RED TECNIKA 28, TECNIKA 35 Use And Installation Manual

USE AND INSTALLATION MANUAL

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COD.8901113900

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1. GENERAL INFORMATION ..................................................................................................... 3

1.1. Symbols used in this manual ................................................................................................... 3

1.2. Proper appliance use............................................................................................................... 3

2. GUARANTEE TERMS .............................................................................................................. 5

2.1. Warnings ............................................................................................................................... 5

The guarantee applies, provided that: .................................................................................................. 5

2.2. Exclusions .............................................................................................................................. 5

2.3. Additional clauses ................................................................................................................... 6

2.4. Liability .................................................................................................................................. 6

2.5. Court with jurisdiction ............................................................................................................. 6

2.6. Liability exclusion.................................................................................................................... 6

2.7. Service call ............................................................................................................................. 7

2.8. Installation standards .............................................................................................................. 7

3. TECHNICAL SPECIFICATIONS AND DIMENSIONS ............................................................... 8

3.1. General information on hot water boilers .................................................................................. 8

3.2. TECNIKA 28-35 boiler description ............................................................................................. 8

3.3. Technical data ........................................................................................................................ 9

3.4. Boiler fuel supply .................................................................................................................. 11

3.5. Main components ................................................................................................................. 12

4. INSTALLING A "TECNIKA" HOT WATER BOILER ................................................................ 16

4.1. Packaging ............................................................................................................................ 16

4.2. Boiler room .......................................................................................................................... 16

4.3. Connection to the flue pipe .................................................................................................... 17

4.3.1 Roof outlet along an external steel flue pipe ........................................................................ 19

5.3.1 Roof outlet along a traditional flue pipe ............................................................................... 20

4.4. System connection ................................................................................................................ 21

4.5. Filling the system.................................................................................................................. 21

4.6. Basic requirements for installing “Tecnika” hot water gasification boiler to allow simple

maintenance and servicing: ............................................................................................................... 22

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5. OPERATION ........................................................................................................................ 29

5.1. “Tecnika” hot water wood gasification boiler interface control panel .......................................... 29

6. START-UP PROCEDURES .................................................................................................... 31

6.1. Basic requirements ............................................................................................................... 31

6.2. Electrical connections ............................................................................................................ 32

6.3.1 Wiring diagram ................................................................................................................. 33

6.3. Boiler start-up preparation procedure ..................................................................................... 34

6.4. Igniting the fuel and heating the boiler ................................................................................... 34

6.5. Adjusting the air flow control thermal valve ............................................................................ 36

6.6. Nominal operating mode of the boiler ..................................................................................... 37

6.7. Fuel hopper loading .............................................................................................................. 38

6.8. Adjusting boiler operating parameters .................................................................................... 40

6.9. Boiler operation in stand-by mode .......................................................................................... 43

6.10. Boiler shutdown ................................................................................................................... 43

7. TROUBLESHOOTING ........................................................................................................... 45

8. CLEANING AND MAINTENANCE ......................................................................................... 47

8.1. Instructions for inspection and maintenance ........................................................................... 47

8.2. Training and end user demonstration of maintenance and adjustment procedures of the boiler ... 53

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General information

The user is NOT permitted to service this boiler. The manufacturer cannot be held liable for personal injury, harm to animals or property damage resulting

from failure to observe the instructions contained in the manuals supplied with the boiler.

1. GENERAL INFORMATION

1.1. Symbols used in this manual

When reading this manual, pay particular attention to the parts marked with symbols. These symbols are used to give the following warnings:

1.2. Proper appliance use

The instruction manual is an integral and essential part of the product and must be kept by the user or system manager.

Read the warnings contained in the manual carefully, since they provide important information about safe installation, use and maintenance.

Keep the manual in a safe place for future reference.

Installation and maintenance must be performed in compliance with the applicable regulations according to the manufacturer's instructions and by qualified personnel trained pursuant to the law.

Incorrect installation or improper maintenance could cause personal injuries, harm to animals or property damage, for which the manufacturer will not be held liable.

Before carrying out any cleaning or maintenance operations, disconnect the appliance from the mains power supply using the system switch and/or the relevant cut-off components and close all cocks.

If the appliance has a fault and/or is not operating correctly, switch the appliance off and do not make any attempt to repair it or service it directly. Contact authorised personnel only. Any repairs to products must be carried out using only original spare parts. Failure to observe the above recommendations may compromise the safety of the appliance.

If the appliance is sold or transferred to a new owner or the owner moves, leaving the appliance in situ, always ensure that the manual is kept with the appliance so that it can be consulted by the new owner and/or installer.

For all appliances with optional equipmement or kits (including electrical kits) use only original accessories. This appliance must be used only for the use expressly intended. Any other use is to be considered incorrect

and therefore dangerous.

DANGER! Serious risk to safety and to life

CAUTION! Potentially hazardous

situation for the product and the environment

NOTE! Recommendations for

users

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The TECNIKA appliance has been built according to the latest technologies and in

accordance with the applicable technical safety regulations. Nonetheless, the incorrect use of the appliance may result in hazards and also endanger the

user or others, or even damage the appliance or other objects. The appliance is intended for the operation of hot water heating systems. Appliance use in accordance with the envisaged purposes includes scrupulous observance of

the instructions provided in this manual.

RED reserves the ri

ht to make any changes to the design and factory settings of the burner and hot water

boiler without having to inform the end users of such changes.

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2. GUARANTEE TERMS

The Manufacturer guarantees the product, with the exception of parts subject to normal wear specified below, for two years from the date of purchase, provided that proof of purchase is supplied in a document specifying the name of the retailer and the date the sale was made and that the completed guarantee certificate was sent within 8 days of said purchase. The product must also be installed and tested by a specialised installer and in accordance with the detailed instructions provided in the instruction manual that accompanies the product.

The guarantee covers the replacement or free repair of parts recognised as being faulty at source due to manufacturing defects.

2.1. Warnings

 Installation, electrical connection, functional check and maintenance of this appliance must only be

performed by qualified or authorised personnel.

 This appliance must not be used by anyone (including children) with reduced physical, sensory or

mental skills and with little experience and knowledge, unless they are supervised or have been instructed to use the appliance by the person in charge of its safety.

The guarantee applies, provided that:

1. The boiler is installed, in accordance with the applicable standards in force and the instructions

provided in the product use, maintenance and installation manual, by legally qualified personnel (Italian Ministerial Decree no. 37 of 22

January 2008);

2. The customer holds the documentation certifying its suitability in all parts: a. INSTALLATION REPORT - filled in by the installer b. TEST REPORT and GUARANTEE APPLICATION - filled in by an authorised serviceman c. The guarantee applies from the date of first start-up of the boiler, which must be

indicated on the boiler manual or from the invoice date. This documentation must be presented to the authorised service centre in the event of servicing.

2.2. Exclusions

The guarantee does not cover any parts found to be faulty due to negligence or inappropriate use, incorrect maintenance, or installation not performed in compliance with the manufacturer's instructions. The manufacturer will not be held liable for any damage which may - either directly or indirectly - be caused to persons, animals or property resulting from failure to observe all the instructions provided in this manual and, specifically, concerning the warnings regarding installation, use and maintenance of the appliance.

The guarantee is not valid if:

1. The terms for the guarantee application were not observed.

2. Installation was not performed in observance of the applicable standards in force and the

instructions provided in the use, maintenance and installation manual.

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The guarantee does not cover:

1. Damage made by atmospheric agents, chemicals, electrochemical elements, incorrect product use,

natural disasters, electrical discharges, fires, faults in the electrical system, modifications to or tampering with the product, and/or other causes not ensuing from the product manufacturing

2. Damage caused by normal corrosion

3. Damage relating to the combustion chamber

4. Damage to seals, claddings, painted/chromed parts, handles and electrical wires

5. Damage to masonry work

6. Damage to parts of the system for the production of DHW not supplied by RED

7. Damage to the heat exchanger if a suitable condensation-proof circuit is not set up to guarantee a

minimum boiler return temperature of at least 55 °C.

8. Servicing for calibration or product adjustments

9. Incorrect or negligent use.

10. All damage caused by transport; we consequently advise you to check the goods carefully upon

receipt, notifying your retailer immediately of any damage, making a note on the delivery note and

on the copy that travels with the carrier. Please contact your retailer and/ or local importer in the event of product failure. RED will not be held liable for any damage which may - either directly or indirectly - be caused to property,

or personal injury or harm to animals ensuing from failure to observe all the instructions provided herein and the applicable regulations regarding installation, use and maintenance of the appliance.

The parts replaced will be guaranteed for the remaining guarantee cover period starting from the original date of purchase of the product.

2.3. Additional clauses

If faulty or malfunctioning parts are detected during normal product use, these will be replaced free of charge ex retailer who made the sale or ex our local technical service centre.

For products sold abroad, the same circumstances will again result in free replacement, ex our retailer, with the exception of specific conditions agreed upon at the time of negotiations with the foreign distributor.

In the case of replaced parts, the guarantee will not be extended. No damages are awarded for the product downtime period. This is the only applicable guarantee and no-one is authorised to provide any other guarantees in the name

of or on behalf of RED.

2.4. Liability

RED will not pay any compensation for direct or indirect damage caused by or dependent upon the product.

2.5. Court with jurisdiction

In the event of any controversy, the court with jurisdiction is the Court of Pordenone (Italy).

2.6. Liability exclusion

The manufacturer is not able to supervise the observance of the instructions provided in this manual. Nor is it able to monitor the conditions and methods of installation, operation, use and maintenance of the product. Incorrect installation could cause damage and endanger persons. Consequently, we cannot be held in any

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way liable for losses, damage or costs ensuing from incorrect installation, improper functioning and incorrect use and maintenance or in any way connected to the latter. Similarly, we will not be held in any way liable for any violations of patents or third party rights ascribable to the use of this product.

The manufacturer reserves the right to make any changes to the product, technical specifications or to the manual without notice.

If hazard-free operation is no longer possible (for instance, due to visible damage), turn off the appliance immediately.

2.7. Service call

Service calls must be made to the retailer, who will forward the call to the technical support department. The manufacturer cannot be held liable if the product and any of its accessories are used incorrectly or

modified without authorisation. Only original spare parts must be used for replacements.

2.8. Installation standards

Tecnika 28-35 is wood-fired boiler. It must be installed according to the provisions of the following standards:

Italian Law Decree no. 93 of 25

February 2000

Implementation of Directive 97/23/EC (P.E.D.) on the subject of pressure equipment. SCOPE OF APPLICATION: liquid fuel (naphtha, gas oil, fuel oil) and solid fuel operated appliances.

ITALIAN LAW no. 46 of 5

March 1990 and related applicative regulations Italian Ministerial Decree no.

447 of 6

December 1991 (and subsequent amendments) System safety standards SCOPE OF APPLICATION: without limits to heat potential.

Standard UNI 10847 of 03/2000

Single flue systems for liquid and solid fuel generators. Maintenance and control. Guidelines and procedures. SCOPE OF APPLICATION: liquid and solid fuel operated systems.

ITALIAN LAW of 9

January 1991 No. 10 and related applicative regulations Italian Ministerial Decree

no. 412 of 26

August 1993 (and subsequent amendments), Italian Ministerial Decree no. 551 of 21

December 1999. Regulations specifying amendments to Italian Presidential Decree 412 on the subject of planning, installing,

running and servicing heating systems in buildings for the purposes of limiting energy consumption. SCOPE OF APPLICATION: without limits to heat potential.

ITALIAN LAW NO. 186 of 01.03.1968

Installation standard CEI 64-8 / II ed. Electrical utility systems at a nominal voltage of no more than 1000 V in alternating current and 1500 V in

direct current.

Installation standard CEI 64-8 / I ed.

Electrical utility systems in buildings intended for residential and similar purposes.

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3. TECHNICAL SPECIFICATIONS AND DIMENSIONS

3.1. General information on hot water boilers

"TECNIKA" hot water wood gasification boilers are have a steel structure and use solid biomass, in the form of wood logs, as fuel. The boiler is designed for connection to hot water heating systems.

Tecnika boilers comply with P.E.D. 97/23/EC.

TECNIKA series hot water wood gasification boilers consist of the following components:

 "TECNIKA" hot water boiler - 1 (one)  ceramic ducting element in combustion chamber - 1 (one)  thermal valve for controlling air flow rate - 1 (one)  steel brush for cleaning ashes - 1 (one)  ash scraper – 1 (one)  "TECNIKA" series hot water boiler use and instruction manual - 1 (one).

3.2. TECNIKA 28-35 boiler description

The "TECNIKA" hot water boiler heat exchanger complies with the operating requirements of this type of appliance, as set out in the operation standard:

EN 303-5/2000.

The hot water boiler consists of the following components/modules:

 heat exchanger, consisting of a welded steel plate structure. The upper part of the boiler

accommodates the fuel hopper which is manually filled with wood logs. The fuel chamber is the ideal environment for the fuel pyrolysis process and volatile gases are conveyed towards the lower section of the boiler, where they are oxidised in the combustion chamber. The combustion chamber contains a ceramic coating, a nozzle and a combustion gas ducting element to ensure combustion process efficiency;

 comb ustion nozzle, made of ceramic material, positioned in the lower section of the fuel hopper

to ensure optimal conditions for combustion process efficiency;

 ceramic ducting element, positioned in the boiler combustion chamber allows high temperature

levels and guarantees optimal fuel oxidation;

 combustion gas fan fitted on the back of the boiler conveys combustion gases outside the boiler

and controls its operation;

 air distrib ution box, provided with primary air control valve. This box doubles as heat exchanger

and pre-heats the ambient air before it is used in the combustion chamber of the boiler. The inlet of this box is provided with an inlet control fin actuated by a thermostat valve and controls the air taking into the boiler;

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 hydraulic connections, have female threading (see table for dimensions) and are positioned in

the lower rear left part of the heat exchanger along the return line and in the upper rear left part of the boiler along the flow line;

 exhaust connection has female threading (see table for dimensions) and must be connected to

the exhaust valve;

 emergency cooling coil is used for emergency cooling of the water circulating the heat exchanger

of the boiler when the water is very hot. The coil has a G½” male union threading;

 comb ustion gas outlet duct (external diameter shown in Table 2.2) is located in the upper rear

part of the boiler;

 the heat exchanger is thermally insulated with mineral wool to minimise thermal dispersion;  doors of the fuel hopper and the combustion chamber are made of cast iron to ensure high thermal

resistance and sealing of the boiler;

 external casing of the boiler is made with sheet steel.

3.3. Technical data

Thermal and technical data of “TECNIKA” hot water wood gasification boilers:

PARAMETERS UNIT OF

MEASURE

VALUES

MODEL 28 35 HEAT OUTPUT AT COMBUSTION CHAMBER kW 28 35 NOMINAL HEAT OUTPUT kW 25 30 OPERATING RANGE (min-max) kW 13-25 15-30 SOLID FUEL USED

Wood logs for heating, max. water content 20%

WOOD LOG CONSUMPTION RATE (min-max) kg/h 3,7-6,9 5,1-9,7 FRESH AIR RATE REQUIRED FOR EFFICIENT COMBUSTION PROCESS AND BOILER OPERATION

kg/h 80-95 110-130

m3/h 55-70 100-110

AVERAGE WOOD LOG CONSUMPTION RATE (the boiler operates in a normal heating system)

kg/h 4.7 6.7

HEATING EFFICIENCY (min-max) % 85 TEMPERATURE OF COMBUSTION GASES AT NOMINAL HEAT OUTPUT

°C 180-230

SOLID FUEL RESIDUE ASH

The quantity depends on the ash contents of the raw fuel, as well as on the operating conditions

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Dimensions and technical data of “TECNIKA” hot water wood gasification boilers:

PARAMETERS UNIT OF MEASURE

ALUES

MODEL 28 35

WEIGHT kg

290 370

WATER SLEEVE CAPACITY dm3

70 90

FUEL CHAMBER CAPACITY

100 130

16-20 20-24

NOMINAL HEAT OUTPUT TIME INTERVAL AFTER LOADING FUEL CHAMBER

Hours

2-3 2-3

MAXIMUM WOOD LOG LENGTH mm

330 500

DIMENSIONS

L=WIDTH

780

P=DEPTH

975 1123

A=HEIGHT

1282

OPERATING PRESSURE OF CIRCULATING WATER bar 2 HYDRAULIC PRESSURE LOSS AT NOMINAL HEAT OUTPUT Pa 20 21 TYPE OF EXPANSION VESSEL FOR THE HEATING SYSTEM - Open or closed PRESSURE TESTED IN THE FACTORY bar 4 RECOMMENDED TEMPERATURE FOR THE WATER CIRCULATING IN THE BOILER

°C 80-85

RECOMMENDED TEMPERATURE FOR RETURN WATER IN THE BOILER

°C 60

DRAUGHT hPa 0.18-0.24

CONNECTIONS

FLOW/RETURN G 1 ½” EXHAUST G ¾” EMERGENCY COOLING COIL G ½”

COMBUSTION GAS DUCT mm 150

POWER SUPPLY -

230 V; 50 Hz

POWER SUPPLY CABLE -

3 x 1.5 mm2

ELECTRICAL CAPACITY VA 37 65 ELECTRICAL PROTECTION - IP20 BOILER CLASS (ACCORDING TO EN 303-5) - 3

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3.4. Boiler fuel supply

The boiler must be supplied with the following fuel:

wood logs, preferably cut, with the following features:

o pure wood, use of contaminated wood is not allowed (i.e. painted wood, subjected to

chemical treatment or other mineral or organic substances)

o the length of the wood logs must correspond to the depth of the combustion chamber of the

boiler

(see boiler technical specifications)

o the crosswise section (diameter) of the wood logs must be: D ≤ 200 mm o the raw material humidity content must be less than 20% (W

≤ 20%)

o wood-based fuel such as sawdust, wood chips and other small combustible particles may be

used in addition to wood logs, but their total amount must be less than 20% of the fuel loaded into the boiler chamber.

Approximate recommended fuel parameters - cut, pre-dried wood logs

PARAMETERS UNIT OF MEASURE VALUES

TYPE OF FUEL WOOD LOGS

WOOD LOG LENGTH mm See previous table

HUMIDITY CONTENT % ≤20%

CALORIFIC POWER OF FUEL USED IN OUR CALCULATIONS

MJ/kg >13.9

kWh/kg >3.9

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EXPLANATION: the maximum percentage of humidity in wood must be 20%. It is advisable to use wood dried for at least 1 year.

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3.5. Main components

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Fig. 3.5.1 View of the “TECNIKA” hot water wood gasification boiler - Description of main components of the boiler

COMBUSTION CHAMBERDOOR

FUELHOPPERDOOR

BOILERCONTROLPANEL

AIRFLOWCONTROL THERMALVALVE

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G 1 ½”

G ½”

”

EXPLANATION: the values of the dimensions indicated by letters: L, A and P are shown in Table page 12.

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Fig.3.5.3 Side view of the “TECNIKA” hot water wood gasification boiler

Fig.3.5.2 Front view of the “TECNIKA” hot water wood gasification boiler

Fig.3.5.4 Rear view of the “TECNIKA” hot water wood gasification boiler

Fig.3.5.5 Top view of the “TECNIKA” hot water wood gasification boiler

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Combustion gas outlet (conveyed to convective ducting of the boiler)

Ceramic combustion gas ducting element in combustion chamber

Combustion chamber

Combustion nozzle

Fuel hopper

Opening for extracting gas from combustion chamber for start-up

Primary air inlet opening

Fig.3.5.6 Section view of the “TECNIKA” hot water wood gasification boiler

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The manufacturer reserves the right to make any changes to design and construction of the boiler without having to inform end users of such changes.

Boiler control box

Upper lid of boiler convective ducting

Combustion gas fan

Combustion gas outlet ducting

Combustion nozzle

Ceramic coated combustion gas ducting element

Lower lid of boiler convective ducting

Fig.3.5.7 Longitudinal view of the “TECNIKA” hot water wood gasification boiler

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4. Installing a "TECNIKA" hot water boiler

CAUTION: be careful not to damage or crack the ceramic element fitted inside the combustion chamber of

the boiler when transporting the boiler (secure the element appropriately or transport it separately from the boiler):

 installing the hot water boiler in rooms not fit for occupancy, including corridors, is not allowed  the "TECNIKA" wood gasification boiler may be connected to a heating system equipped with open

or closed expansion vessel designed according to the water capacity of the entire heating system

 both the heating system and the hot water boiler must be filled with circulating fluid (water) and air

must be bled from the system before starting up the boiler.

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4.1. Packaging

The boiler is delivered complete with assembled electrical and mechanical parts after having been tested at the factory.

The boiler is delivered on one pallet. The boiler must always be handled vertically, using manual or mechanical cranes, which can lift the pallet on which it is packaged or the boiler itself directly.

Take special care not to damage electrical or mechanical parts, with shocks or water sprays once the protective packaging has been removed.

 After removing the packaging, make sure the boiler is complete and undamaged  If in doubt, contact the retailer  The document envelope contains:

System manual An instruction manual for installation, use and maintenance

Appendix G - Technical inspection report for heating system with an output of less than 35 kW

Guarantee

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4.2. Boiler room

Make sure the room complies with the requirements and characteristics set out in the applicable regulations in force. It is also necessary for the room to provide at least as much air as is required for regular combustion. It is therefore necessary to make holes in the walls of the room, which comply with the following requirements:

 Have a free cross-section of at least 6 cm

for every 1 kW (859.64 kcal/h). Nevertheless, the

minimum cross-section of the opening must never be less than 100 cm

The cross-section can also

be calculated using the following ratios: S = K * Q ≥ 100 cm

Where “S” is expressed in cm2, “Q” in kW, “K” = 6 cm2/kW

 The opening must be situated at the bottom of an external wall, preferably opposite the one where

the combustion gases are vented.

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4.3. Connection to the flue pipe

For the connection of the flue outlet pipe, local and national regulations must be observed (see Standards UNI 7129 and UNI 10683).

A flue pipe must comply with the following requirements:

 It must be made of waterproof material resistant to the temperature of the smoke and related

condensation.

 It must ensure sufficient mechanical resistance and weak heat conductivity.  It must be perfectly sealed, to avoid the cooling of the flue pipe itself.  It must be arranged as vertically as possible.  Chimneys both old and new, built without observing the above specifications, may be conveniently

recovered by "intubating" the chimney itself. This means a metal flue shall be inserted inside the existing chimney and the space between the metal flue and the chimney shall be filled with suitable insulation.

 In order to prevent the wind from creating pressure areas around the chimney that prevail over the

rising force of the combustion gases, the outlet aperture must be positioned at least 0.4 metres above any structure adjacent to the chimney itself (including the ridge of the roof) at least 8 metres away.

 The flue pipe must have a diameter of no less than the boiler union; for flue pipes with a square or

rectangular cross-section, the internal cross-section must be increased by 10% compared to the boiler union.

 The useful cross-section of the flue pipe can be calculated using the following formula:

S = K x P/√H S ensuing section in cm

K reduction coefficient:0.045 for wood P boiler output in kcal/h H height of the chimney in metres, measured from the flame axis to the outlet of the chimney into

the atmosphere. When sizing the flue pipe, please take into account the actual height of the chimney in metres, measured from the flame axis t the top, decreased by:

 0.50 m for every change in direction of the union duct between the boiler and the flue pipe  1.00 m for every metre of horizontal development of the union itself.

 We recommend the sole use of outlet ducts which are suitable for the

type of fuel used. The supplier will not be held in any contractual and non-contractual way liable for damage caused by installation and usage errors and in any case due to failure to observe the instructions provided by the manufacturer of the appliance.

 The products of combustion of the boiler cannot be discharged in

collective flue ducts.

 The correct installation of the flue duct is necessary to encourage the

normal flow of smoke from the combustion chamber to the outside in the event of an electrical power failure.

 Remember that a draught of 20 Pa must be guaranteed.

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RED TECNIKA 28, TECNIKA 35 Use And Installation Manual

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