TECHNICAL AND OPERATIONAL DOCUMENTATION

Transcription

1 METAL AND BOILER FACTORY Busko-Zdrój, Owczary, ul Przemysłowa 3 Tel No , fax TECHNICAL AND OPERATIONAL DOCUMENTATION SAS MULTI FLAME BURNER ADAPTED FOR BURNING OF BIOMASS IN THE FORM OF WOOD GRANULATE PELLET* MULTI FLAME * the parameters of the recommended fuel are specified in standard DIN NOTE: The burner of a hot water boiler that is adapted for burning of biomass is protected under patent number W granted by the Patent Office of the Republic of Poland

2 TABLE OF CONTENTS 1 Purpose of the burner 3 2 Description of design and functioning 3 3 Burner equipment 9 4 Protection 9 5 Fuel 10 6 Cleaning the burner 11 7 Terms of the warranty 12 Service repairs 15 Warranty card 17 p LIST OF FIGURES AND TABLES Figure1 Design schematics of boiler type SAS MULTI with burner type SAS MULTI FLAME 4 Figure2 Design schematics of boiler type SAS SLIM with burner type SAS MULTI FLAME 5 Figure3 Design schematics of burner type SAS MULTI FLAME view from the side, cross-section 6 Figure4 Design schematics of burner type SAS MULTI FLAME view from the top 7 Table1 Equipment of burner type SAS MULTI FLAME 10 2

3 1 PURPOSE OF THE BURNER The SAS MULTI FLAME burner is designed to burn biomass in the form of wood granulate pellet*) For the process of burning of alternative fuels to be correct, it is required to adjust settings on the boiler controller ATTENTION! Use of fuels other than those recommended by the manufacturer may cause damage to the burner, which will lead to a loss of the warranty on the burner The pellet burner is designed for installation on boilers using solid fuel with a dispenser as well as an opening adjusted for an automatic fuel feeding system A control module watches over the operation of the device It decides on the operation of burner elements (including the fuel igniter, the moving grate mechanism along with a position sensor hall effect sensor) 2 DESCRIPTION OF DESIGN AND FUNCTIONING The basic elements of a boiler equipped with an SAS MULTI FLAME burner have been presented on fig1 and fig2 After ignition, a boiler equipped with a biomass burner does not require constant (everyday) service and it can operate continuously over the entire heating period Periodical breaks in operation must be made for cleaning (maintenance activities) of the boiler exchanger (see Cleaning the boiler section) and burner (see Cleaning the burner section) The basic elements of the SAS MULTI FLAME burner have been presented on fig3 and fig4 The burner is designed for highly efficient burning of wood granulate pellet It is equipped with a furnace that contains a set of moving grate-bars, the cyclically repeated movement of which makes it possible for the ash created from burning of the biomass to be dropped, which keeps the furnace clean and makes it possible to use different fuels (in the form of biomass) *) Fuel parameters are specified in standard DIN 51731, diameter: 6 8mm, length 20 30mm, max moisture 12%, do not use fuel with coarser granulation than given above, because such fuel may impede the operation of the feeder In particular, during loading or adding of fuel, attention is to be paid to the presence of undesired objects, like stones, which may cause blocking of the feed mechanism FIG 1 DESIGN SCHEMATICS OF BOILER TYPE SAS MULTI WITH BURNER TYPE SAS MULTI FLAME 3

4 1 Boiler housing (body) 15 Temperature regulator (controller) 26 Thermometer 2 Thermal insulation 16 Air draft meter** 27 Installation connector of 3 Water jacket 17 Boiler connection terminal strip temperature sensor with capillary* 28 Side cleanout door 4 Ash pit 18 Emissions chamber hatch 29 Adjustable feet 5 Return water connecting pipe 19 Flue cleaning opening 30 Drain pipe /supply of cooling water*/ 6 Air dosing flap 20 Emissions choke valve 35 SAS MULTI FLAME burner 7 Ash pit door 21 Flue 36 Burner connection terminal strip, 9 Furnace door 22 Fuel dispenser (charging hopper) master switch, fuse 37 Burner operation control module 12 Water grate 23 Safety valve 38 Biomass (pellet) furnace 13 Heat protection grate 24 Top cleanout cover 14 Front cleanout/charging/ingition door 25 Hot water connecting pipe * thermal protection against overheating (Danfoss thermostatic valve type BVTS) is not included in the boiler s standard equipment ** the air draft meter is not included in the boiler s standard equipment 4

5 FIG 2 DESIGN SCHEMATICS OF BOILER TYPE SAS SLIM WITH BURNER TYPE SAS MULTI FLAME 1 Boiler housing (body) 14 Charging and ignition door 24 Safety valve 2 Thermal insulation 15 Cleanout door 25 Thermometer 3 Water jacket 16 Temperature regulator 26 Installation connector of (controller) temperature sensor with capillary* 4 Ash pit 17 Air draft meter** 27 Adjustable screw of air supply to conventional furnace 5 Return water connecting pipe 18 Connection terminal strip 28 Drain pipe /supply of cooling water*/ 6 Air dosing flap 19 Hot water connecting pipe 29 Adjustable feet **) 7 Ash pit door 20 Flue cleaning opening 35 SAS MULTI FLAME burner 9 Furnace door 21 Emissions choke valve 36 Burner connection terminal strip, master switch, fuse 12 Water grate 22 Flue 37 Burner operation control module (igniter, moving grates) 13 Heat protection grate 23 Fuel dispenser (charging hopper) 38 Biomass (pellet) furnace * thermal protection against overheating thermostatic valve, eg Danfoss type BVTS, is not included in the boiler s standard equipment ** the air draft meter is not included in the boiler s standard equipment 5

6 6

7 7

8 3 EQUIPMENT OF THE SAS MULTI FLAME BURNER In an SAS MULTI FLAME burner, fuel is transported from the fuel dispenser to the furnace space by means of a fuel feeding mechanism equipped with two fuel distribution tubes (two transport worms divided by a channel) This solution ensures safe transport of biomass, eliminating the necessity to apply additional protection against the uncontrolled retreat of fire to the fuel dispenser For safety reasons, the hatch that closes the fuel dispenser must be tightly closed during burning of biomass in the burner Furnace elements (housing, moving grates, furnace grate-fixed part, assembly plate) that are exposed to the influence of high temperature are made from heat resistant stainless steel sheet A ceramic tile chamotte is found above the furnace space, and it additionally protects the furnace housing and also causes unburnt combustible parts of fuel to be burned completely The burner fastening plate is lined with thermal insulation that protects the fuel feeding mechanism against heating Air for the combustion process is supplied through air blow-in channel (air distribution) through a system of openings that aerate the furnace Some of the air is supplied to under the furnace grate, and the rest of its is pumped directly to the combustion area through a system of openings found on the sides of the furnace The appropriate depending on the type of burned fuel stream of air is supplied by a blow-in fan, and the boiler controller is responsible for its operation Fuel is supplied by means of two transport worms, which have been divided by a channel for safety The feeding mechanism consists of a motoreducer, which drives the fuel feeding system using toothed wheels and a chain The drive system of the fuel feeder is found under a protective guard It is possible to disassemble the feeding mechanism for the purpose of periodical cleaning (Fig4) fastening screws, sealing cord Biomass is supplied to the furnace area, where the automatic ignition process takes place by means of a heater (electrical lighter) Fig 3 During operation, this device is cooled by a stream of air coming from the blow-in channel After the desired temperature is achieved, automatic fuel ignition and the fire support system make it possible for the boiler to operate at full efficiency even at a low demand for thermal power (capability of continuous operation as well as cooperation with a hot water tank during the summer period) A characteristic quality of the SAS MULTI FLAME burner is its automatic, highly efficient, and self-cleaning furnace, which burns precisely the right amount of fuel that is necessary for achieving the temperature set by the user on the temperature controller

9 The furnace grate has been divided into a fixed part and a moving grate-bar section Cyclically activated moving grates, driven by an eccentric mechanism, make it possible to transport residue from the burning of fuel, that is ash, particularly in the form of slag sinters, from the furnace space to the boiler chamber This solution makes it possible to keep the burner s furnace space in a clean state without interrupting the continuity of the combustion process Moving grates assume positions in gaps located in the lower part of the furnace after performing a furnace cleaning cycle The grate is positioned using a position control sensor (hall effect sensor) The small inflammable part of the fuel - ash - remaining after biomass is burned in the final phase of combustion, is led off to the ash pit chamber, in which there is a pull-out drawer It must be emptied periodically (the ash created during the combustion process may be used as fertilizer) The frequency of emptying the drawer depends on the quality of the burned pellet The burner operation control module* automatically controls the fuel ignition heater as well as the furnace cleaning mechanism along with the positioning sensor (hall effect sensor) The temperature regulator installed on the boiler controls the operation of the blowin fan, the fuel feeding mechanism, and the feeder s temperature sensor Cooperation between the control module (fig1 item 36), the operation of the SAS MULTI FLAME feeder, and the master controller (fig 1 item 15) of the boiler is possible thanks to applied RS wired communication The efficient furnace of the boiler makes it possible to burn the amount of fuel that is necessary to maintain the temperature set by the user on the controller The controller* of the boiler constantly measures the water temperature in the boiler, and based on these measurements, it controls the operation of the circulation pumps in the central heating system and of pumps of the hot water tank * A detailed description of the design, operation, and use of the boiler controller, burner operation control module can be found in the controller instruction manual attached to this documentation One advantage of a boiler equipped with an SAS MULTI FLAME burner is its simple use, based on periodical addition of fuel to the dispenser and removal of ash from the ash pit drawer without the need to extinguish the furnace The SAS MULTI FLAME biomass (pellet) burner is supplied in an assembled state, equipped with a control module, blow-in fan, fuel feeding system with motoreducer, moving 9

10 grates with a drive motor, heater (electric lighter), thermally insulated assembly plate, with elements that are exposed to high temperature made from heat resistant stainless steel sheet Table1 Equipment of burner type SAS MULTI FLAME 1 Technical and Start-up documentation of the burner pcs (instruction manual + warranty card) 2 Warranty card of the blow-in fan pcs 3 Control module, power supply terminal strip pcs 4 Blow-in fan pcs 5 Fuel feeder with motoreducer pcs 6 Moving grates with drive motor set 1 7 Heater (electric lighter) pcs 1 8 Ceramic tile - chamotte pcs 9 Positioning sensor (hall effect sensor) pcs 10 Feeder temperature sensor pcs 11 Biomass furnace (heat resistant stainless steel) pcs PROTECTION In order to ensure safety of boiler operation, the SAS MULTI FLAME burner has been equipped with a multi-level protection system Among other things, it possesses protection against the retreat of flame to the fuel dispenser through the feeder (mechanism of two transport worms divided by a channel, temperature sensor on the fuel route), as well as additional protection against overheating - a thermal switch installed on the boiler Transport of fuel from the fuel dispenser to the furnace chamber takes place in such a way as to eliminate the danger of retreat of flame to the fuel dispenser during normal operation, standstill of the dispenser, as well as in the case of breaks in the supply of electricity, power failure The job of the mechanism is to protect against uncontrolled retreat of flame to the fuel dispenser without the need to apply an extinguishing installation, a so-called water fireman Safe transport of fuel is ensured by the locations of charging openings of fuel distribution tubes and by distance between these tubes The motion of worm feeders is effected by toothed wheels driven by a chain via a motoreducer For safety reasons, the hatch that closes the fuel dispenser must be tightly closed during burning of biomass in the burner 10

11 5 FUEL The SAS MULTI FLAME burner is designed to burn biomass in the form of wood granulate pellet*) For the process of burning alternative fuels to be correct, it is necessary to input settings on the boiler controller ATTENTION! Use of fuels other than those recommended by the manufacturer may cause damage to the burner, which will lead to a loss of the warranty on the burner In addition, the furnace is equipped with an ash removal mechanism that employs moving grate-bars, which makes it possible to use fuels with a tendency of producing slag The correct choice of biomass not only guarantees savings in fuel consumption (efficient burning of fuel), but also reduces time spent on servicing the burner The type of biomass, and to a significant degree, its moisture, is also important to the achievement of the boiler's full heating effect *) Fuel parameters are specified in standard DIN 51731, diameter: 6 8mm, length 20 30mm, max moisture 12%, density >112kg/dm³, do not use fuel with coarser granulation than given above, because such fuel may impede the operation of the feeder In particular, during loading or adding of fuel, attention is to be paid to the presence of undesired objects, like stones, which may cause blocking of the feed mechanism Density indicates the fuel s stability, grindability, its tendency to form pulp, and so, a density that is too low may be a cause of blocking of the feeder mechanism 11

12 6 CLEANING THE BURNER In order for fuel consumption to be economical and to achieve the declared power and thermal efficiency of the boiler, it is necessary to maintain the correct cleanliness in the burner's furnace area and in the convection channels of the exchanger In the furnace area, particular attention is to be paid to periodical cleaning of openings in the automatic furnace plate and on its side walls These activities are to be performed after the boiler is extinguished, when the furnace is cooled to a temperature that enables safe cleaning of the device Access to the furnace is possible after the housing is removed (top part) using available tools (eg poker), by means of the assembly grip on the housing Disassembly of the housing is to be carried out with care so as not to damage the ceramic tiles chammotte installed in it After the housing is disassembled, the surface of the ceramic tiles is also to be cleaned from residue coming from the burning of biomass (ash, sinters) In addition, the air chamber found under the furnace must be cleaned periodically, because ash falling from the automatic furnace plate accumulates in it Such cleaning is carried out through the cleanout of the air chamber, which is found below the automatic furnace After cleaning the furnace, the air chamber cleanout is to be closed and the furnace housing is to be installed along with the ceramic tile (see fig3) Burning of low quality fuels may cause the formation of a greater amount of ash, as a product of the burning process The furnace cleaning mechanism uses cyclic blowing and the motion of grate-bars Burning of low quality fuels may cause the accumulation of residue in the form of ash on the furnace plate (fixed part) If so, the furnace housing is to be disassembled and ash is to be removed to the ash pit The accumulation of ash is not a flaw in the operation of the burner, only the consequence of burning low quality fuels Control of the operation of the fuel feeder, blow-in fan takes place automatically depending on the demand for thermal power The frequency of activation of the moving grate mechanism is to be adjusted depending on the quality of the applied fuel Cleaning of the boiler exchanger and chimney flue (according to the attached Operation and Maintenance Manual of the boiler) is also important for the correct exploitation of the furnace 12

13 7 TERMS OF WARRANTY 1 The Manufacturer grants the buyer a warranty on the SAS MULTI FLAME burner under the principles and terms specified in this warranty This is confirmed by the factory seal 2 The Manufacturer guarantees the efficient operation of the burner if it is installed and operated in accordance with all of the terms and guidelines contained in the Operation and Maintenance Manual 3 The Operation and Maintenance Manual, which specifies the principles of correct burner operation, will be issued to the buyer along with the terms of warranty Familiarity with the Operation and Maintenance Manual of the burner and of the boiler in which the SAS MULTI FLAME burner is installed is mandatory 4 The warranty period runs from the day of issuance of the object of the contract to the buyer and lasts for: a 2 years on the efficient functioning of the burner b 2 years for electronics and automation subassemblies installed on the burner and manufactured by other manufacturers: Control module Blow-in fan Motorized Speed Reducer (Motoreducer) Automatic fuel feeding system Electric heater (fuel lighter) 5 The warranty does not apply to wearing elements: Sealant Condenser Sensors Hall effect sensor Ceramic tile - chamotte 6 Repair of the burner or a change in its design carried out by the buyer or other third parties during the warranty period voids the terms of the warranty 7 All damage caused as a result of incorrect service, improper storage, inept maintenance that is not compliant with the guidelines of the Operation and 13

14 Maintenance Manual or for other reasons not resulting from the fault of the manufacturer result in a loss of warranty 8 Only original spare parts offered by the SAS Metal and Boiler Plant are to be used The Manufacturer is not responsible for the incorrect functioning of the SAS MULTI FLAME burner if improper parts are used 9 The sealing cord is not subject to the warranty This is a consumable material that is to be replaced regularly 10 During the warranty period, the manufacturer will provide free repairs of the object of the contract within 14 days of the date of the claim 11 Claiming of defect removal within the framework of warranty repair is to take place immediately after a flaw has been observed 12 The warranty claim is to be made to the manufacturer s address 13 If the claimant will make warranty repair impossible twice, despite the readiness of the warrantor to perform it, it is considered that the claimant abandoned the demand contained in his warranty claim 14 Replacement of the burner is acceptable if the warrantor states that he cannot repair it 15 In the case of a groundless service call, the customer covers the costs of travel and work of the serviceman 16 A correctly completed warranty card bearing the signature and seal of the seller and the recorded date of sale, constitutes the only grounds for free performance of repair NOTE: The Manufacturer has the right to make changes to the design of the burner within the framework of technical advancement and product modernization These changes may not be accounted for in this documentation (Operation and Maintenance Manual), however the essential qualities of the product as described here will be maintained Please direct all comments and questions concerning the operation of SAS boilers to the following address: 14

15 SAS METAL AND BOILER FACTORY Owczary, ul Przemysłowa Busko-Zdrój Tel No fax biuro@sasbuskopl service: Tel No , serwis@sasbuskopl The Technical and Operational Documentation of SAS boilers and of the subassemblies and controllers installed in them, as well as necessary information and product news can be found on our website: wwwsasbuskopl Operation and Maintenance Documentation in the version valid as of

16 SERVICE REPAIRS 16

17 SERVICE REPAIRS 17

18 WARRANTY CARD A c c o rding to th e sp e cified terms, a warranty on th is SAS MULTI FL A M E b ioma ss (p el let) burn e r, operated acco rd ing to th e Operation and Mainten an c e M anual, is gran ted for a period of 24 mo n th s Boiler no - Heating power - Heating surface - Year of production - Manufacturer s seal and signature Seller s seal and signature Date of sale 18