Vimar VIGAS series, VIGAS 16, VIGAS 25, VIGAS 40, VIGAS 60 Installation & Assembly Manual

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Gasifying boilers VIGAS

Ecological Boilers VIGAS

MANUAL FOR INSTALLATION, ASSEMBLY AND USE

VIGAS and VIGAS

Lambda Control

with AK 3000

Certificate of warranty

VIMAR 2010

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Gasifying boilers VIGAS

Content

Declaration of conformity......................................................................................................

1. Technical description......................................................................................................

2. Technical data................................................................................................................

3. Description of AK 3000 control......................................................................................

4. VIGAS boiler in basic configuration...............................................................................

5. VIGAS boiler in configuration with gases thermometer..................................................

6. VIGAS boiler in configuration with gases thermometer and discharge fan....................

7. VIGAS

Lambda Control

in configuration with gases thermometer..........................................

8. VIGAS

Lambda Control

in configuration with gases thermometer and discharge fan............

9. Time setting....................................................................................................................

10. Hardware and software information...............................................................................

11. Error messages..............................................................................................................

12. Service settings PIN 0000 protected..............................................................................

13. Operating instructions.....................................................................................................

14. Boiler maintainance and repairs....................................................................................

15. Accesories assembly.....................................................................................................

16. Listo fo guarantee and afterguarantee services.............................................................

17. Problems solving............................................................................................................

18. Assembly instruction......................................................................................................

19. Electric scheme of connection VIGAS boilers................................................................

Letter of guarantee.........................................................................................................

Confirmation of VIGAS boilers commissioning..............................................................

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Gasifying boilers VIGAS

DECLARATION OF CONFORMITY

Issued according to Section 12, par. 3, letter a) Act No. 264/1999 Coll.

and 97 / 23 EC

We, VIMAR Vigaš Pavel

hereby declare that the undermentioned products comply with technical regulations and the
products are safe if determined conditions are followed and we took all possible measures to
assure the compliance of products with technical documentations as well as with relevant
instructions requirements of government.

Product: Thermal boiler VIGAS and VIGAS

Lambda Control

with AK 3000 control

Type:

VIGAS 16, VIGAS 16

Lambda Control

VIGAS 25, VIGAS 25

Lambda Control

VIGAS 40, VIGAS 40

Lambda Control

VIGAS 60, VIGAS 60

Lambda Control

VIGAS 80, VIGAS 80

Lambda Control

VIGAS 100, VIGAS 100

Lambda Control

VIGAS 29 UD

Producer:

VIMAR Vigaš Pavel
M. Čulena 25, 974 11 Banská Bystrica,
SLOVENSKO

The above-mentioned products comply with the following standards:

STN 07 7401, STN 73 4210, STN EN 303-5, STN EN 61000-3-

2:2000+A1:2001+A2:2001, STN EN 61000-3-3:2000.

Supplementary data:

Certificates, Test report

Issued in:

Banská Bystrica Name: VIGAŠ Pavel

Date of issue: Title: Owner
Signature:

M. Čulena 25

974 11 Banská Bystrica

SLOVAKIA

IČ DPH: SK 1020548001

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Gasifying boilers VIGAS

1. TECHNICAL DESCRIPTION

Thermal boilers VIGAS are designed for combustion of dry wood material, starting from
sawdust up to logs in the length according to the dimensions of gasification chamber,
maximum 20 cm. Sawdust, chippings, splinters and cuttings must be burn together with logs.
Thermal boiler, VIGAS UD 29 is designed for burning brown coal. It is also possible to use dry
wooden material as a substitute fuel.
Boilers are welded from 4- 6 mm steel sheets. Inner boiler sheets that have contact with
boiler waste gases are 6 mm thick, others are made of 4 mm sheet. Heat exchanger is
welded from steel pipes, 57x 5 mm. Exterior boiler shell is made of 0.8 mm sheet. Thermal
insulation of the boiler is made of insulation material, NOBASIL, 20 and 50 mm thick. Boiler
waste gases go away through steel neck to chimney.
Inner boiler space consists of gasification chamber, where fuel is dried and gasified. Then
created gas goes through fireproof /concrete/ nozzle into combustion chamber, where it
burns with the help of secondary air. Boiler waste gasses are intensively cooled in
exchanger. Wood that is not burnt must be removed from combustion chamber. The boiler has a
lighting up damper that is controled by operating rod at the front part of boiler.
In order the boiler complies with the requirements for non-demanding operation, it is equipped
with AK 3000 control unit that is situated in the upper part of boiler. The used system of control
allows very effective combustion of various kinds of fuel. AK 3000 control with grpahical display,
in basic configuration allows:

 to control temperature of heated water in range 60 ÷ 85 °C
 smooth and automatic control of forced draft fan according to required output and
 to connect discharge fan

 to connect circulation pump
 to connect gases thermometer
 to connect and to control boiler by space temperature regulator
 to connect extended regulation (EXPANDER) via AK BUS
 to connect module with Ethernet interface and SD-card for data saving and concsequtive

evaluation via PC

 grpahical scheme indication of hydraulic connection as requested
 real time set

In configuration VIGAS

Lambda Control

also allows :

 Utilizes informations from lambda sensor of oxygen overflow in gases, to control the

chimney flap of primary and secundary air.

 Gases thermometer as a standard

Boilers are equiped with thermal fuse that ensures disconnection of forced draft fan if boiler
is overheated above 100 0C and safety exchanger against overheating according to the
standard, STN EN 303/5. Its recommended, by producer, to buy a release valve Honeywell TS
130 ¾” for safety exchanger against over heating.

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Gasifying boilers VIGAS

2. Technical data

Tab.1

THERMAL BOILERS

VIGAS 16 25 40 60 80 100 UD 29
Nominal boiler output kW 16 25 40 60 80 100 29
Boiler class according to EN 303-5 3
Max. operating pressure bar 3
Fuel Wood, max. moisture 20% ;heating min. 15 MJ/kg

Brown coal

Output capacity kW 12 - 18 5 - 31 8 - 41 15 - 72 25 - 92

25-100

8-35(8-29)*

Fuel consumption with
nominal output

kg/hod 4,5 7,6 11,2 19 25 30,4

7,8 (8,0)*

Substituite fuel

Wood waste, splinters, saw dust, saw dust briquettes (for UD 29 also wood

of max. moisture 20%)
Chimney daught mBar 0,20 – 0,25 0,20 – 0,35 0,30 – 0,40 0,20 – 0,25
Weight kg 400 430 460 760 930 950 430
Height with regulation A mm 1135 1135 1385 1420 1120
Height of exhaust branch B mm 975 1045 1310 1400 1045
Height of inlet branch C mm 115 125 215 110
Height of feed-water valve D mm 55 60 70 135 55
Height of chimney neck E mm 890 1110 1170 890
Width including rod F mm 645 785 645
Width including shell G mm 590 760 590
Depth H mm 840 1070 1260 1650 1070
Exhaust brand I mm 240 520 240
Diameter od draught neck J mm 160 200 160
Dimmension from edge of

boiler

K mm

188 305 880 1210 230

Spacing of feed pipes L mm 405 70 350
Diameter of inlet brand G/mm 2“
Diameter of exhaust brand G/mm 2“
Diameter of feed-water valve G ½“ ¾“ ½“
Volume of water l 75 93 180 205 215 75
Gases temperature

With nominal output
With minimal output

0

C

0

C

240
150

Dimensions of gasification
chamber
Depth

mm 370

560 750 1150 1090 490/440

Height mm 490 750 730 500
Width mm 440 575 440
Dimensions of gasification

chamber
(width-height)

mm 435 -255

575 – 318 435 - 255

Max. weight of fuel kg 20 30 40 80 150 30
Capacity of gasification

chamber

dm3 80

120 185 315 483 457 105

Noisness dB 45 45,5 47,7 51,4 54,2 45,5
Max. electric input W 70 140 70
Voltage/Frequency V/Hz 230ACV / 50 Hz
Pressure loss of water :

Δt 10 0C
Δt 20 0C

mBar
mBar

9,70
1,00

9,75
1,05

10,48

2,55

12,77

3,19

11,83

2,96

11,53

2,84

9,97
1,15

Time of burning with nominal
output

hod 4,5 4,20 4,30 4,20 4,20 4,0 5,60 (4,10)

Cooling exchanger of heat

- temperature of inlet water

- pressure of inlet water

0

C

bar

4 – 15

min 1 – max 4

Release valve Honeywell TS 130 ¾” for safety exchanger against over

heating, Opening temperature 95°C

Safety

STB fuse, blow temperature 100oC (tolerance: -6oC –- 0 oC)

Weight flow of gases kg/s 0,034 – 0,047

* specification for wood fuel

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Gasifying boilers VIGAS

2.1 DIMENSION CHART AND THE POSITION OF PROTECTIVE SUPPORT PLATE ON
EASILY IGNITABLE FLOOR

2.2 BOILER SCHEMATICS

Pic.1 Pic.2

KEY

1. AK 3000 control

2. Upper door

3. Chimney flap operating rod

4. Fuel bunker

5. Primary air conduction

6. Flap for Lambda control servo

7. Fan

8. Fan cover

9. Heatproof nozzle

10. Secondary air screen

11. Door closing device

12. Fireclay bricks

13. Bottom door

14. Chimney neck

15. Exchanger cap

16. Lighting up damper

17. Upper back cover

18. Outlet water neck

19. Thermal fuse

20. Thermometer

21. Upper front cover

22. Lambda sensor

23. Gases thermometer

24. Exchanger pipes

25. Heat proof /concrete/ filling

26. Secondary air

27. Combustion chamber

28. Direction of gases

29. Neck of reversible water

30. Fillng neck

31. Cleaning flap for 29UD

32. Cleaning hole for 29UD

Scheme VIGAS 60,80

Scheme VIGAS 25 Scheme VIGAS 40

Scheme VIGAS 100

Scheme VIGAS 16

Scheme VIGAS 29 UD

Pic.3

 Inlet water neck
for valve (Danfoss)
 Hole for
submersible case
(Danfoss)
 Exhaust brand of
cooling water
 Exhaust water
neck

 Inlet water neck
 Filling neck

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Gasifying boilers VIGAS

3. DESCRIPTION OF AK 3000 CONTROL

3.1 Safety Instructions

 Check protection (cover) metal sheet before plug-in the power wire
 Avoid any contact of power wire with hot parts of the boiler (f.e. chimney)
 Make sure, no water is allowed under the upper isolation (risk of short circuit)
 Do not stress the power wire
 Always disconnect the power wire when a new electrical components are connecting (f.e.

indoor thermostat, discharge fan or circulation pump)

 Do not remove protection (cover) metal sheet during the boiler operation, especially from

fan

 Compare working voltage displayed on the label with your distribution network
 Always observe safety regulations

3.2 Connecting to the distributing network

AK 3000 control is integral part of VIGAS boilers.
Control is connected when power wire is plugged in to the distributing network 220/230V. Display
is active when power wire is plugged-in (Pic.4). Servo-flat used in VIGAS

Lambda Control

is set to

base position (Pic.5).

3.3 Working conditions

Operation temperature range of AK 3000 control is +5°C to +45 °C. Control may not be used in
humid enviroment or direct sunlight.

3.4 Maintainance of AK 3000 control

Keep in clean and dust-free enviroment. Antistatic, or wet wipper is adivsed to wipe-off dust and
impurities from metal cover and control panel.

3.5 Control panel

Part of the electronic control is panel, equipped with buttons, pictograms and display. Futher
informations will be available in the next part of this manual.

Pic.6

Pic.5

1. Graphical display 128 x 64 pixels

2. Button ◄ with functions

3. Button ▲ with functions

4. Button ► with functions

5. Button (ENTER) with functions

6. LED control

7. Button with functions

Pic.4

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Gasifying boilers VIGAS

Functionality of each button are composite and their functionality deppends accompanying
description on display and from manufacture settings.

3.6 Symbols

1. Real time indication.

2. Indication of current boiler values.
Modification ▲ or .

3. Indication od discharge fan, lambda sensor, gases
thermometer

4. Indication of nominal boiler output when switched off.

5. Graphically indicated hydraulic scheme of
connection.

6. Indication of boiler status.

Pic.

7

Boiler

Storage tank

External boiler

Boiler „ON“

ON

DUOMIX

Heating circuit

Boiler „OFF“

OFF

DUOMIX with
servomotor

Indoor
thermostat

Heating

ON

Pump

3-way
thermostatic
valve

Burning

73 0C

Discharge fan

LADOMAT

Afterflaming

52 0C

Lambda

λ

Fan

End of burning

END

Thermometer

T

Fan change
output

Indoor
termostat
decay

Error indication
value

x

Open flap servo 50%

Adding fuel

Minimal value
of gases

min

Maximal value
of gases

max

Temperature
settings

Parameter
settings

Time setting

Error
messages

Program

Konfiguration
informations

Service
message

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Gasifying boilers VIGAS

4. VIGAS BOILER IN BASIC CONFIGURATION

(without discharge fan, gases thermometer and lambda sensor)

4.1 VIGAS BOILER OPERATING

4.1 .1 Boiler activation

4.1.2 Boiler activated – heating mode

4.1.3 Boiler activated – burning mode

4.1.4 Adding fuel, Disconnection the boiler (manually)

Using graphical control. To call the graphical control, press central button ENTER. Graphical
control offers option to switch off, adding fuel or cancel the graphical control.

If boiler is in unactive status with symbol „OFF“, as displayed on
the picture, by pressing the central button ENTER the boiler start
the operation.

Choose one option

OFF Switch-off

Add fuel

⌧

Cancel the control

bc

Change the indicated value

By pressing „ “ fan will be switched off. By using the rod open
the chimney flap, consequently open the upper door. You can add
fuel, if necessary. Close the upper door and chimney flap.

By pressing „ “ adding fuel will be stopped. Fan will be switched­on automatically.

Boiler is set to heating mode, if temperature of outgoing water is
lower, then set shotdown temperature of the boiler. Shotdown
temeperature is in settings. Usually is set to 50

0

C. Pump is pulse

working in dependence on temperature of the boiler water! The
pump is working, when symbol flash.

The burning mode is active after the shotdown temeprature is
higher + time deviation. In this mode pump is working pulse (bolie

r

protection against low-temperature corrosion), 50C before set
temperature constantly. The pump is working, when symbol flash.
Boiler is responsive to indoor thermostat, when indoor thermostat is
switched off boiler slowly decreasing its output.

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Gasifying boilers VIGAS

„ENTER“

By ▲ buttons set the parameter you want to edit and by
pressing „ENTER“ button, the value starts to flash. ▲ buttons
set requested value.

end

Choose shotdown temperature of the boiler

„ “

Increase or decrease the value, maximal output will be
changed. Is adviced to decrease the value in transition
period (boiler tar level will drop).

Â

Brightness

Roll

Press „yes“ will acitivate the value rolling (Pic.6/2)

Help 0s

Set the time when graphical control will be indicated

4.1.5 Disconnection the boiler (Automatically)

4.2 TEMPERATURE SETTINGS OF OUTLET WATER

4.3 PARAMETERS SETTING OF VIGAS BOILER

When temperature drops under the shotdown temperature (see
Parameter settings of Vigas boiler in basic configuration) boiler is
switch-off automatically. „END“ will be indicated on the display. By
pressing „ENTER“ boiler will start operating again.

To call temperature setting hold „ENTER“ button at any boile

r

status. Symbol of the temperature setting will be indicated on the
display. Press „ENTER“ again. Symbol of the nominal output will
be indicated on the display with value, together with temperature of
outlet water in °C. By pressing the „ENTER“ button, the value start
to flash.

„ENTER“

Temperature is flashing, by using
buttons ▲

choose requested
value. Button ► will exit the
temperature settings.

To call parameters setting hold „ENTER“ button at any boile

r

status and by pressing ▲ button. Press „ENTER“ again Symbol of
the parameters setting will be indicated on the display. By pressing
the „ENTER“ button twice, the values you can set will be indicated
on the display.

„ENTER“ „ENTER“

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Gasifying boilers VIGAS

5. VIGAS BOILER IN CONFIGURATION WITH GASES
THERMOMETER

(without discharge fan and lambda sensor)

The advantage of the gases thermometer is elimination of the maximal gases temperature, if it will
be reached, it will effect the speed drop of fan. As consequence will be increased efficiency
followed by low fuel consumption. In configuration with storage tank, its used for boiler to
shotdown when burn-out all fuel, water boiler temperature in tank has no influence to shotdown.

5.1 VIGAS BOILER CONTROL

5.1.1 Boiler activation

5.1.2 Boiler activated – heating mode

5.1.3 Boiler activated – burning mode

5.1.4 Adding fuel, Disconnection the boiler (manually)

Using graphical control. To call the graphical control, press central button ENTER. Graphical
control offers option to switch off, adding fuel or cancel the graphical control.

Boiler is set to heating mode, if outgoing gases temperature is
lower, then set minimal gases temperature. Minimal gases
temperature, as well as, maximal gases temperature can be set in
boiler settings. Minimal gases temperature is set on 90°C, maximal
gases temperature is on 200°C, which are standard settings.
Pump is pulse working in dependence on temperature of the boile

r

water!

If boiler is in unactive status with symbol „OFF“, as displayed on
the picture, by pressing the central button ENTER the boiler start
the operation.

The burning mode is active after the gases temeprature is highe

r

( end) + 20

0

C. In this mode pump is working pulse (bolie

r

protection against low-temperature corrosion). The pump is
working, when symbol flash. Boiler is responsive to indoo

r

thermostat, when indoor thermostat is switched off boiler slowly
decreasing its output.

Choose one option

OFF Switch off

Add fuel

⌧

Cancell the control

bc

Change the indicated value

By pressing „ “ fan will be switched off. By using the rod open
the chimney flap, consequently open the upper door. You can add
fuel, if necessary. Close the upper door and chimney flap.