TECHNICAL - START - UP DOCUMENTATION

Transcription

1 BOILER CONSTRUCTION SC Z A K Ł A D M E T A L O W O - K O T L A R S K I Busko-Zdrój, Owczary, ul. Przemysłowa 3 Phone: , Fax: TECHNICAL - START - UP DOCUMENTATION ` of water boiler s for heating installations SAS UWG type adopted for black coal combustion of nut coal BOILER SAS UWG 1

2 INDEX page Conformity declaration 3 1. Introduction 4 2. Use of boiler 4 3. Boiler construction description 4 4. Technical data 5 5. Fuel Fuel Alterntive fuel 6 6. Boiler s assembly guidelines Requiremends for boiler-room Boiler s arragement Connecting boiler to a chimney Connecting boiler to a chimney installation 8 7. Operation and installation guidelines Filing with water Boiler s firing up 9 Table (technical exploitation parameters) 10 Boiler s construction scheme Burning Cleaning the boiler End of heating season Terms of safe exploitation States of important boiler s functioning Terms of delivery Recycling Terms of warranty 17 Service repairs 19 Warranty card 20 2

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4 1. INTRODUCTION Dear buyer and user of boiler of SAS UWG type. This technical start-up documentation contains all necessary information required for energy-saving, safe and longstanding exploitation of your boiler. We kindly ask you to get familiar with documentation content prior to assembling and starting the exploitation of a boiler. Hereby documentation shall be kept for future use. Upon familiarization with this manual, the user will be able to utilize this device in the optimum way. Careful reading of the manual will help in effective and safe exploitation of the boiler. 2. USE OF BOILER Boilers of SAS UWG type are designated for water installations of the central heating systems, open type with gravitational or forced water circulation *, protected according to presently being in force, both domestic or the union detailed regulations (e.g. PN-91/B Boilers of SAS UWG type installed in accordance to hereby documentation recommendations are not subject to the commissioning led by the Branch Office of Technical Inspection). Boilers are specifically recommended for the flats heating in single-family homes, pavilions, etc., where calculated feeding water temperature does not exceed 85 C, and working pressure does not exceed 1,5 bar. Required gases draught pressure after a boiler is 0,12-0,30 mbar (depending on boiler s power). These boilers may also work in hot water installations utilizing a heat exchanger. Boiler s selection for building heating should be based on heat balance, according to regulations in force, both domestic and the union (e.g. PN-B-02025:2001). 3. BOILER CONSTRUCTION DESCRIPTION The coal heating boiler of SAS UWG type is a modern construction heating device with lower combustion of solid fuels. Boiler s body consists of combustion part and convection section. Boiler is made of steel metal sheet welded type. Front chamber (pos. 4) serves as a furnace with water grates. Below the grate there is the ash box. Boiler s basic components are presented on the drawing (p ). * Asseblied installation must conform the detailed requirements of local standards for the heating devices protection measures, requirements for open water systems and pressurized vessels of open systems. 4

5 The water jacket (pos. 3) it is a cuboids type with double walls and water baffles partitions. Water grates (pos. 11) together with exchanger constitutes monobloc unit it is not replaceable. Between the water grates the cast iron movable grates are placed (pos. 12). To the upper section of a heat exchanger a pipe connector for hot water is attached (pos. 16), and on the lower section, on the back wall, the return water pipe connector is placed (pos. 20). Blowdown connector (pos. 21) is placed on the sidewall. Fuel load door (pos. 6), furnace door (pos. 7), are traditionally placed on the front wall. Those door render easy access for the purpose of furnace chamber cleaning. In the lower part of the ash box door there is a flap (pos. 10), which is connected with an air draft regulator by means of a string (pos. 14). It doses the volume of air delivered to combustion process. Additionally, on the front wall there are the washout door (pos. 5 for boilers SAS UWG above 17 kw; for boilers up to 14 kw, the washout door and load door make up one unit pos. 5-6), for boiler s convection channels cleaning. In the upper, convection section of the boiler, there is a pair of pulled out swirls (pos. 15), used for improving the fumes heat recuperation (improving boiler s heat efficiency). The whole heat exchanger body is wrapped with insulation material (pos. 2), a mineral wool type, filling the space between the heat exchanger and boiler s casing, (pos. 1). Water temperature In a boiler may be red on the dial thermometer (pos. 22), which is attached to the boiler. Boilers are adapted to operate with natural fumes draught utilization principle. Its exploitation runs without electric power supply, instead, efficient, permeable flue is required. 4. TECHNICAL DATA Basic energetic parameters are structured in the table (p. 10) and on the drawing (p ). 5. FUEL 5.1. FUEL The basic fuel for heating boilers of SAS UWG type is a black coal for energetic applications of the nut grade (acc. PN-91/G type 32.1 class 24/12). That type of fuel guarantees that the declared power may be achieved. 5

6 5.2. ALTERNATIVE FUEL The alternative fuel for coal heating boilers of SAS UWG type is a mixture of the black coal grades as follows: 70% of coal the nut grade ( class 24/12 acc. to above mentioned norm) and 30% of coal the fine coal grade (class 21/15 acc. to above mentioned norm). For this type of boiler it is not recommended to relay only on the fine coal. These boilers are also fit for combusting long flame fuels, such as: brown coal and wood in different forms, e.g. chips, silvers, shavings, etc. The wood has to be seasoned at least one year! Wet wood combustion lowers the efficiency and the lifetime of a boiler. It also obstructs the declared power for slow combustion sustainment. 6. BOILER ASSEMBLY GUIDELINES Boiler s assembling should be performed by qualified and authorized personnel (qualified person upon adequate training and authorized for performing maintenance and repair works). The fitter s obligation is to get familiar with the product, its functioning and protection systems functionality. Prior to boiler s assembling it is strictly necessary to get familiarized with the content of hereby Technical-Start-Up Documentation REQUIREMENTS FOR BOILER-ROOM The boiler room, where the heating boiler for central heating installation shall be installed, must conform the requirements of detailed regulations being in force, at the country of destination (e.g. PN-87/B-02411). In particular, the following requirements shall be fulfilled: the boiler rooms should be located as centrally as possible to rooms which are covered with heating system, and the boiler itself should be placed as close as possible to chimney (chimneys), boiler room entrance door should be opened on the outside, and be made of inflammable materials. the boiler room should have air blow-in ventilation, a channel with section no less than 50% of the chimney section, but not less than 21 x 21 cm, with the exit at the back part boiler s room, (lack of such ventilation or obstruction may cause: smoking, inability to get higher temperature), the boiler room should have air blow-out ventilation under room s ceiling with section no less than 25% of the chimney section, but not less than 14 x 14 cm (the purpose of this system is to carry out harmful gases). NOTE: Employing of mechanical blow-out ventilation is unacceptable. The boiler room should be provided with day and artificial lighting. 6

7 6.2. BOILER ARRANGEMENT Special foundation for boiler is not required, however it is recommended to put it on concrete platform 2 cm high, but it may be also practiced to put it directly on the fire-proof floor. Boiler s layout should ensure easy and safe operation of such elements, as furnace, ash box and fuel loading, and do not obstruct cleaning operations. The front of boiler should be distant from the opposite wall no less than 2 m, and similarly, boiler s sidewalls no less than 0.5 m CONNECTING BOILER TO THE CHIMNEY Chimney channel and connection should be performed according to the requirements of detailed regulations being currently in force in the country of destination (e.g. Ministry of Infrastructure Decree, as of 1 April 2002 Journal of acts no. 75). A boiler should be connected with smoke conduit, which is slightly rising towards the chimney. Smoke conduit length should not exceed 0.5 m. Area of chimney smoke conduit connection should be precisely sealed. Area of chimney smoke conduit connection should be precisely sealed. The chimney s height and section, as well as accurateness of its construction shall ensure obtaining required chimney draught of min mbar (see tab. p.10, point 9). Selection of the chimney s height and section comparing to boiler power should be based on detailed regulations being in force in the country of destination. Assuming that it is not possible to achieve such parameters for chimney, and chimney draught problems are experienced, resulting in improper boiler performance, the gases blow-out fan, or chimney base together with built-in fan may be applied, for supporting and stabilizing the draught. It is important for the chimney to has its beginning at the level of boiler room floor, for the reason that gases leaving the boiler are able to be repelled. It is also important, that in the bottom part of chimney there is washout whole with tight closing. In order to avoid the air back draught possibly appearing in the chimney, its height should be above a crest of roof not less than 1.5 m. Chimney s utility (permeability) should be checked and confirmed by authorized chimney-sweeper at least once a year. PRIOR TO BOILER COMMISSIONING THE CHIMNEY SHOULD BE BASKED! It is recommended that the flue is made of stainless steel material. If boiler is kept with low temperatures for longer time, such a flue is mandatory. Low temperatures in the boiler cause wet gases emission. This may be found as the reason of wetting and corroding of brick chimneys. 7

8 6.4. CONNECTING BOILER TO HEATING INSTALLATION The boiler should be connected to heat in installation with screw connectors. Protecting measures for water heating installations of opened type should be according to detailed regulations being in force in the country of destination. (e.g.pn- 91/B THE SAS UWG BOILERS MAY BE EMPLOYED ONLY IN THE OPEN SYSTEM INSTALATIONS, WITH PROTECTION AIDS ACCORDING TO THE GIVEN STANDARD). Volume of pressure vessel should be equal at least 4% volume o water in the entire heating installation. NOTE: Ascending and descending safety pipe as well as circulation pipe must not be equipped with any valves. In addition, those pipes and the pressure vessel should be protected against freezing. Boilers of SAS UWG type may work with gravitational or forced water circulation. If installation is provided with circulation pump, than on feeding/return pipe the differential valve should be installed. When blackout or pump malfunction occurs, this valve will open and the system start work running by gravitation. NOTE: It is recommended to connect the boiler to heating system provided with three- or four-pass valve. The main advantage of such connection is boiler protection function against low temperature corrosion, preventing it from premature wear. If not satisfactory to comply with manufacturer s recommendations in reference to maintaining given heating water temperature ranges occurs (table TECHNICAL EXPLOITATION PARAMETERS p. 10, point 12, 13, it concerns in particular longlasting return water temperature below 55 C), then the boiler should be connected to the heating installation equipped with three- or four-pass valve protecting it against low temperature corrosion. 7. OPERATION AND EXPLOITATION GUIDELINES 7.1. FILING WITH WATER Boiler and the entire installation water filling is to be performed using blowdown connection. This activity should be performed slowly allowing the air residing in the installation to be removed. It is accomplished when water is going out of overflow pipe. When filling the heating system installation with water it is recommended to loose screw connection at the place of boiler installation assembly (on the hot water connector). Once water is flowing out, tight the connection. 8

9 NOTE: Filling installation with water when boiler is in use, especially if it is very hot is strictly forbidden, as boiler s damage or fracture may be caused. Once heating season is over do not get rid of water from heating installation and boiler. When required, water may be let of through blowdown connection to a drain once it is cooled down FIRING UP A BOILER Firing up a fuel in boiler should be started when checked if heating installation is filled with water, and water is not frozen. It should also be checked, if water is not leaking through thread fittings on boiler. Do not forget to heat the chimney prior to the firs startup. Before the fire up, smoke throttle in the smoke conduit should be fully opened, as well as ash box and furnace door, likewise the fuel charge door which should be fully closed. The operation should be performer slowly, using crimpled pieces of paper and wood. Then thin layer of coal is applied. Once the batch of coal is glowing, ash box and furnace door should be closed. Open fuel load door and fill the combustion chamber with fuel, up to the lower edge of the load door. Then, close the load door and position the smoke throttle in the smoke conduit. Also, in order to obtain the required temperature and heat capacity close air dosing flap placed on the ash box door, using the string and an air draft regulator. During fire up process the boiler should be monitored until it gets feeding water temperature of 45 C. It is important, as v arying fuel quality may cause the boiler to go out. In case of fire in boiler went out during fire up operation a furnace must be cleaned, boiler s channel should be ventilated and fire up should start again. During the process a smoking or sweating of boiler may occur. Once boiler and chimney duct get hot, those adverse phenomena should go away. Person operating the boiler should know that some of boiler s areas are hot, therefore protective gloves should be worn! The same applies to protective goggles. 9

10 TECHNICAL AND OPERATING PARAMETERS OF SAS UWG BOILER * when working at average load (50% of rated power)/ rated load ** if manufacturer recommendations regarding heating water temperature ranges are not observed, boiler must be obligatory connected to central heating system equipped with three- or four ways valve, protecting against so called low temperatures corrosion *** a different heat exchanger construction (see construction scheme for power rate 17-29kW) No. Parameter Unit SAS UWG 1. Boiler power kw Boiler heated surface m Boiler efficiency % 79,1 85,9 4. Fuel consumpcion* kg/h 0,8 1,0 1,2 1,4 1,5 1,7 5. Load chamber capacity dm kg ~12 ~15 ~18 ~21 ~24 ~27 6. Exhaust temperature C Boiler water capacity l Boiler weight (without water) kg Required chimney draught mbar 0, Maximal allowable opperating pressure bar 1,5 11. Maximal allowable working temp. C Reccomended heating water working temp. C Minimal return water temp.** C 55 A mm A1 mm B mm B1 mm H mm H1 mm H2 mm H3 mm C mm C1 mm *** *** *** D mm Smoke conduit diameter mm Ø160 Ø160 Ø160 Ø180 Ø180 Ø Connector pipe diameter (supply/return) mm G 1½ G Load door opening mm x mm 275 x x x x x x Minimal chimney height m Dimensions 19. Minimal chimney dimensions/diameter cm x cm mm 15x15 Ø140 16x16 Ø160 17x17 Ø180 18x18 Ø210 20x20 Ø220 21x21 Ø240

11 BOILER CONSTRUCTION SCHEME OF SAS UWG ( 9-14 kw) 1. boiler casing (body) 8. glow prevention grid 14. air draft regulator 20. return water connector pipe 2. insulation 9. ash box door 15. swirl vanes 21. blowdown connection 3. water jacket 10. air intake dosage flap 16. hot water connector pipe 22. thermometer 4. furnace chamber 11. water grates 17. smoke conduit 5-6 washout fuel load door 12. cast iron grates (movable) 18. smoke conduit cleaning hole 7. furnace door 13. movable grates lever 19. smoke throttle

12 BOILER CONSTRUCTION SCHEME OF SAS UWG ( kw) 1. boiler casing (body) 8. glow-securing grate 14. air draft regulator 20. return water connector pipe 2. insulation 9. ash box door 15. swirl vanes 21. blowdown connection 3. water jacket 10. air intake dosage flap 16. hot water connector pipe 22. thermometer 4. furnace chamber 11. water grates 17. smoke conduit 5. washout door 12. cast iron grates (movable) 18. smoke conduit cleaning hole 6. fuel load door 13. mobile-grates lever 19. smoke throttle 7. furnace door

13 7.3 BURNING During normal exploitation of boiler burning process is based on periodic refueling and raking a grate by moving the arm of mobile grate mechanism (pos. 13). Single load of basic fuel is sufficient for 6 hours of boiler operation at rated power. With lower capacity the period of slow burning (time gap between refueling) may be elongated. In the central heating installation heating requirement is changing along with outdoor conditions, e.g. daytime and temperature. Temperature of water leaving out the boiler depends also on thermal characteristic of building, e.g. construction materials, in particular the insulation one. Combustion intensity and the heat Power of the boiler is to be regulated by opening and closing the air dosing flap (pos. 10), or mechanically, with the air draught regulator (pos. 14), or manually, by adjusting the regulation screw, placed in the air dosing flap. Combustion intensity regulation and heat capacity of a boiler should be performed by opening and closing the air dosing flap CLEANING THE BOILER In order to use fuel in the safe manner, and to get declared boiler s power and heat efficiency, keeping adequate cleanliness of combustion chamber and convection channels is indispensable. As far as furnace chamber is concerned, special attention should be paid when removing ash and slag from between grate orifices and chamber s walls. Such a cleaning should be exercised prior each boiler s fire up process, but not less than after of boiler s continuous work. Cleaning of convection channels, with volatile ashes residues, should be performed every 3 7 days, depending on quality of burned fuel. The cleaning operation is done through washout holes indicated on the drawing (p. 11,12, pos.5). It is also important, that whirling elements placed In the upper part of fumes outlet channel (pos. 15) are regularly cleaned. Once cleaning is finished, those holes should be sealed tightly. Cleaning the chimney duct is not less important. In case of low temperatures in boiler in the longer time, it is necessary to heat the boiler periodically (at least once a week) burning-out in temperature C. This is important for extending the durability of boiler END OF HEATING SEASON Once heating season is finished, or in other cases of scheduled stops, wait the fuel to be completely burned out. Once boiler is out and cooled down, remove from the furnace all remains of burned fuel and apply cleaning and conservation of the entire boiler. Pay special attention to lubricate inner partitions of combustion chamber and all movable elements with oil. After the end of heating season, should be protected also feeder drive mechanism with oil. For the period of brake time, water should not be drained out of boiler and installation. If boiler s stopping took place in emergency conditions, glowing fuel shell be removed into metal box and taken out of boiler room, or alternatively the gloving fuel may be covered with sand. NOTE: it is not allowed to put out the fire with water when in the boiler s room! 13

14 8. TERMS OF SAFE EXPLOITATION In order to maintain safe operation of boiler following rules need to be exercised: keep the boiler in good technical condition and its installation, in particular take care of the installation tightness, as well as keep sealed door and washout openings, keep boiler room tidy, do not stack any objects not related to boiler s operation, in the winter time do not apply brakes in heating process, preserving water in installation against freezing. Especially, if the safety pipe is frozen (overflow pipe) it may be very dangerous because of potential damage of boiler, it is forbidden to fire up a boiler by use of petrol, kerosene, solvents, explosion may occur causing he operator to be burned, in case of installation malfunction and lacking water in a boiler do not fill it in, if boiler is hot, as it may cause its damage, all defects of boiler should be immediately removed. NOTE: The boiler should be regularly cleansed from soot and tarry residues any residue on the convection channels walls disrupts proper heat transfer from the exchanger, lowering this way an efficiency of device and increases fuel consumption. 9. STATES OF IMPROPER BOILER S FUNCTIONING PROBLEM CAUSE/SYMPTOM REMEDY Low heat capacity of device gases channels obstructed lack of fresh air delivered to boiler room burning inadequate fuel power of boiler set improperly boiler power not up to heating area improper design and erection of heating installation clean the channels through washout wholes door (prior to this pull out whirling elements, p , pos. 15) check blow-in ventilation, improve its permeability apply proper quality fuel (see chapter Fuel p.5-6) try to regulate the boiler by means of setting an air draft regulator or air dosing flap placed in ash box door and smoke throttle in the smoke conduit 14

15 Smoking chimney draught not sufficient check chimney s permeability and its parameters (see tab. height and section to boiler s power, p. 10), check if chimney end is not lower than roof ridge gases channels dirty clean up boiler through sealing rope indoor and washout openings worn improper assembly of boiler and chimney connection very low atmospheric pressure washout door replace a rope (to be replaced regularly) check accurateness Sudden temperature and pressure rise Water licking out of boiler Hitting, shooting in boiler improper position of smoke throttle to current chimney draught too much ash gathered on the fumes whirling elements installation valves closed pressure vessel frozen so called boiler s sweating, this is natural process caused by temperature difference in boiler air in the heating installation and boiler due to improperly performed filling in process (see chapter 7.1, p. 8) adjust sprocket position if it is closed to much Clean both fumes whirlin elements and fumes channel with boiler s tools open the valves heat the pressure vessel during boiler s start-up and after each standby "heat the boiler" e.g. burn it up to 70 C and keep that temperature for several hours "heat the boiler" e.g. burn it up to70 C and keep that temperature for a longer time, till the whole air is removed from boiler remove the air from installation by opening the valves on radiators. 15

16 10. TERMS OF DELIVERY Commercially delivered boilers are assembled and supplied with complete set of tools for maintenance together with the technical-start-up documentation. Before connecting a boiler to a heating installation, make check if all boiler s components are in good working condition, and that the boiler is fully equipped. NOTE: Boilers need to be transported in the vertical position! 11. BOILER S RECYCLING In order to recycle the boiler worn device deliver to specialized recycling unit, according to detailed regulations being in force in the country of destination. 16

17 12. TERMS OF WARRANTY 1. Manufacturer grants warranty for proper functioning of the heating boiler SAS UWG, what is confirmed with the stamp of factory. 2. Manufacturer grants warranty for the period covering the boiler installed and operated according to all terms and recommendations included to Technical - Start-Up Documentation (TSD). 3. A buyer gets together with terms of warranty hereby Technical-Start-Up- Documentation (TSD), which is laid down rules for the proper operation and safe exploitation of the heating boiler. Hereby documentation (TSD) must be reading careful and it is obligatory. 4. Warranty terms are binding from the date of the purchase for the period of: a. 4 years for efficient functioning of the boiler, b. 2 years on the heat protective grate, c. 2 years on electronics and automation components mounted on the boiler and produced by other manufacturers: air draft regulator thermometer 5. Warranty does not cover consumable items: sealant (rope) 6. Manufacturer is obligated to carry out the charge free repair under warranty in time period of 14 days starting from the date of application (done by user). 7. Boiler s repair, the construction or insulation alterations made by user or other third parties will cause the warranty to be invalid. 8. Application of reclamation should be addressed at manufacturer. 9. Boiler replacement realized by manufacturer is only possible based o expert opinion, that repair is not workable. 10. If the advertiser does not allow double-warranty repairs, despite the willingness of the guarantor to comply with it, is deemed to have resigned from the advertiser claims contained in the application of reclamations. 11. In case of unfounded service summon, the customer shell pay travelling and work costs. Before you call service, please familiarize yourself with the chapter "States of improper boiler s functioning". We always offer help by telephone. 12. Warranty card makes up the only ground for charge free repair. 17

18 NOTE: Manufacturer reserves the right to introduce changes in the construction of the product for modernization purpose. Such changes may not be reflected in hereby documentation, however basic, described properties of the product shall be maintained. Any remarks and questions on boiler s SAS type exploitation shall be addressed: ZAKŁAD METALOWO-KOTLARSKI Owczary, ul. Przemysłowa Busko - Zdrój Tel.: +4841/ Fax: +4841/ biuro@sas.busko.pl Technical-Start-Up Documentation valid from

19 SERVICE REPAIRS 19

20 WARRANTY CARD No.... According to presented conditions 48 (24 * ) months warranty is given for low temperature boiler of SAS UWG type installed and operated in pursuance of Technical Start - Up Documentation. Boiler no Heating capacity -... Heated surface -... Year of manufacture Manufacturer signature and stamp.. Seller signature and stamp.. Sell date * boilers 48 kw and higher are cover with 24-months warranty 20