Moderator DTR-AZSB-30 Operating Instructions Manual
Operating Instructions
Smok 30÷÷÷÷240kW
Automatic Biomass Burning Set
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Table of Contents
Dear User,....................................................................................................................... 2
1. Overview ...........................................................................................................................2
1.1. Safety Instructions................................................................................................... 2
1.2. Warranty.................................................................................................................. 6
1.3. Fuel.......................................................................................................................... 7
1.4. Technical Description .............................................................................................8
1.5. Equipment ............................................................................................................. 12
2. Assembly .........................................................................................................................12
2.1. General parameters................................................................................................12
2.2. Boiler Room..........................................................................................................12
2.2.1. Boiler Installation...............................................................................................12
2.2.2. Feeder positioning..............................................................................................13
2.3. Connecting to the Chimney................................................................................... 14
2.4. Boiler Connection to the System...........................................................................14
2.5. Protection of the installation .................................................................................15
2.5.1. An open system.................................................................................................. 15
2.5.2. Closed Systems .................................................................................................. 16
2.5.3. Thermal protection............................................................................................. 18
2.6. Installation of the control system and electric connections................................... 19
2.6.1. Description of control box.................................................................................. 20
2.6.2. Control Box Installation.....................................................................................20
2.6.3. Electric connections ........................................................................................... 22
3. Device Operation............................................................................................................31
3.1. Technical Description ...........................................................................................31
3.2. Working Settings................................................................................................... 32
3.3 Burning................................................................................................................... 33
3.3.1. Ignition ...............................................................................................................33
3.3.2. Continuous operation mode ...............................................................................34
3.3.3. Emergency operation of the boiler.....................................................................35
3.4. Cleaning, Ashes.....................................................................................................36
3.5. Program-Initiated Shutdown of AZSB..................................................................38
3.6. Emergency Shutdown of AZSB............................................................................38
4. Troubleshooting, Safe Operation Conditions.............................................................. 39
4.1. Installation of the fuel container in non-heated premises .....................................39
4.2. Anti-freeze protection ...........................................................................................40
4.3. Troubleshooting ....................................................................................................40
4.3.1. Procedure in Case of Worm Shaft Jamming...................................................... 42
5. Spare Parts...................................................................................................................... 43
5.1. Main Spare Parts List............................................................................................ 43
5.2. List of Wearable Parts*.........................................................................................43
6. Disposal ...........................................................................................................................43
“MODERATOR” Company Service Representatives.................................................... 45
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Dear User,
Thank you for your purchase of our equipment. We would like to
congratulate you on your good choice.
Moderator Spółka z o.o. has been manufacturing boilers utilizing
proprietary technological solutions developed in late 70’s in Hajnówka by
engineer Kazimierz Kubacki. During last twenty years these boilers have
undergone multiple technological changes and upgrades. We have also started
production of automatic feeders intended for burning crumbled solid fuels,
which combined with a boiler constitute complete Automatic Biomass Burning
Sets (AZSB). This instruction manual is based on the latest information of the
manufacturer. Due to ongoing development works on the boiler the manual is
only applicable for the boiler it is delivered with.
AZSB is intended for heating water up to maximum 80 degrees Celsius in
central-heating and hot household water installations as well as in process
installations (wood dryers, presses, etc.).
This manual has been designed to assist users in boiler installation,
operation, maintenance and servicing. It shall be read and understood before
commencing with these activities.
1. Overview
1.1. Safety Instructions
The main condition of safe boiler operation is its correct connection to the
central heating installation. This will only be possible after all connection and
operation requirements discussed in these instructions are met and complied
with. Failure to perform any action, due to involved costs of additional
equipment installation will certainly affect the safety or cause the equipment
operating costs to raise in future.
The equipment has been subjected to performance checks and tests, which
all have been performed using carefully selected accessories (safety valves,
thermal protections) and equipment. In order to guarantee preservation of
declared high performance of the equipment, manufacturer-recommended
equipment shall be used exclusively.
We would like to hereby advise against using substitute solutions, which
have not been checked with that boiler and which do not have required
approvals (Technical Supervision Office - UDT) and certificates (declaration of
conformity, CE sign). We also advise against any unauthorized changes in the
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equipment structure and against failing to follow safety instruction described in
these instructions.
A failure to follow these recommendations may lead to serious threats and
expose the operating personnel to health or life hazard.
In case of doubt, please contact our sales department or authorized
servicing agent.
Safety Instructions for basic activities
Maintenance – during maintenance, the device must remain disconnected from
power supply. the switch (fig. 8) must be in 0 (zero) position. During
maintenance always check tightness of connections and conditions of the cover
seals.
Leaks – when filling the tank check if there are any foreign bodies under the
cover, that could prevent it from being properly closed.
Head – keep in mind that the burner head stays hot long after the device has
been switched off. All works on the burner head may only be performed after
the temperature drops. The burner head must not be covered and must be kept
clean.
Fire safety – leaving open covers or inspection holes or overfilling the container
during burner operation may constitute an imminent fire threat. Too much fuel
in the container will prevent tight closing of the cover:
- on each visit to the boiler room (at last once per 12 – 24 hours), it is
necessary to check whether the fire water tank contains sufficient volume
of water (the recommended water volume shall fit between min and max
level indications),
- appropriate fire fighting equipment shall be available in the boiler room
(acc. to fire brigade recommendations, appropriately sized fire
extinguisher, etc.),
- do not store ashes in plastic or cardboard containers. Do not leave ashes in
premises unsupervised (even if in non-combustible containers),
Protective equipment – chips, sawdust and ashes may contain carbon
monoxide, dusts and allergens. When working with this material, use
appropriate means of personal protection. Note that ashes may contain
concealed glowing coal particles. When working with ashes, use suitable gloves.
Clothing – When working in the boiler room, due to personal safety
considerations, use infusible and non-combustible clothing.
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Safety and Warning Signs
Please pay attention to warning and safety signs, minding their meaning
and placement on the equipment. this is to avoid accidents.
Pay special attention in the boiler room keeping in mind that different
parts of the boiler and systems may be hot.
Keep a safe distance.
This boiler may only be operated by people knowledgeable with the
content of this instruction manual.
Do not stand on the housing.
The device may periodically switch on without warning.
Do not perform any works on a connected and switched on
device.
The transport worm may start operating without warning.
Switch off power supply before lifting the cover.
Rotating elements under caver, watch your fingers.
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The container may contain carbon oxygen and dust. Vent
the container before commencing with loading or prior to
its opening.
This sign placed on pages of these instructions indicates a warning.
Please read corresponding section with utmost care so as to avoid many
dangerous situations in future.
Keep in that many parts and surfaces in a boiler room may have high
temperatures. Pay special attention as doors may have higher temperature than
other parts of the boiler. This also applies to smoke conduit and supply and
return pipes. When staying in the boiler room, always stay alert.
Please note that ashes and fuel may cause allergic reactions. Also, during
operation in the charging container, carbon monoxide may accumulate. We
recommend wearing protective gloves and appropriate dust masks.
Remember to keep boiler room clean and in order. Leaving fuel spills on the
floor may lead to a fire.
Note: The container cover must be opened carefully due to escaping
combustion gases and flames from the glowing fuel, forming in result of
sudden inflow of larger volume of oxygen from outside.
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1.2. Warranty
1. Manufacturer grants 24-month warranty for the device, which includes workmanship
and material faults.
2. Manufacturer guarantees correct operation of the Smok AZSB device, which is
confirmed by the company seal.
3. Manufacturer recommends users to follow the guidelines listed below:
• the first run of the device shall be performed by manufacturer’s service
representative * - paid service
• after first year of operation, the device shall undergo obligatory, paid inspection,
performed by Moderator service centre in Hajnówka * – this is the condition of
warranty extension onto further 12 months.
4. The warranty shall not include damages caused as a consequence of incorrect use or
normal wear and tear, refund of installation costs, refund of travel costs, damages
caused by changes or repairs performed without manufacturer’s authorization,
indirect damages and losses resulting from unproductive days and any other resulting
economic losses.
5. The warranty shall not include faults resulting from:
• failure to follow installation guidelines stated in these operating instructions or
resulting from regulations currently in force
• incorrect operation and maintenance or due to the boiler use in a way, which
conflicts with provisions of operating instructions (using incorrect fuel, leaving
ashes after the heating season, failure caused by central heating installation
freezing, inoperable or obstructed combustion gases exhaust system, shortage of
water in the installation)
• boiler application in uses other than specified in these operating instructions
• in case of incorrect selection of the boiler output to the heat demand of the object.
6. All complaints shall be always filed to the boiler vendor. Along with the complaint,
please provide the following:
• photocopy of page 6 of the operating instructions, item 7 (with entered date and
legible signature of the user)
• fault description
• a proof of device purchase
• boiler output, head rated power
•
boiler and Smok device serial numbers
7. User Statement:
I hereby declare that I have acknowledged myself with the Moderator boiler operating instructions and
that the device has been delivered according to order, new, complete and technically operational.
Additionally a specialized company has instructed me on the device operating principles and has
provided a complete set of documentation. I hereby acknowledge the recommendation of the
Moderator boiler manufacturer to subject the device to regular technical inspections. In case of
unjustified Moderator service team call to perform a warranty repair, I will cover full costs related
thereto (man-hours and costs of transport in both directions).
* For addresses and phone numbers see the last page of these
operating instructions
* „MODERATOR” Service Department – Hajnówka,
tel. 085 / 682-75-21
e-mail : serwis@moderator.com.pl
Date, company name or first and last name with legible
signature
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Declaration of Conformity
We,
Moderator Spółka z o.o.
11 Listopada 16a
17-200 Hajnówka
tel. (085) 682-75-20
hereby declare, on our own and sole responsibility that the product: Smok Automatic
Biomass Burning Set, with serial number starting from 250, to which this declaration
applies, meets the following requirements and standards, where applicable:
Directives Standards
98/37/WE EN-PN ISO 12100
97/23/WE
EN-PN 303-5
Hajnówka 2007.11.15
1.3. Fuel
Only recommended fuels may be used.
AZSB is designed to burn crumbled fuels from renewable sources and
wood and vegetable products, such as (chips, sawdust, bark, bricks, pellet) with
humidity content of up to 25% if cast-iron head is used or 40% if ceramic head
is used. As a substitute fuel for cast-iron heads for short period of time pea-coal
may be used. Technical parameters of the device are specified for fuels with
humidity content of up to 25% and calorific value of Q = 16.862 kJ/kg.
The higher the moisture content, the lower the calorific value. Increase of
humidity causes drop of calorific value, which means that one will need twice as
much fuel to achieve the same heating effect. A considerable part of thermal
energy is wasted in the burning process for heating up the fuel and evaporating
water (note: using wet fuel with moisture content of above 40% directly
contributes to shortening of boiler’s operational life and causes it to wear out
prematurely). Additionally there is an increased risk of moisture condensation in
the chimney. Life of a chimney exposed too condensate will be significantly
shorter than in case of a dry fuel, and the draught of the chimney will also
reduce.
During winter periods, increased moisture content of fuel creates the risk
of fuel freezing in the container, which may lead to damage of the feeding
system.
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Avoid burning too fine fuels, in which dust content exceeds 5%. One
shall also pay special attention when burning very dry sawdust (moisture
content up to 10%), and avoid its too tight compacting. Failure to follow
these requirements may lead to fuel sticking and if dusts are burned, to
explosion of gases inside the container.
Chips and shall be crumbled down to particle sizes of 10-30mm. If chips
are too roughly cut, there will be a risk of feeder damage.
Hygrometers are used for moisture content measurements (different types
are used for sawdust and different for wood) and these are necessary equipment,
which should be used when purchasing fuel (to check the actual moisture
content) as well as during normal operation of the device.
Approximate data of different fuels (parameters for a 30 kW device):
Time of 1 c.m.*
burning
weight of 1 c.m.
moisture content
Fuel type
( h.) ( kg ) ( % )
Bricks 96 260 10
Chips 36 155 25
Sawdust 24 145 25
Pellets 168 700 10
*c.m. – cubic meter
1.4. Technical Description
The AZSB consists of a Moderator-type boiler and Smok fuel feeder,
manufactured by Moderator Sp. z o.o. in Hajnówka. The present instruction is
applicable to all versions of the device, and that is to: :
• heat exchangers – 30, 60, 120, 240 kW
• cast-iron heads (40, 60, 120, 240 kW) and ceramic (30, 50, 100 kW)
• containers – 0.6, 1, 2, 6, 8, 10m3 and other, custom-built
Boiler
The boiler (Fig. 1) is a heat exchanger operating in upper combustion
system. Walls and grate are water cooled (the version supporting burners may
have a cast-iron grate) and are made of quality sheet metal plates.
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Lower-power versions of the boiler (30÷60kW) are additionally equipped
with a ceramic barrier in the combustion chamber, which ensures better afterburning of exhaust gases. All versions of the boiler may be equipped with
automatic ash removal system.
1. Ignition doors
2. Ash pan doors
3. Air throttle
4. Upper washout holes cover
5. Smoke conduit
6. Thermometer
7. Supply pipe
8. Head plug
9. Thermal protection sensor G1/2
muff
10. Ash pan washout
11. Return pipe
12. Safety valve
13. G 1/2 muff for thermostat
Fig. 1. Moderator-type boiler (version designed for use in ABB set) – main
parts.
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1
3
4
8
5
7
12
11
10
6
13
9
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After the burner is disconnected, the boiler may be used for burning solid
fuels in traditional system, with manual charging of the combustion chamber.
Such burning shall be however treated as a substitute method to be used in
special situations (e.g. power supply failures, damages to the feeder, etc.) and
one shall aim at restoring the automated operation mode as soon as possible. In
the emergency mode, manual charging is performed through ignition doors (1,
Fig. 1). Bottom (ash pit) doors are equipped with an automatic gate (3. Fig. 1)
ensuring flow of air in case of a power failure.
Head
Depending on the used fuel, two types of heads may be used: cast-iron head
(for humidity of up to 25%) or ceramic head (20÷40%).
Cast-iron head (Fig. 2) is located inside the boiler combustion chamber.
The head operating principle is the following. Fuel from the container (1) is
transported to the head by a worm shaft meshed with mixers (toothed wheels). Fuel
is fed to the head grate where in very high temperature, using air supplied by the
blower, combustion process takes place. Fresh fuel supplied by the worm shaft
pushes remaining ashes to the ash pan of the boiler. Flame, which heats up the
boiler is automatically controlled by the head, according to the main control box
settings.
1. Fuel container
2. Electric motor, gears, shaft
3. Toothed wheel
4. Worm shaft
5. Head cover
6. Head
7. Blower
8. Head washout
9. Maintenance peephole
10. Supply pipe
11. Fire water tank
12. Main control box
13. Fig. 2 Cast-iron head set.
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1
12
11
7
9
8
2
5
10
4
3
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Ceramic head (Fig. 3) is located near the boiler and thus only the flame
enters the combustion chamber. The operating principle of this head is the same
as of the cast-iron head, with the difference that ashes are removed to a special
washout located under the head and may be removed by emptying a special
cassette located there.
1. Fuel container
2. Electric motor, gears, shaft
3. Toothed wheel
4. Worm shaft
5. Limit switch
6. Ceramic head
7. Blower
8. Head washout
9. Maintenance peephole
10. Supply pipe with bee wax plug
11. Fire water tank
12. Main control box
13. Fixing screw
Fig. 3 Ceramic head set.
Containers
AZSB may include containers with varying volume between 0.6m3 and
10m3. The container is made of stainless steel sheet metal plates, and on its
bottom a set of mixing wheels coupled with the worm shaft is installed. The shaft
movement drives the toothed wheel (or wheels) which makes the fuel to move
downwards. Different containers may be connected to the system. Available
connections ensure equipment compatibility.
1
4
11
9
13
6
10
5
7
8
1
12
3
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1.5. Equipment
The boiler is being delivered in completed state. Its basic equipment
include: a thermometer, a G½(G¾) drain valve, a G¾(G1)safety valve, complete
cleaning set, a drawer, cast-iron grate (only in AZSB30).
The feeder is provided partially assembled. Some parts of the feeder, after
workshop tests are disassembled and packed inside the container. This is meant
to facilitate transport and device handling to the boiler room. The feeder is
equipped with all necessary elements permitting its installation outside the
electric installation.
2. Assembly
2.1. General parameters
Maximum supply temperature – 80˚C
Maximum return temperature – 70˚C
Minimum recommended return temperature – 55˚C
Operating pressure - 1.5 bar (for versions above 50kW – 2.5 bar)
Thermal efficiency 84%
Combustion gases minimum temperature – 150ºC
2.2. Boiler Room
The boiler room shall meet requirements of the PN-87/B-02411 standard.
Here are some of the most important of them:
• waterproof flooring
• steel or wooden doors lined with sheet metal, opening outwards
• 21x21 cm air supply hole in the bottom part of the boiler room
• at least 14x14 cm exhaust hole in the upper part of the boiler room
Equipment:
• tap
• sewage well
• sink
Forced ventilation must not be used.
2.2.1. Boiler Installation
Boiler installation shall be performed by installer with appropriate
qualifications and experience (we advice to seek help from representative
centres, whose installers have undergone training in Moderator Sp. z o.o.). A
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faulty installation may cause premature wear of the boiler and threatens fire or
may cause an explosion.
Moderator boilers are delivered assembled. During boiler installation, it
is necessary to ensure its accessibility in such a way, so that boiler room walls
do not render fuel charging, grate cleaning and access to the side washout and
fan difficult.
2.2.2. Feeder positioning
Installation is the same for ceramic and cast-iron head versions.
Preparation:
1. Remove from the container all loose parts, remove the grate from the
boiler (if equipped) and tightly close all air inlets to the device.
2. Make sure to leave 15÷20 cm in front of the burner head so that ashes
could freely fall into the ash pan (this can be achieved by sliding the head
into the boiler opening, prepared by the boiler manufacturer).
3. Find a place for the fire water tank and prepare a hose section of
appropriate length for installation (included in the package). In order to
ensure safe work, the water tank shall be fixed to a wall, rather to the side
panel of the fuel container. Bottom of the water tank shall be at least 50
cm above the upper surface of the supply pipe. Check that water hose is
not bent or twisted.
4. Make sure you have appropriate tools necessary to commence with
installation (a complete set of keys).
Installation (identification of parts according to fig. 2 or 3):
1. Bolt the work shaft casing on to do the container.
2. Slide in worm shaft (4) into the inside of the guide and fix it using a
M12x65 screw, fitted on the end of the worm shaft.
3. Attach the head (6) and fix it with screws (pay attention to careful
installation of the seal).
4. Screw the blower (7) to the burner head.
5. Slide in the head (or smoke conduit) to the assembly opening in the
boiler. After installation and tightening screws, in case of cast-iron head,
install head cover. Install all seals with care.
6. Install the fire water tank (11), open the tap and make sure that the tank
cover (nut) has an air suction hole.
7. Before filling the tank, fix tank’s legs by tightening counter screws
located on inner surface of legs. The tank must be levelled.
8. Connect electric installation and detectors (see description in the
Installation of the control system and electric connections, par. 2.7).
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