Viessmann KOB Pyrotec KPT Series, KOB Pyrotec KPT390, KOB Pyrotec KPT530, KOB Pyrotec KPT720, KOB Pyrotec KPT950 Technical Data Manual
...
Technical Data Manual
for use by engineers and heating contractors
Pyrotec
Wood-fired Boiler
KPT 390 to KPT 1250 Series
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Product may not be exactly as shown
Pyrotec with an attached external grate and a moving
annealing grate to achieve optimal combustion results.
A feed auger continuously moves the wood fuel onto
the burner trough where gasification takes place.
The combustible gases blend with precisely controlled
secondary air, resulting in a complete combustion and
the thermal energy is released into the boiler’s triple-pass
heat exchanger.
Max. output: 390 to 1250 kW (1331 to 4266 MBH)
Min. output: 98 to 370 kW (334 to 1263 MBH)
5443 113 v1.9 05/2013
Product Information
Pyrotec
Pyrotec Technical Data
Steel wood-fired hot water heating boiler. For operation
primarily with modulating boiler water temperatures in
closed loop forced circulation hot water heating systems.
Under certain conditions, open loop systems may also be
considered. Contact Viessmann for details.
Specifications
Fully-automatic underfeed combustion wood-fired
boiler
5 models from 1330 to 4268 MBH
For wood fuels with max. water content of 50%
Efficiency: 85%
Available for 30 or 60 psi max. operating pressure
Benefits at a glance
High efficiency with advanced combustion technology,
triple-pass heat exchanger and modulating output
control (turndown ratio 4:1)
Maximum heat transfer with triple-pass heat
exchanger design.
High efficiency and ultra-low emissions with precisely
controlled primary and secondary air.
Low maintenance with fully-automatic de-ashing,
optional pneumatic cleaning system and flue gas
de-duster.
Advanced safety equipment ensures safe and reliable
operation.
Maximum system performance with heavy-duty
construction and all system components from one
source.
Automatic ignition device limits idling and saves fuel.
Custom design of your system by our team of experts.
Codes
CSA B366.1-M91
Solid Fuel Fired Central Heating Appliances
CSA C.22.2#3-M88 (R2004)
Electrical Features of Fuel Burning Equipment
UL2523
Solid Fuel-Fired Hydronic Heating Appliances, Water
Heaters and Boilers
CSA B365-01
Installation Code for Solid Fuel Burning Appliances
and Equipment
Maximum allowable working pressure (water)...30 or 60 psi
Maximum water temperature…..250° F (120° C) (closed loop)
Maximum boiler temperature………210° F (99° C) (open loop)
This boiler does not require a flow switch.
WARNING
Exposing the boiler to pressures and temperatures in
excess of those listed will result in damages and will
render the warranty null and void.
Note: “Pyrotec” is an alternate/interchangeable trade
name with “Pyrtec”.
2
5443 113 v1.9
Pyrotec Technical Data
Boiler Description
General Information
Description
The PYROTEC Grate Firing System (patent no: EP 0 905
442 B1) was developed for automatic combustion of all dry
to moist wood fuels (remnant wood, pellets and forest wood
chips to max. W50, (see section “Wood Fuel Requirements”)
and combines the benefits of underfeed firing with the
benefits of grate firing.
The PYROTEC Grate Firing System is characterized by
highest efficiencies and perfect combustion in all load
stages. The PYROTEC Boiler Plant has been built to
ASME Sec. IV and has CRN for Canada. It is tested and
approved to the applicable CSA / UL safety standards.
Function:
- The solid, powerful and heat-resistant in-feed auger
moves the fuel over the burner trough into the
descending and moving grate zone. An electrical
and mechanical temperature sensor to operate the
thermal extinguishing valve are located on the in-feed
auger. Above the auger is the metering container with
a light barrier for setting the level of the fuel insulating
layer.
- The fuel is either ignited manually or automatically with
an automatic ignition blower (optional). The boiler
features a reliable burner trough, a descending grate and
a moving burn-out grate made from highly-refractory
cast steel [approx. b in. (12 mm)]. These items allow
to achieve excellent performance control and highest
safety against back-burn in conjunction with an automatic
de-ashing system (optional) for the combustion chamber.
The solid, horizontally positioned and large-volume
fire box has been optimized in terms of combustion,
consists of a high-quality refractory brick lining and
has multiple layers of insulation for the lowest possible
surface temperatures. A variable speed primary air
blower provides preheated air to the combustion grates
in the fire box.
- In the upper part of the fire box, the secondary air is
blown into the gas space of the firing system by
variable speed blower via an encircling ring with
individually adjustable nozzles to achieve high
turbulence. This mixes the fuel gases with fresh
secondary air to achieve perfect combustion and very
low emissions.
The fire box door is solidly constructed, air-cooled and
very well insulated. The fire box door is equipped with
solid double-jointed hinges for easy maintenance.
The heat is transferred to the water in the horizontal
tube heat exchanger. The boiler is well insulated and
highly accessible through the boiler door on the front.
A pneumatic cleaning system (optional) can be installed
at the insulated boiler door.
- The flue gas blower has been specially designed for
wood burning boilers and quiet operation. The spring suspended motor has a solid, heat-resistant design
with a heat dissipation hub. The blower housing on
the intake can be mounted radial by 360° and has a
variable rotation speed and a round blow-out nozzle.
It is mounted directly on the boiler or on the flue gas
de-duster (optional).
5443 113 v1.9
Supplied with:
- Boiler with fire box and pressure vessel / tube heat
exchanger including supply and return temperature
sensors and over pressure monitor
- Fire box with burner trough, descending grate, moving
burn-out grate and light barriers for ember monitoring
- In-feed auger including insulating layer, safety end
switch for maintenance lid, back-burn temperature
sensor, extinguisher valve with strainer, extinguisher
water container with mounting bracket
- Flue gas blower including flue gas temperature sensor
and oxygen sensor
- Boiler cleaning tools for the fire box, combustion
chamber and tube heat exchanger
- Installation fittings including pressure relief valve, drain
valve, low water cut off, safety temperature limiter,
temperature and pressure gauges
- Control cabinet with integrated Pyrocontrol control
system
Customer supplied:
- Counter flanges for the boiler supply and return
- Piping to the mixing valve, boiler pump and hot water
storage tank
- Piping for the safety heat exchanger
- Wiring to the control panel
- Insulation for the flue gas re-circulation line, the flue
gas recirculation system is optional
Accessories for PYROTEC Grate Firing System:
- Flue gas de-duster 63 USG (240 L)
- Flue gas de-duster 211 USG (800 L)
- Automatic de-ashing system in bin, 63 USG (240 L)
- Automatic de-ashing system in bin, 211 USG (800 L)
- Pneumatic cleaning system
- Automatic ignition blower
- Set of displacement rods (for Pyrotec 720, 950 and
1250 only)
- Operating pressure 30 or 60 psi
- Two-stage in-feed auger
- Flue gas recirculation system
- Thermal safety flush valve
- Slide valve / Rotary valve
- Boiler pump and boiler mixing valve
- Pyrocontrol control system options:
- 5 sensor hot water storage tank management system
- External control module for field supplied extraction
system
- Output module / Input module
- Input module 0-10V
- ModBus
- BacNet gateway
- Visualization
3
General Information
Transport and Installation
IMPORTANT
Precautions must be taken to avoid accidents and injury
during the transportation of the boiler.
Only hoist the boiler when it is entirely empty of water,
fuel and ash.
Lifting
The fire box has four lifting lugs that must be screwed in
before lifting. Lifting gear can be attached to these lifting lugs.
The pressure vessel of the PYROTEC has two lifting lugs
to which lifting gear may be attached.
A special crane (provided by the customer on site) is
required to lift the fire box and the pressure vessel.
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.
WARNING
Pyrotec Technical Data
Follow instructions for proper installation.
For wood-fired installations:
This wood-fired boiler must be installed in accordance
with local codes if any; if not, follow B 365-01,
Installation Code for Solid-Fuel Burning Appliances
and Equipment.
A Lifting lugs (screw in before lifting)
B Lifting lugs (pressure vessel)
4
5443 113 v1.9
Pyrotec Technical Data
Delivery Condition
Standard delivery condition
The standard delivery condition of the Pyrotec boiler
includes pre-assembled components as well as
components that need to be assembled by the contractor
in the field.
Components that are attached to the boiler at time of
delivery:
- Tube heat exchanger door is mounted to the tube heat
exchanger
- Fire box door is mounted to the fire box
- Flue gas collector is attached to the tube heat exchanger
- Pneumatic cleaning system (optional) is attached to the
tube heat exchanger door
General Information
Components that are not attached or installed to the
boiler at time of delivery (scope of the contractor):
- The pressure vessel is not mounted to the fire box
- Brickwork to connect the fire box and the combustion
chamber, bricks and mortar are included
- Electrical components which include temperature
sensors, oxygen sensor, light barriers for the fire box,
ignition
blower, low water cut off, safety temperature limiter,
overpressure monitor and light barriers for the
complete extraction system
- All wiring to the control cabinet
- Installation fittings which include pressure relief
valve, drain valve, temperature and pressure gauges
- Drive for the fire box grate is detached
- De-ashing system (optional) and drive for the
de-ashing system
- Air compressor (optional) and connection to the
pneumatic cleaning system (optional)
- The flue gas blower is not attached to the flue gas
collector
- Primary air blowers are not attached to the fire box
- Secondary air blowers are not attached to the fire box
- Re-circulation system (optional)
- Flue gas de-duster (optional) comes in two pieces
- The in-feed auger is detached from the fire box
- Fire extinguishing system for the in-feed auger
- Slide valve (optional) or rotary valve (optional)
- All components of the extraction system (optional),
welding for flanges and support legs required
- Glass fiber insulation between any auger connections
Measurements for the fire box as standard delivery condition
Boiler model KPT390 KPT530 KPT720 KPT950 KPT1250
Minimum size
door (W x H)
Minimum ceiling
opening (W x H)
Measurements for the pressure vessel as standard delivery condition
Boiler model KPT390 KPT530 KPT720 KPT950 KPT1250
Minimum size
door (W x H)
Minimum ceiling
opening (W x H)
59 in. x 59 in.
(1500 mm x
1500 mm)
59 in. x 149 in.
(1500 mm x
3800 mm)
59 in. x 59 in.
(1500 mm x
1500 mm)
59 in. x 112a in.
(1500 mm x
2850 mm)
63 in. x 69 in.
(1600 mm x
1750 mm)
63 in. x 157b in.
(1600 mm x
4000 mm)
63 in. x 69 in.
(1600 mm x 1750
mm)
63 in. x 112a in.
(1600 mm x
2850 mm)
63 in. x 69 in.
(1600 mm x
1750 mm)
63 in. x 196c in.
(1600 mm x
5000 mm)
63 in. x 69 in.
(1600 mm x
1750 mm)
63 in. x 126 in.
(1600 mm x
3200 mm)
74c in. x 73c in.
(1900 mm x
1850 mm)
74c in. x 196c in.
(1900 mm x
5000 mm)
74c in. x 73c in.
(1900 mm x
1850 mm)
74c in. x 130 in.
(1900 mm x
3300 mm)
74c in. x 78c in.
(1900 mm x
2000 mm)
74c in. x 216b in.
(1900 mm x
5500 mm)
74c in. x 78c in.
(1900 mm x
2000 mm)
74c in. x 137c in.
(1900 mm x
3500 mm)
5443 113 v1.9
5
General Information
Wood Fuel Requirements
Pyrotec Technical Data
The Pyrotec is only suitable for burning fuels listed in this
section. A prerequisite for approval is of a fuel by
Viessmann is the approval for the fuel by the responsible
public authorities.
Warranty claims for Viessmann Biomass boilers are
excluded if the following fuel conditions are not met.
Allowed fuels
- Forest wood and plantation wood (complete untreated
trees and trunk wood):
Mature wood from trunks and branches, untreated,
chopped to chips
- Compressed wood, pellets conforming to standards,
as per CAN/CSA-B366.1-M91, size P1, P2, P4.
Untreated wood with limited bark content, compressed by machine and calibrated
Fuel Minimal Diameter Maximal Diameter
P1 - Pellets Small ---
P2 - Pellets Medium
P4 - Briquettes (Pellets Large)
- Wood with an increased proportion of bark, tree
cuttings from roadside trees (untreated):
Wood remnants from the forestry and sawmill industries
or from landscape conservation (likelihood of elevated ash
content).
- Remnants from derived timber products:
Usually a mixture of untreated and treated wood in the
form of shavings from processing machinery and chips
from choppers.
- Used wood:
This is untreated wood that has been used prior to its
energetic utilization (e.g. pallets). It is reduced in size
by shredders for thermal utilization. The metal parts
have to be removed by magnetic separators.
e in. (10 mm) c in. (20 mm)
c in. (20 mm) 2b in. (60 mm)
IMPORTANT
If different fuels are used, Viessmann will not assume any
liability for the functioning or service life of the boiler plant.
Refer to the “Warranty” section in the General Terms and
Conditions of Delivery.
- Burn wood only
- Do not use chemicals or fluids to start fire.
- Do not burn garbage, gasoline, naphtha, engine oil,
or other inappropriate materials.
e in. (10 mm)
Size of Wood Chips as per CAN/CSA-B366.1-M91, Grade C7
Total mass 100% G 30 Fine G 50 Medium
Coarse percentage max. 20% Max. cross-section in.2 (cm2)
Main percentage 60 to 100% Medium sieve nominal mesh width in. (mm)
Percentage of fines
(incl. ultrafine content) max. 20%
CAUTION
Chips have to pass through a 1 in. (25 mm) sieve,
additionally, a fraction of max. 5% of the fuel with a
cross-section of max. c in.² (500 mm²) up to a length
of max. 6a in. (160 mm) can be tolerated.
6
Max. length in. (cm)
Coarse sieve nominal mesh width in. (mm)
Fine sieve nominal mesh width in. (mm)
Size of briquettes:
- Fraction of one-offs. max. 5% with cross-section of
max. c in.2 (500 mm2) up to a length of max. 6a in.
(160 mm).
- Frayed surface by chopping tools (shredders) or slow running choppers.
- Briquettes, diameter max. 2e in. (60 mm).
Consequences of overstepping particle size:
- Increased maintenance because of a substantially
higher risk of malfunction
- Shortened service life of the conveyor augers and drives
b (3) c (5)
3g (8.5) 4c (12)
f (16) 1a (31.5)
d (2.8) a (5.6)
1
/
(1)
25
1
/
(1)
25
5443 113 v1.9
Pyrotec Technical Data
Wood Fuel Requirements (continued)
General Information
Maximum water content
The maximum allowable water content of the fuel for
Pyrotec systems is limited to 50%.
The water content impacts the maximum boiler output.
Non-wood fuels
Non-wood fuels even if consisting of biomass, such as
needles, foliage, grain, straw, fruit pits, etc, are unsuited
as fuel for boiler operation and may not be used.
Suitable fuel types for Pyrotec systems
- Bulk density S in kg/m³ [lb/ft3], water content (W) in %,
size C1, C7, P1, P2, P4 as per CAN/CSA-
B366.1-M91.
Note: Fuel for Pyrotec systems allow for a max. of 50%
water content (W).
Saw dust
Fuel code Bulk Density kg/m³ [lb/ft³] Water content % Fuel Size Description
a S130 [8.1]
b1 S200 [12.5] W20 to W35 C1 Sawdust, untreated (sawmill)
c2 S250 [15.6] W35 to W50 C1 Sawdust, untreated (sawmill)
Wood chips
Fuel code Bulk Density kg/m³ [lb/ft³] Water content % Fuel Size Description
b2 S200 [12.5]
c1 S250 [15.6]
d1 S300 [18.7]
d2 S300 [18.7]
e1 S350 [21.8]
e2 S350 [21.8]
f1 S400 [24.9]
W10 to W20 C1 Sawdust, untreated (planing shop)
W20 C7 Forest wood chips, soft, untreated
W20 to W35 C7 Forest wood chips, soft, untreated
W20 to W35 C7 Forest wood chips, soft/hard, untreated
W35 to W50 C7 Forest wood chips, soft, untreated
W20 to W35 C7 Forest wood chips, hard, untreated
W35 to W50 C7 Forest wood chips, soft/hard, untreated
W35 to W50 C7 Forest wood chips, hard, untreated
Limitation super fines and dust [wood particles smaller
than 1/32 in. (1.0 mm)]
Max. 10.0% of the total mass; if fuel does not comply
with this limit the following process may occur:
- Temperature peaks
- Slag formation
- Even higher temperature
- This process leads to damage by overheating and can
affect refractory materials.
Elevated values are especially critical for remnant wood in
combination with elevated values of Chlorine and Sulphur.
Shavings and chips
Fuel code Bulk Density kg/m³ [lb/ft³] Water content % Fuel Size Description
g S130 [8.1] Less than W15 C7
h S200 [12.5] Less than W15 C7
i S250 [15.6] Less than W15 C7
Pellets and briquettes
Fuel code Bulk Density kg/m³ [lb/ft³] Water content % Fuel Size Description
j S350 [21.8] Less than W15 P4
k1 S650 [40.6] Less than W10 P1
k2 S650 [40.6] Less than W10 P2
Note: For size of wood chips, see page 6.
5443 113 v1.9
Shavings & chips from wood remnants,
dry, mixed
Shavings & chips from wood remnants,
dry, mixed
Shavings & chips from wood remnants,
dry, mixed
Briquettes from wood remnants c in. (20
mm) to max. 2 in. (60 mm)
untreated up to e in. (10 mm)
untreated e in. to c in. (11 mm to 20 mm)
7
General Information
Pyrotec Technical Data
Wood Fuel Requirements (continued)
Content limits for non-combustible substances
- No wood fuels may contain any foreign bodies, such as
pieces of metal, stones, masonry remnants or plastics.
The following limits (per lb/kg of dry fuel) of contained non-combustible substances apply [ash analyzed at a
temperature of 1500° F (815° C)]:
Substance Limit Comparative value untreated forest wood
Chlorine (Cl) max. 300 ppm (300 mg/kg) 10 ppm (10 mg/kg)
Sulphur (S) max. 1000 ppm (1000 mg/kg) 120 ppm (120 mg/kg)
Total Cl, S max. 1000 ppm (1000 mg/kg) 130 ppm (130 mg/kg)
Ash content, total max. 0.25 oz/lb (15.0 g/kg) 0.08 oz/lb (5.0 g/kg)
Alkali oxides in the ash (K2O and Na2O) max. 0.016 oz/lb (1.0 g/kg) 0.006 oz/lb (0.35 g/kg)
Sintering point of the ash min. 1800° F (1000° C) approx. 2200° F (1200° C)
If fuel does not comply with these limits, there is a risk
of corrosion within the heat exchanger and early sintering
and melting of the ash which leads to:
- Shortened life of the tube heat exchanger
- Increased maintenance costs (firing, boiler door)
The maintenance instructions need to be complied with
in order to avoid a process, which will increasingly cause
damage to the boiler.
If maintenance instructions are not complied with the
following process may occur:
- Cinders change the airflow
- Temperature peaks
- More slag is produced
- More cinder builds up and changes the airflow more
This process leads to damage by overheating and may
affect refractory materials.
Additives in remnant and used wood have to be free of
heavy metals and halogen compounds.
Other information
- Ash and cleaning:
Untreated wood without bark produces less than 0.5%
ash of the fuel mass supplied. All the specifications
regarding cleaning are based on untreated wood with
bark attached with an ash amount of 0.8% of the fuel
mass.
If the ash content is higher and/or the ash melting
point is lower, increased maintenance and/or cleaning
are required.
- Changing fuels:
A substantial change in fuel quality, such as bulk
density, water content, dust proportion or ash content
might require a manual correction of the firing
parameters (see Operating section).
8
5443 113 v1.9
Pyrotec Technical Data
Power Failure Provision
Power Failure Provision
Customers must ensure that there is a supply of water
independent of the electrical supply. This design ensures
that in case of a power failure, the boiler will be reliably
cooled by the thermal run-off safety valve.
Venting Requirements
Safety
The PYROTEC Grate Firing System is equipped with
a flue gas blower.
This boiler must be properly vented. Use a vent material
certified for use with solid-fuel fired equipment.
This boiler shall be connected to:
a) a masonry chimney conforming to local regulations
or, in the absence of such regulations, to the
requirements of the National Building Code
b) a certified factory-built chimney (refer to the NFPA
211 standard).
A flue pipe serving this boiler shall be constructed of
steel or other suitable material with a melting point of
not less than 2000° F (1100° C).
IMPORTANT
Do not use galvanized steel
For installations in Canada:
The boiler venting system must be tested and listed by
a Nationally Recognized Testing Lab such as ULC/CSA
for solid fuel burning appliances.
The PYROTEC Grate Firing System is output-controlled
within a range from 30%-100% of the rated boiler output.
This produces flue gas temperatures from min. 212° F
(100° C) to max. 482° F (250° C).
An insulated chimney should be provided to prevent sooting.
The distance from the flue gas blower to the chimney
should be as short as possible. 90° elbows should be
avoided if possible. Flue gas pipes of more than 3 ft. (1 m)
in length must be insulated.
The connection to the chimney should be made such that
it rises at an angle of 30°- 45° (to prevent excess ash
accumulating in the lateral section of the vent pipe).
The flue gas line, including the lead-in into the chimney,
must be gas-tight.
5443 113 v1.9
9
Safety
Mechanical Room
Pyrotec Technical Data
Ensure the mechanical room complies with the requirements
in these instructions and local codes.
Viessmann recommends the installation of an additional
electrical disconnect switch and a fuel shut-off valve (if
possible) outside the mechanical room or enclosed area
of installation.
A separate, dry heating room must always be provided
for the PYROTEC Grate Firing System. No combustible
materials may be stored in the heating room. The heating
boiler may only be set up on a fire- and temperatureresistant floor.
No temperature-sensitive pipes or lines may be installed
in the floor beneath the heating boiler.
The temperature in the heating room must not exceed
104° F (40° C) while the system is in operation
(in the area approx. 3 ft. (1 m) away from the boiler).
The temperature in the heating room must not fall below
50° F (10° C) while the system is in operation (measured
at the inner side of exterior walls).
The load-bearing capacity of the heating room floor must
be designed for the weight of the system plus filling with
water and fuel. The load-bearing capacity of the floor in
the area of the boiler bearing surface must be 512 lb/ft²
(2500 kg/m²).
IMPORTANT
Always follow the most up-to-date local, municipal and
building regulations and codes.
The minimum distance to the walls and ceiling required
according to the table of dimensions for proper cleaning
and maintenance of the boiler must be complied with.
A sufficient supply of fresh air must be provided directly
from outdoors into the heating room. Induced ventilation is
necessary for heating rooms that are confined or enclosed.
Dimensions shown in. (mm)
Hatched surface Heat-resistant floor
Medium grey surface Boiler supporting surface
Foundation dimensions
Boiler Model KPT- 390 530 720 950 1250
a in. (mm)
b in. (mm) 717/8 (1826)
c in. (mm)
d in. (mm)
e in. (mm) 1007/8 (2561)
40e (1026) 40e (1026) 43c (1112) 53b (1360) 53b (1360)
717/8 (1826) 75a (1912)
166d (4221) 166d (4721) 193e (4912) 200f (5096)
49f (1260) 49f (1260)
120b (3061) 122b (3112) 120c (3066) 142d (3611)
551/8 (1400) 641/8 (6030)
85 (2160) 85 (2160)
2221/8 (5641)
64d (1630)
10
5443 113 v1.9
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