Viessmann KOB PYROTEC Technical Manual

Download

Page 1

PYROTEC

Grate combustion 390 to 1250 kW

PYROTEC GRATE COMBUSTION

Fully automatic wood boiler

for the combustion of woodchips, pellets, shavings and mixed wood

5822 511 GB 05/2010

Technical guide

Page 2

Index

1. Principles of wood combustion 1. 1 Principles of pellet combustion for generating heat .................................................... 5

■ What are wood pellets? .......................................................................................... 5

■ Fuel requirements ................................................................................................... 5

■ Forms of delivery .................................................................................................... 5

1. 2 Principles of woodchip combustion for generating heat ............................................. 5

■ What are woodchips? ............................................................................................. 5

■ Fuel requirements ................................................................................................... 5

1. 3 Minimum wood fuel requirements ............................................................................... 6

■ Content ................................................................................................................... 6

■ Non-wood biomass fuels ......................................................................................... 6

■ Wood fuel regulations and standards ..................................................................... 6

2. PYROTEC 2. 1 Product description ..................................................................................................... 7

■ Benefits at a glance ................................................................................................ 7

■ Delivered condition ................................................................................................. 7

2. 2 Specification ............................................................................................................... 8

■ Specification ............................................................................................................ 8

3. Control unit 3. 1 Specification for Pyrocontrol ....................................................................................... 13

■ Functions ................................................................................................................ 13

■ Operation: ............................................................................................................... 13

■ Standard delivery: ................................................................................................... 14

3. 2 Accessories for Pyrocontrol ........................................................................................ 15

■ External drive control .............................................................................................. 15

■ Control of external drive with light barrier ............................................................... 15

3. 3 Accessories for Pyrocontrol output management ....................................................... 16

■ Cylinder management 5 sensors (QM) ................................................................... 16

■ External requirement on/off ..................................................................................... 16

■ Operating message zero volt .................................................................................. 16

■ Output signals 0-10 V ............................................................................................. 16

■ Requirement, additional heat source KP0 .............................................................. 16

■ Requirement, additional heat source KP1 .............................................................. 17

3. 4 Accessories for Pyrocontrol remote transfer ............................................................... 18

■ Fault message device, analogue with battery ......................................................... 18

■ Export of operating data .......................................................................................... 18

■ Visualisation, externally via modem (connected with cable) ................................... 18

■ Visualisation, internal .............................................................................................. 18

■ Data line to internal visualisation ............................................................................ 18

3. 5 Mastercontrol for two-boiler systems .......................................................................... 19

■ Information on the Mastercontrol ............................................................................ 19

3. 6 Accessories for Mastercontrol .................................................................................... 21

■ Heat meter signal .................................................................................................... 21

■ Requirement, additional heat source KP0 .............................................................. 21

■ Requirement, additional heat source KP1 .............................................................. 21

■ Fault message device, analogue with battery ......................................................... 22

■ Export of operating data .......................................................................................... 22

4. Heating water buffer cylinder 4. 1 Specification, buffer cylinder ....................................................................................... 23

5. Installation accessories 5. 1 Boiler accessories ....................................................................................................... 24

■ Flue gas recirculation .............................................................................................. 24

■ Insulation, flue gas recirculation line ....................................................................... 24

■ Displacer rods ......................................................................................................... 24

■ Automatic ignition system ....................................................................................... 24

5. 2 Boiler safety equipment .............................................................................................. 25

■ Thermally activated safety valve 100 °C ................................................................. 25

■ Thermally activated safety valve 50-120 °C ........................................................... 25

■ Thermally activated extinguishing valve ½”, 50-90 °C ............................................ 25

■ Supply screw conveyor two-level ............................................................................ 25

5. 3 Accessories, heat distribution ..................................................................................... 26

■ Motor three-way valve ............................................................................................ 26

■ Pumps ..................................................................................................................... 26

5. 4 Accessories, flue system ............................................................................................ 27

■ Flue gas dust extractor 240/800 ............................................................................. 27

■ Accessories, cleaning pneumatic ............................................................................ 29

■ Price reduction net compressed air on site ............................................................ 30

Index

PYROTEC

5822 511 GB

Page 3

5. 5 Accessories, ash removal ........................................................................................... 31

■ External container ................................................................................................... 31

■ Extension of ascending screw conveyor ................................................................. 32

■ Extension of combustion chamber screw conveyor ................................................ 33

6. Design information 6. 1 System design ............................................................................................................ 33

■ Selection of rated output ......................................................................................... 33

■ Flow temperatures .................................................................................................. 33

■ Safety temperatures ................................................................................................ 33

6. 2 Delivery ....................................................................................................................... 33

6. 3 Handling ...................................................................................................................... 33

6. 4 Installation ................................................................................................................... 34

■ Requirements for boiler room ................................................................................. 34

■ Requirements of Sample Combustion Order .......................................................... 35

■ Combustion air supply ............................................................................................ 35

■ Minimum clearances ............................................................................................... 36

6. 5 Water connection ........................................................................................................ 36

■ Heating connections ............................................................................................... 36

■ Boiler circuit and shunt pumps ................................................................................ 37

■ Safety equipment to DIN EN 12828 ........................................................................ 37

■ System examples .................................................................................................... 37

6. 6 Electrical installation ................................................................................................... 39

■ Positioning of the programming module and control panel ..................................... 39

6. 7 Safety equipment ........................................................................................................ 39

■ Expansion ............................................................................................................... 39

■ Extinguishing facilities ............................................................................................. 39

■ Extinguishing water container ................................................................................. 40

■ Extinguishing facility with cold water supply ........................................................... 40

■ Back burning protection, boiler system ................................................................... 40

■ Prevention of combustion chamber overfilling ........................................................ 41

■ Reignition protection ............................................................................................... 41

■ Back burning protection, fuel supply (RSE) ............................................................ 41

■ Shut-off gate valve .................................................................................................. 41

■ Rotary lock valve ..................................................................................................... 41

■ Dual rotary lock valve with pressure compensation ................................................ 41

■ Low water indicator ................................................................................................. 41

■ Maximum pressure limiter ....................................................................................... 41

■ Minimum pressure limiter ........................................................................................ 42

■ Safety valve ............................................................................................................ 42

■ Expansion vessel .................................................................................................... 42

6. 8 Fire protection ............................................................................................................. 42

■ Fire protection, fuel store ........................................................................................ 42

6. 9 Commissioning ........................................................................................................... 42

■ Fuel for commissioning ........................................................................................... 42

■ Filling the heating system ....................................................................................... 42

6.10 Fuel ............................................................................................................................. 43

■ Suitable fuels .......................................................................................................... 43

6.11 Fuel discharge by means of screw conveyor .............................................................. 43

■ Discharge conveyor, pellet, D = 120 mm ................................................................ 43

■ Drive, discharge conveyor, pellets .......................................................................... 44

6.12 Fuel discharge by means of agitators ......................................................................... 45

■ Spring core discharge AF ....................................................................................... 45

■ Discharge screw AF to spring core discharge ........................................................ 47

■ Horizontal discharge AH ......................................................................................... 47

■ Discharge screw AH for horizontal discharge ......................................................... 50

■ Protective panel AH for bunker ............................................................................... 50

■ Cover panel AH for pellets ...................................................................................... 50

6.13 Fuel discharge by means of funnel discharge ............................................................ 51

■ Funnel discharge .................................................................................................... 51

■ Additional outlet flange ............................................................................................ 52

■ Funnel, large .......................................................................................................... 52

6.14 Fuel discharge by means of a push floor (sizing) ....................................................... 52

■ Number and length of the pushrods with a maximum dumping height ................... 52

■ Specification for the pushrod drives ........................................................................ 53

■ Forces on the building ............................................................................................. 53

■ Slot discharge, for pulling ........................................................................................ 54

■ Centre discharge ..................................................................................................... 55

■ Slot discharge with fill function ................................................................................ 57

Index

(cont.)

PYROTEC

5822 511 GB

Page 4

6.15 Fuel discharge by means of push floor (accessory) ................................................... 59

■ Pushrod drive, individual ......................................................................................... 59

■ Weld base, pushrod drive, individual ...................................................................... 59

■ Pushrod drive, twin ................................................................................................ 59

■ Weld base, pushrod drive, twin ............................................................................... 59

■ Weld base, bunker .................................................................................................. 59

■ Pushrod ................................................................................................................... 60

■ Hydraulic drive, AS individual ................................................................................. 60

■ Hydraulic drive, AS twin .......................................................................................... 61

■ Push floor screw conveyor D = 190 mm ................................................................. 61

■ Push floor screw conveyor D = 250 mm ................................................................. 61

■ Drive, push floor screw conveyor, standard ............................................................ 62

■ Drive, push floor screw conveyor, higher-power ..................................................... 62

■ Cover, push floor screw conveyor ........................................................................... 62

6.16 Charging the boiler with fuel ....................................................................................... 62

■ Trough screw conveyor ........................................................................................... 62

■ Drive, trough screw conveyor, standard ................................................................. 63

■ Pipe screw conveyor ............................................................................................... 63

■ Drive, pipe screw conveyor, pellets ........................................................................ 65

■ Drive, pipe screw conveyor, standard ..................................................................... 66

■ Drive, pipe screw conveyor, high-power ................................................................. 66

6.17 Fuel storage in on-site pellet store (sizing) ................................................................. 66

■ Sizing the pellet storage room ................................................................................ 66

■ Pellet storage room design and required system components ............................... 67

■ Additional safety instructions for pellet stores ......................................................... 68

■ Protective boards with Z profiles ............................................................................. 68

■ Fill connector and return air connector ................................................................... 68

6.18 Fuel storage in on-site pellet store (accessories) ....................................................... 71

■ Deflector 1.42 x 1.25 m ........................................................................................... 71

■ Blast pipe, straight .................................................................................................. 71

■ Blast pipe with 45° bend ........................................................................................ 71

■ Extension, blast pipe, straight ................................................................................. 72

■ 45° bend for blow line ............................................................................................. 72

6.19 Fuel storage in on-site bunker (accessories) .............................................................. 72

■ Silo cover, manual FDM 2.9/1.3 m .......................................................................... 72

■ Bunker cover hydraulic FDH ................................................................................... 73

■ Fall protection grille 120 for FDH ........................................................................... 75

■ Fall protection grille 200 for FDH ........................................................................... 75

■ Bunker cover, movable FDB ................................................................................... 75

■ Fall protection grille, 120 for FDB ........................................................................... 77

■ Fall protection grille, 200 for FDB .......................................................................... 77

■ Shaker motor for fall protection grille ...................................................................... 77

■ Hydraulic drive, bunker charging cover, ASH ......................................................... 77

■ Cover drives for hydraulic drive, ASH .................................................................... 78

■ Silo filling screw conveyor FS 300 .......................................................................... 78

■ Drive, silo filling screw conveyor ............................................................................ 78

6.20 Back burning protection .............................................................................................. 79

■ Rotary lock valve ..................................................................................................... 79

■ Shut-off gate valve MA 220 ..................................................................................... 80

■ Downpipe L = 1.0 m ................................................................................................ 80

■ Special adaptor ....................................................................................................... 80

6.21 Connection on the flue gas side ................................................................................. 81

■ Chimney .................................................................................................................. 81

■ Flue pipe ................................................................................................................. 81

6.22 Sound insulation ......................................................................................................... 82

■ Braces ..................................................................................................................... 82

7. Appendix 7. 1 Sizing the expansion vessel ....................................................................................... 82

■ Selection example ................................................................................................... 82

7. 2 General information regarding low pressure hot water boilers with safety temperatures

of up to 110 ºC ............................................................................................................ 83

7. 3 Pipe connections ........................................................................................................ 83

7. 4 Electrical installation ................................................................................................... 83

7. 5 Operating instructions ................................................................................................. 83

7. 6 Flue system ................................................................................................................ 84

7. 7 Checks as part of the Building Regulations approval process .................................... 84

8. Keyword index .............................................................................................................................................. 85

Index

(cont.)

PYROTEC

5822 511 GB

Page 5

1.1 Principles of pellet combustion for generating heat

What are wood pellets?

Wood pellets are made from 100% natural wood residues. This raw material is waste matter created by the wood industry in large volumes through planing or sawing. Wood remnants are compressed under high pressure and formed into pellets, i.e. pressed into a cylindrical shape. The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage conditions. Perfect and effective combustion can only be ensured under these conditions.

Fuel requirements

For combustion in the PYROTEC, use pellets with a diameter of 6 mm, a length from 5 to 30 mm (20 % up to 45 mm) with a maximum residual moisture content of 10 %. The wood pellets used for combustion in the PYROTEC must comply with the requirements of DINplus or ÖNORM M 7135.

Demand DINplus Ö-NORM

M 7135

Abrasion resistance %

≤ 2.3 ≤ 2.3

Raw density

kg/dm

≥ 1.12 ≥ 1.12

Water content %

≤ 10 ≤ 10

Ash content %

≤ 0.5 ≤ 0.5

Net calorific value MJ/kg

≥ 18 ≥ 18

kWh/kg

≥ 5 ≥ 5

Sulphur content %

≤ 0.04 ≤ 0.04

Chlorine content %

≤ 0.02 ≤ 0.02

Nitrogen content %

≤ 0.3 ≤ 0.3

Compression additive %

≤ 2 ≤ 2

Ext. production control yes –

Quality characteristics

High quality pellets:

■ smooth shiny surface

■ uniform length

■ low proportion of dust

■ sink in water

Low quality pellets:

■ cracked rough surface

■ severely varying length

■ high proportion of dust

■ float in water

Forms of delivery

In their loose form, pellets are transported by silo tanker and blown into the storage room via a hose system.

Careful handling of pellets enables a low proportion of dust, perfect boiler charging and a constant wood boiler output.

1.2 Principles of woodchip combustion for generating heat

What are woodchips?

Woodchips are made from 100% natural wood from forests and plantations. This raw material comes in the form of trunks or branches. The wood is then processed with high speed cutting tools in accordance with ÖNORM M 7133.

The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage conditions. Perfect and effective combustion can only be ensured under these conditions.

Fuel requirements

For combustion in the PYROTEC, use woodchips with a maximum percentage of coarse chippings of 20%, a maximum cross-section of 5 cm² and a maximum length of 12 cm (5 % with max. 16 cm). The water content of the woodchips may be max. 50 % (W50).

Bulk density S (kg/m³, water content W (%), size G (mm) as per ÖNORM M 7133 S 200 W20 G30/50 Soft natural woodchips from forest thinnings S 250 W20 to W35 G30/50 Soft natural woodchips from forest thinnings S 300 W20 to W35 G30/50 Soft/hard natural woodchips from forest thinnings S 300 W35 to W50 G30/50 Soft natural woodchips from forest thinnings S 350 W20 to W35 G30/50 Hard natural woodchips from forest thinnings S 350 W35 to W50 G30/50 Soft/hard natural woodchips from forest thinnings S 350 W50 to W60 G30/50 Soft natural woodchips from forest thinnings S 400 W35 to W50 G30/50 Hard natural woodchips from forest thinnings S 400 W50 to W60 G30/50 Soft/hard natural woodchips from forest thinnings

Quality characteristics

Good woodchips:

■ As per ÖNORM M 7133

■ Size up to G30 or G50

■ Max. 5 % outliers

■ Smooth surfaces

Principles of wood combustion

PYROTEC

5822 511 GB

Page 6

Poor woodchips:

■ Frayed surface

■ More than 5 % outliers

■ Coarse percentage higher than 20 %

■ Greater than G50

1.3 Minimum wood fuel requirements

Content

When procuring wood for combustion, it is important to ensure that foreign matter (e.g. stones, metal parts, brick fragments, plastics, etc.) is avoided. These change the composition of the charge and therefore the critical parameters of the combustion process.

The values must not exceed or fall below the following limits (per kg of dry fuel) for the non-combustible contents (ash at an analysis temperature of 815 °C):

Limit Comparison with natural wood from forest

thinnings

Chlorine Cl mg/kg max. 300 10 Sulphur S mg/kg max. 1000 120 Total Cl, S mg/kg max. 1000 130 Ash content total g/kg max. 15.0 5.0 Alkali oxides in the ash (K2O and Na2O) g/kg max. 1.0 0.35

SB starting of ash sintering °C min. 1000 approx. 1200

A consequence of exceeding the above limits is a shortened combustion chamber and wood boiler service life. This also means that the maintenance work is increased and the servicing intervals are shortened.

The proportion of dust-like and fine-grain materials should also be minimised (in accordance with ÖNORM M 7133).

Non-wood biomass fuels

Non-wood biomass fuels, such as needles, leaves, grain, straw, husks, fruit kernels, etc., are generally unsuitable as a fuel for trouble-free operation and therefore not permissible.

In some cases, the fuel properties (essential composition, ash sintering point, etc.) differ considerably from those of wood. Combustion in a PYROTEC can lead to impairment of the combustion characteristics and to greater stress on the fireclay lining and the heat exchanger surfaces. Warranty claims can therefore only be asserted when using permissible fuels.

Wood fuel regulations and standards

Germany 1.BImSchV in the revised version dated 22.03.2010 Austria FAV dated 18.11.1997 "Ordinance for Combustion Systems" § 3.(1) 3. Solid fuels Switzerland Clean air regulations LRV dated 16.12.1985 (as at 28.03.2000) ÖNORM M 7133 Woodchips for energy purposes (1998) EN 303-5 Boilers for solid fuels, table 8 "Test fuels" CEN/TS 14961 Solid biofuels

Principles of wood combustion

(cont.)

PYROTEC

5822 511 GB

Page 7

2.1 Product description

3-pass boiler (3 bar or 6 bar)

External grate with primary air 2

Safety heat exchanger

Secondary air

Ignition fan

Supply screw conveyor with separating barrier

Combustion retort with internal grate and primary air 1

Removal of ash

Combustion chamber door

Moving infeed grate

Pneumatic heat exchanger cleaning

The PYROTEC grate combustion has been specially developed for the automatic combustion of dry and moist wood fuels (waste wood, wood pellets or woodchips from forest thinnings up to max. W50). It combines the benefits of underfeed combustion with the advantages of grate combustion to optimum effect. The PYROTEC grate combustion is particularly impressive thanks to its maximum efficiency and perfect combustion in all load stages. The horizontal heat exchanger with pneumatic cleaning is ideal for the use of fuels with a high fine percentage.

The ash is removed automatically from the combustion base and transported into a standard container. Efficiency of over 90 % enables maximum seasonal efficiency in modulating operating mode. The use of a PYROTEC grate combustion as a base load boiler is practical in terms of a building heat load of 300 kW. Combination with a solar thermal system is also easily possible. The PYROTEC grate combustion is tested and permissible to EN 303-5. It is produced in accordance with the Machinery Directive and has a CE designation. It is also subject to ongoing monitoring by the TÜV.

Benefits at a glance

■ High efficiency thanks to proven combustion technology, 3-pass heat exchanger, modulating output control and regulated primary and secondary air supply

■ Easy service thanks to fully automatic ash removal and optional pneumatic cleaning system

■ Highly developed safety devices ensure a safe and reliable operation

■ Optimum system output is the result of manufacture and delivery of all system components from a single source

■ Automatic ignition device prevents having to maintain the incandescent bed and saves fuel (option – only for fuels with water content below 40 %)

■ Individual planning of your system by our team of experts

■ Excellent output control from 30 to 100 %

Delivered condition

Preassembled steel boiler for wood pellets and woodchips according to DINplus and ÖNORM M7135. With integral return temperature raising facility, combustion chamber door, ash doors, ash boxes, cleaning device. 1 supply screw conveyor with separating barrier, incl. extinguishing valve with dirt trap 1 Pyrocontrol programming unit 1 flue gas fan 1 extinguishing water container with holder 1 automatic ignition system 1 secondary air device (draught stabiliser); for the installation in the flue pipe

Pyrocontrol

■ Programming unit

■ Update-compatible software

■ Data line 10 m

■ Control panel

■ Infrared light barrier for level monitoring, separating barrier, supply screw conveyor

■ Safety limit switch on inspection cover of supply screw conveyor

■ Contact sensor PT-100 at the supply screw conveyor

■ Infrared light barriers for level monitoring of the fuel in the combustion chamber

■ Zirconium dioxide probe with measured value transducer

■ Flue gas temperature sensor PT-100

■ Return temperature sensor KTY

■ Boiler water temperature sensor KTY

■ High limit safety cut-out

■ Underpressure sensor

■ Sensor KTY with sensor well

■ Overpressure limiter

■ Light barrier ash removal

■ Limit switch, combustion chamber door

PYROTEC

5822 511 GB

Page 8

2.2 Specification

Specification

Trade name PYROTEC grate combustion Rated output 390 530 720 950 1250 Part no.: 7423 674 7423 675 7423 676 7423 677 7423 678 Output data

Rated output kW 390 530 720 950 1250 Continuous output

kW 390 530 720 950 1250

Minimum output Q

min

kW 97 132 180 238 312

Output with woodchips W 45

kW 380 515 700 920 1210

Heating data Content on hot gas side l 1540 2280 2830 4050 5210 Permissible shutdown temperature of the high limit safety cut-out

°C 100 100 100 100 100

Minimum return temperature °C 65 65 65 65 65 Grate ash container capacity l 240 240 240 240 240 Ash container capacity, flue gas dust extractor l 240 240 240 240 240 Boiler water content l 1150 1444 1861 1943 2482 Water-side pressure drop (diff. 15 K) mbar 13 23 43 26 45 Permiss. operating pressure Test pressure bar 7.8 7.8 7.8 7.8 7.8 Maximum operating pressure bar 6 6 6 6 6 Heating surface

26.32 42.50 55.50 74.80 91.00

CE designation CE CE CE CE CE Boiler class to DIN EN 303-5 3 3 3 3 3 Overall dimensions

Total length mm 4370 4870 5257 5447 5992 Total width (boiler) mm 1274 1247 1380 1612 1612 Total width (boiler with supply screw conveyor) mm 2382 2382 2488 2852 2852 Total height (boiler) mm 2378 2536 2834 3035 3230 Total height (boiler with induced draught fan) mm 3186 3186 3378 3452 3717 Weight Boiler kg 1680 2707 3291 4874 5563 Combustion block kg 2970 4238 4953 5779 6520 Displacer rods kg 394 394 394 538 538 Flue gas fan kg 60 62 78 82 107 Supply screw conveyor kg 153 153 153 190 190 Total dry weight kg 5230 7554 8869 11463 12919 Total wet weight kg 6380 8998 10730 13406 15400 Max. power consumption Ignition unit W 1600 1600 1600 1600 1600 Electrical connections (total) W 5410 7020 8120 9350 11150 During heating operation W 2880 3570 4560 5170 6790 Supply screw conveyor W 1100 1500 1500 2200 2200 Primary air fan 1 W 140 300 300 480 480 Primary air fan 2 W 900 900 900 900 900 Secondary air fan W 900 1500 1500 1850 1850 Flue gas fan W 1100 1100 2200 2200 4000 Grate drive W 120 120 120 120 120 Electrical power consumption with Q

W 2880 3570 4560 5170 6790

Electrical power consumption with Q

min

W 2340 2900 3710 4150 5470

Boiler connections Boiler flow and return DN 100 100 100 125 125 Extinguishing water connection R ¾ ¾ ¾ ¾ ¾ Boiler drain and fill valve R 1½ 1½ 1½ 1½ 1½ Safety heat exchanger R 4 x ½ 4 x ½ 8 x½ 8 x ½ 8 x ½ Sensor well for TS R ½ ½ 2 x ½ 2 x ½ 2 x ½

Levelled output as base load boiler in continuous operation with pneumatic cleaning

Q ≥ Q

min

: Output operation modulating control (variable output control)

Q ≤ Q

min

: Low load with ON Q

min

/ OFF (Stop and Go operation)

Wet fuels: > W45 further limitation-related output, efficiency and control characteristics

PYROTEC

(cont.)

PYROTEC

5822 511 GB

Page 9

Trade name PYROTEC grate combustion Rated output 390 530 720 950 1250 Part no.: 7423 674 7423 675 7423 676 7423 677 7423 678

Flue gas

Average temperature (gross*5) Mean flue gas temperature with Q

°C 160 160 160 160 160

Mean flue gas temperature with Q

min

°C 120 120 120 120 120

Mass flow rate QN; W5; O2 8 % g/s 219 297 404 532 700

W35

; W45; O2 10 % g/s 303 412 560 736 968

Flow rate QN; W5; O2 8 %; 150 °C

m3/s

0.26 0.36 0.48 0.63 0.83

W35

; W45; O2 10 %; 150 °C

m3/s

0.37 0.50 0.67 0.88 1.15

CO2 content in the flue gas % 14.7 14.7 14.7 14.7 14.7

Flue outlet 7 mm 350 350 350 400 450 Required draught (at full load) Pa 0 0 0 0 0 Efficiency

At full load

% 91 91 91 91 91

At partial load % 90 90 90 90 90

Values for calculating the size of the flue system to DIN EN 13384, based on 12.0% CO2.

Actual flue gas temperature as average gross value as per EN 304 at 20 °C combustion air temperature.

Flue gas temperature: Reduction possible by inserting displacer rods (QN-20 °C; Q

min

- 10 °C).

For dry fuels (W5-W20) without recirculation, lower. For PYROTEC 720–1250 without displacer rods, lower.

PYROTEC

(cont.)

PYROTEC

5822 511 GB

Page 10

678

f e

470

KR KV

800

940

KR Boiler return KV Boiler flow

Dimensions Rated output kW 390 530 720 950 1250

a mm 2378 2536 2834 3035 3230 b mm 2328 2486 2784 2981 3176 c mm 4370 4870 5257 5447 5992 d mm 2060 2560 2562 2562 3107 e mm 577 577 577 657 657 f mm 1200 1200 1200 1275 1275 g mm 2405 2905 2993 2861 3406 h mm 1086 1086 1380 1612 1612 k mm 803 803 803 929 929 l mm 453 453 453 479 479 m mm 2077 2331 2491 2444 2639 n mm 308 308 308 440 440 o mm 1274 1274 1380 1612 1612 p mm 1263 1417 1413 1317 1566

PYROTEC

(cont.)

PYROTEC

5822 511 GB

Page 11

960

220

ABC

FGH

Boiler drain and fill valve

Boiler return

Return temperature sensor

Drive, ash removal

High limit safety cut-out

Safety heat exchanger

Primary air fan 1

Boiler water temperature sensor

Boiler flow

Secondary air fan

Supply screw conveyor

Dimensions Rated output kW 390 530 720 950 1250

a mm 3282 3782 3877 3835 4380 b mm 3800 4300 4434 4392 4937

GHK

KV Boiler flow KR Boiler return

Removal of ash

Cleaning cover, heat exchanger

Combustion chamber temperature sensor

Overpressure limiter

PYROTEC

(cont.)

PYROTEC

5822 511 GB

Page 12

Light barrier, incandescence

Ignition unit

Cleaning cover, combustion retort

Cleaning cover, external grate

Light barrier ash removal

Boiler door

Cleaning, pneumatic

Combustion chamber door

Limit switch, combustion chamber door

Primary air fan 2

Drive, infeed grate

Contact sensor, supply screw conveyor

Limit switch, maintenance cover

Light barrier, supply screw conveyor

Extinguishing water connection

Boiler drain and fill valve

PYROTEC

(cont.)

PYROTEC

5822 511 GB

Page 13

3.1 Specification for Pyrocontrol

Programmable logic control (PLC) for the PYROTEC boiler system incl. the control of equipment for fuel charging according to the articles listed separately. Modulating matching of the boiler output to heat consumption is carried out.

The control circuit of combustion optimisation with a Lambda probe overlaps the output control circuit. With regard to fire protection and personal safety, the highest possible quality criteria are fulfilled.

Rated output range kW 390 530 720 950 1250

Part no. 7423 692 7423 693 7423 694 7423 695 7423 696

Functions

■ Output control circuit with modulating output operation (25-100 %)

■ Air-controlled by means of variable speed ventilation fan subject to flow temperature

■ Exact fuel supply via the supply screw conveyor from dosing container with separating barrier

■ Level monitored top up of dosing container

■ Limitation and distribution of the fuel in the combustion chamber

■ Emissions optimised control circuit with fine tuning of the fuel/air mixture using the Lambda probe

■ The pressure control unit ensures a constant underpressure in the combustion chamber.

■ Limitation of the combustion chamber temperature with corresponding variation of air ratio for protection of the fireproof lining

■ Keeping up the return temperature through the boiler ensures a long boiler service life

■ Protection to avoid: – Excessive temperature – Burn-back – Opening of the combustion chamber door – Opening of a charging cover – Pressure in the combustion chamber

■ Zero volt output (fault message)

Operation:

Operation is carried out via a 8” touch-screen module. All operating data can be shown on the display. The set values of all important parameters can be entered easily. Fault messages are displayed in plain text and output in the sequence of occurrence.

Programming module:

For operating the heating system. The 8” touch-screen module integrated in the control panel door enables visualisation and graphical evaluation via the system.

0,0 °C0,0 °C

Einstellungen Analyse

Archiv Kessel Ein

Kessel Aus

Sperren

25,9 °C

21,0 %

Aus

30,0 °C 26,6 °C

26,4 °C

27,0 °C

26,2 °C

26,4 °C

27,0 °C

Übersicht

Status: Level 0

Zeit: Text:

05.10.07 10:45:01 Warnung Feuerrauntüre offen

KOB

PYROTEC

Control unit

PYROTEC

5822 511 GB

Page 14

Standard delivery:

■ Control panel loose; surface powder-coated. Version as per ÖVE/ VDE directives fully wired to terminal strips, fed 3 x 400 V 50 Hz; control voltage 230 V or 24 V; – Freely programmable control unit, CE tested – Motor overload relay for all drives according to the separate price

item – Inverter for fan motors – Motor overload relay for boiler pump

■ In the control panel door: – 4-pole main isolator – 8” touch-screen, 640 x 480 mm – Documentation incl. fixed wiring diagram, terminal connection dia-

gram with cable designation, operating and maintenance instructions, and installation instructions in a plan wallet

■ Sensors and switches installed at the supply screw conveyor: – Infrared light barrier, level monitoring, separating barrier, supply

screw conveyor – Safety limit switch on inspection cover of supply screw conveyor – Contact sensor PT-100 at the supply screw conveyor

■ Sensors and switches at the combustion block and in the flue outlet (installation on site): – Combustion chamber temperature sensor NiCrNi – Infrared light barriers, level monitoring, fuel in combustion cham-

ber

– Zirconium dioxide probe with measured value transducer (Lambda

probe) – Flue gas temperature sensor PT-100 – Underpressure sensor – Overpressure limiter

■ Sensors and switches installed at top of boiler: – Boiler water temperature sensor PT-1000 in connector flow – Return temperature sensor PT-1000 in connector return – High limit safety cut-out

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 15

3.2 Accessories for Pyrocontrol

External drive control

Part no. 7387 802

Control of an external conveyor drive or a rotary lock valve without reversing. The motors are protected against overload and switched off early in the case of a pressing risk.

Standard delivery

■ Motor overload relay/contactor combination for drive motor fully integrated in control panel.

■ Input in control panel for safety limit switch at maintenance cover

■ Output in control panel for external conveyor drive

Note

The customer is resopnsible for the delivery and installation of the safety switch of the external conveyor drive.

Note

Only with defined limited material supply (upstream supply screw conveyor). The electrical output data of the existing conveyor device (kW, Ampere, Volts) must be given.

Control of external drive with light barrier

Part no. 7387 816

Control of an external conveyor drive without reversing, with interruption of the upstream charging where there is a risk of overfilling in the inlet by means of an integral light barrier. The motors are protected against overload and switched off early in the case of a pressing risk.

Standard delivery

■ Motor overload relay/contactor combination for drive motor fully integrated in control panel.

■ Input in control panel for safety limit switch at maintenance cover

■ Output in control panel for external conveyor drive

■ Infrared light barrier installed at the supply screw conveyor inlet

Note

For the control of a supply screw conveyor with external motor downstream of the external discharge.

Note

The electrical output data of the existing conveyor device (kW, Ampere, Volts) must be given.

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 16

3.3 Accessories for Pyrocontrol output management

Cylinder management 5 sensors (QM)

Part no. 7387 809

Modulating output operation is optimised with the use of a DHW cylinder. Short term heat demand peaks are also covered. The temperature sensors record the heating of the cylinder. The specification for the charging level of the cylinder is weather-compensated and carried out via the external sensor. The combustion output is matched to the charging level of the cylinder.

Standard delivery:

■ 5 additional sensors PT-1000 with sensor well 1/2" x 280 mm

■ 1 weather sensor PT-1000

External requirement on/off

Part no. 7387 986

Input for automatic switching on/off of the system via external zero volt N/O contact.

Note

For external requirement, an automatic ignition system is necessary

Operating message zero volt

Part no. 7387 987

Issue of the operating condition "Load operation" (zero volt output) to higher control technology.

Output signals 0-10 V

Part no. 7387 835

Issue of boiler output as voltage signal and connection preparation to receive a maximum limit of the boiler output included in standard delivery.

■ Issue of the output signals.

■ Receipt and processing of an external output restriction.

■ Receipt and processing of an external output restriction. – Incandescent bed – Output operation

Note

Note: The installation of "Output signals 0 – 10 V" downstream of QM wood heating plants is possible irrespective of additional control modules to be used.

Requirement, additional heat source KP0

Part no. 7387 973

Function

The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder, which is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the motorised shut-off device is open.

Standard delivery:

■ Sub-menu on touch-screen

■ Motor protection, boiler circuit pump, additional heat source

■ Control of motor, shut-off device

■ Zero volt contact for the control of the burner

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor)

Note

The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given.

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 17

Requirement, additional heat source KP1

Part no. 7387 905

Function

The additional heat source supplies, individually or jointly with the boiler, heat to the cylinder. This is designed as a low loss header. Taking into consideration the inertia of the boiler, control is carried out so that the additional heat source covers the peak load and the boiler covers the base load. In the operating phase of the additional heat source, the boiler pump is operating and the control unit of the boiler mixer is enabled.

Standard delivery:

■ Sub-menu on touch-screen

■ Motor protection, boiler circuit pump, additional heat source

■ Control of motor, shut-off device

■ Zero volt contact for the control of the burner

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return of additional heat source)

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor)

Note

The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given.

Pt1000

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 18

3.4 Accessories for Pyrocontrol remote transfer

Fault message device, analogue with battery

Part no. 7387 840

Transmission of fault messages of boiler system either as SMS on a mobile or as a fax. Four different text messages are possible, as the fault message modem has four independent digital inputs.

Standard delivery:

■ Analogue modem in control panel

■ Battery station (also works in the event of a power failure)

To be carried out on the customer side:

■ Electrical connection of the phone line to the modem

■ Configuration in accordance with the documentation

Export of operating data

Part no. 7387 890

Issue of relevant boiler system operating data and fault messages as ASCII dataset via serial interface to higher control technology on the customer side. All selectable parameters can be changed by higher control technology if this is planned by control technology.

Standard delivery:

■ Interface at the control panel

■ Software module

■ MOD BUS report (Baud rate 9600)

Note

Additional fault message device, analogue with battery station [ECO-SME / 7387994] possible Additional visualisation, wired [ECO-SVD] or wireless [ECO-SVG / 7388003], not possible

Visualisation, externally via modem (connected with cable)

Part no. 7387 997

Package for the transmission of relevant data to an EDP workstation (internal and/or external) for the visualisation, remote maintenance and operating data archiving of the PYROTEC boiler system. Hardware and software are integrated into the Pyrocontrol control unit. All selectable parameters can be changed from the EDP workstation.

Standard delivery:

■ Industrial PC with interfaces for screen, keyboard and PC mouse for EDP – workstation close to boiler room

■ Analogue modem in control panel

■ Windows operating system, remote maintenance software pcAnywhere and visualisation/archiving software installed and tested on the industrial PC.

Images on the screen:

■ Cross-section image of boiler, 3D with display fields

■ Installation scheme for heat source with display fields

■ Table of parameters (with change option)

To be carried out by customer:

■ It is the responsibility of the customer to organise the EDP workstation for remote maintenance together with modem, and installation of pcAnywhere and modem independently.

Note

Additional fault message device, analogue with battery station [ECOSME / 7387994] possible Also, export of operating data [ECO-SED / 7388038] not possible

Visualisation, internal

Part no. 7387 902

With a data line (max. 30 m) to the PC, all data is fed via the serial interface RS 232 at the programming module to the PC. The current operating data for the boiler system is shown visually on a function screen with all options for inputting values and functions and reading out the operating conditions (exception "Start boiler"). All operating data is archived cyclically and can be evaluated graphically in an extremely simple way. PC and data line are not included in the price.

Note

The PC and data line are not included in the price.

Standard delivery:

■ CD with visualisation software and installation instructions

Note

Requirements for on-site PC: Operating system Windows 98 / 2000 / XP Free hard disk memory at least 50 MB At least 128 MB RAM Per boiler 1 free serial interface

Data line to internal visualisation

Part no. 7379 404

Data line comprising:

■ D-SUB connector for connection between programming module and data line, soldered

■ 30 m data line 3–pole (cut to length as required on site)

■ D-SUB connector with threaded fittings 9–pole for connection to the PC

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 19

3.5 Mastercontrol for two-boiler systems

The Mastercontrol optimises the entire heat generation of two biomass boilers (PYROTEC dual system) incl. control of an oil, gas or electric boiler as a redundancy and/or as a peak load boiler.

Trade name Mastercontrol for Boiler combination A B Boiler Boiler 1

Pyrotec

Boiler 2

Pyrotec

Boiler 1 Pyrotec

Boiler 2 Pyrotec

Part no.: 7387 863 7387 848

Information on the Mastercontrol

Function

■ Heat management: Optimum division of the required heating output between the two biomass boilers with the main load on the lead boiler and the remainder load on the lag boiler via a defaulted output value. The defaulted output is calculated in accordance with QM wood heating stations in line with the required set temperature in the common low loss header. Automatic switchover of the two boilers between the lead boiler and the lag boiler is possible. This ensures an even boiler load over a long operating time (e.g. weekly changeover).

■ Charging: If fuel for the two biomass boilers is taken from a common fuel store, charging is controlled up to fuel distribution by the Mastercontrol.

■ Operating data archiving: Relevant operating data of the past 31 days is stored in a ring buffer and can easily be displayed in graph form on the Mastercontrol touch-screen.

Operation:

Operation is carried out via a 10“ touch-screen integrated in the control panel.

Standard delivery:

■ Control panel: Surface powder coated in RAL 7035 (grey) texture. Version as per ÖVE/VDE directives fully wired to terminal strips, fed 3 x 400 V 50 Hz; control voltage 230 V or 24 V

■ Freely programmable control unit, CE-tested, program and real time clock are battery backed

■ Contactor/overload relay combinations for all common charging drives (3 x 400 V) according to separate price items

■ Ethernet interface (network connection) on touch panel

■ Zero volt output (fault message)

■ 10“ touch-screen

■ 4-pole main isolator

■ Documentation incl. fixed wiring diagram

■ Terminal connection diagram with cable designation in plan wallet

■ Cylinder management 5 sensors (QM)

■ 5 sensors PT-1000 with sensor well 1/2" x 280 mm

■ 1 weather sensor PT-1000

■ Defaulted output value for both biomass boilers for further processing in the subordinate boiler control units via CAN-BUS

Note

Remote maintenance with PC or network, water-side and electrical installation is the responsibility of the customer.

Visualisation with the touch-screen

■ Operating data archive

■ Display and archiving of the relevant

■ operating data of both wood boiler systems and the Mastercontrol

■ Easy operation of the wood boiler systems at the touch-screen of the Mastercontrol

■ Installation scheme for heat source with display fields

■ Table of parameters (with parameter setting options)

■ Fault history

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 20

Schematic diagram

PYROCONTROL

PYROTEC 1 PYROTEC 2

M M

B28.1

B28.5

B28.4

B28.3

B28.2

MASTERCONTROL

PYROCONTROL

MASTERCONTROL

(ECOTRONIC)

PYROCONTROL

Additional heat source

Flow consumers

Cylinder as low loss header

Return consumers

Charging exclusively boiler 1 in control unit boiler 1

Charging exclusively boiler 2 in control unit boiler 2

Common charging, control unit modules

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 21

3.6 Accessories for Mastercontrol

Heat meter signal

Part no. 7387 975

Function

With this analogue input (0-10 V signal), the external heat meter can be read into the Mastercontrol. The current values can be displayed. The heat meter data is archived in the visualisation.

Requirement, additional heat source KP0

Part no. 7387 973

Function

Standard delivery:

■ Sub-menu on touch-screen

■ Contactor and overload relay, boiler circuit pump, additional heat source

■ Control of motor, shut-off device

■ Zero volt contact for the control of the burner

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor)

Note

The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given.

Requirement, additional heat source KP1

Part no. 7387 905

Function

Standard delivery:

■ Sub-menu on touch-screen

■ Contactor and overload relay, boiler circuit pump, additional heat source

■ Control of motor, shut-off device

■ Zero volt contact for the control of the burner

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return of additional heat source)

■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low loss header - system sensor)

Note

The electrical output data of the on-site boiler pump (kW, Ampere, Volts) must be given.

Pt1000

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 22

Fault message device, analogue with battery

Part no. 7387 840

Transmits the boiler system fault messages as a phone message. The fault message must be acknowledged. Four different text messages are possible, as the fault modem has four independent digital inputs.

Standard delivery:

■ Analogue modem in control panel

■ Battery station (also works in event of a power failure)

To be carried out on the customer side:

■ Electrical connection of the phone line to the modem

■ Configuration in accordance with the documentation

Export of operating data

Part no. 7387 890

Issue of relevant operating data and fault messages of the boiler system via MOD-BUS as ASCII dataset via a serial interface to higher control technology on the customer side. All selectable parameters can be changed by higher control technology if this is planned by control technology.

Standard delivery:

■ Interface at the control panel

■ Software module

■ MOD BUS report (Baud rate 9600)

Note

■ Additional fault message device, analogue with battery station possible, part no. 7387 840

■ Additional visualisation, wired (part no. 7387 997) or wireless (7387

874) possible

Control unit

(cont.)

PYROTEC

5822 511 GB

Page 23

4.1 Specification, buffer cylinder

Note

Specification and information on request.

Heating water buffer cylinder

PYROTEC

5822 511 GB

Page 24

5.1 Boiler accessories

Flue gas recirculation

Standard delivery:

■ Inlet line made from heat-resistant steel, from flue outlet to inlet adaptor

■ Inlet adaptor, supply air, with motorised cover

■ Recirculation fan in heat-resistant version

Note

The primary air fans do not apply.

■ Supply line for gas mixture incl. covers for the combustion block (internal and external grates)

■ Software module in the control unit

Rated output kW 390 530 720 950 1250

Part no. 7388 043 7387 418 7387 982 7387 837 7387 881

Insulation, flue gas recirculation line

High temperature resistant insulation 35 mm thick made from mineral wool with aluminium lamination and side adhesive strips for straight elements of the gas recirculation line. Incl. adhesive strips made from aluminium foil for the faces.

Note

This is the responsibility of the customer as part of the general insulation work on flue gas and heating pipes.

Displacer rods

The installation of the displacer rods in the heat exchangers results in a better heat transfer and therefore a considerable reduction in flue gas temperature. Use is only recommended when particularly low flue gas temperatures are required and when used as a base load boiler.

Rated output kW 390 530 720 950 1250

Part no. - - 7387 419 7387 921

Note

In the boilers Pyrotec 390 and Pyrotec 530, boiler pipes NW40 are used. For this reason, the flow velocity of the flue gas in these boilers is higher. No displacer rods are therefore provided for these boilers.

Automatic ignition system

Part no. 7387 420

The heating element is electronically protected against overload, eliminating the need for visual heating element monitoring. It reliably achieves the specified maximum temperatures.

Function

If the combustion chamber is filled accordingly with fuel, the ignition process is triggered. The fuel is ignited by means of hot air. If ignition is successful, the ignition system cuts out. The fan of the ignition system runs on for approx. 1 minute. This cools the heating element and supplies the combustion chamber with fresh air. Automatic ignition only functions with a water content in the fuel of max. W40.

Specification Ignition system

Operating voltage V / Hz 230/50 Pressure Pa 2800 Weight kg 1.1 Length mm 335 Width mm 85 Height mm 85 Diameter, blast tube Ø mm 31.5 Connection, pressure compensation line

mm 38

Max. temp. °C 650 Length, connection line mm 2000 Connected load kW 1.4

Note

In conjunction with the Mastercontrol, the automatic ignition system is essential.

Installation accessories

PYROTEC

5822 511 GB

Page 25

5.2 Boiler safety equipment

Thermally activated safety valve 100 °C

Part no. 7387 405

Standard version for response temperature fixed approx. 100° C, connection R ¾

Standard delivery:

■ Thermally activated safety valve incl. sensor well

Note

We recommend the thermally activated safety valve. Even if there is no need to use it in accordance with the local safety regulations.

Thermally activated safety valve 50-120 °C

Part no. 7387 406

Special version for response temperature of 120 ° C, connection R ¾

Standard delivery:

■ Thermally activated safety valve incl. sensor well

Note

Replacement for art. no. K-TS-131; only use with manufacturer declaration

Thermally activated extinguishing valve ½”, 50-90 °C

Part no. 7387 521

Thermally opening extinguishing valve with adjustable opening temperature for on-site connection to a pressurised water line or an extinguishing water container.

Standard delivery:

■ Extinguishing valve Danfoss AVTA, adjustable 50-90 °C with dirt trap

Supply screw conveyor two-level

Part no. 7387 804

Version with two-level supply screw conveyor for optional optimised operation for shavings/chippings (high level) on the one side and for pellets (low level) on the other

Standard delivery:

■ Geared motor, supply screw conveyor, pole-changing 750/ 300 rpm

■ Starttec for geared motor, pole-changing

■ Software module in the control unit

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 26

5.3 Accessories, heat distribution

Motor three-way valve

Designation Part no.

Motor three-way valve, VBF 21.80/SQL 33 (ZH-3-80) 7388 260 Motor three-way valve, VBF 21.100/SQL 33 (ZH-3-100) 7388 165 Motor three-way valve, VBF 21.125/SQL 33 (ZH-3-125) 7388 053

Rated output Type DN [mm]

Kvs [m3/h]

Servomotor 230VIncl. complete fitting

390 and 530 kW ZH-3-80 80 100 SQL 33 Mating flanges, gaskets 720 kW ZH-3-100 100 160 SQL 33 Mating flanges, gaskets 950 and 1250 kW ZH-3-125 125 550 SQL 33 Mating flanges, gaskets

Note

No individual issue: delivery only as part of an overall system

Pumps

Rated output Designation Part no. DN

Voltage V

Output W

Output m3/h / mWS

Incl. complete fitting

390 kW Wilo TOP-S 50/7 DM

(ZPS-506-4)

7338 271 50 400 245-625 28.0/7.0 Mating flanges,

gaskets

530 kW Wilo TOP-S 65/10 DM

(ZPS-656-4)

7388 221 65 400 400-960 42.0/9.0 Mating flanges,

gaskets

720 kW Wilo TOP-S 80/7 DM

(ZPS-806-4)

7388 224 80 400 320-880 30/4.5 Mating flanges,

gaskets

950 kW Wilo TOP-S 80/10 DM

(ZPS-8012-4)

7388 131 80 400 710-1500 30/6.0 Mating flanges,

gaskets

1250 kW Wilo IL 100/145-1,1/4

(ZPS-1060-4)

7388 202 100 400 1100 40/5.7 Mating flanges,

gaskets

Note

We reserve the right to select the pump manufacturers and types. Delivery only as part of an overall system.

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 27

5.4 Accessories, flue system

Flue gas dust extractor 240/800

The flue gas dust extractor minimises dust emissions and is designed as a multi-cyclone with axial function. The dust extractor is fully insulated and has three covers for cleaning. The crude gas space is cleaned via the side cleaning cover. The clean gas space is cleaned via the upper or back cleaning cover (unused fan connection). The ash box has a carriage and is connected to the dust extractor with quick-action fasteners. It can easily be pulled out for emptying. The fan can be installed either on the side or top.

Note

The flue gas dust extractor is required for fuels with an increased fine percentage. (Fine percentage > 4 %)

Standard delivery:

■ 1 flue gas dust extractor 240 or 800

■ 1 ash container with a hopper volume of 240 or 800 litres

Note

Additional ash containers must be ordered separately.

Flue gas dust extractor 240 Rated output

kW 390 530 720 950 1250

Volume of ash box 240 240 240 240 240

Part no. 7423 679 7423 680 7423 681 7423 682 7423 683

Flue gas dust extractor 800 Rated output kW 390 530 720 950 1250 Volume of ash box l 800 800 800 800 800

Part no. 7423 684 7423 685 7423 686 7423 687 7423 688

Ash container 240 l, reserve

Part no. 7387 993

Ash container 800 l, reserve

Part no. 7387 783

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 28

øa

< 200

øa

450

< 200

19,19 mm

1200

940

240 l

800 l

940

1200

Positioning in 4x 90° possible. (Removal, ash container.)

Flue gas fan (with variable rotation)

■ Either top or side

■ Unused connection as cleaning cover, clean gas space

Cleaning cover (crude gas space)

Dust extractor (axial cyclone)

Ash station

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 29

Dimensions Rated output kW 390 530 720 950 1250 Volume l 240 240 240 240 240 Part no. 7423 679 7423 680 7423 681 7423 682 7423 683

Weight with flue gas fan kg 500 500 517 535 559 Dimensions a mm 350 350 350 400 450 b mm 447 447 461 579 579 c mm 2359 2359 2491 2444 2639 d mm 3186 3186 3378 3452 3717 e mm 1330 1330 1462 1462 1657 f mm 1256 1256 1256 1300 1300 g mm 600 600 660 690 760 h mm 2080 2359 2491 2446 2641 k mm 1670 1670 1730 2083 2153 l mm 620 620 620 620 620 m mm 1260 1260 1260 1020 1020 n mm 1330 1330 1462 1462 1657

Dimensions Rated output kW 390 530 720 950 1250 Volume l 800 800 800 800 800 Part no. 7423 684 7423 685 7423 686 7423 687 7423 688

Weight with flue gas fan kg 641 641 691 709 749 Dimensions a mm 350 350 350 400 450 b mm 447 447 461 579 579 c mm 2359 2359 2491 2444 2639 d mm 3186 3186 3378 3452 3717 e mm 1330 1330 1462 1462 1657 f mm 1256 1256 1256 1300 1300 g mm 600 600 660 690 760 h mm 2080 2080 2491 2446 2641 k mm 1670 1670 1730 2083 2153 l mm 620 620 620 620 620 m mm 1260 1260 1260 1020 1020 n mm 1330 1330 1462 1462 1657

Accessories, cleaning pneumatic

The whole tubular heat exchanger is cleaned with periodic blasts of compressed air during operation. The process of cleaning itself is carried out in consecutive blasting of the individual sections. The ash is removed from the heat exchanger pipes by means of an extremely short but strong pressure pulse. The loosened particles are carried in the gas flow to the dust extractor, where they are largely separated out. The device is integrated in the boiler door. The compressor should preferably be installed where possible in a cool place in the boiler room. Function of the control unit: The number of cleaning processes within a unit of time (e.g. per hour) is matched according to the boiler load. An individual, complete cleaning process comprises a sequence of pressure pulses across all sections of the heat exchanger.

Standard delivery:

■ Nozzle part integrated in the flue gas collector; incl. connectors with heat deflection discs

■ Compressed air distributor with container and valves; with heatresistant hoses connected to the nozzle part

■ Compressor (rotation compressor) for utility applications – Supply output 160 l/min – Container 90 l – Pressure max. 10 bar – Motor 1.5 kW – 1450 rpm – 3 x 400 V – Incl. pressure regulator and pressure switch – Sound power level 68 dBA

■ Compressed air hose up to max. 4.0 m length

■ Valves fully wired on terminal strip

■ Software module in the control unit

To be carried out on the customer side:

■ Provision of a socket 400 V / 16A

■ Connector for compressor 400 V / 16A

Specification Rated output kW 390 530 720 950 1250 Part no: 7423 689 7423 689 7423 690 7423 691 7423 691

Number of zones/valves pce 8 8 5 6 Size of valves 6/4” 6/4” 6/4” 6/4” 6/4” Max. air consumption under full load l/h 3500 3500 4400 5300 5300 Additional weight (at the boiler) kg 78 78 86 104 104

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 30

Price reduction net compressed air on site

Part no. 7388 288

This eliminates the need for the compressor listed in the item "Cleaning pneumatic". The compressor provided by the customer must supply at least the specific quantity and quality of the air and has an adjustable pressure regulator and protection against the hose breaking (e.g. runtime limiter). The compressor must meet the following minimum requirements:

■ Compressor (rotation compressor) for utility applications – Supply output 160 l/min – Container 90 l – Pressure max.10 bar – Motor 1.5 kW – 1450 rpm – 3 x 400 V – incl. pressure regulator and pressure switch – Sound power level 68 dBA

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 31

5.5 Accessories, ash removal

External container

Complete screw conveyor ash removal from the ash chamber into an external movable zinc-plated ash box. The level in the ash trough is monitored by means of the light barrier. If a certain level is exceeded, a certain quantity of ash is fed into the container. In this way, the ash can anneal in the ash trough under the combustion system and only cool, annealed ash is fed into the container in normal operation. For cleaning purposes, the ash removal can be switched to continuous operation in the event of a boiler standstill.

Standard delivery:

■ Combustion chamber conveyor made from heat-resistant steel

■ Ascending ash conveyor as a pipe conveyor with direct transfer from the ash removal conveyor Drive via geared conveyor motor

■ Connection station with mobile ash container

■ Control of the conveyor drives

■ Infrared light barrier, level monitoring, ash in combustion chamber

Connection station with mobile ash container can be installed in each case at 90°. It is possible to select the direction in which the ash container is pulled out.

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 32

30,27 mm

9,13 mm

1,20 mm9,13 mm

8,74 mm

22,07 mm

25,93 mm

16,14 mm

1793

2106

742

710

1311

742

1096

2459

Ash removal into an external container with a hopper volume of 240 l

Ash container hopper volume l 240 Part no. 7387 415

22,07 mm

28,77 mm

21,03 mm

16,00 mm

14,89 mm

1,17 mm

16,37 mm

30,27 mm

14,77 mm

1793

1200

1330

2459

2337

1299

1708

1210 95

Ash removal in external container 800 l

Ash box hopper volume l 800 Part no. 7387 953

Extension of ascending screw conveyor

Part no. 7387 826

Note

Per metre Max. 2 m permissible

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 33

Extension of combustion chamber screw conveyor

Part no. 7388 037

Note

Per metre

Design information

6.1 System design

Selection of rated output

Select the wood boiler according to the required heat load. The Pyrotec should be planned as a base load boiler and always operated in conjunction with a buffer cylinder (management). The correct system design point therefore does not depend on the nominal load specification (i.e. the building heat load) but rather on the required duration of use (length of the heating period, heat demand).

Note

In places more than 1800 metres above sea level, the project enquiry must include information about the exact geographical location (altitude and address of the location).

Flow temperatures

To minimise distribution losses, we recommend that you size the heat distribution system and the DHW heating to a max. flow temperature of 70 ºC.

For wood boilers supplied with a boiler control unit, the max. boiler water temperature is limited to 85 ºC. The flow temperature may be increased by adjusting the control thermostat.

Safety temperatures

The boilers comply with EN 303 and DIN 4702, and all are CE-designated and can be used in sealed heating systems as per EN 12828.

■ Permissible flow temperatures (= safety temperatures): Up to 110 ºC To EN 12953: up to 120 ºC

■ Max. possible flow temperature: Approx. 15 K below the safety temperature

■ High limit safety cut-out of the boiler control unit: Delivered condition 110 ºC Adjustable to 100 ºC

6.2 Delivery

KÖB delivers to the site. The system is unloaded on site.

A special crane is required on site for unloading. The personnel carrying out transportation must be aware of any accident hazards. These hazards are to be prevented by suitable countermeasures.

Only lift the boiler when it is completely empty (water, fuel, ash). To lift the combustion base, lifting eyes should be screwed to the points provided. After unloading, the lifting eyes must be removed. The heat exchanger is lifted by the lifting eyes provided for this purpose, placed on the combustion base and then secured to it with screws.

6.3 Handling

The combustion base has four eyes that must be screwed in before lifting. Lifting gear can be attached to these eyes. The heat exchanger of the PYROTEC has two lifting eyes to which lifting gear may be attached. A special crane (on site) is required to lift the combustion block and heat exchanger.

Our experts can undertake the handling and installation on prepared foundations upon request (chargeable option). Recommended minimum clearances to walls for installation and maintenance work must be observed. An anti-vibration boiler support should be provided if anti-vibration measures are required.

Installation accessories

(cont.)

PYROTEC

5822 511 GB

Page 34

20,42°

33,57°

45°

Lifting eyes (screw in before lifting)

Lifting eyes (heat exchanger)

6.4 Installation

Requirements for boiler room

A separate dry boiler room must be provided for the system. No combustible materials should be stored in the boiler room. The wood boiler may only be installed on a fire and temperature-resistant floor. No temperature-sensitive pipes or lines should be routed through the floor under the boiler. The load bearing capacity of the boiler room floor should be sized to the system weight plus the water fill volume and the fuel. Floor load bearing capacity in the area of the boiler supporting surface 2000 kg/m². The minimum clearances from walls and the ceiling according to the measurement sheet, which are required for cleaning and maintenance, must be observed. An adequate fresh air supply directly from outside into the boiler room must be ensured. If a boiler room is narrow and/or internal, forced ventilation is required. The temperature in the boiler room when operating the system must not exceed +40 °C (measurement point: in boiler proximity approx. 1 m away from boiler). The temperature in the boiler room when operating the system must not fall below +10 °C (measurement point: inner side of external wall).

■ Avoid air contamination through halogenated hydrocarbons (e.g. as in sprays, paints, solvents and cleaning agents)

■ Avoid very dusty conditions

■ Avoid high levels of humidity

■ Prevent frost damage and ensure good ventilation

In rooms where air contamination through halogenated hydrocar- bons can occur, install the boilers and flue gas/water heat exchangers only if adequate measures can be taken to provide a supply of uncontaminated combustion air. If these instructions are not observed, any consequential losses directly related to any of these causes are excluded from our warranty. If in doubt, please contact us.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 35

4,36 mm

250

< 400< 400

250

< 400

250

Hatched surface Floor in heat-resistant version Surface medium grey Boiler supporting surface

Foundation properties Trade name PYROTEC grate combustion Rated output kW 390 530 720 950 1250 Part no: 7423 674 7423 675 7423 767 7423 677 7423 678

a mm 1026 1026 1112 1360 1360 b mm 1826 1826 1912 2160 2160 c mm 4221 4721 4912 5096 5641 d mm 1260 1260 1400 1630 1630 e mm 2561 3061 3112 3066 3611

Requirements of Sample Combustion Order

The installation room must meet the standards laid down by the "Fire Regulations" of the respective country. Observe the Building Regulations and Fire Regulations of the respective country of installation.

Emergency stop switch

The burner, the fuel supply equipment and the burner control units must be able to be switched OFF at any time by an emergency stop switch installed outside the installation room.

Provide a sign adjacent to the emergency stop switch with the inscription "EMERGENCY STOP SWITCH - COMBUSTION".

Combustion air supply

For open flue combustion equipment with a total rated output in excess of 35 kW, the fresh ventilation is deemed to have been verified if the combustion equipment is located in areas which provide an aperture or duct leading outdoors. At 35 kW rated output, the cross-section of the aperture must be at least 150 cm2. For every kilowatt rated output in excess of 35 kW, the aperture must be 2 cm2 larger than stated above. Pipes must be sized to provide equivalent flow rates. The required cross-section may be split over a maximum of 2 apertures or pipes.

A = 150 cm² + 2

cm²

x (Σ²n – 35 kW)

= total of all rated outputs in kW

Design information

(cont.)

PYROTEC

5822 511 GB

Page 36

Never close or obstruct combustion air apertures and lines. Use special safety measures to ensure that the combustion equipment can only be operated when the aperture is open.

The required cross-section must not be blocked by any closure or grille.

Minimum clearances

10,20 mm

26,39 mm

12,25 mm

14,68 mm

> 880

> 800

> a

> 500

Dimensions and clearances Trade name PYROTEC grate combustion Rated output kW 390 530 720 950 1250 Part no: 7423 674 7423 675 7423 676 7423 677 7423 678

a mm 1350 1850 1800 1600 2100

6.5 Water connection

Heating connections

Existing systems

Flush the heating system thoroughly before connecting the boiler to an existing heating system, to remove dirt and sludge residues. Otherwise, these dirt and sludge residues would be deposited in the boiler and could lead to local overheating, noise and corrosion. Boiler damage caused by such deposits is excluded from our warranty. Where necessary, install dirt traps.

Connections on the heating water side

it is the customer's responsibility to ensure that there is a water supply independent of the power supply. This (redundant) version guarantees that the boiler is reliably cooled in the event of a power failure via the thermally activated safety valve. We also refer to the standards and regulations listed in this document.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 37

Connect all heat consumers or heating circuits to the boiler flow and return connectors. Never make any connections to the safety flow or to other connections. We recommend you install shut-off valves into the heating flow and return lines, so that the entire water content will not have to be drained, should work be required on the boiler or heating circuits.

Easy installation

For safety temperatures up to 110 ºC, the boiler requires no intermediate flow piece for the connection of safety equipment. All connections required for the various pieces of equipment, e.g. for water level or pressure limiters, are provided on the boiler.

Boiler circuit and shunt pumps

In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C. The boiler has variable output control. This requires a constant boiler flow rate of the water to be heated. The boiler circuit with boiler pump and boiler mixer should therefore be installed in accordance with the design recommendations.

The sizing of the boiler circuit should be carried out in such a way that the temperature differential between the flow and return is 15 °C or smaller. The control of the boiler pump and boiler control valve is integrated in the control unit supplied.

Safety equipment to DIN EN 12828

Installation of the safety equipment of the heating system should be carried out by the authorised heating installer. EN 12828 applies to the design of DHW heating systems with safety temperatures up to max. 110 ºC. This standard contains safety requirements laid down for boilers and boiler systems.

■ Sealed expansion vessel.

■ A safety valve at the highest point of the boiler or a pipe connected to the boiler. The pipework between the boiler and the safety valve must not be able to be shut off. Pumps, fittings or restrictions must not be present in this pipework. The blow-off line should be constructed so as to prevent the possibility of increases in pressure. Any expelled heating water must be able to be drained off safely. Arrange the outlet of the blow-off line so that any water expelled from the safety valve can be safely observed and drained off.

■ A low water indicator is not required, except in attic heating centres (water level limiter available as an accessory).

■ Thermometer and pressure gauge.

System examples

General information

■ In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C. A boiler circuit pump with boiler mixer should be provided in accordance with the system scheme.

■ The sizing of the boiler circuit should be carried out in such a way that the temperature differential between the flow and return is 15 °C or smaller.

■ Integrating heat consumers

■ The expansion vessel must be connected to the boiler without shutoff devices via the boiler flow.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 38

Sizing recommendation for systems with sealed expansion, cylinder circuit if required

--B28.1--

--B28.4--

--B28.5--

--B28.2----B28.3--

--B28.2--

--B28.5--

--B28.3--

--B28.1--

--B28.5--

--Y20--

--M20--

--B28.1--

Example

Additional heat source

1 cylinder as low loss header (5 sensors)

Distributor, heat consumer

Design information

(cont.)

PYROTEC

5822 511 GB

Page 39

Buffer cylinder

More than 1 buffer cylinder as low loss header (5 sensors)

Buffer cylinder 2

Buffer cylinder 1

Low loss header Possible with large water volume in mains

TS131 (2 pce from Pyrotec 720)

Additional heat source controlled with a directional control valve for

- Oil/gas boiler

- Electric heater

With additional heat source, dual mode

- Oil, gas, electric M20 Boiler pump Y20 Boiler mixer KW Cold water supply min. 2.5 bar, max. 3.5 bar

Sizing recommendation Trade name PYROTEC grate combustion Rated output kW 390 530 720 950 1250

Boiler circuit NW 80 NW 80 NW 100 NW 125 NW 125 Thermally activated safety valve TS-131 pce 1 1 2 2 2 Required water flow rate at 2.5 bar l/h 1637 2224 3020 3986 5246 Cylinder capacity l 3200 4300 5800 7600 10000 Supply line ZLg R ¾ ¾ 1 1 1¼ Supply line ZLv R ¾ ¾ ¾ ¾ ¾ Drain line ALv R ¾ ¾ ¾ ¾ ¾ Safety valve type SV 68 M R 1¼ 1½ 1½ 2x 1½ 2x 1½ Safety line SL NW 50 NW 65 NW 80 2x NW 65 2x NW 80

6.6 Electrical installation

This should be carried out in accordance with the wiring diagram. In the vicinity of hot parts (flue gas fan, flue pipe), cables must be routed in steel pipes for temperature protection with appropriate clearances.

The cable entries for the motors and equipment should be dust-proof and provided with strain relief.

Positioning of the programming module and control panel

The programming module should be installed by the electrical company responsible for installation in a place that is easily accessible for operation. Optimal positioning of the control panel can minimise cable lengths and therefore reduce costs. The location of the programming module and control panel should be selected so that negative influence caused by thermal radiation (boiler front panel, boiler back panel with flue gas collector and flue gas fan, as well as flue pipe) and exposure to dust during cleaning is minimised.

The ambient temperature of the control panel (approx. 10 cm away from the control panel) when operating the system must not exceed 40 °C. In case of doubt, the control panel should preferably be located outside the boiler room near to the boiler room door.

Note

The regulations of the local power supply utility must be observed.

6.7 Safety equipment

Expansion

The required expansion vessels should be selected according to the system-specific circumstances (pressure, water content, etc.).

In the case of sealed expansion, the pre-charge pressure of the expansion vessel should be equal to the max. system height plus 0.2 bar.

Extinguishing facilities

A water extinguishing facility is required on the supply screw conveyor. This facility is intended to reliably prevent burn-back in the event of a fault (e.g. power failure). For safety reasons and in order to avoid damage caused by flooding, it is not advisable to connect the extinguishing facility directly to the water mains. This extinguishing facility is equipped with an extinguishing water container 25 l with float switch and an adjustable Danfos extinguishing valve.

In accordance with TRVB 118, the container should be equipped with fill level monitoring. The boiler automatically switches off in case of a water shortage. In the case of excessive temperature, the supply screw conveyor safety is flooded, but to a limited extent.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 40

Extinguishing water container

Part no. 7387 785

17,34 mm

< 500

N25 fill level monitoring

Extinguishing water container 25 l

Material supply

Combustion

Note

Part of the boiler.

Note

■ Adjustment, valve, Danfos AVTA 15 50–90 °C 3 corresponds to 80 C°.

■ Lines should be secured in metal pipes (½“).

■ The cold water supply must not be able to be isolated without the aid of a tool.

Extinguishing facility with cold water supply

Part no. 7388 521

Combustion

Dosing container with separating barrier

KW Cold water supply DN 15 ½“ min. 2.0 bar, max. 3.0 bar

Note

■ Lines should be secured in metal pipes (½“).

■ The cold water supply must not be able to be isolated without the aid of a tool.

Note

Alternative or additional safety equipment. A shut-off gate valve is required as standard for an unpressurised material store or a rotary lock valve for a material store with overpressure or underpressure (charging with fan, e.g. wood processing operations).

Back burning protection, boiler system

The boiler system back burning protection is part of the standard delivery.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 41

Prevention of combustion chamber overfilling

In accordance with TRVB 118, a fill level monitor should be installed to prevent overfilling of the combustion chamber. The boiler has two light barriers for incandescence monitoring. A sensor directly on the insert pipe is used to detect any sign of a burn-back risk and to counteract this early on by means of a short-term output increase (increasing in material feed).

As a result, any prescribed protection device does not come into effect and normal operation is maintained with regard to the greatest possible heat supply reliability.

Reignition protection

In accordance with TRVB 118, reignition protection is prescribed for all systems over 150 kW. If a spark detection and extinguishing facility is not used, TRD 414 prescribes a constantly available separating barrier (TRD 414 relates primarily to waste wood from the preparation and distribution of wood and wood materials). There are simpler ways of achieving this for woodchips from the forestry and sawmill sector.

The boiler is equipped with a separating barrier and is operated permanently with underpressure. The boiler is then equipped with reignition protection in accordance with both TRVB 118 and TRD 414.

Back burning protection, fuel supply (RSE)

Additional "material transportation back burning protection" depends on the relevant requirements (location, size of the fuel store, material, pressure, regulations) and is a separate item from the standard delivery ordered from KÖB Holzfeuerungen GmbH.

For this boiler, we recommend installing a rotary lock valve. In addition to the back burning protection, the penetration of infiltrating air via the supply screw conveyor is also prevented.

Shut-off gate valve

The shut-off gate valve is permissible in all unpressurised fuel stores and is considered suitable back burning protection in accordance with TRVB 118 (test certificate BV 2979/89).

Rotary lock valve

If the wood remnants are introduced with fans in fuel storage rooms, due to the pressure load, at least one rotary lock valve is required to reduce pressure between the fuel store and the boiler. The rotary lock valve is suitable for reducing pressure and at the same time is considered suitable back burning protection in accordance with TRVB 118 (test certificate BV 2979/89).

■ Max. permissible overpressure in the fuel store: + 500 Pa

■ Max. permissible underpressure in the fuel store: + 0 Pa

Dual rotary lock valve with pressure compensation

If, due to special circumstances, mechanically generated underpressure or extremely high overpressure can be expected in the fuel store, then in accordance with the relevant project plan, two rotary lock valves with a pressure compensation to outside should be installed in the material transport path. The maximum pressures that can be expected are to be confirmed by the supplier of the chip extraction system. Leaks may occur in the rotary lock valve under the silo discharge system as a result of wearing of the sealing elements or due to larger pieces of wood that cannot be transported. Such leaks may allow the back flow of low temperature carbonisation gases from the combustion system into the silo. Between the rotary lock valve and the silo discharge system, a flue gas alarm should be installed, which, when responding, switches off the system causing the silo underpressure.

■ Max. permissible overpressure in the fuel store: + 3000 Pa

■ Max. permissible underpressure in the fuel store: - 3000 Pa

Low water indicator

EN 12828 specifies that boilers must be equipped with a low water indicator (water level limiter). Tests have verified that the burner will be automatically switched OFF in the event of water shortage due to a leak in the heating system and oil burner operation, before the boiler or the flue system reach unacceptably high temperatures.

Maximum pressure limiter

If the rated output of the wood boiler is more than 300 kW, a maximum pressure limit is required for each boiler in a system.

For installation purposes, the wood boilers have a R½ connector on top of the boiler.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 42

Minimum pressure limiter

Recommended for flow temperatures in excess of 100 ºC. One required per multi boiler system.

Safety valve

Equip the boilers to EN 12828 with a type-tested safety valve. For all other operating conditions, this must be identified in accordance with TRD 721 with "D/G/H":

The pipework between the boiler and the safety valve must not be able to be shut off. Pumps, fittings or restrictions must not be present in this pipework.

Expansion vessel

For boilers above 300 kW, install an expansion vessel with blow-off and drain line near the safety valve. In order to prevent a risk caused by escaping steam, the blow-off line must be routed to the outside. The blow-off line on the safety valve should be constructed so as to prevent the possibility of increases in pressure. Arrange the outlet of the drain line so that any water expelled by the safety valve can be safely observed and drained off.

Replacement, expansion vessel

An additional expansion vessel and blow-off line are not required if a second high limit safety cut-out and a second maximum pressure limiter are installed.

6.8 Fire protection

The fire safety regulations for wood combustion systems vary depending on the country.

The regulations valid for the relevant installation location must be observed.

Fire protection, fuel store

The measures necessary for this are not part of the standard delivery from KÖB Holzheizsysteme GmbH.

Note

In this regard, the conditions of the local planning office must be fulfilled by the operator.

6.9 Commissioning

Initial commissioning of a newly installed system may only be carried out by KÖB Holzheizsyteme GmbH or another contractor trained and authorised by KÖB. Prior to commissioning, the system must be filled with water, fuel must be stored for the commissioning and the installation must be monitored.

Fuel for commissioning

As the boiler system is cold and residual moisture is also extracted from the refractory concrete during commissioning, the fuel for commissioning must be at least air dry. The heat-up process should be carried out in the first three hours with low output. In order to check the function of the silo discharge system, not too much fuel should be stored so that, in the event of a fault, the discharge system can be quickly released to remedy the cause. For commissioning, dry fuel with a max. water content of 20 % (W20) should be stored. The quantity corresponds to consumption of approx. 10 – 24 full operating hours.

Rated output Quantity of the fuel to be stored

390 kW approx. 2500 kg 530 kW approx. 3000 kg 720 kW approx. 4000 kg 950 kW approx. 5300 kg 1250 kW approx. 6800 kg

Filling the heating system

Usually, the system is initially filled with raw water without chemical treatment. This must be filtered and be free of suspended solids. Particular attention should be paid to careful ventilation during filling. In the case of difficult water conditions (high hardness, etc.) and/or large water volumes, VDI directive 2035 "Prevention of damage through corrosion and scaling in hot water heating systems" must be observed. Measures recommended by the directive for water treatment should be carried out.

Note

The fill pressure of the cold hydraulic seal should be approx. 0.1 bar higher than the pre-charge pressure of the sealed expansion vessel. However, it must not exceed a maximum of 3 bar.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 43

6.10 Fuel

Suitable fuels

The Pyrotec is suitable for the following dry to moist wood fuels in accordance with ÖNORM M 7133:

Note

The following are unsuitable types of fuel: Fossil fuels and those containing sulphur, such as anthracite and coke, as well as plastics, grain, straw, material soaked in flammable liquids and waste wood treated with plastics or wood preservatives.

Bulk density S (kg/m³) Water content W (%) Size G (mm) Fuel

S 130 W10 to W20 G30/50 Natural sawdust S 200 W20 to W35 G30/50 Natural sawdust S 200 W20 G30/50 Soft natural woodchips from forest thinnings S 250 W20 to W35 G30/50 Soft natural woodchips from forest thinnings S 250 W35 to W50 G30/50 Natural sawdust S 300 W20 to W35 G30/50 Soft/hard natural woodchips from forest thinnings S 300 W35 to W50 G30/50 Soft natural woodchips from forest thinnings S 350 W20 to W35 G30/50 Hard natural woodchips from forest thinnings S 350 W35 to W50 G30/50 Soft/hard natural woodchips from forest thinnings S 400 W35 to W50 G30/50 Hard natural woodchips from forest thinnings S 130 < W15 G30/50 Dry, mixed shavings, chippings from waste wood S 200 < W15 G30/50 Dry, mixed shavings, chippings from waste wood S 250 < W15 G30/50 Dry, mixed shavings, chippings from waste wood S 350 < W15 G30/50 Briquettes from waste wood D 40 to 60 mm S 650 < W10 Standardised natural pellets D 6 to 10 mm S 650 < W10 Standardised natural pellets D 11 to 15 mm

6.11 Fuel discharge by means of screw conveyor

Discharge conveyor, pellet, D = 120 mm

Part no. 7837 954

As pellet transportation from a rectangular room with the possibility of filling from the top. The pellets trickle via a tilted intermediate floor into the conveyor channel. The supply screw conveyor found inside this channel transports the pellets to the outlet.

Standard delivery:

■ Discharge conveyor for pellets according to project drawing

To be carried out on the customer side:

Delivery and installation of the intermediate floor (preferably made of wood) incl. static calculation and sizing. The forces resulting from the weight of the combustion material (approx. 650 kg/m3) should be transferred to the silo floor and not through the discharge conveyor. Observe this when constructing the intermediate floor.

Note

Price given per m; total length in m = length of conveyor channel

Note

For increases of 0° to 8°; exclusively for pellets; boiler output up to max. 1250 kW

Specification Pellet discharge conveyor D=120 mm Part no. 7837 954

a mm < 9250 b mm > 750 c mm < 10000

Design information

(cont.)

PYROTEC

5822 511 GB

Page 44

14,03 mm

4,96 mm

14,79 mm

3,84 mm 12,13 mm

23,07 mm

1,48 mm

102,15 mm

~ 500

166 500

260

130

540

45°

8,87 mm

20,67 mm

10,20 mm

24,31 mm 40,28 mm

6,65 mm

2,09 mm

6,21 mm9,79 mm

110 66

201

< 30

115

274

454

D D

C - C

3,10 mm

5,92 mm 77,60 mm

24,36 mm

7,53 mm

5,15 mm

3,28 mm

8,02°

180x180

<110

250

<200

<30

0-8°

Possible outlet into a bunker

Optional drive left or right

Intermediate floor

Intermediate floor with anti-vibration measure

Drive, discharge conveyor, pellets

Part no. 7387 998

The system is driven via a spur geared motor and chain in a dust-proof chain guard. The geared motors are sized at the factory.

Standard delivery:

■ Drive unit

■ Spur geared motor matched to boiler size and pump rate

Design information

(cont.)

PYROTEC

5822 511 GB

Page 45

■ Control of spur geared motor 3 x 400 V according to boiler control unit

■ Inspection cover with safety limit switch and sealed outlet

6.12 Fuel discharge by means of agitators

Spring core discharge AF

Part no. 7387 964 for spring core discharge 3.5 m Part no. 7387 977 for spring core discharge 4.5 m

Silo or bunker discharge with bottom agitator in lightweight version, especially for smaller bunker volumes and/or lower boiler outputs. The fuel supply is carried out via a bottom agitator with two leaf spring arms, which fills a screw channel let into the floor (or intermediate floor). If the silo is full, the leaf spring arms move to the cover disk. Drive is via a geared conveyor motor to the discharge screw and via an angular gear to the agitator. The spring core discharge is suitable for round, square and rectangular rooms.

Standard delivery:

Spring core discharge according to the project drawing

■ Bottom agitator with two leaf spring arms

■ Drive unit with geared conveyor motor 3 x 400 V

■ Control according to boiler control unit with enabling by the following conveyor device; speed/output: Project-related and subject to boiler output and fuel

■ Light barrier for monitoring the fill level at the end of the sealed screw channel

■ Outlet with inspection cover and safety limit switch

To be carried out on the customer side:

■ Installation of an intermediate floor required (preferably wooden boards)

Note

1. Discharge screw must be ordered for this!

2. Speed/output of the drives: Sizing by KÖB design department.

Specification Spring core discharge AF AF 3.5 m AF 4.5 m Part no. 7387 964 7387 977

a Max. length of discharge screw m 6 6 b Discharge circuit m 3.5 4.5 c Boiler output at angle of inclination 0° 15° Torque at shaft Nm 450 450 Pellets S 650 kW 540 540 Woodchips from forest S 200 kW 300 220 Shavings kW 220 150 Maximum fill level Pellets S 650 m 2.7 2.7 Woodchips from forest S 200 m 5.0 5.0

Design information

(cont.)

PYROTEC

5822 511 GB

Page 46

Sizing

4,47 mm

47,24 mm

73,85 mm

< 6000

160

FED

2,20 mm9,93 mm

3,85 mm

5,42 mm

13,75 mm

6,88 mm

8,25 mm

13,20 mm

8,80 mm

22,00 mm

7,56 mm

10,59 mm

18,93 mm

24,75 mm

3,03 mm

900

ø a

361

205

140

500

250

ø 110

300

480

320

800

275

385

700

4,14 mm

4,40 mm

11,89 mm72,64 mm

52,24 mm

8,25 mm1,16 mm

11,00 mm

4,40 mm

160

ø 150

170

440

< 6000

400

> 42

> 250

ø a

Second leaf spring

Installation opening (seal with fire-retardant panel)

Rotational direction

Shavings

Remainder

Pellets

Base (height adjustable)

Design information

(cont.)

PYROTEC

5822 511 GB

Page 47

Note

1. Installation position, horizontal: preferably in concrete with recess for screw conveyor and central gear

2. Installation position, angled: exclusively with intermediate floor, preferably made from wood

3. Suitable for woodchips up to G30/50; not suitable for wood briquettes and shredded matter from used or waste wood

4. Sloping installation position reduces the discharge output and the degree of emptying (by approx. 2.3% per 1 degree slope)

5. Speed/output: Project-related and subject to boiler output and fuel, sizing by KÖB design department

Discharge screw AF to spring core discharge

Part no. 7388 035

The fuel is moved by the spring core discharge arms into the open conveyor channel in the silo. Outside the bunker, the screw channel is sealed.

Standard delivery:

■ Conveyor channel with specially matched discharge screw

Note

Article price per m, always round up to whole numbers! The max. length of the discharge screw AF is 6 m. Total price = total length a in metres (max. 6 m) x individual price

Horizontal discharge AH

Part no. 7387 979 for horizontal discharge up to D = 5.0 m Part no. 7387 854 for horizontal discharge up to D = 6.5 m

Horizontal discharge with bottom agitator in heavy version, especially for larger bunker volumes and/or high boiler outputs. The two agitator arms each comprise one or two (depending on size) articulated arm(s) and an externally fitted leaf spring package. The agitator is driven subject to the fill level of the discharge screw (control via light barrier). The discharge screw itself is enabled independently of the agitator by a separate drive unit according to the boiler requirement. The result is trouble-free operation and a long service life. When using pellets, a cover panel is required over the screw channel. Maximum fill level and maximum slope must be observed.

Standard delivery:

Horizontal discharge according to the project drawing

■ Bottom agitator with two arms and external drive with shaft routed to

inside

■ Drive for bottom agitator 3 x 400 V, with geared conveyor motor and

torque support; control according to boiler control unit with enabling of discharge screw

■ Drive unit for discharge screw with spur geared motor 3 x 400 V and chain drive; control according to boiler control unit with enabling of the following conveyor device; speed/output: project-related and subject to boiler output and fuel

■ Light barrier for monitoring the fill level at the end of the sealed screw channel

■ Outlet with inspection cover and safety limit switch

To be carried out on the customer side:

■ Installation of an intermediate floor required (preferably made from wooden boards)

Note

1. Discharge screw (part no.: 7387 603) must also be ordered!

2. Speed/output of the drives: Sizing by KÖB design department.

Specification Horizontal discharge AH AH up to 5 m AH up to 6 m Part no. 7837 979 7837 854

Discharge circuit f m 3.8 4.5 5.0 5.0 5.5 6.0 Weight excluding conveyor channel kg 480 480 480 500 500 500 Torque of the drives

Nm ~2900 ~2900 ~2900 ~2900 ~2900 ~2900

Nm ~800 ~800 ~800 ~800 ~800 ~800

Design information

(cont.)

PYROTEC

5822 511 GB

Page 48

42,99 mm

29,62 mm

34,54 mm37,56 mm14,59 mm

7,29 mm

2,96 mm

246

< 200

d c

> 10000

585

3,46 mm

4,33 mm

410

287

18,03 mm

ø 1490

ø g

ø f

Axis, agitator

Screw axis

Rotational direction

Centre, agitator

Sizing the horizontal discharge AH with agitator and discharge screw

a Min. length of protective panel for bunker walls b Sealed channel c Open conveyor channel downstream of agitator centre d Open conveyor channel upstream of agitator centre max. 2.8 m e Wall clearance to centre f Discharge circuit from 3.9 to 6.1 m depending on bunker situation g Effective scope 0.8 to 0.95 x f

Depending on: fuel, installation position, compression, etc.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 49

3,65 mm

4,85 mm4,00 mm

76,25 mm

4,81 mm

406

< 330

< 200

361

> 10000

< 170

287

< 600

< 300

D E

13,59 mm

14,67 mm

33,67 mm

1360

1260

L1 + 200

0,96 mm

1,52 mm

< 330

630630

1260

< 200

> 10000

< 330

> 725

E D

A-A B-B

C-C

Design information

(cont.)

PYROTEC

5822 511 GB

Page 50

A Installation position, horizontal (version 1) B Installation position, sloping (version 2) C Finished floor, concrete-lined (concrete block out for recessed

installation)

Finished floor

Seal installation opening with fire-retardant panel

Height adjustable base

Axis, screw conveyor

Axis, agitator

Sub-structure

Building floor

Centre, agitator

Concrete block out (for recessed installation)

Fuel-specific limits Maximum fill level

Pellets S 650 m 4.5 Briquettes S 350 m 6.0 Woodchips from forest S 250

m 8.0

Boiler output max. Pellets S 650 kW 2000 Briquettes S 350 kW 720 Woodchips from forest S 250

kW 720

a Angle of inclination max. Pellets S 650 6° Briquettes S 350 0° Woodchips from forest S 250

15°

Note

For pellets, the cover panels part no. 7387 895 are required.

Discharge screw AH for horizontal discharge

Part no. 7387 603

The fuel is moved by the horizontal discharge agitator arms into the conveyor channel, which is open across the entire bunker length. Outside the bunker, the screw channel is sealed.

Standard delivery:

■ Conveyor channel running through the entire system with specially matched discharge screw

Note

Article price per m The max. length is 10 m. Total price: Total length L in m (max. 10) x individual price

Protective panel AH for bunker

Part no. 7387 985

Metal cover to protect against damage to the bunker wall caused by the agitator arms. Mounting on the internal wall of the silo.

Standard delivery:

■ Protective panel, painted Length and number matched to the project

■ Rawl plugs and screws

Cover panel AH for pellets

Part no. 7387 895

Metal cover of the open screw conveyor area to reduce the inlet cross section.

Note

Observe the following when changing the fuel:

1. Changeover from woodchips from forest thinnings to pellets: Before filling the silo with woodchips from forest thinnings, remove the cover panels from the discharge screw.

2. Changeover from pellets to woodchips from forest thinnings: The discharge system is to be extended by means of cover panels.

Standard delivery:

■ Cover panel, painted Length and number matched to the project

■ Screws

Design information

(cont.)

PYROTEC

5822 511 GB

Page 51

6.13 Fuel discharge by means of funnel discharge

Funnel discharge

Material discharge for round silos is carried out with an agitator integrated in the discharge casing. In its centre, the discharge screw is driven via a solid universal joint. When the silo is full, the screw conveyor moves into a vertical position. The funnel limits the angle of the screw conveyor when the silo is empty. Drive is via a spur geared conveyor motor to the agitator. In the case of material compression in the discharge casing, as a result of increased drive power consumption, the supply direction of the screw conveyor is changed automatically for a period set at the factory. This releases the compression, preventing a fault.

Standard delivery:

■ Funnel discharge as per order data with drive unit 3 x 400 V

■ Automatic control of the drive for the spur geared conveyor motor for both rotational directions

■ Safety limit switch installed on inspection cover of discharge casing

Version and drives Funnel discharge AP-11 AP-12 Part no. 7837 899 7837 929

Diameter, discharge circuit, max. m 6.0 7.5 Boiler outputs with Pellets S 650 kW 3000 2500 Woodchips from forest S 200 kW 1250 2500 Shavings S 130 kW 1250 2500 Torque at screw conveyor Nm ~1500 ~3000

ø b

ø a

< 1,8 x a

320

< 600

210

40°

11,22 mm

17,94 mm

5,15 mm

6,69 mm

18,86 mm

2,26 mm

57,48 mm

2,21 mm

8,32 mm

40,00°

Design information

(cont.)

PYROTEC

5822 511 GB

Page 52

Version and drives Funnel discharge AP-11 AP-12

AP-Z02

Part no. 7387 899 7387 929 7388 042

a m 6.0 7.5 7.5 b mm 2205 3005 3005 c mm 708 1030 1030 d mm 282 310 e Nm 431 469 -

Additional outlet flange

Part no. 7388 520

Additional connection option for supply equipment to discharge casing for twin-boiler system.

Funnel, large

Part no. 7388 042

Surcharge for a funnel diameter of 3000 mm. Note

In the case of funnel discharge AP-12, a funnel diameter of 3000 mm is required.

6.14 Fuel discharge by means of a push floor (sizing)

Number and length of the pushrods with a maximum dumping height

Applies to pushrods for pushrod drive (AS) individual and for the pushrod with discharge function of the AS-twin (standard version). Permissible dumping heights below are maximum values and should not be exceeded.

Special version as individual rod with a width of up to 3.00 m possible on request.

Max. permissible dumping height and length of the pushrods in S200 Trade name Pushrod Type AS-2.50 AS-2.25 AS-2.0 AS-1.75 AS-1.5 Part no.: 7387 992 7387 995 7387 836 7387 956 7387 989 Dumping height with length:

12 m 3.1 3.6 4.1 4.9 5.8 10 m 3.9 4.6 5.3 6.3 7.4 8 m 5.3 6.1 7.0 8.4 9.8 6 m 7.5 8.6 9.8 12.3 14.9

Max. permissible dumping height and length of the pushrods in S350 Trade name Pushrod Type AS-2.50 AS-2.25 AS-2.0 AS-1.75 AS-1.5 Part no.: 7387 992 7387 995 7387 836 7387 956 7387 989 Dumping height with length:

10 m 2.6 3.0 3.5 4.1 4.8 8 m 3.4 4.0 4.55 5.4 6.4 6 m 4.9 5.6 6.4 8.0 9.7

Max. permissible dumping height and length of the pushrods in S450 Trade name Pushrod Type AS-2.50 AS-2.25 AS-2.0 AS-1.75 AS-1.5 Part no.: 7387 992 7387 995 7387 836 7387 956 7387 989 Dumping height with length:

10 m 2.1 2.4 2.7 3.2 3.8 8 m 2.7 3.1 3.6 4.2 5.0 6 m 3.8 4.4 5.0 6.2 7.5

Option for article AP-11. Required for AP- 12.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 53

Max. permissible dumping height and length of the pushrods in S650 Trade name Pushrod Type AS-2.50 AS-2.25 AS-2.0 AS-1.75 AS-1.5 Part no.: 7387 992 7387 995 7387 836 7387 956 7387 989 Dumping height with length:

12 m 1.5 1.8 2.0 2.4 2.9 10 m 1.9 2.3 2.6 3.1 3.7 8 m 2.6 3.0 3.5 4.2 4.9 6 m 3.7 4.3 4.9 6.1 7.4

Specification for the pushrod drives

Trade name Pushrod drive Type Individual stand-

ard

Twin standard Heavy

Version

Part no.: 7387 978 7387 915 On request

Piston diameter mm 180 180 220 Piston rod diameter mm 90 90 110 Lift mm 600 600 800 Test pressure bar 240 240 240 Pressure force at 190 bar FZD kN 484 484 722 Tensile force at 190 bar FZZ kN 362 362 542 Length from centre of cylinder - piston boss

Type K

1080

Type L

1230

1575

Forces on the building

In the case of pushrod drives for discharge push floors with several pushrods, the hydraulic cylinders have pipes laid in opposite flow directions, i.e. the first cylinder pulls, the second cylinder pushes, the third cylinder pulls, etc. The cylinder with the lowest pressure drops generally moves first into the end position, then the next one.

When all cylinders are in the end position, the oil pressure increases up to the response pressure for the pressure diverter valve (set to 190 bar at the factory) and this switches to the opposite direction.

FG1 Maximum tensile force on the weld base of the bunker upwards

per metre length

FS Total standard forces on the front panel (slot discharge)

FR Total standard forces on the back panel FR1 Standard force of a pushrod on the back panel FS1 Standard force of a pushrod on the front panel

Design information

(cont.)

PYROTEC

5822 511 GB

Page 54

FZD Maximum pressure force on the weld base for the pushrod

drive

FZZ Maximum tensile force on the weld base for the pushrod drive

Number of pushrods 1 2 3

FS mm 1x FS1 1x FS1 2x FS1 FR mm 1x FR1 1x FR1 110

FS1 FR1 FZZ FZD FG1 FM1 Z

Standard version AS-001/2

160 kN 130 kN 362 kN 484 kN 12 kN 100 kN 125 mm

Heavy version Y article

240 kN 195 kN 542 kN 722 kN 15 kN 150 kN 150 mm

Slot discharge, for pulling

The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design.

Note

Only KÖB original weld bases are permissible for the pushrod drive.

Specification Slot discharge, for pulling Screw

D = 190 mm

Screw

D = 250 mm

a mm 650 700 b mm 380 430 c mm 350 400 d For max. dumping height, see page 52 For max. dumping height, see page 52 e mm > 3200 > 3200 f mm 1500-2500 1500-2500

Design information

(cont.)

PYROTEC

5822 511 GB

Page 55

7,92 mm

10,29 mm

6,02 mm

9,50 mm19,48 mm0,89 mm

27,72 mm

5,54 mm

1,98 mm

500

600

1230

> 1750

125

95,02 mm

0,48 mm

15,84 mm

(4000 - 12000)

50 - 150

A B

A - A

A A

49,44 mm

19,80 mm

0,79 mm

1,19 mm

19,68 mm

0,79 mm

42,36 mm

> 100

1500 - 2500 1500 - 2500

> 150

FS1

FR1

FZZ

FZD

Required order data for the above example: Position Part no. Quantity Unit Designation

7387 978 2 pce Pushrod drive AS individual with hydraulic cylinder type L

7387 924 1 pce Cover for push floor screw conveyor (optional)

7387 952 2 pce Weld base, AS individual

7387 830 2 pce Weld base, bunker

Hydraulic compartment

Corresp. to length

See pricelist

2 pce Pushrod (incl. stop wedges)

Corresp. to dimensions

See pricelist

1 pce Push floor screw conveyor

7387 904 1 pce Version and drive, AQ standard

Corresponding boiler output

See pricelist

1 pce Hydraulic drive, ASH individual

Centre discharge

The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design.

Note

Use only KÖB original weld bases for the pushrod drive!

Design information

(cont.)

PYROTEC

5822 511 GB

Page 56

Specification Centre discharge Screw

D = 190 mm

Screw

D = 250 mm

a mm 350 400 b mm 270 360 c For max. dumping height, see page 52 For max. dumping height, see page 52 d In the middle third of the silo length In the middle third of the silo length e mm > 3200 > 3200

A - A

3,96 mm

9,50 mm17,10 mm0,84 mm

33,26 mm

2,09 mm

250

600108050

125

> 2100

8,07 mm

12,67 mm

5,54 mm

4,28 mm

500

800

+10 0

FM1

95,02 mm

(5000 - 12000)

15,84 mm

0,43 mm

50 - 150

A A

46,86 mm

0,51 mm

19,69 mm

1,30 mm

19,73 mm0,79 mm 1,58 mm

43,16 mm

1500 - 2500

> 150

1500 - 2500

50 - 150

Design information

(cont.)

PYROTEC

5822 511 GB

Page 57

Required order data for the above example: Position Quantity Unit Designation

2 pce Pushrod drive AS individual with hydraulic cylinder type K

2 pce Weld base, bunker

Cover, centre discharge

1 pce Push floor screw conveyor

4 pce Pushrod (incl. stop wedges)

1 pce Version and drive, AQ standard

Hydraulic compartment

1 pce Hydraulic drive, ASH individual

2 pce Weld base, AS individual

Slot discharge with fill function

The drawing below is a general arrangement and should not be used for construction design. A project-related drawing must be produced for construction design.

Note

Use only KÖB original weld bases for the pushrod drive!

Specification Slot discharge with fill function Screw

D = 190 mm

Screw

D = 250 mm

a mm 650 700 b mm 380 430 c mm 350 400 d Charging chute e For max. dumping height, see page 52 f mm > 3200 > 3200

Design information

(cont.)

PYROTEC

5822 511 GB

Page 58

7,70 mm

5,86 mm

9,71 mm

500

9,32 mm16,78 mm

3,57 mm

46,60 mm

600

1080

235

> 3000

5,44 mm

2,04 mm

3,57 mm

230

125

A - A

46,60 mm 46,60 mm

93,20 mm

0,50 mm

< 8000 < 12000

(< 20000)

50 - 150

1,90 mm

15,53 mm

230

FR1

FS1

FZZ

FZD

3,03 mm0,54 mm

19,42 mm 0,78 mm

1,16 mm

19,42 mm

0,78 mm

41,55 mm

49,60 mm

390

50 - 150

> 100

1500 - 2500

> 150

> 100

F E

C D

Design information

(cont.)

PYROTEC

5822 511 GB

Page 59

Required order data for the above example: Position Quantity Unit Designation

2 pce Pushrod drive AS twin with hydraulic cylinder type K

1 pce Cover for push floor screw conveyor (optional)

2 pce Weld base, bunker

2 pce Pushrod (incl. stop wedges)

1 pce Push floor screw conveyor

1 pce Version and drive, AQ standard

1 pce Hydraulic drive, ASH twin

2 pce Weld base, AS twin

6.15 Fuel discharge by means of push floor (accessory)

Pushrod drive, individual

Part no. 7387 978

With hydraulic cylinders, pushrods to which transport wedges are attached, are moved forwards and backwards. Stop wedges are fixed to the floor between the transport wedges. As a result of this movement, the wood fuel is dispensed from the bunker and fed into the trough of the push floor screw conveyor.

Standard delivery:

■ Mount with hinge lug connection for the cylinder

■ Hydraulic cylinder with 2 HP ball valves and 2 hydraulic hoses

■ Pushrod up to bunker wall with hinge lug connection

■ Material for complete hydraulic pipework

Weld base, pushrod drive, individual

Part no. 7387 952

Solid steel structure for installation in concrete to secure the pushrod drive. The structure has been load tested and permanently withstands the dynamic stress. A prerequisite for this is the prescribed embedding in concrete.

Standard delivery:

■ 1 weld base per pushrod drive

To be carried out on the customer side:

■ Location, positioning and connecting of the weld base with the iron reinforcement on the customer side

■ Embedding the weld base in concrete

■ Static calculation and sizing of the iron reinforcement on the customer side

Note

Only KÖB original weld bases are permissible!

Pushrod drive, twin

Part no. 7387 915

With hydraulic cylinders, pushrods to which transport wedges are attached, are moved forwards and backwards. Stop wedges are fixed to the floor between the transport wedges. In the case of a twin pushrod drive, each longitudinal section of the bunker is moved with two pushrods working independently of one another.

■ Charging pushrod for quick removal of the fuel filled at the bunker end in the direction of the bunker centre.

■ Discharge pushrod for the dispensed discharge of the wood fuel into the trough of the push floor screw conveyor.

The two pushrod drives are located one above the other and are supported by a joint mount.

Standard delivery:

■ Mount for two cylinders with a hinge lug connection

■ Two hydraulic cylinders with 2 HP ball valves and 2 hydraulic hoses

■ Discharge pushrod up to bunker wall with hinge lug connection

■ Charging pushrod up to start of level charging function with hinge lug connection

■ Material for complete hydraulic pipework

Weld base, pushrod drive, twin

Part no. 7387 916

Solid steel structure for installation in concrete to secure the pushrod drive. The structure has been load tested. If embedding in concrete has been carried out in accordance with the regulations, the weld base permanently withstands dynamic stress.

Standard delivery:

■ 1 weld base per pushrod drive

To be carried out on the customer side:

■ Location, positioning and connecting of the weld base with the iron reinforcement on the customer side

■ Embedding the weld base in concrete

■ Static calculation and sizing of the iron reinforcement on the customer side

Note

Only KÖB original weld bases are permissible!

Weld base, bunker

Part no. 7387 830

Steel profiles for welding the pushrod guide elements and the trough of the push floor screw conveyor. The weld base in the bunker is also the slide rail for the pushrod.

Standard delivery:

■ Rolled profiles UNP 240 with anchoring irons per pushrod over the entire length

■ Angle profiles 50/50/5 with anchoring irons over the entire width (push floor screw conveyor)

Design information

(cont.)

PYROTEC

5822 511 GB

Page 60

To be carried out on the customer side:

■ Manufacturing the concrete floor

■ Installation of the profiles level with the concrete floor (max. deviation of 5 mm to 10 m)

Note

Article price per m Total price is calculated as follows: For pushrod drive, individual: (pushrod drives in pce x length of bunker in m) + (1 x width of bunker in m) x article price For pushrod drive, twin: (pushrod drives in pce x length of bunker in m) + (2 x width of bunker in m) x article price

Pushrod

Pushrod in solid structure with crosswise transport wedges, side connection profiles, stop wedges and guide elements. Length x width of the pushrod gives the floor area moved with the transport wedges.

Standard delivery:

■ Pushrod split into rod, transport wedges and guide elements (welding during installation)

■ Stop wedges incl. fixing materials

Note

Number width transport wedge in m; article price per m; Total price: Length in m x article price (for max. length, see table 3)

Specification

Pushrod B 1.50 B 1.75 B 2.00 B 2.25 B 2.50 Part no. 7837 989 7387 956 7387 836 7387 995 7837 992

Width m 1.50 1.75 2.00 2.25 2.50

Hydraulic drive, AS individual

Hydraulic drive to actuate single pushrod drives with discharge function. When the required fill level of the push floor screw conveyor is reached, the discharge function is switched off.

■ Hydraulic drive comprising: – Gear pump 3 x 400 V – Oil container – Non-return valve – Pressure limit valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling – Hydraulic hoses – Wall mounting brackets

■ Control: According to the boiler control unit, fuse protected with temperature and level switch in the oil container

Use of the hydraulic drives for various push floors (drives plus rods)

Hydraulic drive, AS individual V9 V18 V40 Rated output of the boiler/s kW 100-720 750-1250 1250-2500 Part no. 7387 912 7387 901 7387 806

Output, gear pump

*10

kW 4 4 7.5

Supply volume Stage 1

l/min 9 9 20

Draught Stage 1

bar 200 200 200

Supply volume Stage 2

l/min - 18 40

Draught Stage 2

bar - 100 100

Oil content l 30 55 80 Max. number of pushrods

*11

pce 3 3(4) 3(4)

Additional equipment for driving hydraulically controlled silo covers possible.

*10

Information on function: with a 2-stage gear pump, the pump runs in standard mode at stage 2, which means that the pushrods move quickly. Only when the pressure drop is increased (e.g. in the case of a forward movement of the discharge pushrod with a high fill level) does the pump switch to stage 1.

*11

Values in brackets: option only in coordination with project management at the factory.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 61

Hydraulic drive, AS twin

Hydraulic drive to activate twin pushrod drives with discharge and fill function. When the required fill level of the push floor screw conveyor is reached, the discharge function is switched off. If there is free space above the discharge push floor to accommodate top-up fuel, the top and back pushrod carries out the fill function. When the fuel is required by the heating system, the fill function is interrupted and switched to the discharge function of the bottom and front pushrod.

■ Hydraulic drive comprising: – Gear pump 3 x 400 V – Oil container – 4/2-way solenoid valve – Non-return valve – pressure limiting valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling – Hydraulic hoses – Wall mounting brackets

■ 2 infrared light barriers for level monitoring, bunker

■ Control of discharge function: according to the boiler control unit, fuse protected with temperature and level switch in the oil container

■ Control of fill function: According to the light barrier enabling in the bunker

Use of the hydraulic drives for various push floors (drives plus rods)

*12

Hydraulic drive, AS twin V18 V40 Rated output of the boiler/s kW 100-1250 1250-2500 Part no. 7387 812 7387 969

Output, gear pump

*13

kW 4 7.5

Supply volume Stage 1

l/min 9 20

Draught Stage 1

bar 200 200

Supply volume Stage 2

l/min 18 40

Draught Stage 2

bar 100 100

Oil content l 55 80 Max. number of pushrods

*14

pce 3(4) 3(4)

Push floor screw conveyor D = 190 mm

Part no. 7387 811

In order to transport the discharged fuel away from the pushrods, the push floor screw conveyor extends over the entire push floor width as an open trough screw conveyor. For further transportation, the push floor screw conveyor, depending on the transfer situation, is designed in the sealed version as a trough or pipe.

Standard delivery:

■ Push floor screw conveyor according to the project drawing

Note

Article price per m

Push floor screw conveyor D = 250 mm

Part no. 7387 887

Standard delivery:

■ Push floor screw conveyor according to the project drawing

Note

Article price per m

*12

Additional equipment for driving hydraulically controlled silo covers possible.

*13

*14

Values in brackets: option only in coordination with project management at the factory.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 62

Drive, push floor screw conveyor, standard

Part no. 7387 925

Standard version for push floor screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard.

Standard delivery:

■ Drive unit with spur geared motor 400 V and chain drive

■ Light barrier across the entire open area for monitoring the fill level (overfill protection)

■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version)

Drive, push floor screw conveyor, standard Part no. 7837 925

Torque at screw conveyor Nm ~800 ~800 ~800 Push floor screw conveyor Type AQ-L150 AQ-L150 AQ-L190 Function, push floor screw conveyor Pulling Pushing Pulling Max. length, push floor screw conveyor m 10 8 10 Max. boiler output with woodchips kW 300 300 1250

Drive, push floor screw conveyor, higher-power

Part no. 7387 880

Special, powerful version of the push floor screw conveyor for more difficult applications (high pump rate and/or pushing function). The system is driven via a more powerful version of a spur geared motor, bearing and chain in a dust-proof chain guard.

Standard delivery:

■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 400 V and chain drive; matching and control on project basis;

■ Light barrier across the entire open area for monitoring the fill level (overfill protection)

■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version)

Drive, push floor screw conveyor, higher-power Part no. 7837 880

Torque at screw conveyor Nm ~1200 ~1200 ~1200 Push floor screw conveyor Type AQ-L190 AQ-L250 AQ-L250 Function, push floor screw conveyor Pulling Pushing Pulling Max. length, push floor screw conveyor m 10 8 10 Max. boiler output with chippings kW 1500 2500 2500

Cover, push floor screw conveyor

Part no. 7387 924

Cover for the open trough of the push floor screw conveyor and the bunker slot. The cover is fitted to the front bunker panel and can be opened via a hinge. It helps to protect maintenance personnel against contact.

Standard delivery:

■ Cover of the push floor screw conveyor with wall mounting bracket and hinge according to project drawing

■ Limit switch for emergency stop of the push floor and the push floor screw conveyor when opening the cover

Note

Article price per m; Total price: Length A in m x article price [A = width of bunker]

6.16 Charging the boiler with fuel

Trough screw conveyor

Part no. 7387 941 for trough screw conveyor D = 150 mm Part no. 7387 873 for trough screw conveyor D = 190 mm Part no. 7387 955 for trough screw conveyor D = 250 mm

The trough screw conveyor is an extremely reliable means of transportation for all granulated wood fuels. Observe the restriction in the angle of inclination.

Standard delivery:

■ Trough screw conveyor according to the project drawing

Note

Article price per m; total price; length L in m x article price

Design information

(cont.)

PYROTEC

5822 511 GB

Page 63

58,32 mm

8,75 mm

6,40 mm

1,11 mm

2,32 mm

4,53 mm

5,10 mm

14,52 mm

1,47 mm

6,38 mm

2,32 mm

8,30°

500

176

< 10000

166

> 30

a/b

300

5,80 mm

8,12 mm

7,54 mm

7,31 mm

5,51 mm

A - A

13,77 mm

4,82 mm

14,51 mm

3,77 mm

7,54 mm

15,67 mm

7,54 mm

~ 500

166

500

Drive (optionally on the l.h. or r.h. side)

Inspection clearance

Trade name Trough screw conveyor Type MF 150 MF 190 MF 250 Part no: 7387 941 7387 873 7387 955

a mm 180x180 220x220 280x280 b mm 7180 7200 7200 c (woodchips from forest thinnings) 20° 20° 20° c (pellets) 45° 45° 45° d mm 140 280 380 e mm 220 260 352 f mm 216 256 317 g mm 150 190 250 h mm 130 130 154 k mm 260 260 350 l mm 540 540 665

Drive, trough screw conveyor, standard

Proven version for the trough screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard.

Standard delivery:

■ Drive unit with spur geared motor 3 x 400 V and chain drive

■ Inlet with light barrier for monitoring the fill level (overfill protection)

■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device

Trade name Drive, trough screw conveyor Part no: 7387 984

Torque at screw conveyor Nm ~800 ~800 ~800 Diameter, screw conveyor mm 7150 7190 7250 Function Pulling Pulling Pulling Max. length m 10 10 8 Max. boiler output (pellets) kW 2000 3200 Max. boiler output (woodchips from forest thinnings) kW 600 1500 2500

Pipe screw conveyor

Part no. 7387 990 for pipe screw conveyor D = 120 mm Part no. 7387 962 for pipe screw conveyor D = 190 mm Part no. 7387 928 for pipe screw conveyor D = 250 mm

Design information

(cont.)

PYROTEC

5822 511 GB

Page 64

The pipe screw conveyor is ideal for conveying pourable wood fuels and/or in the case of steep ascending inclines.

Standard delivery:

■ Pipe screw conveyor according to the project drawing

Note

Article price per m Total price: Length L in m x article price

Trade name Pipe screw conveyor Part no: 7387 990 7387 962 7387 928

Diameter of the screw conveyor max. mm 120 190 250

Trade name Pipe screw conveyor Type MR-L120 MR-L190 MR-L250 Part no: 7387 990 7387 962 7387 928

a mm 140 280 380 b mm 150x150 220x220 280x280 c mm 140 220 324 d mm 120 190 250 Angle of inclination max. with pushing screw conveyor e mm - 90° 90° Angle of inclination max. with pulling screw conveyor e mm 65° 65° 65° f mm

7150 7200 7200 g mm 140 280 380 h mm 540 540 665 k mm 130 130 154 l mm 260 260 350

Design information

(cont.)

PYROTEC

5822 511 GB

Page 65

51,94 mm

4,08 mm

2,58 mm

5,99 mm

46,27°

6,23 mm

2,56 mm

3,77 mm

168

< 10000

250

12,26 mm4,35 mm12,92 mm

3,36 mm10,55 mm

13,90 mm

500

166

~ 500

k l

4,60 mm

1,94 mm

76,92 mm

4,29 mm

9,30 mm

4,61 mm

5,25 mm

168

< 10000

355

3,72 mm

5,55 mm

45,58°

Drive (optionally on the l.h. or r.h. side)

Distributing container

Distributing screw conveyor

Pipe screw conveyor, vertical, pushing

Pipe screw conveyor, horizontal, pushing

Drive, pipe screw conveyor, pellets

Part no. 7387 931

Simple version of the pipe screw conveyor MR 120 with pulling drive and only permissible for pellets. The system is driven via a spur geared motor and chain in a dust-proof chain guard.

Standard delivery:

■ Drive unit with spur geared motor 3 x 400 V and chain drive

■ Inlet/discharge in simple version for pellets; incl. downpipe/adaptor for the following conveyor device

Trade name Drive, pipe screw conveyor, pellets Type MR-11 Part no: 7387 931

Diameter of the screw conveyor max. mm 120 Torque at screw conveyor Nm ~800 Function Pulling Length of the screw conveyor max. m 10 Boiler output max. kW 1200

Design information

(cont.)

PYROTEC

5822 511 GB

Page 66

Drive, pipe screw conveyor, standard

Part no. 7387 843

Standard version for pipe screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared motor and chain in a dust-proof chain guard. For MR 150 and exclusively with pellets, it is also possible as a pushing version.

Standard delivery:

■ Drive unit with spur geared motor 3 x 400 V and chain drive

■ Inlet with light barrier for monitoring the fill level (overfill protection)

■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version)

Trade name Drive, pipe screw conveyor, standard Type MR-12 Part no: 7387 843

Diameter of the screw conveyor max. mm 150 150 190 Torque at screw conveyor Nm ~800 ~800 ~800 Function Pulling Pushing Pulling Length of the screw conveyor max. m 10 8 10 Boiler output max. when using: Pellets kW 200 1200 3200 Woodchips from forest thinnings kW 300 - 1250

Drive, pipe screw conveyor, high-power

Part no. 7387 963

Special, powerful version of the pipe screw conveyor for more difficult applications (high pump rate and/or pushing function). The system is driven via a more powerful version of a spur geared motor, bearing and chain in a dust-proof chain guard.

Standard delivery:

■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 3 x 400 V and chain drive

■ Inlet with light barrier for monitoring the fill level

■ Discharge with inspection cover, safety limit switch and downpipe/ adaptor for the following conveyor device (not required in pushing version)

Trade name Drive, pipe screw conveyor, high-power Type MR-13 Part no: 7387 963

Diameter of the screw conveyor max. mm 190 250 250 Torque at screw conveyor Nm ~1100 ~1100 ~1100 Function Pulling Pushing Pulling Length of the screw conveyor max. m 10 8 10 Boiler output max. when using: Woodchips from forest thinnings kW 1500 2500 2500

6.17 Fuel storage in on-site pellet store (sizing)

Sizing the pellet storage room

The storage room should be more rectangular than square and should be of a size which allows an annual quantity of fuel to be stored. The size of the storage room depends on the heating load of the building. The floor area should, however, not be less than 2 x 3 m. The required size of the storage room for the annual fuel volume in m3 (incl. empty space) is calculated by multiplying the building heating load (in kW) by a factor of 0.9 (m3/kW).

Example:

Heating load of the building 150 kW

150 kW x 0.9 (m3/kW) = 135 m

Available space (storage room less unusable area due to sloping floors) = 135 m3 x 2/3 +135 m3 = 225 m

Amount of pellets

= 225 m3 x 650 kg/m

= 146250 kg/m3 ≈ 147 t

Storage room size

= 135 m3/ 2.3 m (room height)

= 59 m2 floor area In order to store the annual fuel quantity, a room size of 7 m x 8.5 m is sufficient. Stored amount of energy = 58500 kg x 5 kWh/kg = 292 500 kWh

Design information

(cont.)

PYROTEC

5822 511 GB

Page 67

A B

200 mm

≥ 500 mm

40°

Fill connector

Return air connector

Air space

Slanted floor

Empty space

Discharge system

Available volume = ⅔ of the room

Pellet storage room design and required system components

B D

A C

< 9250

<10000

100

≥

Protective boards at the entrance to the storage room

Supply area, screw supply system

Deflector

Discharge to supply screw conveyor

Min./max. length of the discharge area

Max. storage room length

Return air connector

Fill connector

Slanted panel to compensate for the lengths of the storage room/ supply area

Design information

(cont.)

PYROTEC

5822 511 GB

Page 68

■ The pellet storage room must be dry, as pellets will swell up markedly if exposed to moisture. This leads to substantial difficulties in delivering the fuel to the boiler.

■ The pellet storage room must be of solid, leak-proof construction, as loading pellets into the room creates dust and the pellets will exert high pressure against the walls.

■ Doors or access hatches into the pellet storage room must open outwards and must be sealed against dust egress (with an all-round seal). From a pellet amount in excess of 6.5 tonnes, doors must be self-closing and fire-retardant T30.

■ Fit protective boards on the inside of the door opening, so that pellets do not push against the door (see page 68).

■ Avoid electrical installation in the pellet storage room. Essential electrical installations must be of explosion-proof type – in accordance with current regulations.

■

a In Austria, surrounding walls and separating ceilings in the storage room must be designed in accordance with fire resistance class F90, and doors or access hatches in accordance with T30. Observe the fire regulations to TRVB H118 and the respective legal requirements.

■ Avoid the installation of water pipes inside the storage room because of condensation and the risk of burst pipes.

■

Pellet storage rooms should be equipped with a delivery H and a return air connector G with a coupling 4” DW100 (fire hose connector) with extension hoses leading into the pellet storage room. Pipes should be metal (not plastic), should be connected to the brickwork and should be earthed.

■

Fit a deflector C opposite the fill connector to protect the pellets and the brickwork.

■ The pellet storage room must be free from foreign bodies (small stones, wood particles, etc.).

■ The wall outlet for the room discharge from the storage room should be fire-proofed (e.g. rendered).

The screw conveyor system may be up to max. 10 m long.

Additional safety instructions for pellet stores

To operate the pellet store, we also recommend observing the following safety instructions:

Access by unauthorised persons is not permitted, and doors must be kept sealed

Smoking, fires and other sources of ignition are prohibited

Risk to life due to odourless carbon monoxide (CO) and a lack of oxygen

Before entering, ensure sufficient ventilation is in place - keep door open when entering

Entry into the storage room is only permitted with the supervision of a person standing outside the storage room

Risk of injury caused by moving parts

Ensure filling is carried out under the conditions stipulated by the heating installer and pellet supplier

Protect the pellets from moisture

Protective boards with Z profiles

A B A

Z profile (length 2000 mm)

Protective board (30 mm thick; on-site)

Door towards the storage room

Z brackets are available as accessories for the installation of the protective boards. Never install Z brackets up to the ceiling, to facilitate the (future) removal or addition of protective boards.

Fill connector and return air connector

Arrange the connectors so that no overpressure is created in the pellet storage room during the filling process. Keep the return connector unrestricted, even when the maximum filling level in the storage room has been reached (see page 67). The connectors should be located as high as possible inside the storage room to enable it to be filled to its maximum. To prevent pellets hitting the ceiling, the fill connector should be at least 20 cm below the ceiling (fit protective boards if the ceiling is plastered). The connectors should be located along the narrow side of the storage room. Pellets are blown approx. 4 - 5 m with straight fill connectors. Where a 2 x 45° bend fitting is located before the entry into the storage room, fit a straight pipe of at least 0.5 m length on the other side to protrude into the storage room. This enables the pellets to reach the required filling velocity and therefore the necessary "blow-in" depth.

Earthing

The connectors must be earthed in order to prevent static loads during the filling process. Generally the connection of each pipe element to the bonding of the building earth is recommended. At the very least, connect each pipe element securely to the brickwork, either by setting the pipe into the brickwork (without thermal insulation) or via pipe clips set into the brickwork.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 69

Connector length and location

The length of the fill connector is subject to the distance from the return air connector. Connectors may be spaced out < 500 mm if both connectors are set into a cellar window.

~ 100

≥ 500

Connector clearance ≥500 mm

Fill connector

Return air connector

~ 100

≥

500

< 500

Connector clearance < 500 mm

Fill connector

Return air connector

B A

approx. 100 mm

≥200 mm

Alternating filling

Deflector

Fill and return air connector

If connectors must be located on the long side of the storage room, we recommend alternating the filling between the connectors. This ensures more efficient filling. In any case both connectors should be earthed. A deflector should be installed opposite both connectors.

Internal pellet storage room

If the fill and return air connectors must be routed through an adjacent room, clad both with a fire-resistant material compliant with class F 90 (rockwool, or similar). Earth each extension piece via pipe clips. Plastic pipes should not be used as extension pieces.

A B C D

Connector

Fire resistant cladding (F 90)

Extension pipe

Pipe clip

Design information

(cont.)

PYROTEC

5822 511 GB

Page 70

Connector installation options

Setting into brickwork The connector is bricked into the opening without thermal insulation.

Fill connector

Wall outlet Ø 150 mm

Wall installation with screws

The connector is secured to the outside wall with screws and is earthed via a pipe clip.

B D

Fill connector

Screws

Pipe clip for earthing

Wall outlet Ø 110 mm

Window installation with screws

A plate is set into the window opening. The connector is fitted through the plate, secured with screws and earthed via a pipe clip.

BCA

D E

Fill connector

Screws

Pipe clip for earthing

Outlet Ø 110 mm

Window aperture

Design information

(cont.)

PYROTEC

5822 511 GB

Page 71

Installation into a lighting duct

Connectors may be installed through a wall or through a window opening. The shortened fill and return connectors are inserted in a 45 º bend. The bend is inserted into an extension pipe routed through the wall or the window opening.

Fill connector

Pipe clip for earthing

Extension pipe

Wall outlet Ø 110 mm or Outlet Ø 110 mm

45º bend

6.18 Fuel storage in on-site pellet store (accessories)

Deflector 1.42 x 1.25 m

Part no. 7388 188

The deflector comprises 4.0 mm thick chipboard with a fabric lining for high strength. Install the deflector B at a clearance of at least 100 mm from the wall opposite the fill connector. This deflector protects the pellets as well as the brickwork or the rendering/plaster. Pieces of plaster/render or wall that have been prised off can hinder the pellet supply and the ash removal from the boiler combustion chamber.

Standard delivery

■ Deflector 1.4 x 1.25 m

■ Section anchor with snap link for fastening

≥200 mm

A B

Fill connector

Deflector (1000 x 1200 mm)

Fill width approx. 4 - 5 m

Blast pipe, straight

Part no. 7388 213

Standard delivery:

■ Blow-in connector with Storz coupling 4”

■ Mounting flange 200 x 200 x 2 mm

■ Zinc-plated steel pipe with male thread M 107 x 2.0

■ Dummy coupling with imprint and padlock

Blast pipe with 45° bend

Part no. 7388 154

Standard delivery:

■ Blow-in connector with Storz coupling 4”

■ Mounting flange 200 x 200 x 2 mm

■ Zinc-plated steel pipe with male thread M 107 x 2.0

■ Dummy coupling with imprint and padlock

Design information

(cont.)

PYROTEC

5822 511 GB

Page 72

Extension, blast pipe, straight

Part no. 7388 056 Standard delivery:

■ Extension DN 100, length 700 mm, zinc-plated

■ Union nut for fitting

■ Clip for fastening

45° bend for blow line

Part no. 7388 052 Standard delivery:

■ Zinc-plated bend DN 100

■ Union nut for fitting

6.19 Fuel storage in on-site bunker (accessories)

Silo cover, manual FDM 2.9/1.3 m

Part no. 7387 782

Cover for secure sealing of openings for wood fuel delivery. The cover is controlled manually with leg springs as an opening aid. The opening has a fall protection grille to prevent anyone falling in when the cover is open.

Note

For the filling process (opening, filling, closing), the local regulations on accident prevention must be observed (e.g. enclosure, safety of personnel)

Standard delivery:

■ Steel supporting structure – Permissible load 250 kg/m² – Sand-blasted – Primed with zinc dust and painted

■ Welded fall protection grille with rod clearance 150 mm

■ Cover – Surface, aluminium button plate – Watertight, welded

■ Leg springs as opening aid

To be carried out on the customer side:

■ Creating the ceiling recess with concrete collar

■ Seal between cover frame and supporting surface, concrete collar

■ Padlock to protect against incorrect operation

Design information

(cont.)

PYROTEC

5822 511 GB

Page 73

All-round seal (not included in standard delivery)

Rod clearance, fall protection grille

Secured with 10 x screws

Bunker cover hydraulic FDH

Cover for secure sealing of openings for wood fuel delivery. The cover is controlled manually using a hydraulic cylinder. The silo cover is prevented from falling shut in the event of a hose break.

Note

For the filling process (opening, filling, closing), the local regulations on accident prevention must be observed (e.g. enclosure, safety of personnel). Where wind is strong (greater than 10 m/s), the cover must not be opened.

Standard delivery:

■ Supporting structure: permissible load 250 kg/m² made from steel, sand-blasted, primed with zinc dust and painted

■ Cover surface: Aluminium button plate, watertight, welded

■ Hydraulic cylinder with hinge lug connection, pipe break protection, mount, hydraulic hoses 1 m long

■ Rubber apron to deflect chippings on the hinge side

To be carried out on the customer side:

■ Creating the ceiling recess with concrete collar

■ Seal between cover frame and supporting surface, concrete collar

Design information

(cont.)

PYROTEC

5822 511 GB

Page 74

40,55 mm

62,77 mm

Fall protection grille (optional)

Rubber apron

All-round seal, required, not included in standard delivery Recommendation: Kemperol combi roof seals

Specification Type

*15

Part no.

FDH 4.0/2.4

7388 011

FDH 5.5/2.4

7387 903

FDH 7.0/2.4

7387 834

FDH 8.5/2.4

7387 884

Opening length x width

a mm 4020 5520 7020 8520 c mm 2400 2400 2400 2400 Dimensions, concrete collar b mm 4420 5920 7420 8920 d mm 2800 2800 2800 2800 e mm 250 250 250 250 Dimensions, cover, external f mm 3025 3025 3025 3025 g mm 4500 6000 7500 9000 h mm 2924 2924 2924 2924 Number of hydraulic cylinders pce 1 1 1 2 Weights, cover kg 1029 1231 1516 1823

*15

Type 7.0/2.4 and 8.5/2.4 with covered expansion joint for heat expansion

Design information

(cont.)

PYROTEC

5822 511 GB

Page 75

Fall protection grille 120 for FDH

Fall protection grille for corresponding bunker cover in several elements to prevent anyone falling in when the cover is open. Each element is prepared for installation of a shaker motor (shaker motor at an additional charge).

Standard delivery:

■ Support profile for installation in ceiling recess

■ Fall protection grille in several elements, mesh size: 200 x 120 mm

Specification Fall protection grille, type 120 for FDH 4.0/2.4 FDH 5.5/2.4 FDH 7.0/2.4 FDH 8.5/2.4 Part no. 7387 914 7387 817 7388 014 7387 922

Quantity pce 2 2 3 4 Weight per pce kg 117 161 133/141 124/120

Fall protection grille 200 for FDH

Fall protection grille to prevent anyone falling in when the cover is open. Suitable for corresponding bunker cover in several elements. Each element is prepared for installation of a shaker motor (shaker motor at an additional charge).

Standard delivery:

■ Support profile for installation in ceiling recess

■ Fall protection grille in several elements, mesh size: 200 x 200 mm

Specification Fall protection grille, type 200 for FDH 4.0/2.4 FDH 5.5/2.4 FDH 7.0/2.4 FDH 8.5/2.4 Part no. 7387 910 7387 824 7387 930 7387 983

Number of elements pce 2 2 3 4 Weight per pce kg 104 143 118/125 110/106

Bunker cover, movable FDB

Cover for secure sealing of openings let into travel planes for wood fuel delivery. The surface of the cover is flush with the travel plane. The sub-structure has a drip channel. The cover is controlled manually using a hydraulic cylinder. The silo cover is prevented from falling shut in the event of a hose break.

Standard delivery:

■ Supporting structure: Perm. wheel load: FDB 3.0/2.0: 7.5 to; FDB 3.8/2.4 and FDB 3.2/3.2:

10.0 to; steel, sand-blasted, primed with zinc dust and painted.

■ Cover surface: For filling with asphalt or concrete on the customer side.

■ Sub-structure: Has drip channel and two drain connectors NW 100.

■ Hydraulic cylinder: With hinge lug connection, pipe break protection, mount and hydraulic hoses 1 m long

To be carried out on the customer side:

■ If the travel surface is sloping, the water flowing to the cover must be drained away upstream of the cover frame by means of a drain channel

■ Drain line for rainwater, channel heating

■ Seal between cover frame and supporting surface of cover frame

■ Filling of the cover surface with a bitumen layer and asphalt or concrete, watertight design (max. permissible own weight of the fill 2200 kg/m3)

Design information

(cont.)

PYROTEC

5822 511 GB

Page 76

56,10 mm

1,90 mm

ø102

C B

58,53 mm1,87 mm 1,87 mm

5,30 mm

40,20 mm

1,68 mm

47,31 mm

9090

290

C D

< 10%

±0,0

39,71 mm2,26 mm31,97 mm

37,68 mm

86,08°

86°

120

~ 1730

6,78 mm

(120)

Filling on customer side (concrete or asphalt)

Channel for rainwater

Rainwater drain (on site)

Threaded fitting

Filling level

Fall protection grille (optional)

All-round seal (required) (on site)

Drain channel, running water (on site)

Design information

(cont.)

PYROTEC

5822 511 GB

Page 77

Specification Bunker cover, movable FDB FDB 3.0/2.0 m FDH 3.8/2.4 m FDH 3.2/3.2 m Part no. 7387 850 7387 793 7387 974

a mm 3000 3800 3200 b mm 2110 2510 3310 c mm 2000 2400 3200 d mm 3150 3950 3350 e mm 2530 2930 3730 f mm 2150 2550 3310 Weight, cover, FDB kg 1520 2360 2680 Max. permissible wheel load t 7.5 10 10

Fall protection grille, 120 for FDB

Standard delivery:

■ Support profile for installation in ceiling recess

■ Fall protection grille in several elements

■ Mesh size: 200 x 120 mm

Specification Fall protection grille, type 120 for FDB 3.0/2.0 m FDH 3.8/2.4 m FDH 3.2/3.2 m Part no. 7387 889 7388 016 7387 868

Number of elements pce 2 2 2 Weight per pce kg 130 205 230

Fall protection grille, 200 for FDB

Standard delivery:

■ Support profile for installation in ceiling recess

■ Fall protection grille in several elements

■ Mesh size: 200 x 200 mm

Specification Fall protection grille, type 200 for FDB 3.0/2.0 m FDH 3.8/2.4 m FDH 3.2/3.2 m Part no. 7387 798 7387 801 7388 019

pce 2 2 2 Weight per pce kg 120 180 210

Shaker motor for fall protection grille

Part no. 7387 810

The shaker motor sets the fall protection grille in an oscillating motion. This prevents the delivered fuel from bridging the fall protection grille and therefore ensures a steady material flow during filling.

Standard delivery:

■ Shaker motor, 3 x 400 V incl. control, thermal protection and installation material

■ Key switch

To be carried out on the customer side:

■ Electrical connection of shaker motor and key switch

Note

One shaker motor is required per fall protection grille element. In addition, when using shaker motors, a large control panel must be included in the plans.

Hydraulic drive, bunker charging cover, ASH

Part no. 7388 856

The hydraulic drive is used exclusively for actuating a bunker cover, which is opened hydraulically. The cover is opened by the hydraulic cylinder when the key switch button is pressed. When the key switch button is released, the load holding valve fixes the cover in position.

Standard delivery:

■ Hydraulic drive comprising: – Gear pump 4 l/min incl. motor 1.5 kW 3 x 400 V – Oil container 12 l, non-return valve – pressure limiting valve – Pressure diverter valve – Return filter – Oil level indicator – Pressure gauge – Shut-off valve – Oil filling

Design information

(cont.)

PYROTEC

5822 511 GB

Page 78

– Hydraulic hoses – Wall mounting brackets

■ Control: – According to the boiler control unit, fuse protected with tempera-

ture and level switch in the oil container

■ Key switch button OPEN/OFF/CLOSED for installation of a locking cylinder on the customer side (installation close to cover)

Note

Application in the case of silo discharge systems without hydraulic activation (AF, AG, AP, external discharge)

Cover drives for hydraulic drive, ASH

Type ASH 1 ASH 2 ASH 3

Part no. 7388 010 7387 913 7387 897

The auxiliary equipment for the hydraulic drive ASH of the pushrod discharge for activating hydraulically opening bunker covers. The covers are opened by the hydraulic cylinder when the key switch button is pressed. When the key switch button is released, the load holding valve fixes the cover in position.

Standard delivery:

■ 1 valve block per cover, each equipped with: – 2 solenoid valves – 1 load holding valve – 2 non-return throttle valves

Control:

According to the boiler control unit One key switch button OPEN/OFF/CLOSED per cover for installation of a locking cylinder on the customer side (installation close to bunker cover so that the motion process can be monitored).

Silo filling screw conveyor FS 300

Part no. 7387 808

Supply screw conveyor in open version for filling a fuel store located inside a building from an external tipping trough. Generally, at least two silo filling screw conveyors are required. The silo filling screw conveyors are routed through the fuel store in such a way so as to maximise filling.

Standard delivery:

■ Silo filling screw conveyor according to order data

■ Mounting brackets for wall mounting

■ Duct for routing through a wall

Note

Screw conveyor length with drive unit max. 10 m

Note

Price per m: Total length = wall inner up to end of screw conveyor in drop area (silo cover)

Note

The load bearing capacity of the walls must be verified on site by a structural engineer!

Drive, silo filling screw conveyor

Part no. 7387 898

The drive is located inside the building but outside the fuel store. This means that the silo filling screw conveyor has a pulling effect. For safety reasons, the key switch button must be located close to the tipping trough. The operator must permanently monitor the filling process from outside. Releasing the button stops the screw conveyor immediately.

Standard delivery:

■ Drive unit, silo filling screw conveyor

■ Spur geared motor with matched torque and pump rate, 3 x 400 V

■ Control of screw drive according to boiler control unit

■ Key switch button ON/OFF for installation of a locking cylinder on the customer side (installation close to cover).

Design information

(cont.)

PYROTEC

5822 511 GB

Page 79

8,72°

> 10°

100,13°

100°

2,58 mm

1,54 mm

10,19 mm

1300

350

200

9,59 mm

< 800

12,36 mm

59,18 mm

13,51 mm

2,31 mm

22,06 mm

< 1500

> 10000

< 1500

2860

ø300

A-A

6.20 Back burning protection

Rotary lock valve

Rotary lock valve for fire protected separation of combustion system and fuel store with overpressure or underpressure, and with simultaneous material transportation for installation in a drop section. The rotary valve is made entirely from steel and is permissible as a fire protection between the combustion system and woodchip silos in wood processing operations with overpressure or underpressure. The drive device is a spur geared motor with sprung torque support. If the woodchips are extremely coarse, briefly running the system in reverse avoids jamming. Fire protection: RSE according to TRVB and VKF Max. permissible overpressure in the fuel store: + 500 Pa Max. permissible underpressure in the fuel store: ± 0 Pa

Standard delivery:

■ Rotary lock valve according to order data

■ Control of spur geared motor for both rotational directions according to boiler control unit

Positioning:

■ Directly above the supply screw conveyor

■ Exception for funnel discharge: directly at the casing

Note

Rotary lock valve 190 for supply system D 120 mm Rotary lock valve 260 for supply system D 150 mm and D 190 mm

10,67 mm

13,24 mm

27,93 mm

7,86 mm

14,00 mm

øb

Design information

(cont.)

PYROTEC

5822 511 GB

Page 80

Trade name Rotary lock valve Type MZ 190 MZ 260 Part no: 7387 967 7387 422

a mm 260 330 b mm 7193 7264 c mm 662 709 d (Di) mm 150 202 e (Da) mm 200 250 e (Di) mm 150 202 e (Da) mm 200 250 f mm 274 346 Output, drive kW 0.75 0.75 Drive speed rpm 252 25

Shut-off gate valve MA 220

Part no. 7388 020

Fire protected appliance for installation in a drop section, for mechanical separation of the combustion system and unpressurised fuel store. The shut-off gate valve opens automatically and closes with zero volts via a spring balancer in the event of burnout, risk of burn-back or power failure. Material: Steel/brass Drive: Spring return motor, fire protection: RSE according to TRVB and VKF

Standard delivery:

■ Shut-off gate valve according to order data

■ Control of shut-off gate valve according to boiler control unit

■ Spring return motor (torque 30 Nm)

158

350

12,36 mm

13,91 mm

240

220x220

230

410

605

785

230

1015

287

Shut-off gate valve closed

Shut-off gate valve open

Downpipe L = 1.0 m

Part no. 7387 942

Connection of a drop section between the discharge system or conveyor device and an onward conveyor device by means of a downpipe.

Note

The length of the downpipe is 1 m. Design (diameter, profile) of the downpipe is matched to the relevant project at the factory.

Special adaptor

Part no. 7387 939

Connection of a drop section between the external discharge system and an onward conveyor device by means of a special adaptor.

Note

Design (diameter, profile) of the special adaptor is matched to the relevant project at the factory.

Design information

(cont.)

PYROTEC

5822 511 GB

Page 81

6.21 Connection on the flue gas side

Chimney

The system is equipped with a flue gas fan and therefore combustion equipment without draught requirement. The chimney sizing should be carried out in the same way for combustion equipment with a pressurejet oil or gas burner without draught requirement (flue gas temperature at rated load 160 - 200 °C). The PYROTEC grate combustion has output control in the range of 25 - 100 % of the rated output. This results in flue gas temperatures in the range of min. 100 °C to max. 250 °C. In order to avoid a risk of soot contamination, there should be an insulated chimney. The route from the flue gas fan to the chimney should be as short as possible. 90° bends should be avoided wherever possible. Flue pipes more than 1 m long should be thermally insulated. The chimney should be connected rising at an angle of 30- 45°. The flue pipe incl. inlet to the chimney must be gas-tight. For the operation of the PYROTEC grate combustion in accordance with the regulations, a draught stabiliser (draught limiter) is required in the chimney.

A chimney compliant with regulations relevant to the rated boiler output is required for efficient boiler operation. Provide verification to DIN EN 13384. Note that in its lower output range, flue gas temperatures below 90 ºC may be generated. Therefore connect the boiler to a moisture- resistant chimney (thermal resistance class I to DIN 18160 T1). If the boiler is not being connected to a moisture-resistant chimney, carry out a chimney calculation or request a chimney assessment (values for a chimney calculation, see page 9).

Flue pipe

The induced draught fan may cause vibrations, which can lead to excessive noise. We therefore recommend connecting the connector to the chimney with a flexible flue pipe adaptor.

Observe the following when connecting the flue:

5,57 mm6,90 mm

6,64 mm

20,54 mm

6,16 mm

> 1000

Draught limiter

Recirculation

Lambda probe with measured value transducer

Flue gas temperature sensor

Flue gas fan

■ Install the flue pipe rising to the chimney (with 45º if possible).

■ Never push the flue pipe too far into the chimney.

■ Ensure the full flue gas path (incl. cleaning aperture) is gas-tight.

■ Do not fit the flue pipe with mortar into the brickwork of the chimney. Instead, use a flexible flue pipe adaptor. Provide a cleaning aperture.

■ Wall liners to adapt to flue systems by third party manufacturers.

■ Provide the flue with thermal insulation of at least 30 mm thickness.

Trade name PYROTEC grate combustion Rated output kW 390 530 720 950 1250 Part no: 7423 674 7423 675 7423 676 7423 677 7423 678

a mm 447 447 461 579 579 b mm 350 350 350 400 450 c mm 450 450 450 450 450 d mm 600 600 660 690 760

Design information

(cont.)

PYROTEC

5822 511 GB

Page 82

6.22 Sound insulation

Braces

To avoid the transmission of structure-borne noise during the operation of the fuel transportation equipment, the braces and the anchors of the relevant conveyor device are placed on high quality Sylomer bases (plastic anti-vibration mounts for noise attenuation) or anchored with a Sylomer support and a fixing plate in the building structure. The anchors with heavy load anchors are separated from the braces with Sylomer washers.

Standard delivery:

■ Sylomer washer

■ Sylomer support

■ Sylomer base

■ Fixing plate for the braces of the relevant equipment

Trade name Sound insulation, braces Type Discharge

conveyor

Screw

conveyor

Supply Spring core

discharge

Horizontal

discharge

Removal of

ash

Flue gas

dust extractor

Part no: 7419 991 7419 992 7419 995 7419 996 7419 997 7419 998 7419 999

Note

■ Depending on the means of fuel transportation, the sound insulation article should be used once, e.g. 1 AH + 1 sound insulation AH-AS

■ Installation room characteristics relating to the physical building structure largely determine the transmission of structure-borne noise in the building. It is important to note that the specified measures do not offer full sound insulation.

■ Building related measures (brick openings, fire barriers, floating screeds, etc.) must be coordinated with structural engineers and architects and are not part of standard delivery and therefore not within our area of responsibility.

Appendix

7.1 Sizing the expansion vessel

In accordance with EN 12828, water heating systems must be equipped with a diaphragm expansion vessel. The size of the expansion vessel is subject to the heating system specification and should be checked in each case.

Quick selection table for calculating the vessel size V

Safety valve p

bar 3.0 Vn

Pre-charge pressure

bar 1.0 1.5 1.8

litres

System volume V

litres 220 — — 25

340 200 — 35 510 320 200 50

840 440 260 80 1050 540 330 100 1470 760 460 140 2100 1090 660 200 2630 1360 820 250 3150 1630 990 300 4200 2180 1320 400 5250 2720 1650 500

Selection example

Datum:

psv= 3 bar (response pressure of the safety valve) H = 13 m (static ceiling of the system)

Q = 18 kW (rated output of the heat source) v = 8.5 l/kW (specific water capacity)

panel radiators 90/70 °C

VPH= 1000 l (volume of buffer cylinder)

The specific water capacity v was determined as follows:

■ Radiators: 13.5 l/kW

■ Panel radiators: 8.5 l/kW

■ Underfloor heating: 20 l/kW

Calculation:

VA= Q x v + 1000 VA= 18 kW x 8.5 l/kW + 1000 l = 1153 l

If possible, when calculating the gas pre-charge pressure, select a supplement of 0.2 bar: p

≥ H/10 + 0.2 bar

≥ (13/10 + 0.2 bar) = 1.5 bar

From the table:

With p

= 3 bar, p0 = 1.5 bar, VA = 1153 l

Vn = 250 l (for VA max. 1360 l)

Design information

(cont.)

PYROTEC

5822 511 GB

Page 83

Selected:

1 x diaphragm expansion vessel N 250 (from Vitoset pricelist)

■ All details relate to a flow temperature of 90 °C.

■ The tables have allowed for a hydraulic seal to DIN 4807-2.

Recommendations:

■ Select a sufficiently high safety valve response pressure: psv ≥ p0 + 1.5 bar

■ For circulation pumps, due to the inlet pressure required, select at least 0.3 bar above the pre-charge pressure even for attic/roofspace installations: p0 ≥ 1.5 bar

■ Set the water side filling/starting pressure of vented systems in their cold state at least 0.3 bar above the pre-charge pressure: pF ≥ p0 + 0.3 bar

Conversion factor for flow temperatures other than 90 °C

Flow temperature °C 50 55 60 65 70 75 80 85 90 95 100 Conversion factor 3.03 2.50 2.13 1.82 1.59 1.39 1.24 1.11 1.00 0.90 0.82

Divide the vessel size found in accordance with the above tables by the conversion factor.

7.2 General information regarding low pressure hot water boilers with safety temperatures of up to 110 ºC

The pressure equipment (hot water boiler) has been built in accordance with TRD 702 and should be equipped in line with that Directive. Observe the operating conditions in that Directive. Subject to type, this boiler meets the following standards regarding its stated rated output and technical requirements:

■ DIN 4702 or EN 303

■ EN 297

■ EN 483

■ EN 677 (See details on the type plate and the enclosed documentation). During installation and commissioning of these boilers, observe all local Building Regulations and regulations concerning combustion systems, as well as the following Standards, Regulations and Directives:

■ DIN 18160-1: Flue system (design versions).

■ DIN 1988: Technical Regulations for Drinking Water Installations

(TRWI).

■ DIN 4753: DHW systems for DHW and process water.

■ EN 12828: Heating systems in buildings – Design of DHW heating

systems.

■ EN 13384: Flue systems – Thermal and flow calculations.

■ TRD 702: Equipment level for steam boiler systems with hot water

boilers class II

■ Also observe EN 12953 with:

– Low pressure hot water boilers with safety temperatures > 110 to

120 ºC.

■ EN 12953-1: Boilers with large water chambers – General informa-

tion.

■ EN 12953-6: Boilers with large water chambers – Equipment requirements.

■ EN 12953-7: Boilers with large water chambers – Requirements for combustion systems for liquid or gaseous fuels for the boiler.

■ EN 12953-8: Boilers with large water chambers – Safety valve requirements

■ EN 12953-10: Boilers with large water chambers – Feed water and boiler water requirements

Use of oil combustion

■ DIN 4755: Oil combustion equipment.

■ DIN 4787-1: Atomising oil burner (in excess of 100 kg/h throughput).

■ DIN 51603-1: Liquid fuels; fuel oil EL, minimum requirements.

■ EN 230: Atomising oil burners as mono block version – equipment for safety, monitoring and control, as well as safety times.

■ EN 267: Pressure-jet oil burner.

■ TRD 411: Oil combustion for steam boilers (where applicable).

Use of gas combustion

■ EN 298: Burner control units for gas burners and boilers with or without fans.

■ EN 676: Pressure-jet gas burner.

■ DVGW Code of Practice G 260/I and II: Technical rules for gas quality.

■ DVGW-TRGI 2008: Technical rules for gas installations.

■ TRD 412: Gas combustion for steam boilers (where applicable).

■ TRF 1996: Technical rules for LPG.

7.3 Pipe connections

All pipe connections to the boiler should be made free from stress and torque.

7.4 Electrical installation

Carry out the electrical connection and installation in accordance with VDE regulations (DIN VDE 0100 and DIN VDE 0116), local regulations and the technical connection requirements laid down by your electricity supply company.

■ DIN VDE 0100: Installation of HV systems with rated voltages up to 1000 V.

■ DIN VDE 0116: Electrical equipment for combustion systems.

7.5 Operating instructions

According to EN 12828, section 5 and EN 12170/12171, the system installer must produce operating instructions for the whole system.

Appendix

(cont.)

PYROTEC

5822 511 GB

Page 84

7.6 Flue system

Only flue pipes that meet Building Regulations may be used with condensing systems.

7.7 Checks as part of the Building Regulations approval process

As part of the Building Regulations approval process, condensing combustion equipment is tested by the flue gas inspector (where applicable) for adherence to Building Regulations and any generally recognised technical rules.

The State Building Regulations, their implementation orders and the combustion equipment orders, as well as the general building approvals and permits of the higher supervisory authority, in individual cases, are part of the Building Regulations requirements.

Appendix

(cont.)

PYROTEC

5822 511 GB

Page 85

Accessories

■ For control unit......................................................15, 16, 18, 19, 21

■ For the boiler.................................................................................25

Agitators

■ Discharge system.........................................................................45

Boiler circuit pump............................................................................37

Boiler room.......................................................................................34

Building Regulation approval process..............................................84

Bunker cover

■ Bunker filling.................................................................................73

■ Movable........................................................................................75

Chimney...........................................................................................81

Cleaning pneumatic

■ Accessories...................................................................................29

Combustion air.................................................................................35

Connection on the flue gas side.......................................................81

Content

■ Limits...............................................................................................6

Control unit

■ Accessories.................................................................15, 16, 18, 21

■ Specification, function.............................................................13, 19

■ Standard delivery..........................................................................14

Delivered condition.............................................................................7

Delivery............................................................................................33

Design..............................................................................................33

Diaphragm expansion vessel...........................................................82

Emergency stop switch....................................................................35

Expansion vessel.......................................................................42, 82

Extinguishing facilities......................................................................39

Extinguishing water container..........................................................40

Fall protection grille

■ Bunker filling.................................................................................75

Flow temperature.............................................................................33

Flue pipe..........................................................................................81

Fuel..............................................................................................5, 43

■ Limits...............................................................................................6

Halogenated hydrocarbons..............................................................34

Handling...........................................................................................33

Heating connections.........................................................................36

Horizontal discharge

■ AH.................................................................................................47

Low water indicator..........................................................................41

Mastercontrol.............................................................................19, 21

Maximum pressure limiter................................................................41

Minimum pressure limiter.................................................................42

Minimum wood fuel requirements......................................................6

Output management........................................................................16

Pellet storage room design..............................................................67

Positioning........................................................................................33

Pyrocontrol.......................................................................................13

■ Accessories...................................................................................15

■ Functions......................................................................................13

■ Operation......................................................................................13

■ Standard delivery..........................................................................14

Requirements for boiler room...........................................................34

Safety equipment.......................................................................37, 39

Safety temperature...........................................................................33

Shunt pump......................................................................................37

Sizing the pellet storage room..........................................................66

Sound insulation...............................................................................82

Specification, control unit.................................................................13

Specification - boiler...........................................................................8

Spring core discharge

■ AF.................................................................................................45

Two-boiler systems....................................................................19, 21

Woodchips.........................................................................................5

■ Quality characteristics.....................................................................5

■ Requirements..................................................................................5

Wood fuel

■ Regulations and standards.............................................................6

Wood pellets......................................................................................5

■ Forms of delivery............................................................................5

■ Quality characteristics.....................................................................5

■ Requirements..................................................................................5

Keyword index

PYROTEC

5822 511 GB

Page 86

PYROTEC

Page 87

PYROTEC

5822 511 GB

Page 88

PYROTEC

5822 511 GB

Printed on environmentally friendly,

chlorine-free bleached paper

Subject to technical modifications.

Köb Holzheizsysteme GmbH Flotzbachstrasse 33 A-6922 Wolfurt Telefon: +43 (0)5574 6770-0 Telefax: +43 (0)5574 65707 www.koeb-holzfeuerungen.com

Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com

Viessmann KOB PYROTEC Technical Manual

Specifications and Main Features

Frequently Asked Questions

User Manual