Guntamatic POWERCHIP 20, POWERCHIP 30, POWERCHIP 75, POWERCHIP 100, POWERCORN 50 Special Planning And Installation
...
Woodchip boiler englisch
POWERCHIP
/ POWERCORN 50 Special
Planning and installation
PH-01
EN-B31-009-V17-0815
2
Information on this documentation
BS-01
Please read through this documentation carefully.
It is intended as a reference document and contains important
information on the design, safety, operation, maintenance and
care of your heating system.
We are always looking to improve our products and
documentation. Any ideas and suggestions you may have will
be gratefully received.
GUNTAMATIC Heiztechnik GmbH
Bruck 7
A-4722 PEUERBACH
Tel: 0043 (0) 7276 / 2441-0
Fax: 0043 (0) 7276 / 3031
Email: office@guntamatic.com
It is important that you pay particular attention
to the safety issues highlighted in the text by
these symbols.
The entire contents of this document are the property of
GUNTAMATIC and therefore protected by copyright.
Reproduction of any kind, communication to third parties by any
means or use for purposes other than those intended without
the written consent of the owner is prohibited.
Subject to printing errors and technical amendments.
3
Contents
PH-01
Page
1 Introduction ............................................................................4
1.1 Safety instructions 4
1.2 Guarantee and liability 4
1.3 Commissioning 4
1.4 Site requirements 4
2 PLANING .................................................................................5
2.1 Fire safety 5
2.2 Minimum fire safety requirements 6
2.3 Boiler room requirements 8
2.4 Flue requirements 10
2.5 Flue draught regulator and pressure-surge compensator 11
2.6 Fuel store requirements 12
2.7 Examples for Planning 15
2.8 Automatically ash System 17
2.9 Heating circuit Rules 19
3 Construction.........................................................................21
3.1 Delivery 21
3.2 Carrying to installation site 21
3.3 Positioning and aligning the boiler 21
3.4 Fuel out feed installation 22
3.5 Plumbing connections 26
3.6 Filling and bleeding the system 29
3.7 Connecting the flue 30
4 Electrical connections .........................................................31
4.1 Heating system electrical connections 33
5 Final checks..........................................................................34
6 Standards / Regulations ......................................................35
7 Plumbing diagrams..............................................................36
7.1 Backup Memory HP0 36
8 Technical data ......................................................................54
8.1 Powerchip 20/30 and 40/50 54
8.2 Powerchip 75 and 100 55
8.3 Powercorn 50 Special 56
8.4 Removal 57
8.5 Celling filling spiral 59
4
1 Introduction
BS-01
1.1 Safety instructions
GUNTAMATIC heating systems represent state-of-the-art
technology and meet all applicable safety regulations. Incorrect
installation can endanger life and limb. Heating boilers are
combustion systems and are potentially dangerous if handled
incorrectly. Installation, commissioning and servicing must,
therefore, only be carried out by adequately qualified
technicians observing all regulations and the manufacturer's
instructions.
1.2 Guarantee and liability
The manufacturer's guarantee is subject to correct installation
and commissioning of the heating system. Defects and
damage caused by incorrect installation, commissioning or
operation are not covered by the guarantee. To ensure that the
system functions as intended, the manufacturer's instructions
must be followed. Furthermore, only genuine replacement
parts or parts explicitly approved by the manufacturer may be
fitted to the system.
1.3 Commissioning
Commissioning of the boiler must be carried out by an
authorised GUNTAMATIC specialist or other qualified persons.
They will check whether the system has been installed
according to the plans, adjust the system settings as required
and explain to the system operator how to use the heating
system.
1.4 Site requirements
When establishing the site requirements, it is absolutely
essential to take account of the locally applicable planning,
building and implementation regulations and the dimensional
specifications in the fitting guidelines, installation examples and
technical data. Compliance with the locally applicable
regulations and the correct implementation of the measures
required on site are solely the responsibility of the system
owner and are a requirement of the manufacturer's guarantee.
GUNTAMATIC provides no guarantee of any kind for any type
of site work. Without making any claims as to completeness or
non-applicability of official requirements, we recommend the
following specifications based on the Austrian Guidelines pr
TRVB H 118:
5
2 Planning
01
2.1 Fire safety
BS-01
The fire security instroductions are obligatory needed
on the construction place
The Compliance from counties ore states fire security
law is obligatory and stands higher then the
GUNTAMATIC fire security instruction
Austria State legislation of the federal states
Technical Directive on Preventative Fire Safety (pr TRVB H118)
Germany Standard boiler regulations (M-FeuVO)
Hessen and Saarland – in these states §16 FeuVO Hessen applies
Switzerland Fire safety regulations
(www.vkf.ch)
any other exporting countries Any fire safety office
You have to follow you specific country fire safety
rules obligatory. Your country safety rules are higher
then our GUNTAMATIC minimum rules.
If there are no specific fire security rules in your
country, you have to follow the GUNTAMATIC
introductions
6
2.2 Minimum fire safety requirements
PH-01
Boiler room Floor of concrete construction, either bare or tiled. All materials
for floor, walls and ceiling must be fire-resistant to F60/REI60
rating.
Boiler rooms door: The Boiler room’s door also might close
single handed and it has to be possible to close off the door.
Connecting doors to the fuel storeroom must also be Class
T30/EI230-C fire doors, self-closing and lockable. There must
be no direct connection to rooms in which flammable gases or
liquids are stored.
Sprinkler: Connected to the outfeed unit there must be a
sprinkler device set to trip at 55°C. With storeroom volumes up
to 50 m³, this is used instead of the temperature monitor. When
the sprinkler is triggered, the sloping outfeed auger enclosure –
which also serves as a burn-back inhibiting device – is
completely flooded. The quantity of water required to do so is
at least 20 litres. If the temperature drops back below 55°C, the
flooding is stopped.
The sprinkler system must be
connected on all systems regardless
of local regulations!
Fuel storeroom The same minimum fire safety requirements apply as for the
boiler room.
Storeroom doors/hatches: Storeroom doors/hatches must be
fire safe to Class T30/EI230-C, self-closing and lockable. There
must be a warning sign carrying the message "Do not enter
when feeder system is running" attached to the storeroom
door/hatch.
> 50 m³
TÜB - Temperature monitor: If it is possible to store 50 m³ of
fuel or more, a temperature monitor connected to a warning
device must be installed in the fuel storeroom at the point
where the fuel conveyor exits the fuel store and enters the
boiler room. The warning device must be triggered when the
temperature exceeds 70°C. Because of the sprinkler system,
the temperature monitor on the outfeed auger is not required
for storerooms with a capacity of less than 50 m³.
> 50 m³
HLE - Manual fire extinguisher: If 50 m³ of fuel or more can
be stored, a manually operated fire extinguishing facility must
be installed. It must be protected against freezing and
connected to a pressurised water pipe (DN20 conduit). The
discharge point must be located directly above where the fuel
outfeed channel exits the storeroom. The fire extinguishing
facility must be identified by a sign carrying the inscription
"Fuel storeroom fire extinguisher".
7
SLE - Automatic fire extinguishing facility:
For storage rooms in farm building it is possible to dispense
with a F90 / REI90 cladding for fuel storage and if the fire
compartment is less than 500 sq meters . The fuel but
separately ( wooden planking ) must be stored on other goods
. If furthermore a firewall to a residential wing before, so an
automatic extinguishing device ( SLE ) is also required.
This extinguishing equipment must be connected either directly
to a pressurized water supply or to a water -supply container .
The amount of water to need three times the volume of the
loading device shall be not less than 20 liters .
Inspection covers: There must be a lockable F90-class
inspection hatch above the fuel out feed channel.
Services area: For storerooms in the services area, it is
possible to dispense with F90/REI90 jacketing of the fuel store.
The fuel must be stored separately (wooden boarding) from
other materials and the fire containment zone must be less
than 500 m².
Filler pipes: Filler pipes through rooms where there is a fire
risk must be provided with Class F90/REI90 cladding.
8
2.3 Boiler room requirements
PH-01
Minimum room height
PH 30 / 50 / 50 S ideal solution
H 225 cm
1)
possible
H 210 cm
PH 75 / 100 ideal solution
H 240 cm
1)
possible
H 230 cm
1)
= Mindestraumhöhe bei abgeschraubtem Wärmetauscherdeckel
Minimum room size
PH 30 / 50
B 240 cm x
2)
T 230 cm
(
3)
T 240 cm)
PH 75 / 100 / 50 S
B 270 cm x
2)
T 230 cm
(
3)
T 240 cm)
2)
T = The room with boiler´s bodies front seeing from behind
3)
= Minimum size from the automatic ash suction system
Clear access opening
PH 30 / 504) ideal
B 120 cm x H 185 cm
5)
possible
B 80 cm x H 170 cm
7)
possible
B 75 cm x H 165 cm
PH 75 / 100 / 50 S4) ideal
B 195 cm x H 210 cm
(
6)
185 cm)
5)
possible
B 100 cm x H 190 cm
(
6)
170 cm)
7)
possible
B 90 cm x H 180 cm
4)
Contribution from the ready constructed boiler on the pallet
5)
Constribution without Stoker, cleaning unity and pallet
6)
minimum height of boiler type powercorn 50 S
7)
dimensions with additional to point 5) with unrigged cover panel
Combustion air supply The pressure in the boiler room must not be less than 3 Pa
(0.3 mm H2O). The air vents for boiler rooms must have a
clear, net cross-sectional area of at least 200 cm² and must not
be sealable. With combustion boiler systems with a fuel heat
output upwards of 50 kW, the net, clear cross-sectional area
must be increased to at least 5 cm² per kW rated output
according to the combustion air requirement of the boiler
system. The air supply ducting must connect directly to the
outside and if the ducting passes through other rooms, it must
be jacketed to Class F90/REI90. On the outside of the building,
air vents must be covered by a protective grille with a mesh
size of > 5 mm. The supply of combustion air should, if
possible, enter at floor level in order to prevent cooling of the
boiler room.
Electrical installation The lighting and the electrical wiring in the boiler room must be
permanently installed. There must be a clearly marked
emergency off switch in an easily accessible position outside
the boiler room, close to the boiler-room door.
The line connector 400 VAC, 50 Hz, 13 A is needed.
Fire extinguisher A hand-held fire extinguisher (6kg gross weight, EN3) must be
mounted outside the boiler room near the boiler-room door.
Protection against freezing
The boiler room, pipes carrying water and any district heating
pipes must be protected against freezing.
9
Installation site You have to plan the furnace in the near of the chimney to avoid a long
flue pipe.
A →
Integration version of Energy saving draft regulator with Ex flap and with fire tube
respect the local fire security rules- dust information possible
B →
BEHIND distance
ideal
70 cm minimum
possible
50 cm
without Ash suction system
60 cm
with Ash suction system
C →
The discharge for overheating
D →
Line Connector 400V 13A
E →
Drain
F →
Sparger complex
G →
flue
wet non- sensitive chamotte-flue advised
H →
installation variant energy-saving damper with explosion damper in the flue
c
a. 50 cm under the flue – please follow the local laws
I →
LEFT distance
ideal
70 cm minimum
possible
40 cm
J →
fire extinguisher
6 kg filling weight EN3
K →
escape switcher
L →
fireproof door
T30 / EI230-C lockable and self depended
M →
RIGHT distance
ideal
70 cm minimum
possible
40 cm
N →
HLE manual release arc control device
O →
Mauerdurchbruch
Höhe 70 cm / Breite 45 cm
P →
AHEAD distance
ideal
100 cm minimum
possible
80 cm
Q →
Air combustion supply
R →
TÜB Warning device for to heaters spiral’s temperature
10
2.4 Flue requirements
PH-01
Use heat-insulated fireclay flues that are
insensitive to damp.
The flue gas temperature can be less
than 100°C.
The system must only be connected to the flue if the flue
meets the legal requirements and the technical specifications.
The flue must be matched to the boiler output and
dimensioned in accordance with DIN 4705. In order to be able
to accurately dimension the flue, the calculations must be
based on the flue gas figures. When designing new flues, high
thermal insulation chimneys (DIN 18160 T1 heat transmission
resistance group I) or suitable fireclay flues that are
insusceptible to damp and have general building regulation
approval should be used. It is advisable to involve those
responsible for approving the flue system early on in the
planning phase.
Flue height The minimum flue height is 5 - 10 m depending on boiler
output. The flue must terminate at least 0.5 m above the
highest part of the building. In the case of flat rooves, the flue
must terminate at least 1.5 m above the surface of the roof.
Flue diameter The flue hast to adjust on the fire power. The following datas
are approximate values and could be used for planning. We
recommend to calculate the flue by a professional.
PH 30 / 50 / (PC 50-S)
PH 75 / (100)
eff. high above 6 m D = 160 (180) mm
eff. high under 6 m D = 180 (200) mm
eff. high above 6 m D = 220 (250) mm
eff. high under 6 m D = 250 (250) mm
Flue dimensioning data Dimension the flue for rated output!
(Averaged figures with used heat exchanger)
Rated output:
Type Flue gas CO2 Mass flow rate
Required
draught
PH 30 180°C 12,5% 0,025 kg/s 15 Pascal
PH 50 190°C 13,0% 0,040 kg/s 15 Pascal
PC 50-S 185°C 12,5% 0,040 kg/s 15 Pascal
PH 75 180°C 12,5% 0,065 kg/s 15 Pascal
PH100 195°C 12,5% 0,082 kg/s 15 Pascal
Sub-maximum output:
Type Flue gas CO2 Mass flow rate
Required
draught
PH 30 130°C 9,5% 0,010 kg/s 2 Pascal
PH 50 145°C 10,0% 0,015 kg/s 2 Pascal
PC 50-S 140°C 9,5% 0,015 kg/s 2 Pascal
PH 75 140°C 9,5% 0,020 kg/s 2 Pascal
PH100 150°C 10,5% 0,025 kg/s 2 Pascal
11
2.5 Flue draught regulator and pressure-surge compensator
BS-01
Fitting an energy-saving flue draught
regulator/pressure-surge compensator
(Class RE) is absolutely imperative.
The flue draught should not differ by more than +/- 3 pascals
from the figure specified in the flue dimensioning data. If the
flue draught cannot be reduced to the required figure, either a
larger draught regulator should be fitted or an additional flue
baffle fitted between the flue and the draught regulator.
Purpose
• To ventilate the flue when the system is not in operation
• To compensate for pressure surges
• To regulate and limit the flue draught
Fitting requirement The energy-saving flue draught regulator must be fitted in
accordance with the local regulations, preferably in the flue
approx. 0.5 m below the point where the flue connecting pipe
joins or alternatively in the flue connecting pipe close to its
junction with the flue.
Flue draught setting
• Adjusting the flue draught is only of any use at
outside temperatures below +5°C.
•
The system must have been in operation for at least an hour
• Ensure there is sufficient demand for heat for the boiler to
be run at rated output for at least 15 minutes
• Measure the flue draught between the boiler and the flue
draught regulator (distance of measuring point from boiler
ideally 3 x flue diameter from connection between boiler
and flue connecting pipe).
Too much flue draught
May cause the flue gas temperature to increase
and accelerate combustion as a result. Poor
boiler output adjustability, increased dust
discharge and malfunctions can result.
Too little flue draught
Performance problems, incomplete combustion
and malfunctions when operating below rated
output can result.
12
2.6 Fuel store requirements
PH-01
Please note:
the specific national rules for your fuel store
(for example. ÖNORM M7137, VDI 3464,..
.) are strictly
adhered blindly
Annual demand for fuel store The fuel store should be able to pick up the stock for a year .
Per 1 kw building heat is expected with the following annual
fuel demand .
→ per 1 kW/Year ca. 2,00 m³ = ca. 550 kg
beech
→ per 1 kW/Year ca. 2,50 m³ = ca. 500 kg
spruce
→ per 1 kW/Year ca. 0,65 m³ = ca. 450 kg
Pellets
→ per 1 kW/Year ca. 0,75 m³ = ca. 550 kg
Energycorn
→ per 1 kW/Year ca. 4,30 m³ = ca. 470 kg
Miscanthus
Fuel store arrangement You have to built your Storeroom in a quadratic frame, to use
the filling spiral optimally.
Fuel store air sparging To avoid an high perilous Co² consentration you have to lift the
store and Broiler room.The opening for the lifting might
discharge into the atmosphere. There must be an air change
between the Storeroom and the ambient atmosphere. If the
natural thermal isnt´t enough you have to take technical
measures.
If the filling stubs (the openings) discharges not into the
atmosphere you have to lift it with another lifting opening. you
have to be careful, that there is no rainwater into the storeroom
from the filfting opening. The construction site from the
permeable to air storage container might have a port in to the
atmosphere. A ventilator shifts from 200cm² is enough.
Up to 30 t storage volume the requirement is prepossessed, if:
• The filling stub (opening) is leading into atmosphere for
minimum 2 caps with an air inlet
• The diameter from 2 ventilation pipes is per pipe
minimum 90 mm
• The ventilator shift from the exhaust port from both
Ventilation pipes from 2 m minimum 40 cm² and must be
higher then a lenghth from 2 me but minimum 60 cm ².
INFO: The whole ventilation shift from 2 caps from our
filling sets is 60 cm².
Over 30 t storage volume the requirements
• a combination between natural and manual lifting, based
on a Co² Sensor. If there is no natural lifting you have to
install forced ventilation- in cas of a high Co²
Concentration ventilation is lifting automatically.
13
Storeroom filling The hackchips are delivered by a tip truck. A fired drive at your
house to the storeroom is needed, if it´s possible. Ideally the
storeroom is on the external wall and is reachable and reflable
form the gate. To avoid damages on the agiator during
insertion of the hack chips, you shall fill the storeroom with a
front loader. The filling opening should be 30 up to 40 cm
minimum higher than the deepest point of the springroom. If
the fuel storeage room is pneumatic filled through a pump
carrage. In this kind of fillimg you have to care if there is a
dustproff speration.
Access doors/hatches Above-ground fuel stores must be provided with a door or
hatch that opens outwards. So that the fuel cannot run out if
the fuel store is opened by mistake, the inside of the access
door/hatch opening must be covered with boarding (which
must be removable from the outside). During to the risk of
injury when the system is in operation, access doors/hatches
must be lockable and kept locked when the system is in
operation. There must be a warning sign carrying the message
"Do not enter when feeder system is running" attached to the
access door/hatch.
Electric Installation Electronic installation in the fuel stores are not allowed
Filler couplings must be single ended.
Structural requirements The enclosing walls must be capable of withstanding the
possible static loads created by the fuel and the pressure when
filling the fuel store.
Damp-proofing The fuel must be protected against contact with water or damp
floors/walls. The storeroom must remain dry all year round. If
there is a risk of temporarily damp walls, fitting a backventilated facing to the walls and lining them with wooden
material may be required.
Doors Aboveground fuel stores must be accessible via a door
(lockable) of at least 1,80 m² cross-section to the outside,
inside and planked removable from the outside, so that the fuel
can not fall out when erroneous opening the door.
floor planking For operation with heating corn or pellets, a ground-planking or
a concrete floor is absolutely necessary. If it is only running by
hack chips, dry wood chips may be introduced instead of the
soil.
14
Celling agitator The drive motor and the necessary electrical installations must
be installed outside of the storage room. A lockable emergency
stop switch with motor protection must be installed in the
immediate vicinity of the charging slot switches, which
interrupts the power supply of the auger when opening the
door, secured. The filling shaft must be secured with a grating.
.
wall breakthrough The following measure table shows the measure for positioning
from the wall breakthrough. The measures apply to the serial
production.
serial production = discharge unity + 0,55 m hutch and agitator
Measure wall breakthrough
wide 45 cm
length 70 cm
Agitator Measure A Measure B
1,5 m 50 cm 37 cm
2,0 m 50 cm 41 cm
2,5 m 50 cm 44 cm
3,0 m 50 cm 47 cm
3,5 m 50 cm 50 cm
4,0 m 50 cm 53 cm
4,5 m 50 cm 54 cm
5,0 m 50 cm 55 cm
15
2.7 Examples for planning
PH-01
For working with Pellets oder Energy corn is a own
filling set needed.
(please have a look at the price list).
Example 1 The storrage filling occurs through a gate.
The maximal length of feed with the agitator is 7 meter.
Example 2 The storage filling occurs with a ceiling filling spiral through a shaft.
Deliverable ceiling filling spirals are available in following sizes: 3 m, 4 m, 5 m, 6
m or 7 m. The maximal length of holding included the agitator is 7 m.
Example 3 The storage filling occurs through a shift in the storage room ceilling.
The maximal length of holding included the agitator is 7 m.
16
For working with Pellets oder Energy corn is a
own filling set needed.
(please have a look at the
price list).
Example 4 The boilers charging occurs with a horizontal installed agitator.
A droft shaft extension is needed. (please have a look on the price list)
The maximal length of holding included the agitator is 7 m.
Example 5 The boilers charging occurs with a horizontal installed agitator.
A in the length shortened downpipe is need.
(Please have a look on the price list).
The maximal length of holding included the agitator is 7 m.
Example 6 The boilers charging occurs with an additional feeder spiral.
A operation set and some spiral´s trags are needed.
(Please have a look on the price
list).
The maximal length of feeder spiral included operation set might have a 7 m
length.
The maximal length of holding included the agitator is 7 m.
17
2.8 AUTOMATIC ASH SUCTION SYSTEM
PC-01
The following Introductions are for Device
planning- for installation of ash vacuum suction
system there is another Introduction included.
Optional there is a automatic ash vacuum system. The
accumulated ash will go through the firing build Feedsystem
and flexible metal tube in a big removable ashton. The
deashing is automatically.
Retofit the system It´s possible to retrofit the ash vacuum suction system, if the
minimum difference between the wall and the system ist 60
cm.
A → 153 cm
B → 59 cm
C → 72 cm
D → 107 cm
Construction side: If possible, you have the opportunity to plan the ash ton at a
ground level beside the boiler’s body. Basic requirement for
the construction is a good lifting through the installation site,
The ash ton must have a 25 cm minimum difference to
inflammable materials. You have to be a look that there is no
inflammable ground.
Not permitted construction side for an ash ton:
• in an garage
• in the atmosphere in living rooms;
• in storerooms with inflammable materials or gases.;
18
Permited Construction plaeces for the ash ton:
• in the boiler room
• in an secondary
room
Hauling of a suction pipe through fire zones
A → wall penetration with Rockwoolpipesprialclamp;
B → wall penetration with boiled Steel pipe;
C → fire security clamps 54 – 60;
(maximal 1 m difference)
D → flexible suction metal tube
(minimum 10 cm difference)
E → not inflammable mad
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