and Installation Instructions The installation instructions for the Unit pressure jet oil burner is included in the pressure jet oil burner pack.

Transcription

1 Technical Guide and Installation Instructions MKS / MUS Steel boiler kw The installation instructions for the Unit pressure jet oil burner is included in the pressure jet oil burner pack. The control unit installation and service instructions included in the control unit pack. Wolf GmbH Mainburg Postfach 1380 Telephone /74-0 Fax / Part no /03 TV GB 1

2 Oil- and gas-fired steel boiler for pressure jet combustion in accordance with EN 303 and EC Directive 90/396/EEC (gas consuming equipment), 73/23/EEC (Low Voltage Directive), 89/336/EEC (EMC Directive), 92/42/EEC (Hot Water Boiler Efficiency) and 93/ 68/EEC (Identification Directive) for heating systems with heating circuit pumps and flow temperatures up to 110 C and 4 bar permissible operating pressure in accordance with DIN 4751 and max. DHW cylinder pressure 10 bar in accordance with DIN The NO x limits required by the 1st BImSchV 7(2) are maintained. Suitable for heating systems in accordance with DIN 4751 part 1 and 2 with maximum flow temperatures up to 120 C. Oil- and gas-fired steel boilers Type MKS Oil-fired Unit steel boilers with two-stage pressure jet oil burner Type MUS 2

3 Specification Boiler type MUS MKS Output range oil/gas (MKS) kw Recommended range (MKS) kw Upper range oil (MUS) kw Set output UNIT burner MUS kw Flue gas temperatures 1) from/to C st stage flue gas temperature C Flue gas mass flow rate 1) Fuel oil EL CO 2 =13% kg/h Flue gas mass flow rate 1) Natural gas E CO 2 =9.5% kg/h Flue gas mass flow rate 1) Natural gas LL CO 2 =9.0% kg/h Flue gas mass flow rate 1) LPG CO 2 =11% kg/h Relative standby loss q B % Total weight MKS kg Total weight MUS kg Boiler dim. Width mm Height 2) mm Length MKS mm Length MUS mm Flue pipe Ø mm Burner aperture MKS mm ) 245 3) 305 3) 305 3) 305 3) Minimum blast tube length MKS mm Foundation / plinth Height mm 80/80 80/80 80/80 80/80 80/80 80/- 80/- 80/- Width mm 800/ / / / / /- 1100/- 1100/- Length mm 1360/ / / / / /- 2000/- 2000/- Boiler flow (flange) DN Safety flow, air-vent valve (male thread) R 1¼" 1¼" 1¼" 1½" 1½" 2" 2" 2" Boiler return (flange) DN Filling, draining, safety return (male thread) R 1½" 1½" 1½" 1½" 1½" 1½" 1½" 1½" Boiler water content l Boiler gas content l Heating surface m Flue gas resistance 1) mbar Heating water resistance (at Dt=20K) 1) mbar Combustion cham. dia. Length mm Diameter mm Type approval ID ÖVGW-Reg.-Nr. G2,416 CE designation CE-0085AR0034 Electrical connection 230V / 50Hz / 10A Max. perm. temperature 4) C 120 Max. boiler pressure bar 4 1) At a mean boiler water temperature of 60 C for the upper and lower output of the recommended range. 2) Including control unit 3) Plain burner plate, drill on-site. 4) Adjustable high limit safety cut-out: 120/110/100 C at R31 STAV, R32, R33 and R33/4 (not applicable to installations in Austria). The chimney stack dimensions must be calculated in accordance with DIN 4705, or local regulations. For flue gas temperatures below 160 C, combustion equipment must be connected to highly insulated chimney stacks (heat conductivity resistance class I acc. to DIN T1) or use suitable, moisture-resistant, type-tested, flue gas systems. 3

4 Safety instructions General These installation instructions apply exclusively to WOLF oil- and gas-fired boilers as well as to WOLF Unit steel boilers. Authorised personnel should read these instructions before any installation, commissioning or maintenance work. Adhere to the instructions given in this document. Non-adherence to these installation instructions voids WOLF warranty. Reference symbols Please note: The following symbols and references are used in these installation instructions: Non-observance of these references can put individuals at risk. Non-observance of these references can lead to damage to the oil/gas-fired boiler or the Unit boiler. In addition to the installation instructions, operating instructions and adhesive labels are included or fitted to the boiler. These must also be observed. Observe the enclosed references for heating system installers. Safety instructions Only qualified and trained personnel may install, commission and maintain these boilers. In accordance with VDE 0105 part 1, work on electrical components (e.g. control unit) may only be carried out by qualified electricians. The regulations of VDE/ÖVE and those of your local electricity supplier as well as all other local regulations are apply to electrical installation work. Only operate the boiler within its output range which is stated in the specification supplied by WOLF. Appropriate use of the boiler refers to the exclusive use in hot water heating systems in accordance with DIN Never remove, bypass or otherwise disable any safety and monitoring equipment. Only operate the boiler in perfect technical condition. Any faults and damage with a potential impact on safety, which might limit the safe use of the equipment, must be remedied immediately by a qualified contractor. Replace faulty components or equipment only with original WOLF spare parts. Standards and regulations The boilers described in these installation instructions are low-temperature boilers according to HeizAnlV and 92/42/EEC (Hot Water Boiler Efficiency). In accordance with the Heating System Order, heating systems above 70 kw may not be operated in single stage mode. Retain the enclosed operating instructions clearly visible in the boiler room. Insert all further documentation in a clear wallet and clip to the boiler side casing. Your boiler and burner should be maintained and cleaned on an annual basis by a heating contractor, to ensure the reliable and economic function of your heating system. We would recommend a maintenance contract. Boilers may only be installed and operated in boiler rooms which are suitable according to the Landes-FeuVo [or local regulations]. 4

5 Positioning Installation references The boiler should be installed on a level surface which is substantial enough to carry its weight. It is recommended to place the boiler on a foundation or plinth. For dimensions see the specification. During the boiler installation observe all building regulations, the FeuVo and VDI 2050 [in Germany] and local regulations, particularly regarding the size of the boiler room, the fresh air and exhaust air ventilation as well as the chimney stack connection. Please note: Please note: Only install the boiler in boiler rooms which are free from frost and where adequate ventilation is ensured. Drain the boiler, the DHW cylinder and the entire heating system if there is a danger of frost, if the system has been shut down. Position the boiler horizontally or slightly rising towards the back to ensure adequate venting of any trapped air. Boilers should not be installed in areas subject to aggressive vapours or very dusty/ highly humid conditions (workshops, washrooms, hobby rooms etc). The combustion air must be free from halogenated hydrocarbons (e.g. as contained in sprays, solvents and cleaning fluids, paints and adhesives) and high dust concentration. Clearances towards walls and combustible materials must comply with local fire regulations. The above clearances are recommended. Keep the flue pipe connection as short as possible and inclined towards the chimney stack. Thoroughly seal-in the flue pipe. Use flue pipe bends with clean-out covers to facilitate the cleaning of the flue pipe. Repositioning the fixing screws enables the boiler door to be opened in the opposite hand. 5

6 Casing installation Control unit cable Boiler sensor 2 nd stage 1 st stage Burner cables 1 Thermal insulation: Position (overlapping) around the boiler block and secure with spring clips. 2 Spacers: Secure on the boiler with nuts enclosed. (MKS-85 to 500) Four spacers at the real panel. (MKS-85 to 140) Two bottom spacers per side. (MKS-190 to 500) Three bottom spacers per side and one central top spacer. 3 Thermal insulation: Loosely fitted to the rear boiler wall. 4 Rear panels: Centrally locate both parts and secure with self-tapping screws and with the screws (M8x16) supplied on the rear boiler wall spacers. 5 Thermal insulation: Insert from the top between door and boiler front and locate on the boiler front. 6 Thermal insulation: Fit loosely to the boiler front and secure with spring clips. 7 Thermal insulation: Fit loosely to the boiler front and secure with adhesive strips. 8 Side panels: Push the l.h./r.h. casing over the rear panel and secure with the screws (MUS-85 to 100 / MKS-85 to 140) (M8x16) supplied to the lower two spacers. 8 Side panels: Secure the l.h./r.h. front and rear panels with screws (M6x10) then push over the rear panel (MKS-190 to 500) and secure with the screws (M8x16) supplied on the lower three spacers. 9 Wolf label: Hook into the front panel lid (10). 10 Front panel lid: Locate and click into the panel with fitted control unit. Only complete the fitting of the casing after the control unit has been installed (page 7). 10 Panel lid l.h. rear: Locate on the panel and click into place. 10 Panel lid r.h. rear: Locate on the panel and click into place. 13 Type plate: Affix to the boiler in a clearly visible position. Accompanying documentation: Affix with the clips supplied to the side of the boiler. 6

7 Control unit installation High limit safety cut-out Please note: Ensure, during the control unit installationthat the sensor capillaries are not kinked or twisted and have only been pulled out of the boiler casing as far as necessary. Do not route on-site cables for outside temperature and flow temperature sensors together with mains power cables. Electrical wiring in accordance with the wiring diagram enclosed. Ensure that cables which are not required are secured against contact. Observe the respective installation and operating instructions for R32, R33 and R33/4 control units. R31-STAV control unit 1 st stage Burner cable 2 nd stage Boiler sensor Mains supply cable Heating circuit pump cable Loading pump cable DHW cylinder cable Control unit Guide the cable through the casing lid cut-out, and secure the control unit housing on the casing lid with the self-tapping screws supplied. Guide the burner cables through the boiler front cut-out. Push the boiler sensors in any order into the boiler sensor well. Guide the mains supply cable, and the heating circuit pump cable through the boiler back cut-out. Guide the loading pump cable (for DHW cylinder connection accessories) through the boiler back cut-out. Guide the DHW cylinder cable (for DHW cylinder connection accessories) through the boiler back cut-out. Adjusting the boiler thermostat If necessary, the boiler thermostat can be adjusted from 80 C to 90 C. To do this, turn the boiler thermostat clockwise to its end-stop (80 C); pull out the rotary selector approx. 3 mm and continue to turn clockwise to its end-stop (90 C). Please note: The boiler thermostat must not be set to 90 C if the high limit safety cut-out has been adjusted to 100 C. Changing the setting of the high limit safety cut-out (STB) for R31-STAV The high limit safety cut-out (STB) is factory-set to 120 C. Change the setting of the STB, if required. Such changes are irreversible. Disconnect the control unit from its power supply. Remove the control unit lid with a screwdriver. Unscrew the plastic cap and locking nut. Remove the high limit safety cut-out. Adjust the setscrew in accordance with the scale. Install in reverse order. Control accessories Please note: Installation and electrical wiring according to the wiring diagram supplied with the control accessories. If Wolf boilers are equipped with control units not supplied by Wolf or if technical modifications are carried out on Wolf control units, Wolf will not be liable for any consequential losses which may occur. 7

8 Installation / maintenance Connections Venting Safety flow Boiler flow Boiler return Flue pipe connection Draining, filling Pipework Central heating boiler Connect the heating flow and return to the respective boiler fittings. For connections, see above. Install a check valve behind the boiler circuit pump(s) to prevent incorrect circulation. Install a safety equipment assembly. Please note: The pipework between the boiler and the safety valve must not be able to be shut off. Connect underfloor heating via a four-way mixer. Provide system separation by means of a heat exchanger, when using pipes which are not impermeable to oxygen. Filling the heating system The boiler and central heating system may only be filled, if a type-tested safety valve (opening pressure max. 3 bar) has been installed at the "ventilation connection of the boiler. Install a filling/drain valve to fill the central heating system at the "drain, filling connection, and connect a water hose. Observe the pressure gauge in the safety equipment assembly when filling the system with water. Check the safety valve function. Ventilate the boiler (automatic air-vent valve). Draining the heating system Shut down the heating system and let it cool down. Open the drain valve on the boiler. Open the radiator bleed valves. 8

9 Minimum return temperatures / return temperature raising facility Minimum return temperatures To prevent falling below the dewpoint, the following measures for raising the return temperature are required in order to maintain the minimum temperatures t Rmin listed in the table. System Fuel Oil Gas Control unit R31, R32 R31, R32 R33, R33/4 R33, R33/4 Radiator central heating t Kmin C less than 20l/kW t Rmin C Design 80/60 Return temp. raising 1-3 2/3 acc. to sys. example Low-temp. central heating t Kmin C with less than 20l/kW; t Rmin C Design temperature Return temp. raising 1-3 2/3 55/45 and above acc. to sys. example Systems with more than t Kmin C l/kW underfloor/ t Rmin C low-temp. central heating Design temperature Return temp. raising 2/3 2/3 under 55/45 acc. to sys. example t Kmin = min. boiler temperature t Rmin = min. return temperature Please note: A weather-compensated control unit is equipped with soft boiler start, which prevents condensate being formed during the start-up phase. Sizing shunt pump The flow rate of shunt pump V is calculated according to the following formula: V Q N c p ρ W Q N x 3600 V = in m 3 /h c p x t x ρ W = Shunt pump volume flow in m³/h = Rated boiler output in kw = Specific energy 4.2 kws/kgk = Specific weight of water 1000 kg/m³ t = Temperature differential between the flow temperature and bypass temperature (recommended design temperature differential 30k) The shunt pump head results from the boiler pressure loss at the selected volume flow, the pipework pressure loss as well as all individual boiler circuit pressure losses. System example A return temperature limit stat T switches the shunt pump ON, when the permissible return temperature is no longer maintained. A return temperature limit stat T1 switches the shunt pump ON, when the minimum return temperature is no longer maintained. If the return temperature falls further, the return temperature limit stat T2 signals to the control unit R, which throttles the heat transfer via one or several mixers M in the heating circuit. A return temperature limit stat T regulates a distribution valve M, so that if the permissible return temperature is no longer maintained, the heating circuit flow will be partially or fully closed. After the boiler has been heated up, the distribution valve M will open as wide as the permissible return temperature requires. The distribution valve M, can also be installed as mixer into the return. 9

10 Fill water / burner connection Fill water Water guidelines for heating systems in accordance with VDI 2035 at operating temperatures up to 100 C: Group Total of rated boiler output Q Filling and top-up water Heating water kw *) for exceptions see VDI 2035 (+) may be required, see VDI 2035 Total alkaline earths in mol/m³ ph value Diamide Na 2 SO 3 Excess in mg/kg 0 Q 100 -*) < Q to 3 8 to < Q to 2 8 to to 5(+) 5 to 20(+) Water guidelines for heating systems in accordance with VdTÜV guidelines at operating temperatures above 100 C: Filling and top-up water Circulating water Residual hardness p value ph value Diamide Na 2 SO 3 mval/kg mval/kg Excess in mg/kg < Burner connection Observe the TRD 411 (oil combustion) and TRD 412 (gas combustion) guidelines. The gas installation and operation of heating systems must comply with the DVGW Code of Practice "Gas" and the technical connection conditions of your gas supply company and/all local regulations. Burner size MKS Acc. to EN 226 adjustable to burner size connection MKS Burner plate in acc. with blast tube dia. MKS-500 cut-out and tap thread. Match the door insulation to the blast tube diameter of the burner. The blast tube must protrude into the combustion chamber at least 25 mm beyond the door installation. Use fixing screws for the burner flange, which cannot the inserted into the boiler door more than 15 mm. Connect the ventilation fitting at the sight glass with the burner fitting. After the control unit installation, plug the burner cable into the burner. Ensure that the combustion output matches the rated boiler output. Observe the details provided by the burner supplier. Minimum boiler output To prevent the system falling below the dewpoint, the following minimum boiler output for two-stage burners are required for the first stage: MKS MUS Type Output range kw Min. boiler output burner stage 1 kw

11 Electrical connection Electrical connection Connect the heating circuit pump(s), the return shunt pump and the DHW cylinder loading pump(s) on-site via contactors, if: - three-phase pumps (400 V) are connected. - burner and pump draw more than 2 A each. - the total control unit power consumption is exceeded. Mains power connection 230V 50 Hz 10 A Heating circuit pump(s) / return shunt pump connection To the control unit To the control unit 3 x Return limit thermostat 3 x ye/gn PE br L1 bl N bl N ye/gn PE br L1 PE L1 N Heating system emergency stop switch (on site) Heating circuit pump on-site Return shunt pump Burner two-stage without socket part To the control unit To the control unit 7 x x Burner with socket part Burner plug plug into the control unit Burner plug on the control unit blk ye/gn blu br w gr r x x blk ye/gn bl br w gr r Burner connection Remove the burner plug from the control unit, connect the black to the brown core and connect the white core to the burner phase. Burner socket part Burner socket part 1 st stage 2 nd stage Connection for on-site safety equipment To the control unit blk y blk y To the burner y blk y blk Terminals for low water indicator Control unit junction box Terminals for safety pressure switch Terminals for remote pressure monitoring 11

12 Safety equipment Safety equipment acc. to DIN 4751 part 1 Scope: Open and sealed, physically protected heat generator systems with flow temperatures up to 100 C. Fresh air ventilation/ exhaustion Thermometer Safety valve Expansion vessel Test line Heat consumer Cap valve Shut-off valve Boiler fill and drain valve Safety valve Expansion vessels of sealed heating systems are provided with a standpipe as safety equipment in accordance with DIN 4750 or a safety valve in accordance with TRD 721. Expansion vessels Install an expansion vessel compliant with DIN 4807 T2 for each boiler system at its highest point. Thermometer A thermometer with sensor well is fitted to the flow of each boiler. Water level indicator Each boiler is equipped with a water level indicator which is visible from the boiler control position, which enables the static pressure of the heating system to be checked that any time. Mark the lowest permissible water level on the water level indicator. Please note: The pipework between the boiler, the expansion vessel and the safety valve must not be able to be shut off. A valve which has been protected against unauthorised closure, e.g. a cap valve, would also be acceptable. The system diagram only indicates the safety requirements but is not a recommendation for specific types of heating network control. 12

13 Safety equipment Safety equipment acc. to DIN 4751 part 2 Scope: Sealed, thermostatically protected heat generator systems with flow temperatures up to 120 C. Thermometer Heat. circ. pump Safety valve Open flash trap Low water indicator Maximum pressure limiter Pressure gauge Heat consumer External pressure monitoring Fresh air ventilation/ exhaustion Cap valve Expansion vessel Drain valve Minimum pressure switch Boiler fill and drain valve Safety valve Every boiler must be protected against exceeding the permissible operating pressure by a diaphragm safety valve or other spring-biased safety valves. Safety valves must comply with TRD 721. A maximum of three safety valves may be applied to each heat generator. A flash trap must be installed immediately next to each safety valve for boilers with a rated output in excess of 350 kw. The installation of flash traps is not required for hot water heating systems, if each heat generator is equipped with one or an additional STB and one or an additional pressure switch. Sizes and internal diameters of diaphragm safety valves, dimensions of supply lines and blow-off lines. Diaphragm safety valve Blow-off output in kw Size, internal diameter, DN Fitting thread for supply line G ½" G ¾" G 1" G 1¼" G 1½" Fitting thread for blow-off line G ¾" G 1" G 1¼" G 1½ G 2" Expansion vessels The water and gas chamber of pressure expansion valves must be calculated in accordance with DIN 4807 part 2. If the permissible operating pressure is lower than the highest working pressure of the pressure dwell valve, protect the expansion vessel by suitable type-tested safety valves against excessive pressures. Size open expansion vessels for a minimum pressure of 2 bar. Arrange all expansion vessels with shut-off facilities towards the heating system. Ensure that the shut-off equipment is sufficiently protected against unintentional closure (e.g. cap valve protected with a wire and seal). Low water indicator Equip each boiler with a type-tested low-water indicator. A low-water indicator is not required for boilers up to 350 kw, since excessive heating at low water conditions is prevented. This was verified as part of the type testing of the STB installed in the control unit. 13

14 Safety equipment Thermometer Install a temperature indicator and a facility for checking the flow temperature into the boiler flow line, so that the actual heating water flow temperature can be recorded. The permissible flow temperature must be permanently marked on the display scale. Pressure gauge The boiler must be equipped with a pressure gauge with immediate connection to the water chamber or in immediate proximity of the flow, as well as a suitable connection for the pressure testing device according to DIN or DIN The response pressure of the boiler safety valve and the minimum system pressure must be permanently marked on the display scale. Equip every boiler, which is protected above 3 bar or which has a rated output higher than 350 kw, with a maximum pressure switch (type-tested according to VdTÜV Code of Practice Issue 100/l). External pressure monitoring Monitor the operating pressure of hot water heat generator systems with a minimum pressure switch, type-tested in accordance with the VdTÜV Code of Practice Issue 100/I, in order to prevent water evaporating inside the heating system as a result of insufficient external pressure. Please note: Install a check valve downstream of the boiler circuit pump to prevent incorrect circulation. The pipework between the boiler, the safety valve and the low-water indicator must not be able to be shut off. The system diagram only indicate the safety requirements, but is not a recommendation for specific types of heating network control. 14

15 Approximate sizing of chimney cross-sections Approximate calculation: Circular cross-sections Required chimney diameter in cm Rated output in kw Effective chimney height in m Square cross-sections Required chimney size in cm x cm Rated output in kw Effective chimney height in m Please note: We recommend that you let your chimney manufacturer design the chimney. 15

16 Part numbers 1 Thermal insulation 2 Spacers 3 Thermal insulation 4 Back panels 5 Thermal insulation 6 Thermal insulation 7 Thermal insulation 8 Side panels 9 Wolf label 10 Front panel lid 11 Left-hand rear panel lid 12 Right-hand rear panel lid 13 Type plate Steel boiler MKS / MUS 70 up to 550 kw Part no Packing cord for boiler door, 3200 mm long X X X X X X X X Gasket for clean-out aperture X X X X X X X X Flat seal/flue gas collector box to approx. 3 rd quarter of X X X Flat seal/flue gas collector box to approx. 3 rd quarter of X X - - Flat pack./flue gas collector box to approx. 3 rd quarter of X X X Sight glass flat packing X X X X X X X X Cleaning brush X X Cleaning brush X Cleaning brush X X Cleaning brush X X X Sight glass X X X X X X X X Sensor well (up to model M 2850) X X X X X X X X Sensor well (from model M 2851) X X X X X X X X Turbulators X X Turbulators X Turbulators X X Turbulators X X X Jamb brick X X X Jamb brick X X Jamb brick X X X Casing and insulation from approx. 3 rd quarter of X X Casing and insulation from approx. 3 rd quarter of X Casing and insulation from approx. 3 rd quarter of X X Casing and insulation from approx. 3 rd quarter of X X X MKS 16

17 Troubleshooting Fault Cause Remedy Burner does not start No voltage present Check fuse, electrical connections, position of ctrl.unit, or enters fault state ON/OFF switch and heat. system emerg. stop switch Oil tank empty / Fill oil tank / Gas supply line shut off Open gas supply line Burner fault High limit safety cut-out has switched OFF Oil filter clogged Press the reset button at the boiler control unit (see burner installation instructions) Press the reset button on the control unit. Replace oil filter Heating circuit System in summer mode Check summer/winter switch position pump does not start Heating circuit pump locked up Turn the pump shaft with a screwdriver Heating circuit pump faulty Replace the heating circuit pump Cylinder loading pump DHW cylinder thermostat faulty Check the DHW cyl. thermostat and replace, if nec. does not run DHW loading pump locked up Turn the pump shaft with a screwdriver Cylinder loading pump faulty Replace the DHW loading pump The heating system operates, Maximum boiler temperature Raise maximum boiler temperature. but room temp. too low set too low 17

18 18 Notes

19 Notes 19

20 Declaration of Conformity in accordance with the 97/23/EC Pressure Device Directive Appendix VII Product designation: Applied conformity assessment procedure: Steel boiler type MKS, MUS Module B + C1 Name and address TÜV Süddeutschland Bau und Betrieb GmbH of the named body: Westendstraße Munich ID of the named body: CE 0036 Applied standards TRD 702 and specifications: DIN EN 297 and 656 We, Wolf GmbH, Industriestraße 1, Mainburg, hereby declare that the above boiler complies with the appropriate regulations laid down in the 97/23/EC Directive, when the safety temperature has been set to > 110 C. This declaration loses its validity, if the product is modified without our express permission. Observe the safety instructions in the documentation and the operating instructions. Mainburg, pp. Steppe 20