SAS BIO SOLID 19,BIO SOLID Series,BIO SOLID 36,BIO SOLID 14,BIO SOLID 48,BIO SOLID 25 Operation And Maintenance Manual
TABLE OF CONTENTS
Declaration of Conformity CE 3
Fact Sheet 4
Test certificate for the SAS BIO SOLID water boiler 5-6
EcoDesign certificate for the SAS BIO SOLID 14kW boiler 7
EURO TOPTEN award 8
1. Preface 9
2. Purpose, boiler operational conditions 9
3. Boiler design and operation 10
4. SAS BIO SOLID boiler equipment 17
5. Technical and operational parameters 18
6. Fuel 23
7. Boiler installation guidelines 24
7.1 Boiler room requirements 25
7.2 Noise and noise reduction methods 26
7.3 Boiler placement 26
7.4. Boiler stack connection 27
7.5. Boiler connection to a heating system 28
7.5.1. Open vented system 29
7.5.2. Sealed system 31
7.6. Boiler connection to a power supply system 37
8. Guidelines for use and operation 38
8.1. Filling with water 38
8.2. Boiler firing and operation 39
8.3. Boiler cleaning 41
8.4. End of burning 43
9. Conditions for safe operation 44
10. Operation and maintenance of the feeder and burner 45
11. Statuses of incorrect boiler work 46
12. Protective devices 48
13. Delivery terms and conditions 51
14. Boiler disposal 52
15. Warranty terms and conditions 55
Warranty card 55
LIST OF FIGURES AND TABLES
page
. 1 SAS BIO SOLID boiler equipment
Table
. 2 Technical and operational parameters for the SAS BIO SOLID 14-f 48 kW boiler
Table
. 3 Basic parameters of pellets intended for SAS BIO SOLID boilers
Table
. 1 Moving grate positioning sensor (hall effect sensor)
Figure
. 2 Connection terminal strip supplying control equipment
Figure
. 3 Module controlling burner operation
Figure
. 4 The flue gas temperature sensor mounted in flue pipe
Figure
. 5 Location of the temperature sensor with a capillary tube
Figure
– thermal protection sensor
. 6 Diagram of SAS BIO SOLID boiler design with heat output of 14 -f 48 kW
Figure
. 7 Diagram of SAS MULTI FLAME burner design - side view, sectional view
Figure
. 8 Diagram of SAS MULTI FLAME burner design - upper view
Figure
. 9 Installation of adjustment feet in SAS BIO SOLID boiler
Figure
. 10 General connection diagram - an open vented system with a four-way valve
Figure
. 11 General connection diagram - an open vented system with a plate exchanger
Figure
. 12 General connection diagram - sealed system
Figure
. 13 Flue gas turbulator
Figure
. 14 The location of the STB safety temperature limiter and temperature sensor
Figure
2
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23
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20
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27
32
33
34
42
49
Zakład Metalowo-Kotlarski „SAS”
Directive 2006/42/EC
(MD) Machinery Directive
Directive 2004/108/EC
Owczary, ul. Przemysłowa 3
28-100 Busko-Zdrój
tel. +4841 378 46 19 fax +4841 370 83 10
www.sas.busko.pl
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e-mail: biuro@sas.busko.pl
SAS BIO SOLID / DZ/01/2015 Busko-Zdrój, 9 February 2015
EC DECLARATION OF
CONFORMITY
Zakład Metalowo-Kotlarski SAS
28-100 Busko-Zdrój, Owczary, ul. Przemysłowa 3
declares with full responsibility that the product:
Automatic central heating boiler type
The Ordinance Of The Minister Of
(Official Journal No 199/2008, item 1228)
The Economy
with the heat output 14 to 48 kW
equipped with SAS MULTI FLAME burner
complies with the provisions of:
and harmonized standards:
PN-EN ISO 12100: 2012
PN-EN 61000-6-2:2008P
PN-EN 61000-6-3:2008P
This is confirmed by the sign placed on the device
Mieczysław Sas
PN-EN 303-5:2012
SAS BIO SOLID
(Official Journal No. 82/2007, item 556)
(EMC) Electromagnetic
Compatibility Directive
This Declaration of Conformity is invalidated if any design changes are made to the product without
If the product is resold to another owner, this Declaration of Conformity must be enclosed with the
the consent of the manufacturer.
product.
Fact Sheet in accordance with the European Commission (EU) Regulation No. 2015/1187 of April 27, 2015
Model ID
Energy efficiency class
BIO
SOLID 14
A
BIO
SOLID 19
+
A
BIO
SOLID 25
+
A
+
BIO
SOLID 36
+
A
Rated boiler output
15 kW 19 kW 26 kW 36 kW 49 kW
Energy Efficiency Index (EEI)
116 116 118 118 119
Room seasonal heating
energy efficiency (
Special precautions:
The boiler should be installed and operated solely by adults only in conditions meeting those
1.
specified in the operation and maintenance manual delivered with the equipment!
Any changes in the design aiming at adapting the boiler to perform functions not intended by
2.
its manufacturer are strictly forbidden and shall void the warranty!
3. Only recommended fuel must be used!
The boiler is not designed to heat water above the maximum working temperature declared,
4.
i.e. > 85°C.
Flue gases emitted from an obstructed stack are hazardous. The stack and the connector
should be kept clean; they should be cleaned according to the instruction provided by the
5.
manufacturer. The boiler flue gas ducts should be kept clean.
All activities related to the boiler installation and operation should be performed with
caution. Personal protective equipment should be used, and health and safety regulations
6.
should be observed. Some boiler surfaces are hot and protective gloves must be worn before
touching them! Safety goggles should also be used!
Before maintenance, the boiler must be disconnected from the mains supply, and the
manufacturer's instructions must be observed.
All connections to the power supply system can only be made by a person holding relevant
7.
qualifications — SEP (Polish Electricians Association) licence up to 1 kV. Any attempt to
perform unauthorised repairs/changes in the control system may lead to electrocution and
shall void the warranty.
h
)
s
79% 79% 80% 80% 81%
BIO
SOLID 48
+
A
4
56789
1. PREFACE
Dear Buyer and User of the low-temperature SAS BIO SOLID boiler. This operating and maintenance manual contains all necessary information for energy-efficient, safe and long operation of your boiler. The device is delivered together with
a set of operating and maintenance manuals for operation of the boiler, burner and
controller.
Before installation and operation of this device you must read and understand
contents of this operating and maintenance manual. After acquainting with this manual you will be able to use this device in an optimum way. By becoming thoroughly
acquainted with this manual you will be able to operate the boiler in an effective and
safe way.
Boilers manufactured by the Zakład Metalowo-Kotlarski “SAS” meet the requirements of relevant EU directives and are CE-marked, and this is confirmed in the
enclosed EC DECLARATION OF CONFORMITY.
THIS DOCUMENTATION SHOULD BE KEPT FOR FUTURE USE, IT IS ALSO
A WARRANTY CARD FOR THE BOILER.
2. PURPOSE, BOILER OPERATIONAL CONDITIONS
SAS BIO SOLID boilers with a fuel tank and SAS MULTI FLAME burner are
designed for installation in water central heating systems, open/close system*
with gravitational or forced water flow, secured according to current local or EU
regulations (PN-EN 12828+A1:2014-05 Heating installations in buildings. Design of water-based heating systems). They are recommended, in particular, for
heating of residential flats in one- and multi-family houses, and for commercial,
services, catering and workshop facilities, etc., in which maximum acceptable
working temperature of supplied water does not exceed 85°C, and a maximum
working pressure in the system does not exceed 1.5 bar. Required minimum
flue gas pass downstream the boiler od 0,20-0,30 mbar, depending on the nominal thermal power (according to PN-EN 13384-1:20152008 Chimneys. Methods for thermal and flow-through calculations. Part 1: Chimneys serving one
heating appliance).
* The installed system must meet specific requirements of standards in force in a country of destination con-
cerning safety devices for water-based heating equipment in open vented systems,and expansion vessels in
an open vented or sealed systems together with accessories: diaphragm expansion vessel, pressure relief
valve, equipment for control and measurements, or devices for removing excess heat.
These boilers may also work with domestic hot water systems through a heat
exchanger (domestic hot water) of any producer that meets current standards.
The boiler cannot be used as a continuous flow water heater. The SAS BIO SOLID
boiler is also not intended to be used as an air heater.
A boiler for heating a building should be selected on a basis of an energy heat
balance of that building, developed in accordance with specific current national
or EU regulations (PN-EN 12831:2006 Heating systems and water based cooling
systems in buildings - Method for calculation of the design heat load).
NOTE 1: The boiler should be installed and operated only in conditions me-
eting those specified in the operation and maintenance manual (manufacturer documentation delivered together with the device)!
NOTE 2: Any changes in the design aiming at adapting the boiler to perform func-
tions not intended by its manufacturer are strictly forbidden and result in
a loss of warranty rights and documents associated with the product!
3. BOILER DESIGN AND OPERATION
SAS BIO SOLID bolier is a low-temperature CH boiler with automatic fuel supply to the furnace. SAS BIO SOLID with power of 14÷48 kW is designed and
programmed for combustion of the solid fuel in automatic mode. The fuel is biomass in the form of wood granules wood (pellets) with parameters defined by EN
14961-2 or PN-EN ISO 17225-2:2014-07p
Basic boiler components are specified in a figure 6.
The SAS MULTI FLAME burner elements are shown in fig. 7 and 8.
NOTICE: The SAS MULTI FLAME burner is affected by Protective Law no
67681 – provided by the Polish Patent Office for the utility model, entitled
“Water boiler burner suitable for combustion of biomass”.
The boiler consists of a water body made of welded steel plates. The boiler
water shell forms a double-walled cuboid divided with water chambers. Internal
partitions of the heat exchanger is made of boiler-grade steel P265GH with a
thickness of 6 mm, external water shell is made of design steel with grade S235JR
with a thickness of 4 mm. The boiler exchanger contains a permanently fixed
system of stud bolts bracing its covers (strengthening components in form of
“seams”). Covers are tested for their strength and tightness under a test pressure
of 3 bar during the production of each boiler. Water compartments of the boiler
and its parts are designed in such way that during its normal operation according
to this operating manual and following correct installation all air will be removed
and no local boiling of water will occur.
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OPERATION PRINCIPLE FOR AUTOMATIC FUEL DELIVERY SYSTEM:
The boiler operates using a set consisting of:
• a fuel feeder with dual auger and transfer duct,
• blow furnace equipped with the moving grate,
• fan supplying air to the furnace;
• and an electronic temperature regulator – controller.
The fuel is transported from the fuel reservoir into the furnace chamber using
the feed fuel mechanism fuel with two distribution pipes (two transport augers driven by an electric motor) separated with a transfer duct providing distance between. This solution provides secure transport of biomass, eliminating the need for
additional protection against uncontrolled retraction of fire into the fuel reservoir.
For safety reasons the gate closing the fuel reservoir during the combustion of
biomass in the burner must be sealed. The feeding mechanism consists of gear
motor that drivers the fuel feeding system by means of sprockets and a chain. The
feeder drive is under the safety cover. The fuel feeding mechanism – transport augers are located in the closed isolating-and-guiding pipe. The biomass furnace is
installed in the combustion chamber. It is possible to remove the feed mechanism
to periodic cleaning (Fig. 8) – mounting screws, sealing cord.
Biomass is supplied to the furnace chamber, where the automatic combustion
process is performed using the heater (electrical burner). The device is cooled by
a stream of air coming from the air duct. After reaching the preset temperature,
the automatic fuel ignition and fire support system enables the boiler the possibility of efficient operation even with low power thermal demand (possibility of continuous operation with domestic hot water reservoir during the summer period).
A characteristic feature of the SAS MULTI FLAME burner is an automatic, highly-
-effective and self-cleaning furnace burning exactly the portion of fuel necessary
to obtain the value set by the user on the temperature controller.
The burner is provided with a self cleaning furnace fitted with moving grates,
whose cyclic movement enables dropping the biomass ash and slag, ensuring
furnace purity over a long period of time.
The furnace elements (housing, moving grate, furnace grate, mounting plate)
exposed to high temperatures are made of stainless steel heat-proof sheet. Over
the furnace chamber there is a ceramic shape, which further protects the furnace
housing and causes reburning of unburned parts of flammable fuel. The burner
mounting plate is lined with a thermal insulation protecting fuel feeding mechanism from heat.
Air for combustion is supplied by the fan driven by the electric motor and
connected to the furnace using an air-blowing duct. Part of the air is led under the
furnace grate, and the rest is blown directly into the combustion zone through the
distribution holes located on the sides of the furnace. The proper – depending on
the type of fuel burned – air flow is delivered by the blowing fan controlled by the
boiler controller.
11
The furnace grate was divided into a fixed part and the moving section. Cyclically actuated moving grates driven by a eccentric mechanism enables evacuation of fuel combustion residues from the furnace into the boiler chamber, i.e. the
ash in the form of slag. This solution is used to maintain the continuation furnace
in “clean” condition without interrupting the continuity of the combustion process.
After the furnace cleaning cycle, the moving grates take position in the slots of the
lower part of the furnace. The grate is positioned with a position control sensor
(hall effect sensor, see Fig.1 and Fig. 6). A small part of non-combustible fuel –
ash – remaining after combustion of biomass in the final stage of combustion is
transferred to the ash-box in which a drawer is situated. It must be cleaned periodically (the ash resulting from the combustion process can be used as a fertilizer).
The frequency of drawer emptying depends on the quality of the pellet.
Figure 1 Moving grate positioning sensor (hall effect sensor).
NOTICE:
Correct operation of the moving grate mechanism requires a correct setting
of the Hall effect sensor. A distance between the position sensor and the moving
grate drive string should be 3 to 5 mm, these components should be aligned
axially.
The controller (temperature regulator) located in the upper boiler cover uses
the readings from the temperature sensors to control all regulating devices, ensuring the efficient and economic use of available power in order to maintain the
operating conditions of the installation. An efficiently working boiler furnace burns
the amount of fuel necessary to maintain the temperature set on the regulator by
the user. Thus, the controller continuously measures a temperature of water in
the boiler, and on this basis appropriately controls operation of the boiler and the
fan. At the same time the controller controls operation of pumps: central heating,
domestic hot water, floor and circulating (if the heating system is equipped with
pumps). The boiler can also be used outside the heating season in a system with
an exchanger, for domestic hot water. In a system equipped with a mixing valve
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with a cylinder, the mixer can be controlled directly from the boiler controlled.
Connection points for circulatory pumps, temperature sensors and the mixer are
located on the boiler side wall (see Fig. 2 and Fig. 6).
Figure 2 Connection terminal strip supplying control equipment
(An example of the power strip depending on the model of the controller mounted on the boiler)
The control unit (see Fig. 3, Fig. 6) of the burner automatically controls the
heater and the mechanism of furnace cleaning with the positioning sensor (hall
effect sensor). The temperature regulator mounted on the boiler controls the blowing fan, fuel feeding mechanism and the feeder temperature sensor. The cooperation between the controller (Fig. 6 item 39) of the feeder SAS MULTI FLAME
type, the master boiler controller (Fig. 6 item 28) is possible thanks to the wired
RS communication system. The control unit has the power cord, main switch and
a fuse. If there is no power supply to the control unit, the regulator displays “No
communication with M1” message and emits the audible alarm. An efficiently
working boiler furnace burns the amount of fuel necessary to maintain the temperature set on the controller by the user.
13
Figure 3 Module controlling burner operation.
(An example of the power strip depending on the model of the controller mounted on the boiler)
An advantage of a boiler is its simple operation in form of periodic replenishment of fuel in the tank and removing ash from the ash drawer without a need to
put the furnace off. After firing, the boiler does not require a continuous operation,
and it can be used, generally, in a continuous mode during the heating season
(excluding breaks for periodical cleaning and repairs). Systematically performed
maintenance and cleaning ensures long and trouble-free operation of the boiler.
A boiler room with a solid fuel boiler is not maintenance-free and requires periodic monitoring. During boiler operation certain daily control activities must be performed, to prevent emergency situations.
BOILER DESIGN:
With the boiler structure based on three-pass layout of a flue gas duct in the
exchanger with ceramic panels, flue gas heat is fully recovered and used in a
water-based central heating system. Also the upper part of the furnace chamber
is closed with a water jacket.
Flue gases are directed to a stack through a flue located in the back part of
the boiler. A flue gas damper is installed in the flue, which can reduce the flue gas
flow when it becomes too strong (regulation). A clean out openings are located
on the side of the flue pipe. The flue pipe is fitted with the exhaust gas temperatu-
14
re sensor (solid state, PT1000), which regulates the combustion process and reduces the stack loss (blowing air adjustment). The adapter cube allows for quick
and simple exchange, when necessary (see Fig. 4).
Figure 4 The flue gas temperature sensor mounted in the flue pipe
NOTICE:
For correct operation of the regulator controlling the combustion process –
operation of the automatic fuel feeder – we encourage you to periodically clean
the sensor surface from dust/soot.
Clean out door, furnace door and ash-box door are located on the front wall of
the boiler. The furnace door enables the access to periodic cleaning of the boiler
and burner.
Front clean out door and top clean out (located under the cover) enables easy
access to cleaning of heat exchanger cartridges and gas turbulator. Side clean
out and ash-box door are used to remove dust settling in the flue gas duct.
Due to an overpressure in the whole inner space of the boiler, it is provided
with fire doors and inspection hatches with circumferential sealing (ceramic rope,
gaskets) and screwed connection, ensuring for its tight closing. Furthermore, it
is also provided with adjustment systems for hinges, and for closing systems for
doors and a fuel tank cover.
Non-flammable insulating materials were installed to reduce heat losses and
secure against excessive increase in a temperature of external boiler surfaces.
The heat exchanger surface is insulated from the environment with external
cladding of powder-coated steel sheets, under which a thermal insulation layer
of asbestos-free non-flammable mineral wool is installed. The insulating material tightly fills space between the exchanger and the boiler casing (external,
powder painted insulating sheet). The boiler door and the top clean out have
a multi-layer construction made of stainless steel and insulating material which
restricts heat loss (temperature of the external surface of the boiler on a safe
level). And additional insulating partition made of stainless steel and insulating
material in the furnace door was implemented, as well as a stainless steel partition in the clean out door. The boiler has an additional layer on front door in
the form of an opening external cover, protecting from an accidental contact
with surfaces susceptible to excessive heat. Door, clean out hatch, and flue gas
damper handles are made of non-flammable components significantly reducing
15
heat transfer, In addition, for safety reasons a pictogram and a message on the
nameplate was used that informs the user about uninsulated hot elements –
(flue pipe).
The moving parts (gear motor, sprocket mechanism and chain driving the
fuel feeder, moving grate drive, blowing fan) located underneath the hopper was
secured against direct access with detachable shields. Furthermore, for safety
reasons, a pictogram informing a user about presence of the mobile components
was used.
HOT
SURFACE
The fuel tank is provided with a loading opening with sealing and a closing
system. The design of the tank equipped with the hopper ensures free transport
of fuel (gravitational discharge). In addition it is fitted with a limit switch that stops
the blowing fan operation and fuel feeder after opening the cover! (See fig. 6) A
message appears on the display: „Cover Open” and an audible alarm is heard
(reminder and signal appear cyclically for a few seconds). When the fuel reservoir
cover is closed, the operation is resumed. Inside the cover there is an information
for the user about the presence and operation of the limit switch (reservoir cover
opening sensor).
NOTE:
Due to the installation of the limit switch, the fuel reservoir cover must always be sealed (during normal operation of the boiler)!
Directly above the furnace and on the side wall of the boiler opposite the SAS
MULTI FLAME burner the heat exchanger chamber has horizontal/vertical partitions made of refractory ceramic material increasing the combustion temperature
and reducing the emission of harmful gases into the atmosphere. The number
and layout of horizontal ceramic partitions over the furnace is dependent on the
power of the boiler.
Additionally, the exchanger is equipped with a gas turbulator which forces hot
flue gas whirl and enhanced transmission of heat to the heat exchanger. The flue
gas impacts the turbulator walls, causing the dust fall to the bottom of the boiler.
The dust can be removed by side clean outs of the heat exchanger chamber.
NOTE!
MOVING PARTS
16
A supply water connector is welded to the upper part of the heat exchan-
ger, while a return water connector is welded at the bottom, on the back wall. A
discharge connector (G ¾”) is located on a side wall in the bottom part of the
boiler. It is also used for connection of cooling water (from a water system) when
overheat thermal protection – a thermostat valve (a device removing excess heat,
according to Fig. 11 and Fig. 12) is installed. On the side wall of the top of the
boiler there is a connector (G ½”) for connecting the temperature sensor with a
capillary L=150 mm from thermal protection valve (see fig. 5).
Figure 5 Location of a temperature sensor with a capillary tube– thermal protection
sensor
Adjustment feet (does not apply to boilers with power over 25 kW) with the
adjustment range of 30 mm ensure the boiler final alignment versus the floor.
The user is responsible for possible installation of adjustment feet, according to
guidelines provided in this instruction (Fig. 9).
4. SAS BIO SOLID BOILER EQUIPMENT
SAS BIO SOLID automatic boiler with control is delivered with a controller,
blowing fan, pellet burner (SAS MULTI FLAME), fuel reservoir, ash-box doors,
furnace doors, clean out doors, partitions with refractory ceramic panels. Additional isolation partitions made of stainless steel protect the furnace door and
clean out door. The boiler body has a thermal insulation made of mineral wool
that has the form of the shell made of powder painted steel sheets with high
resistance to corrosion. The SAS BIO SOLID boiler is equipped with the pellet
burner and fuel reservoir installed on the left (L) or the right (R) side. The burner
and fuel reservoir location should be clearly stated (in the order), as it is not
possible to move them to the other side afterwards.
The digital equipment (control systems) for the SAS BIO SOLID boiler is specified in the attached operating manual for the temperature controller.
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