence of any char particles in the ash material the amount of these particles should be small compared to the total ash mass The cleaning of the ash in the combustion chamber could be performed at operation mode of the boiler but should be done in exceptional cases the boiler 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 the boiler s room and thus suffocation could influence the person who is making the above mentioned process take care to make intensive ventilation of the boiler s room In case that such ash cleaning is a must process then the ignition flap should be opened the door of the combustion chamber should opened and the ash should be scrapped and collected in a special container which is equipped with appropriate lid take care not to get burned by the hot particles After the ash has been cleaned close the door of the combustion chamber then close the ignition flap Take the ash container away and leave it to get cooled down to ambient temperature levels then empty the ash i
68. tent of the wood logs the moisture is mechanically conserved water in the fuel The biomass is a natural product and the moisture content of a raw material could be 40 to 60 the just cut down material can contain up to 80 In order to achieve economic operation of the boiler and to achieve efficient combustion process it is necessary to supply fuel with minimal water content for pyrolisis types of boilers it is recommended the moisture content to be up to 20 which is practically realized 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 protected from accident moistening from example by rain or snow In order to achieve uniform and intensive during it is highly recommended to chop the wood logs into smaller pieces However it the wood logs are stored for a longer period more than two years its calorific value is also decreased due to devolatilization of the biomass The so called Low Calorific Value of the fuel LHV the heat energy achieved at combustion but the latent heat of the water vapor in the flue gases is not retrieved could be calculated from the following equation Me E MJ kg where LHV Low Heating Value of the fuel MJ kg HHV 18 0 MJ kg High Heating Value of the fuel this is the energy of the fuel which includes the latent heat of evaporation of the wa
69. ter vapor in the flue gases i e the water has been condensed LHV The dependency of the Low Heating Value as function of the moisture content W is given on the following figure p 10 69 aust Low heating 18 000 value MJ kg 16 000 14 000 12 000 10 000 ene Low heating 6 000 value kWh kg 4 000 2 000 0 000 E O 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85 Figure 2 1 Low heating value of wood log abscise moisture content W ordinate low heating value LHV Moisture content Low heating value Ww E e a Co O y o A a o O LB 0458 Table 2 4 Low Heating Value of wood logs as function of moisture content W of the raw fuel w b p 11 69 3 Description of the wood gasification hot water boiler of series Pyrotherm The heat exchanger of the hot water boiler of series Pyrotherm complies with the acting requirements for such kind of units defined in operating norm EN 303 5 2000 Heating boilers for solid fuels hand and automatically fired nominal heat output up to 300 kW Terminology requirements testing and marking The hot water boiler consists of the following elements modules e Heat exchanger is steel plate welded construction In the upper section of the boiler is the fuel hopper which is manually fed with wood logs This fuel cha
70. tween fuel charging and or decreasing the amount of the fuel charged at any process of boiler s wood logs charging In principal the decreased thermal capacity of the boiler is accompanied with decreased thermal efficiency but practice shows that this decrease is relatively low some percents and does not influence the overall efficiency of the system but should be considered when calculations of the thermal capacity of the boilers are done e In case the heat exchanging surfaces of the boiler have been deposited with ash as well as tar particles the intensity of heat exchange rate will be decreased which will lead to decreased efficiency of the boiler and the net heat energy transferred to the heating system 5 3 8 1 Decreasing the thermal capacity of the boiler In practice the thermal capacity of the boiler 1s achieved by decreasing the amount of the fuel charged in the fuel hopper of the boiler The decrease of the thermal capacity could be achieved by increasing the period between two 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 description above in order to sustain the optimal performance of the boiler as well as high efficiency of the system 5 3 8 2 Increasing the thermal capacity of the boiler In practice the increase of the thermal capacity of the boiler could be achieved b
71. ws easy control of its thermal capacity which guaranties high thermal comfort and fuel savings High efficiency Low pollutants Opportunity to heat up domestic hot water DHW Simplified maintenance and service Minimal running costs p 7 69 2 Technical data of wood gasification hot water boiler of series Pyrotherm e Thermal and technical data for the wood gasification hot water boiler of series Pyrotherm are given in Table 2 1 e Dimensions and technical data for the wood gasification hot water boiler of series Pyrotherm are given in Table 2 2 e Parameters of the recommended fuel are given in Table 2 3 e Low heating value of wood logs is given in Table 2 4 Parameter Dimension Value _ _ Oe ae a Nominal thermal capacity W 235 Thermal capacity a 13 25 16 32 21 42 26 52 operation range Utilized fuel Wood logs for heating purposes water content up to 20 Wood logs consumption rate at nominal thermal kg h capacity required for effective EEE A s e e boiler operation epee e p mee Averaged wood logs consumption rate the boiler kg h is operating in a popular heating system nominal capacity Flue gasses temperature at nominal thermal 180 250 capacity Eoin a The quantity depends on the ash contents in the raw fuel as well as operating conditions Table 2 1 Thermal and technical data for the wood gasification hot water boiler of series Pyrotherm
72. y increasing the fuel rate charged in the hopper of the boiler In case that the boiler should run for a long period in this operating mode then it is highly recommended to make appropriate air flow adjustments see the description above As the heat consumption is increased it will lead to more frequent fuel charging of the hopper of the boiler ATTENTION it is strictly forbidden to increase the thermal capacity of the boiler above the nominal one EXPLANATION the practice shows that the decrease or increase of the thermal capacity of the boiler is relatively difficult to control process especially when high efficiency is required It is highly recommended to run the boiler at nominal thermal capacity i e nominal operating mode and the variations of the of the heat energy consumption will be covered by a heat accumulator tank The practice shows that a heating system p 48 69 equipped with heat accumulator shows optimal thermal efficiency high reliability and economic exploitation of the system The heat accumulator tank also allows flexible fuel charging and boiler s operation see figure 4 5 where a heating system with heat accumulator is installed 5 4 Operation of the boiler in stand by mode During the exploitation of the of the heating system the fuel consumption rate varies in wide range even in a period of 24 hours The thermal capacity of the boiler is result of the thermo chemical processes organized in
73. ystem The fuel hopper chamber should be charged with small amount of small kindle particles for example dry laths branch timber etc and these particles should form a pile arranged above the burner s nozzle lying in lower section of the fuel chamber of the boiler It is recommended to use no more than 5 kg of this igniters in order to start stable combustion process The orifice of the burner should not in any case being blocked by the particles as the volatile gases should pass through the nozzle down to the combustion chamber p 32 69 3 5 Ignition of the fuel and boiler s heating up ATTENTION before ignition of the boiler it is necessary to check the position of the ceramic element in the combustion chamber of the boiler it should be centered and should touch the back vertical wall of the boiler combustion chamber e The operating thermostat of the boiler should be set to 80 C or any other temperature level of the circulating water in the hot water boiler ATTENTION in order to achieve efficient wood gasification and combustion process it is necessary to keep the circulating water temperature above 60 C e Turn the set point of the flue gases thermostat to minimal position e Switch off the flue gas fan turn into off position the START switch The status of the operating mode of the flue gas fan 1s indicated with the lamp mounted above this switch The ignition of the fuel as well as the boiler s heating
74. ystem should be commissioned i e the so called hot tests should be done considering the requirements and legislations NOTES e 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 flow the cold flow temperature should not be below 60 C because there is great chance to achieve local cooling of the flue gases in the boiler which will lead to intensive vapor condensation and will be followed with chemical corrosion of the heat exchanging surfaces e tis not recommended to operate the boiler at thermal capacity below the minimal one depicted in the operating range of the unit as such regimes are low efficient and decrease the reliability of the boiler Such low thermal capacity conditions could lead to conditions which will result in decomposition and failure of some components of the boiler also could lead to life threatening conditions as well mainly carbon monoxide as well as tar which will deposit condensation on the internal surfaces of the boiler and corrosion will follow e In case the boiler should operate at thermal operating mode which is below its nominal thermal capacity it is highly recommended to install a heat accumulator in order to allow efficient and economic operation of the boiler and flexible operation of the heating system The heat accumulator tank serves are energy depot i e it accumulates the excessiv

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