KOB PYROMAT DYN, Pyromat DYN 45, Pyromat DYN 85 Operating And Maintenance Instructions Manual
Operating and Maintenance Instructions for the
PYROMAT DYN 45 to 85
ID: 103708-G English
© by Köb Holzfeuerungen GmbH
Flotzbachstrasse 33
A-6922 Wolfurt
All rights reserved, including photomechanical reproduction and storage in electronic
media.
Viessmann Group
1 General information _____________________________________________________________________ 4
1.1 Foreword ____________________________________________________________________________ 4
1.2 Latest developments in the technology ___________________________________________________ 4
1.3 Intended use _________________________________________________________________________ 4
1.4 Technical specs_______________________________________________________________________ 4
1.5 Documented information _______________________________________________________________ 4
1.6 CE-Symbol___________________________________________________________________________ 4
2 Important information____________________________________________________________________ 5
2.1 Safety information_____________________________________________________________________ 5
2.2 Excess temperature & power failures _____________________________________________________ 5
2.3 Fire hazard___________________________________________________________________________ 6
2.4 Minimum requirements for wood fuels ____________________________________________________ 6
2.5 Filling the fuel storage unit______________________________________________________________ 7
2.5.1 By dumping _________________________________________________________________________ 7
2.5.2 By blowing in ________________________________________________________________________ 7
2.6 Correcting malfunctions of the conveyor equipment ________________________________________ 7
2.7 Correcting malfunctions in the de-ashing system___________________________________________ 7
3 Burner design __________________________________________________________________________ 8
4 Starting up / Operation ___________________________________________________________________ 9
4.1 Initial start-up_________________________________________________________________________ 9
4.2 Automatic operation ___________________________________________________________________ 9
4.2.1 Heating up__________________________________________________________________________ 9
4.2.2 Operation___________________________________________________________________________ 9
4.3 Log operation _______________________________________________________________________ 10
4.3.1 Filling_____________________________________________________________________________ 10
4.3.2 Heating up_________________________________________________________________________ 10
4.3.3 Operation__________________________________________________________________________ 11
4.3.4 Adding fuel ________________________________________________________________________ 11
5 The ECOTRONIC Control System _________________________________________________________ 12
5.1 General information __________________________________________________________________ 12
5.1.1 Battery replacement _________________________________________________________________ 12
5.2 The functions of the buttons ___________________________________________________________ 12
5.3 The burner and its loading F3, F4 _______________________________________________________ 13
5.3.1 F3 button "PYROMAT parameters"______________________________________________________ 13
5.3.2 F4 button "PYROMAT loading" _________________________________________________________ 14
5.4 The F5-F8 extended control systems ____________________________________________________ 15
5.4.1 Room heating unit ___________________________________________________________________ 15
5.4.2 Utility water heater___________________________________________________________________ 17
5.4.3 Air heater__________________________________________________________________________ 18
5.4.4 Neighbouring buildings _______________________________________________________________ 19
5.4.5 Pipeline ___________________________________________________________________________ 20
5.4.6 Additional boilers____________________________________________________________________ 21
5.4.7 Solar _____________________________________________________________________________ 22
6 Cleaning______________________________________________________________________________ 23
6.1 Automatic operation __________________________________________________________________ 23
6.1.1 Cleaning of de-ashing system (optional)__________________________________________________ 24
6.1.2 Cleaning of main combustion chamber___________________________________________________ 24
6.1.3 Cleaning of exhaust gas deduster (optional)_______________________________________________ 24
6.2 Chopped wood operation______________________________________________________________ 25
7 Shutdowns____________________________________________________________________________ 26
8 Waste disposal ________________________________________________________________________ 26
9 Enclosures
- Spec Sheet 1010-1, 2
- Error Reports / Error Correction
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1 General information
1.1 Foreword
Dear System Owner, you have made a good selection in the PYROMAT DYN. It will provide you
with all the advantages of a modern, economically
efficient heating system. Fully developed technology in combination with a sturdy design guarantee
a high degree of operational reliability and long
service life.
These Operating and Maintenance Instructions
contain important information for the intended use,
correct operation and proper maintenance of the
PYROMAT DYN.
Non-compliance with the Operating and Maintenance Instructions will result in loss of the
guarantee.
If you still need any further information after studying the Operating and Maintenance Instructions:
The Assembly and Installation Instructions contain
important information about:
- Standards and regulations,
- Structural surroundings of the burner
- Transport & assembly
- Water installation and electrical installation,
- Fire protection,
- Starting up,
as well as an appendix with diagrams of connections and dimensions as well as the complete technical specifications.
Our sales and services offices will be glad to provide you with any further information. Their addresses can be found on the reverse side of these
Operating and Maintenance Instructions.
1.2 Latest developments in the technology
The Operating and Maintenance Instructions are in
keeping with the PYROMAT DYN at the time it is
delivered. In the interest of our customers, we reserve the right to make, without any notification requirement, the following changes resulting from
further technology developments.
1.3 Intended use
The intended use of the PYROMAT DYN is for incinerating wood fuels.
The intended use of the PYROMAT DYN is stipulated:
- in the regulations of the Assembly and Installation Instructions
- by the limits of the technical specifications
- in Spec Sheet 1010 "Minimum requirements for
wood fuels – instructions",
- by the safety regulations in these Operating and
Maintenance Instructions.
Any other use of the PYROMAT DYN or use of it
going beyond this will be considered as unintended
use unless written approval by the manufacturer
has been obtained.
The following, among other things, will be considered as unintended use:
- Operation of the PYROMAT DYN by unqualified
personnel, without any training or knowledge of
the Operating and Maintenance Instructions.
- Disabling the safety or monitoring devices on the
PYROMAT DYN.
- Removal of any protective covers or cladding on
the PYROMAT DYN by unauthorised individuals.
- Making any conversions or alterations to the PYROMAT DYN without approval by the manufac-
turer.
- Using spare parts or accessories from other
manufacturers without approval by the manufacturer.
The operating organisation will be liable for
any damage or accidents in case of any unintended use.
1.4 Technical specs
The following important limits apply to the PYROMAT DYN heating boiler:
- Max. operating pressure allowed: 3.0 bar
- Max. boiler temperature allowed: 100°C
- Min. return temperature: 70°C
The complete technical specifications listed in the
appendix of the Assembly and Installation Instructions.
1.5 Documented information
The Operating Instructions contain the information
required according to the EC Directive on Machinery 98/37/EEC, Appendix 1, Number 1.7.4.
Issue: 2007-09 _English
Prepared by: KaW/ScM
1.6 CE-Symbol
The PYROMAT DYN is delivered with a CEsymbol on its type plate an EC attestation of conformity in accordance with II A or the EC Directive
on Machinery 98/37/EEC.
If the PYROMAT DYN is altered by equipment
from other manufacturers being added, or the
safety equipment or control system are combined
with a different system and/or integrated into an
overriding system (building control system), then in
the European Union a new attestation of conformity has to be issued before it is put on the market.
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2 Important information
2.1 Safety information
When carrying out work on the heating system,
such as cleaning and maintenance, wear appropriate protective equipping when required.
There is a danger of getting injured through:
burning, knocking against corners and edges,
crushing in moving parts and noise.
Mains supply: 400V
In dangerous situations, the PYROMAT DYN can
be disconnected from the electrical mains system
using the master switch (1) delivered unmounted
along with the system (which the customer should
install next to the control panel),
or by means of the plug connection for the power supply on
the rear side of the burner (2),
disconnecting all the pins.
Doors
When the access door is not opened all the way, it
automatically falls back shut.
The burner must never be operated with the
doors open!
Any burning bits that escape could result in a fire.
Only open the doors in manual operation and then
only during the starting phase or during the burnout phase (for refilling, exhaust gas temperature
less than 130°C). If the doors were opened during
operation, sparks and tongues of fire could leap
out.
Equipment for dissipating excess heat
The functioning of the thermal run-off safety valve
must be inspected every year by a competent specialist.
The safety heat exchanger must not under any circumstances be used as an operational heat exchanger.
Seals
It is important for the functioning and controllability
of the burner that no unwanted air be able to enter
unchecked through leaks.
The doors and lids have to close tightly without
leakage. Any damaged seals must be immediately
replaced. Tighten snugly the fastening bolts and
handles.
Operation, cleaning & maintenance
Bear in mind that only if operated and maintained
properly can even the best of products fulfil their
functions well, for a long time and free of malfunctions.
Compliance with the "Cleaning" section is mandatory!
2.2
Excess temperature & power failures
Do not open the doors or lids on the burner!
• Switch on additional heat consumers.
• The exhaust fan goes out of operation.
• The temperature-limiting safety switch triggers.
• The valve for the thermal run-off safety valve
opens at approx. 95°C. The excess heat is
conducted off into the channel.
If the temperature-limiting safety switch (TLSS)
has triggered, then it has to be manually unlocked.
To reset, unscrew the black cap and press the button.
IMPORTANT
: Only as of a temperature of approx.
70°C is resetting possible.
Possible causes for excess temperature
:
• Incorrect setting on the control module.
• Defective component of the system (pump or
valve).
• Sudden drop in output to zero. The feed auger
still has to be run empty. The heat then produced by this can result in excess temperature.
Activate the "Eliminate Excess Heat" function!
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2
The TLSS (temperaturelimiting safety switch) is
situated in the front
metal plate beneath the
refill access lid.
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2.3 Fire hazard
With insertion-type firing systems, the conveying
route creates a connection between the silo and
the burning material in the burner. With the PY-
ROMAT DYN insertion-type heating boiler, the
feed auger is also the metering auger, and thus
always filled full with material during operation.
There are various safety devices provided to prevent back burn.
Temperature sensors:
By means of temperature sensors on the feed auger, in case of excess temperature the loading to
the feed auger is interrupted, and the feed auger's
material is inserted into the combustion chamber.
Slide valve (option):
This closes in case of a standstill, danger of back
burn or power failure (spring return motor).
Rotary valve (option):
Instead of a slide valve, in silos with pressurisation.
Drop-off route:
A vertical drop-off route interrupts the connected
line of burning material.
Fire-extinguishing system (option):
This system, which functions independently of the
electrical power, brings about a flooding of the material to be burned that is located in the feed auger.
The activation temperature is approx. 95°C.
2.4 Minimum requirements for wood fuels
The PYROMAT DYN is only suitable for incinerating the fuels listed in Spec Sheet 1010 "Minimum
Requirements for Wood Fuels" (see enclosure)
and here.
Logs for manual loading
:
Untreated, air-dried logs, such as split wood, billet
wood and round wood.
Hardwood: max. ∅ 15 cm
Soft wood: max. ∅ 12 cm
Benchmark figures for storage (in dry storage)
Hardwood: 2 to 2
1
/2 years
Soft wood: 1 to 1
1
/2 years
If different fuels are used, KÖB will not assume
any liability for the functioning or service life of
the burner. Refer to the "Warranty" section in
the General Terms and Conditions of Delivery.
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2.5 Filling the fuel storage unit
2.5.1 By dumping
Rotary sweep extraction and spring-operated
extraction
Heating system in operation:
- If the articulated arms or spring-mounted plates
are still covered by fuel
, refilling can be carried
out immediately.
- If the articulated arms or spring-mounted plates
are no longer covered by fuel
, fill the silo evenly
to approx. 30 cm above the articulated arm or
over the spring-mounted plates. As soon as the
articulated arms or spring-mounted plates have
retracted through a request for material, the refilling can be continued.
Heating out of operation:
- If the articulated arms or spring-mounted plates
are still covered by fuel
, refilling can be carried
out immediately.
- If the articulated arms or spring-mounted plates
are no longer covered by fuel
, fill the silo evenly
to approx. 30 cm above the articulated arm or
over the spring-mounted plates. Then activate
the "SILO FILLING" function. To do so, press
the LOADER SYSTEM key (F4) and then the
LEFT ARROW KEY (<). Then select "YES" and
confirm with "OK". Wait until the articulated
arms or the spring-mounted blades go under
the cup washer, and then finish evenly
filling
the silo. The "SILO FILLING" function brings
about the filling of the fire box.
NOTE: The "SILO FILLING" function cannot be
activated until the heating system has been out
of operation for one hour.
Moving floor conveyor
- Fuel can be refilled automatically.
Funnel extraction system
- It is mandatory that the heating system be in
operation!
2.5.2 By blowing in
The heating system has to be out of operation
(danger of excess pressure or negative pressure caused by the action of blowing-in). Filling
procedure as described in section 2.6.1.
2.6 Correcting malfunctions of the conveyor equipment
The cause of motor malfunctions in conveyor systems is usually clogging by large pieces of wood or
foreign matter
(e.g. pieces of wood or stones).
CAUTION
DANGER OF INJURY:
Always turn off the master switch before carrying out any repair of a malfunction on feed systems and every time before a maintenance lid
is opened or a protective device is removed!
Due to the facility's automatic operation, the point
in time for the conveying means to be switched on
is not foreseeable.
2.7 Correcting malfunctions in the de-ashing
system
The cause of motor malfunctions in the de-ashing
system is usually clogging by large pieces of foreign matter or stones.
Important:
The main switch must be switched off
each time
before correcting a malfunction in the de-ashing
system! The automatic operation of the system
makes it impossible to foresee the time point when
the de-ashing auger will switch on!
Safety instructions:
− Use gloves and protective eyewear.
− Set the boiler control system to "Out of opera-
tion".
− Allow the boiler to cool down.
− The foreign matter will be hot! For this reason,
remove the foreign matter with the kindling utensil or with pliers.
− Never reach into the feed system with your fin-
gers! Use tools!
Procedure:
− Mark the position of installation for the grate
elements.
− Then remove the grate elements.
− Remove the foreign matter with pliers.
− If the foreign matter gets jammed:
Remove the protective lid at the motor de-
ashing unit.
Turn the fan wheel on the motor to make the
auger move slightly. This will loosen the foreign matter.
Remove the foreign matter with pliers.
After the final cleaning of the components taken off
(protective lid, grate elements, etc.) put back on
properly.
Functional test:
When the mechanical cleaning system is operating, the de-ashing system should also be running.
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3 Burner design
(Picture: PYROMAT DYN 45)
(1) Electronic burner control panel
(2) Feed auger and degassing grate with primary
airflow
(3) Automatic ignition device
(4) Main combustion chamber made of heat-
resistant refractory concrete
(5) Post-combustion chamber (secondary airflow
via firebox door)
(6) De-ashing system for the combustion chamber
Explanation of illustration: The position of the
sweeper adjusts in the mechanism and has to
support the "flow" of the ash toward the ash
compartment. (Note: the inoperative position for
the sweeper is not shown in the illustration.)
(7) Large ash compartment with utilisation of re-
sidual burning embers
(8) Front combustion chamber with filling on top
(9) Firebox door with air vent control
(10) Pipe-type heat exchanger with automatic
cleaning system
(11) Drive for automatic de-ashing and cleaning
(12) RPM-controlled exhaust fan
(13) Lambda sensor
(14) Safety heat exchanger
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4 Starting up / Operation
4.1 Initial start-up
The initial start-up is carried out either by Köb
Holzfeuerungen GmbH or another heating specialist.
Be absolutely sure to follow the instructions in
the Assembly and Installation Instructions. No
guarantee may be claimed in cases of initial
start-ups carried out improperly by oneself.
First check:
• Is there enough water in the heating system?
• Has the heating system been bled?
• Are the slide valves open to the heating forward
and reverse flow?
• Can enough fresh air get into the heating
room?
• Are the doors and lids on the burner all closed
leak-tight?
4.2 Automatic operation
CAUTION: Do not start automatic operation
with the filling shaft filled Æ Danger of explosion!
4.2.1 Heating up
• Press the F2 button "PYROMAT Auto". The
loader modules will be switched on in the order
required. When there is enough fuel in the
combustion chamber, the entire loader system
switches off.
• The automatic ignition then takes place. The
ignition process stops as soon as the fire is
started.
4.2.2 Operation
With hydraulically switched heat storage tank
• The material is supplied depending on the light
barriers in the metering container and in the
combustion chamber, allowing for the residual
oxygen.
• The primary and secondary air vents change
their positions depending on the exhaust gas
temperature and residual oxygen.
• Using the setting "Storage Management, Temperature, Storage, Average", it is possible to
keep the facility in continuous high-performance
operation for as long as possible – with fewer
ignitions, better efficiency and lower emissions.
• When the boiler temperature set is reached, the
facility switches to "run auger empty". When
the feed auger has been run empty, and the
exhaust gas temperature is less than 90°C, the
exhaust gas fan switches off and the air vents
close.
• When the "System Temperature Setting" is
fallen short of, the facility is automatically
started back up.
With ECO function (option), heat accumulator
with storage control valve
An additional storage control valve for exact temperature stratification in the accumulator and optimum exploitation of the residual boiler heat.
How to switch off
• Press the F2 button "PYROMAT Auto". As
feedback to this, "Run Auger Empty" will appear
on the control panel.
I M P O R T A N T:
Do NOT use the master button to switch off
Æ DANGER OF BACK BURN !!!
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4.3 Log operation
Check the storage unit temperature! Check
whether the storage unit temperature has dropped
so far that heating up is practical, and whether the
amount of heat to be expected can be accepted or
stored.
Maximum storage unit temperature: 90°C
4.3.1 Filling
CAUTION: Never fill shavings or woodchips di-
rectly from the grate Æ There is a danger such
going up in flames suddenly!
• The slots in the grate have to be free of ash.
Only charcoal (approx. 2 cm) may remain lying
on the grate. Evenly spread out paper on this
(better than cardboard) and easily combustible
wood over the entire width of the burner
(approx. 25 cm high). Position the pieces of
wood crosswise such that a layer permeable to
air is created.
Finer material may only be filled on the layer of
chopped wood.
• Neatly lay the billet wood and logs horizontally
and compactly over the entire width of the firebox.
• When closing the access door, be sure that the
supporting surface for the refill access lid seal
is clean.
Note that even a small ember remaining can
also inadvertently ignite the kindling wood.
With hydraulically switched heat storage tank
Only fill the firebox partially – only reduced log operation is possible!
Load with logs to a maximum of 20 kg to 40 kg per
filling, depending on the thermal acceptance.
With ECO function (option), heat accumulator
with storage control valve
• Full operation with logs.
• Only refill as much wood as energy that the
storage unit can still accommodate until the
maximum storage unit temperature of 90°C is
reached.
4.3.2 Heating up
Kindling
• Is the airway (1) to (3) clear through the entire
area of the grate, through fuel at the bottom and
into the combustion chamber? Is the lower part
of the wood loaded (2) permeable to air?
• Open the ash pan lid. Ignite, ideally doing so
over the entire width of the firebox,
• such that the fire spreads over the entire area
of the grate as quickly as possible.
Aim to keep the heating-up procedure short,
quickly producing a lot of heat and embers.
Rapid heating up of the combustion chamber
rapidly produces perfect incineration.
• Press the F1 button "PYROMAT Manual".
• Leave the ash pan lid approx. 10 cm open until
the material to be burned has started to burn
well.
• When the temperature of the exhaust gas
reaches approx. 110°C, close the ash pan lid.
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