KOB PYROMAT ECO SERIES, PYROMAT ECO 35, PYROMAT ECO 151, PYROMAT ECO 55 Operating And Maintenance Instructions Manual

Operating and Maintenance Instructions for the
PYROMAT ECO 35 to 151

ID: 104642-B 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 Suitable and approved fuels _______________________________________________________ 6

3 Burner design______________________________________________________ 7
4 Starting up / Operation ______________________________________________ 8

4.1 Initial start-up ___________________________________________________________________ 8

4.2 Starting up______________________________________________________________________ 8

4.2.1 Filling___________________________________________________________________________ 8

4.2.2 Heating up_______________________________________________________________________ 8

4.2.3 Operation _______________________________________________________________________ 9

4.2.4 Adding fuel ______________________________________________________________________ 9

4.3 Oil burners_____________________________________________________________________ 10

4.3.1 Burner slide_____________________________________________________________________ 10

4.3.2 Operation with oil burners__________________________________________________________ 10

5 The ECOTRONIC Control System ____________________________________ 11

5.1 General information _____________________________________________________________ 11

5.1.1 Battery replacement ______________________________________________________________ 11

5.2 The functions of the buttons ______________________________________________________ 11

5.3 Boiler, F3 ______________________________________________________________________ 12

5.3.1 F3 Key "PYROMAT parameters" ____________________________________________________ 12

5.4 The F4-F8 extended control systems _______________________________________________ 13

5.4.1 Room heating unit________________________________________________________________ 13

5.4.2 Utility water heater _______________________________________________________________ 15

5.4.3 Air heater ______________________________________________________________________ 16

5.4.4 Neighbouring buildings ____________________________________________________________ 17

5.4.5 Pipeline________________________________________________________________________ 18

5.4.6 Additional boilers_________________________________________________________________ 19

5.4.7 Solar __________________________________________________________________________ 20

6 Cleaning _________________________________________________________ 21
7 Shutdowns _______________________________________________________ 22
8 Waste disposal____________________________________________________ 22

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 ECO. In conjunction
with a heat storage unit, it will provide you with all
the advantages of a modern, economically efficient
heating system. 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 ECO.

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 ECO 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 ECO is for in­cinerating wood fuels.

The intended use of the PYROMAT ECO is stipu­lated:

- in the regulations of the Assembly and Installa­tion Instructions

- by the limits of the technical specifications

- in the section, "Suitable and approved fuels"

- by the safety regulations in these Operating and

Maintenance Instructions.

Any other use of the PYROMAT ECO 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 ECO by unqualified
personnel, without any training or knowledge of
the Operating and Maintenance Instructions.

- Disabling the safety or monitoring devices on the
PYROMAT ECO.

- Removal of any protective covers or cladding on
the PYROMAT ECO by unauthorised individuals.

- Making any conversions or alterations to the PY­ROMAT ECO 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 ECO heating boiler:

- Max. operating pressure allowed: 3.0 bar

- Max. boiler temperature allowed: 100°C

- Min. return temperature: 65°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: 2007-08_English
Prepared by: KabW/SclM

1.6 CE-Symbol

The PYROMAT ECO 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 ECO 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: 230V

In a risky situation, the PYROMAT ECO can be
disconnected from the electrical mains at all the
leads by plug connector on the rear of the boiler
(1).

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 doors during the starting phase and the

burn-out 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

: Resetting is only possible at a boiler

temperature of less than 70° C.
Possible causes for excess temperature

:

- Incorrect setting on the control module.

- Defective component of the system (pump or

valve).

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The TLSS (tempera­ture-limiting safety
switch) is situated in
the front metal plate
beneath the refill ac­cess lid.

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2.3 Suitable and approved fuels

The KÖB PYROMAT ECO is designed for heating
chopped wood and wood waste and can be op­tionally equipped with an oil or gas burner.

Important prerequisites for the wood

The wood must be air-dry. One to two and a half
years are necessary for natural drying. This drying
can be carried out outdoors (covered) in part and
should then be continued for at least one year in a
suitable shed. The water content should amount to
a maximum of 25% (w 25).

Bear in mind:
Wood that has been stored for too short a time
and is still moist only has about half of its po­tential thermal power!

Types of wood

The KÖB PYROMAT ECO is especially well suited
for the types of wood listed below:

- Air-dry, chopped wood in its natural state, such
as split wood, billet wood and round wood.
Hardwood: max. ∅ 15 cm
Soft wood: max. ∅ 12 cm

Guideline figures for storage (for dry storage)
Hardwood: 2 to 2½ years
Soft wood: 1 to 1½ years

- Non-pelletised wood in its natural state (max.
water content of 25%) in the form of coarse
chips, woodchips, including bark adhering with
an edge length of Æ greater than 5 cm

- Compressed wood from chips, unless manufac­tured using bonding agent. Diameter Æ greater
than 4 cm

- Carpentry shop waste in the form of glued
wood and wood remnants, provided no wood
preservatives have been applied or are con­tained.
Edge length Æ greater than 5 cm

- Addition of a max. of 20% of brown coal bri­quettes to extend the combustion time.

Length of wood

Pyromat 35, 45, 55, 65, 75, 85 Æ max. ½ m
Pyromat 61, 81, 101, 151 Æ max. 1 m

Be sure to note:

The boiler is only suited for incinerating the wood
fuels and wood mixtures listed here.

If different fuels are used, KÖB will not assume
any liability for the functioning or service life of
the boiler.

It is not allowed to incinerate wastes or wood in
these heating systems that has been treated with
wood preservatives or the coating of which con­sists of halogenated organic compounds. In addi­tion to the development of highly toxic exhaust
gases, severe corrosion damage may also occur in
the boiler due to these chemical compounds (hy­drochloric acid).

The following must not be incinerated:

- Hard coal or coke

- Wood waste with coatings made of halo-

genated organic compounds (PVC)

Operation with an oil/gas burner:

Fuel: Extra-light heating oil

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3 Burner design

(Picture: PYROMAT ECO 55)

(1) Large firebox with easily accessible access

door
(2) Downwardly conical firebox
(3) Electronic boiler control panel
(4) Degasification zones with cast iron grating and

fireclay bed
(5) Hot tunnel made of highly refractory concrete

for re-incineration
(6) Large, easily accessible ash pan for the grate

ash

(7) Vertical pipe-type heat exchanger
(8) Cleaning lid on top
(9) Ash container under heat exchanger
(10) Exhaust fan
(11) Maintenance cover or burner connection
(12) Safety heat exchanger
(13) Lambda sensor
(14) Ash pan lid

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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 Starting up

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

4.2.1 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.

- 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.

- 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.

4.2.2 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 Wood".

- 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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3

2

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4.2.3 Operation

- All the lids and doors have to be closed with no
leakage during the burn-off.

- The temperature of the exhaust gas should rise
to 130°C to 150°C in just a few minutes, and be
between 160°C and 200°C in continuous opera­tion.

- If the temperature of the exhaust gas prema­turely drops back down during the burn-off, you
have a hollow fire.
Cause:

Pieces of wood have been poorly
stacked or are irregular.
Remedy:

Carefully open the ash pan lid and
with a poker spread the wood over the entire
bed of embers.

Combustion time for:

- Each loading of wood from deciduous trees:
approx. 4 hours

- Each loading of wood from coniferous trees:
approx. 3 hours

4.2.4 Adding fuel

First check:

- Check the storage unit temperature! Can the

energy to be expected be accepted or stored?
Maximum storage unit temperature: 90°C.

- Is the burner already in the burn-out phase (ex-

haust gas temperature below 130°C)?

- Is the exhaust gas fan already out of operation?

Adding fuel:

- If the exhaust gas fan is already out of opera-

tion:
Press the F1 button "PYROMAT Wood".

- If the exhaust gas fan is still in operation:

Before adding

, press the F1 button "PYROMAT
Wood" (Add Fuel function). This will bring
about fast stabilisation of the operation.

- First only raise the access door slightly,

so that
any accumulation of low-temperature gas pre­sent in the upper part of the firebox can be suc­tioned off.

- Then unlock the safety lock (1) and open the lid
all the way.

- Neatly lay the billet wood and logs horizontally
and compactly over the entire width of the fire­box. Only refill as much wood as energy that
the storage unit can still accommodate.

I M P O R T A N T: Do not put any wood shav­ings or fine chips directly onto the embers Æ
There is a DANGER such GOING UP IN FLA­MES SUDDENLY!

- Close access door. Be sure that the supporting
surface for the refill access lid seal is clean.

Afterwards check:

- The surface of the ceramic combustion cham­ber should remain white.

- The vertical pipe-type heat exchanger must not
have any shining soot or tar deposits.

- The ash content is very low when the wood in­cinerates in a controlled fashion (approx. 1 per­cent by weight). The ash should be grey!

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