Viesmann. VITOFLEX 300-UF Solid fuel boiler 390 to 1250 kw. Technical guide VITOFLEX 300-UF

Transcription

1 Viesmann VITOFLEX 300-UF Solid fuel boiler 390 to 1250 kw Technical guide VITOFLEX 300-UF Fully automatic solid fuel boiler with grate combustion for the combustion of woodchips, wood pellets, shavings and mixed wood 5/2015

2 Index Index 1. Principles of wood combustion 1. 1 Principles of wood combustion for generating heat... 6 General principles... 6 Determining the amount of fuel required... 7 Energy density of various fuel types compared with fuel oil (standard values) Principles of wood pellet combustion for generating heat... 8 What are wood pellets?... 8 Fuel requirements... 8 Delivery methods for wood pellets Principles of woodchip combustion for generating heat... 9 What are woodchips?... 9 Definition of woodchip size classes according to EN ISO Fuel requirements Minimum fuel requirements Constituents Non-wood biomass fuels German Immissions Order (1st BlmSchV) Contents of the 1st BImSchV Update of the 1st BImSchV Tightening of the emission limits Emission limits for dust and carbon monoxide (CO) according to 1st BImSchV, Stage 2 (rticle 5) Vitoflex 300-UF 2. 1 Product description Benefits at a glance Delivered condition Specification Specification Control unit 3. 1 Ecocontrol specification Function: Operation: Standard delivery Ecocontrol accessories External drive switching External drive switching with light barrier ccessories for Ecocontrol output management Cylinder management, 5 sensors External demand ON/OFF Operating message potential-free Output signals 0-10 V Demand for an additional heat source (peak load heat source) ccessories for Ecocontrol remote transfer Fault message device, analogue with battery Exporting operating data via Modbus TCP/IP Mastercontrol for two-boiler systems Function Operation Standard delivery Visualisation with the touchscreen ccessories for Mastercontrol Heat meter signal dditional heat source demand Fault message device, analogue with battery Exporting Mastercontrol operating data Mastercontrol external visualisation (hardwired) Heating water buffer cylinder 4. 1 Buffer cylinder specification Installation accessories 5. 1 Boiler accessories Flue gas recirculation Flue gas recirculation line insulation Displacer rods utomatic ignition system Feed screw conveyor, 2-stage Pneumatic cleaning Boiler safety equipment Thermally activated safety valve 100 C Thermally activated extinguishing valve C Viesmann VITOFLEX 300-UF

3 Index (cont.) 5. 3 Heat distribution accessories Motorised three-way valve (return temperature raising facility) Pumps ccessories for flue gas routing Flue gas dust extractor sh removal accessories sh removal into an ash container scending screw conveyor extension Combustion chamber screw conveyor extension ccessories for mobile cleaning Cleaning set with ash vacuum cleaner, 90 l Cleaning set with ash vacuum cleaner, 240 l WS ash vacuum cleaner DS ash vacuum cleaner Specification sh vacuum cleaner accessories Safety equipment for burn-back protection Rotary lock valve Shut-off gate valve M Drop chute L = 1.0 m Special adaptor Fuel discharge 6. 1 pplication options for discharge systems by fuel Overview Fuel discharge with screw conveyor Pellet discharge screw conveyor, D = 120 mm Pellet discharge screw conveyor drive Fuel discharge with agitators Horizontal discharge H Discharge screw conveyor H to horizontal discharge H Substructure H Protective panel H for the fuel store wall Cover panel H for wood pellets Fuel discharge with funnel discharge Funnel discharge dditional outlet flange Funnel, large Fuel discharge with pushrod discharge Pushrod discharge Maximum dumping heights Pushrod drive specification Forces on the building Slot discharge for pulling Centre discharge Slot discharge with fill function Pushrod drive, individual Weld base, pushrod drive, individual Pushrod drive, twin Weld base, pushrod drive, twin Fuel store weld base Pushrod Hydraulic unit, S single Hydraulic drive, S twin Push floor screw conveyor, D = 190 mm Push floor screw conveyor, D = 250 mm Push floor screw conveyor drive, standard Drive, push floor screw conveyor, high power Push floor screw conveyor cover Fuel transport 7. 1 pplication options for the transportation systems according to fuel Overview Fuel transport by means of screw conveyor Trough screw conveyor Standard trough screw conveyor drive Pipe screw conveyor Pipe screw conveyor drive, pellets Pipe screw conveyor drive, standard Pipe screw conveyor drive, high power VITOFLEX 300-UF Viesmann 3

4 Index (cont.) 8. Fuel storage 8. 1 Fuel storage in on-site pellet store Sizing the pellet storage room Pellet storage room design and required system components dditional safety instructions for pellet stores Protective boards with Z brackets Fill connector and return air connector ccessories for the on-site pellet store Filling the on-site fuel store Manual silo cover FDM 2.9/1.3 m FDH hydraulic bunker cover Fall protection grille 120 for FDH Fall protection grille 200 for FDH FDB drive-over bunker cover Fall protection grille 120 for FDB Fall protection grille 200 for FDB Shaker motor for fall protection grille Bunker charging cover hydraulic drive unit Cover drive for hydraulic unit Design information 9. 1 Sizing the system Selecting the rated heating output Flow temperatures Safety temperatures Delivery Handling Siting Boiler room requirements Requirements of the Muster-Feuerungsverordnung [Sample Combustion Ordinance - Germany] Combustion air supply Minimum clearances Water connection Heating connections Boiler circuit and shunt pumps Safety equipment to EN System examples Safety equipment Expansion Extinguishing devices Boiler system burn-back protection Preventing overfilling with fuel Reignition protection Protection against burn-back during fuel handling Shut-off gate valve Rotary lock valve Dual rotary lock valve with pressure compensation Minimum pressure limiter Maximum pressure limiter Safety valve Expansion vessel Fire safety Fuel store fire safety Commissioning Fuel for commissioning Filling the heating system Fuels Connection on the flue gas side Chimney Flue pipe nti-vibration fittings Supports Frost protection Corrosion on the water side Prevention of damage through corrosion on the water side ppendix Sizing the expansion vessel Selection example General information on low pressure hot water boilers with safety temperatures of up to 110 C Pipe connections Viesmann VITOFLEX 300-UF

5 Index (cont.) Electrical installation Operating instructions Flue system Checks as part of the building inspectorate approval process Keyword index VITOFLEX 300-UF Viesmann 5

6 Principles of wood combustion 1.1 Principles of wood combustion for generating heat 1 General principles Net calorific value of wood biomass as a function of moisture content The energy content of wood is generally given as the net calorific value H u. The net calorific value is the energy that can be obtained from burning one kilogram of damp wood. The water contained in the flue gas is present in the form of water vapour. The gross calorific value H o additionally takes account of the latent heat of condensation in the water vapour, which is released as it cools back down to the initial temperature. The moisture content of a fuel charge is the main factor that influences combustion. It determines the energy content and therefore the energy conversion that can be achieved during combustion. In practice, the net calorific value of fuels is between 5.0 kwh/kg (18 MJ/kg) at a moisture content of 5 % and 1.5 kwh/kg (5.4 MJ/kg) at a moisture content of 60 %. This depends on the type of wood and, more importantly, on the moisture content or moisture level in the wood. The moisture content is crucial for the controllability at partial load and the emissions from the system. Determining the moisture content The moisture content is generally determined with reference to the so-called drying cabinet procedure, on which the CEN standard is also based. s part of this, a fuel sample is weighed when wet, dried in a drying cabinet at approx. 105 C for several hours, and then weighed again. The proportion of water in the fuel is given as the moisture content M. pplication range of fuel according to moisture content The boiler can be operated with wood biomass with a moisture content between 5 and 50 %. Moisture level (u) in % Net cv (Hu) in MJ/kg B Water content (w) in % Net cv (Hu) in kwh/kg Soft wood B Hardwood Net calorific value for various types of wood, source: Technologie- und Förderzentrum (Technology and Support Centre) (TFZ) Straubing, Bavaria, Germany Water content in % Type of tree Unit of measurement Spruce kwh/kg kwh/smt kwh/stcm kwh/tcm Viesmann VITOFLEX 300-UF

7 Principles of wood combustion (cont.) Water content in % Type of tree Unit of measurement Scots pine kwh/kg kwh/smt kwh/stcm kwh/tcm Beech kwh/kg kwh/smt kwh/stcm kwh/tcm Oak kwh/kg kwh/smt kwh/stcm kwh/tcm Relation of moisture content to moisture level in fuel The proportion of water in woodchips, pellets, shavings and mixed wood is given as either the moisture content or the fuel moisture level. The moisture content (in %) is relative to the moist fuel mass or the fresh substance (FS); the fuel moisture level is relative to the absolutely dry fuel mass (TS). The specifications for Viessmann products use the moisture content M. Example: If 100 kg of fuel contains 50 kg of water, it has a moisture content of 50 % (M50) and a fuel moisture level of 100 % (u=100) Water content (w) in % Fuel moisture level (u) in % Determining the amount of fuel required The amount of fuel required can be calculated on the basis of the net calorific value and the required rated heating output. Significant influencing factors for this are the moisture content of the fuel and the efficiency of the system. B = Q N H u x η B Q N mount of fuel required in kg/h Required rated heating output in kw H u Net calorific value kwh/kg η System efficiency in % VITOFLEX 300-UF Viesmann 7

8 Principles of wood combustion (cont.) Energy density of various fuel types compared with fuel oil (standard values) 1 Fuel oil nthracite Wood pellets Beech logs Spruce logs Woodchips Tip/ Stack density 840 kg/m³ 860 kg/t.m³ 650 kg/t.m³ 459 kg/t.m³ 297 kg/t.m³ 217 kg/t. m³ Fuel oil equivalent kilogram 0.84 kg 1.28 kg 2.16 kg 2.35 kg 2.30 kg 2.25 kg Fuel oil equivalent litre 1.00 l 1.49 l 3.33 l 5.11 l 7.73 l l 1.2 Principles of wood pellet combustion for generating heat What are wood pellets? Wood pellets are made from 100 % natural wood remnants. This raw material is waste matter created by the wood industry in large volumes through planing or sawing. Wood remnants are compressed under high pressure and formed into pellets, i.e. pressed into a cylindrical shape. The raw material is stored and transported under completely dry conditions. System users should also ensure completely dry storage conditions. This is the only way to guarantee optimum and effective combustion. Fuel requirements For combustion in the Vitoflex 300-UF, use wood pellets that have the following properties: Diameter of 6 mm Length of 3.15 to 40 mm (1 % to 45 mm) Max. moisture content of 10 % The wood pellets used for combustion in the Vitoflex 300-UF must correspond to the requirements of EN ISO Requirement ENplus-1 EN ISO quality 1 Diameter mm 6 ± 1 D06 Length mm maximum of 1 % may be longer 3.15 to 40 than 40 mm, but no longer than 45 mm. Bulk density in the delivered condition kg/m³ 600 to 750 BD600 Net calorific value in the delivered condition MJ/kg kwh/kg Q16.5 Q4.6 Water content in the delivered condition m-% 10 M10 Fines content in the delivered condition m-% 1 F1.0 Mechanical strength in the delivered condition m-% 97.5 DU 97.5 sh content, free from water % sh softening temperature C 1200 This value is only binding for pellets certified to ENplus. It indicates the temperature at which the wood ash is deformed and can therefore cause fusions in the combustion chamber. Chlorine content, free from water m-% 0.02 Cl0.2 8 Viesmann VITOFLEX 300-UF

9 Principles of wood combustion (cont.) Requirement ENplus-1 EN ISO quality 1 Sulphur content, free from water m-% 0.04 S0.04 Nitrogen content, free from water m-% 0.3 N0.03 m-% = percentage by mass EN was superseded by the new standard EN ISO in September It describes the essential properties of wood pellets. 1 Quality characteristics Good wood pellets: Smooth, shiny surface Uniform length Low proportion of dust Sink in water Low quality wood pellets: Cracked rough surface Widely varying length High proportion of dust Float in water Delivery methods for wood pellets In their loose form, wood pellets are transported by silo tanker and pumped into the storage room via a hose system. Careful handling of wood pellets ensures a low proportion of dust, trouble-free boiler charging and a constant heating output by the solid fuel boiler. 1.3 Principles of woodchip combustion for generating heat What are woodchips? Woodchips are made from 100 percent natural wood from forests and plantations. This raw material comes from tree trunks or branches. The wood is then processed with high speed cutting tools in accordance with EN ISO The fuel should also be kept in dry storage at the operator's premises. This is the only way to guarantee optimum and effective combustion. Definition of woodchip size classes according to EN ISO Size class Main percentage (at least 60 % of the mass), a) Fine fraction ( 3.15 mm) Coarse fraction (in brackets particle length) Maximum particle length, b) Size in mm In % of the mass In % of the mass in mm In cm 2 P16S 3.15 to % 6 (> 31.5 mm) 45 2 P31S 3.15 to % 6 (> 45 mm) P45S 3.15 to % 10 (> 63 mm) Maximum cross-section area of the coarse fraction, b) c) a) The number in the size class refers to the maximum particle size in the main percentage. The particles have to pass through a strainer with a circular mesh (ISO standard), in which the sieve apertures are of the specified size for the size class. The lowest possible property class should be specified. b) Only determine the length and cross-sectional area of particles in the coarse fraction. In a sample of about 10 l 2 pieces at the most can exceed the maximum length if the cross-sectional area is < 0.5 cm 2. c) To measure the cross-sectional area, you are advised to use a transparent set square, arrange the particles at right angles behind the set square and use a cm 2 grid to estimate the maximum cross-sectional area of these particles. Fuel requirements For combustion in the Vitoflex 300-UF, use woodchips of size class P31S that have the following properties: Max. coarse fraction of 6 % (> 45 mm) Max. cross-section of 4 cm² Max. length of 15 cm (1 % up to 45 mm) Max. moisture content of 50 % (M50) Bulk densities of woodchips as defined by water content, according to EN ISO Water content based on % of the mass 8 to to to to 45 moisture mass Bulk density for coniferous kg/m to to to to 270 species Property class BD150 BD150 BD200 BD200 Bulk density for deciduous kg/m to to to to 380 species Property class BD200 BD250 BD250 BD300 VITOFLEX 300-UF Viesmann 9

10 Principles of wood combustion (cont.) 1 Quality characteristics Good woodchips: Low, homogeneous water content, no moisture pockets or mould Low proportion of needles, leaves, fine branches and bark Low proportion of fine wood material (hardly any particles < 3 mm) No contamination from mineral soil and foreign matter or impurities Uniform particle size (no excess length) Smooth edges, no fraying Low quality woodchips: High proportion of fraying surfaces or edges High proportion of needles, leaves, fine branches and bark Contamination from mineral soil and foreign matter or impurities Heterogeneous particle size High fine fraction and water content 1.4 Minimum fuel requirements Constituents When buying wood for combustion, it is important to ensure that the following foreign matter is avoided: Stones Metal particles Masonry remnants Plastics Foreign matter would change the composition of the fuel and therefore the critical parameters of the combustion process. Observe the following limits per kg of dry fuel or dry matter content of the non-combustible constituents. The limits for ash were determined at an analysis temperature of 815 C. Limit Comparison with natural wood from forests Chlorine Cl mg/kg Max Sulphur S mg/kg Max Total Cl, S mg/kg Max sh content total g/kg Max lkali oxides in the ash (K 2 O and Na 2 O) g/kg Max Start of ash sintering (SB) C min approx Exceeding the above limits will shorten the service life of the combustion chamber and the solid fuel boiler. This also means more maintenance work and shorter service intervals. Non-wood biomass fuels Non-wood fuels made from biomass such as needles, leaves, cereals, straw, husks, fruit stones, etc. are unsuitable as fuels for faultfree operation, and are therefore not permitted. In some cases, the fuel properties (elemental composition, ash sintering point, etc.) differ considerably from those of wood. Combustion of such fuels in a Vitoflex 300-UF can lead to an impairment of the combustion characteristics. The fireclay lining and the heat exchanger surfaces will be subject to increased stress. Warranty claims can therefore only be asserted when using approved fuels. 1.5 German Immissions Order (1st BlmSchV) Contents of the 1st BImSchV The German Immissions Order (1st BImSchV) regulates the following for small and medium-scale biomass combustion systems which do not require approval: The conditions under which small and medium-scale biomass combustion systems can be sited and operated. The specified emission limits for small and medium-sized systems How often and to what extent a system must be monitored in order to protect the environment from emissions. Update of the 1st BImSchV Tightening of the emission limits The update of the 1st BImSchV, which contains the following essential new points, came into force from 22 March 2010 onwards: Regulation of emission limits for solid fuel boilers with a rated heating output of 4 to 1000 kw Verification of the required emission limits in the form of periodic on-site measurements to be carried out by the flue gas inspector when commissioning new systems (with subsequent periodic checks every 2 years) Emission limits tightened to 20 mg/m³ for dust and to 400 mg/m³ for CO in stage 2 of the 1st BImSchV fter a transitional period, emission limits will also apply to old systems. Sizing of the heating water buffer cylinder in manually fed systems: min. 12 litres for each litre of fuel hopper or 55 litres/kw of rated boiler heating output Sizing of the heating water buffer cylinder in automatically charged systems: min. 20 litres/kw of rated boiler heating output 10 Viesmann VITOFLEX 300-UF

11 Principles of wood combustion (cont.) Emission limits for dust and carbon monoxide (CO) according to 1st BImSchV, Stage 2 (rticle 5) Emission limits in periodic on-site measurements (relative to 13 % oxygen) 1 Fuel according to rticle 3, paragraph 1 For new systems installed: Rated heating output in kw Dust in mg/m³ CO in mg/m³ Solid fuel boilers affected Wood pellets From 1 January to Vitoligno 300-P Vitoligno 300-C Vitoligno 300-H Vitoflex 300 Woodchips From 1 January to Vitoligno 300-H Vitoflex 300 Natural, non-bulky pieces of wood (sawdust, shavings and sanding dust), wood briquettes From 1 January to Vitoligno 250-S Vitoflex 300 Split logs From 1 January to Vitoligno 100-S Vitoligno 200-S Vitoligno 250-S on dust emission limits Depending on both the type of fuel used, e.g. wood pellets or woodchips, and fuel quality (according to EN ISO 17225) additional emission reduction measures may be required in order to adhere to the dust emission limits demanded by the 1st BImSchV. These are secondary measures, such as a fine-dust filter (e.g. an electrostatic filter) or tertiary measures in the form of the support of a Viessmann engineer when measuring. Viessmann should be consulted on this. VDI 4207, Sheet 2 (Emission measurements at small firing installations) VDI 4207, Sheet 2 (Emission measurements at small firing installations) specifies the requirements for the initial and periodic testing and measurement of dust emissions in accordance with the 1st BImSchV or the Kehr- und Überprüfungsordnung (KÜO - sweeping and inspection regulation) when using solid fuels. lso described are the system and operation-related measures that need to be implemented in advance in order to ensure that the emissions measurements are carried out correctly. VITOFLEX 300-UF Viesmann 11

12 Vitoflex 300-UF 2.1 Product description 2 Three-pass boiler B External grate with primary air 2 C Safety heat exchanger D Secondary air E Ignition fan F Feed screw conveyor with barrier layer G Combustion retort with internal grate and primary air 1 H sh removal K Combustion chamber door L Moving infeed grate M Pneumatic cleaning The Vitoflex 300-UF grate combustion system has been specially developed for the automatic combustion of dry and moist fuels (waste wood, wood pellets or woodchips from forest thinnings up to max. M50). It combines the benefits of underfeed combustion with the advantages of grate combustion to optimum effect. The Vitoflex 300-UF grate combustion system is characterised by highest efficiency levels and perfect combustion in all load stages. The horizontal heat exchanger with pneumatic cleaning is ideal for the use of fuel with a high percentage of fines. Benefits at a glance High efficiency thanks to proven combustion technology, threepass heat exchanger, modulating output control and regulated primary and secondary air supply Easy servicing thanks to fully automatic ash removal and optional pneumatic cleaning system Highly developed safety equipment ensures safe and reliable operation Delivered condition Fully assembled steel boiler for wood pellets and woodchips With integral return temperature raising facility, combustion chamber door, ash doors, ash pans, cleaning device 1 feed screw conveyor with barrier layer, incl. extinguishing valve with dirt trap, extinguishing water container with bracket 1 flue gas fan 1 automatic ignition system (optional) Sensors and measuring equipment: Infrared light barrier for level monitoring, barrier layer, feed screw conveyor Safety limit switch on inspection cover of feed screw conveyor Pt1000 contact sensor on the feed screw conveyor The ash is removed automatically from the combustion base and transported into a standard container. Efficiency of over 90 % enables maximum seasonal efficiency in modulating operating mode. Use of the Vitoflex 300-UF as a base load boiler is practical for building heat loads of 300 kw and above. Combination with a solar thermal system is also easily possible. The Vitoflex 300-UF is tested and approved in accordance with EN It is also manufactured in accordance with the Machinery Directive and has a CE designation. It is also subject to on-going inspections by TÜV. Optimum system output results from the design and delivery of all system components from a single source utomatic ignition removes the need to maintain the firebed and saves fuel (option only for fuel with moisture content below 40 %, that is < M40) Individual design of your system by our team of experts Output control from 30 to 100 % Infrared light barriers for level monitoring of the fuel in the combustion chamber Zirconium dioxide probe with measured value transducer (Lambda probe) Pt1000 flue gas temperature sensor Pt1000 return temperature sensor Pt1000 boiler water temperature sensor High limit safety cut-out Underpressure sensor Overpressure limiter Light barrier, ash removal Limit switch, combustion chamber door 12 Viesmann VITOFLEX 300-UF

13 Vitoflex 300-UF (cont.) 2.2 Specification Specification Trade name Vitoflex 300-UF Rated heating output kw Part no. ZK02055 ZK02056 ZK02057 ZK02058 ZK02059 Output data Rated heating output with standard fuel M45 *1 kw Rated constant heating output with standard kw fuel M45 *2 Minimum heating output Q *3 min kw Heating data Content on hot gas side l Permissible shutdown temperature of the high C limit safety cut-out Water flow rate Flow rate (diff. 10K) m³/h Flow rate (diff. 15K) m³/h Flow rate (diff. 20K) m³/h Minimum return temperature C sh box capacity, grate ash l sh box capacity, flue gas dust extractor l Boiler water content l Pressure drop on the water side Pressure drop on the water side (diff. 10 K) Pa Pressure drop on the water side (diff. 15 K) Pa Pressure drop on the water side (diff. 20K) Pa Permiss. operating pressure Test pressure bar Maximum operating pressure bar Heating surface m CE designation CE CE CE CE CE Boiler category to EN Overall dimensions Total length mm Total width (boiler) mm Total width (boiler with feed screw conveyor) mm Total height (boiler) mm Total height (boiler with flue gas fan) mm Weight Boiler kg Combustion block kg Displacer rods kg Flue gas fan kg Feed screw conveyor kg Total dry weight kg Total weight (wet) kg Max. power consumption Ignition unit W Electrical connections (total) W During heating operation W Feed screw conveyor W Primary air fan 1 W Primary air fan 2 W Primary air fan 3 W Secondary air fan W Flue gas fan W Grate drive W Electrical power consumption at Q N W Electrical power consumption at Q min W *1 When the boiler and combustion chamber have been cleaned and the boiler is equipped with pneumatic boiler cleaning. *2 Levelled output when boiler is used as base load boiler in continuous operation, fitted with pneumatic boiler cleaning and a runtime (time between 2 cleaning operations of the boiler) of 600 hours. *3 Q Q min : output operation modulating control (variable output control) Q Q min : low load with ON Q min / OFF (stop and go operation) VITOFLEX 300-UF Viesmann 13

14 Vitoflex 300-UF (cont.) 2 Trade name Vitoflex 300-UF Rated heating output kw Part no. ZK02055 ZK02056 ZK02057 ZK02058 ZK02059 Boiler connections Boiler flow and return DN Extinguishing water connection R ¾ ¾ ¾ ¾ ¾ Boiler drain valve R 1 1 1½ 2 2 Safety heat exchanger R 4 x ½ 4 x ½ 8 x ½ 8 x ½ 8 x ½ Sensor well for thermally activated safety valve RP ½ ½ 2 x ½ 2 x ½ 2 x ½ (TS) Flue gas *4 verage temperature (gross *5 ) verage flue gas temperature at Q *6 N C verage flue gas temperature at Q min C Mass flow rate Q N ; M5; O 2 8 % g/s Q M45 ; O 2 10 % g/s Flow rate Q N ; M5; O 2 8 %; 150 C m 3 /s Q M45 ; O 2 10 %; 150 C m 3 /s Flue outlet 7 mm Required draught (at full load) Pa -10 to 0-10 to 0-10 to 0-10 to 0-10 to 0 Efficiency t full load *7 % t partial load % *4 Values for calculating the size of the flue system to EN based on 12.0 % CO 2. *5 ctual flue gas temperature as average gross value per EN 304 at 20 C combustion air temperature. *6 Flue gas temperature: reduction possible by employing the displacer rods (Q N -20 C; Q min - 10 C). *7 For dry fuel (M5-M20) lower without recirculation. For Vitoflex 300-UF lower without displacer rods. 14 Viesmann VITOFLEX 300-UF

15 p c 678 d KR KV k a b m l Vitoflex 300-UF (cont.) 2 h g f e 470 n q. o KR Boiler return KV Boiler flow Dimensions Rated heating output kw a mm b mm c mm d mm e mm f mm g mm h mm k mm l mm m mm n mm o mm p mm q mm VITOFLEX 300-UF Viesmann 15

16 Vitoflex 300-UF (cont.) B D F H C E G K L 220 M b a Sensor well for thermally activated safety valve B Boiler return C Return temperature sensor D Drive, ash removal E High limit safety cut-out F Safety heat exchanger G Primary air fan 1 H Boiler water temperature sensor K Boiler flow L Secondary air fan M Feed screw conveyor Dimensions Rated heating output kw a mm b mm KR KV B C D E F L K H G M N O V U T S R Q P KV Boiler flow KR Boiler return sh removal B C D Cleaning cover, flue gas collector Combustion chamber temperature sensor Pressure sensor 16 Viesmann VITOFLEX 300-UF

17 Vitoflex 300-UF (cont.) E F G H K L M N Light barrier, firebed Ignition unit Cleaning cover, combustion retort Cleaning cover, external grate Light barrier, ash removal Boiler door Cleaning, pneumatic Combustion chamber door O Limit switch, combustion chamber door P Primary air fan 2 Q Drive, infeed grate R Contact sensor, feed screw conveyor S Limit switch, maintenance cover T Light barrier, feed screw conveyor U Extinguishing water connection V Boiler drain valve 2 VITOFLEX 300-UF Viesmann 17

18 Control unit 3.1 Ecocontrol specification Controller for the wood combustion system incl. activation of equipment for fuel charging according to the articles listed separately The heating output is modulated to match the heat consumption. The control circuit for combustion optimisation with a Lambda probe overlaps the output control circuit. With regard to fire safety and personal safety, the highest possible quality criteria are fulfilled. Menu Charging 0 % Secondary air Primary air 0.0 % OFF 10:07 Flow Flue gas fan 0 % Flue gas temp. 0.0 % 0.0 % Overview 3 Function: Output control circuit with modulating output operation ( %) ir-controlled with variable speed supply air fan subject to flow temperature Exact fuel supply via the feed screw conveyor from dosing container with barrier layer Level-monitored top-up of dosing container Limitation and distribution of the fuel in the combustion chamber Emissions-optimised control circuit with fine tuning of the fuel/air mixture using a Lambda probe The pressure regulator ensures constant underpressure in the combustion chamber Operation: Operation is via a touchscreen. ll operating data can be read from the display. The set values of all important parameters can be entered easily. Fault messages are displayed in plain text and issued in the sequence of occurrence. Standard delivery Control panel, supplied separately Powder-coated surface Version as per ÖVE/VDE guidelines, fully wired to terminal strips Supply V, 50 Hz, control voltage 230 V or 24 V Freely programmable control unit Motor overload relay for all drives according to the separate price items Inverter for fan motors In the control panel door 4-pole mains isolator Graphics-capable touchscreen Documentation incl. fixed wiring diagram, terminal connection diagram, operating instructions, installation instructions in the guide folder Sensors and switches installed on the feed screw conveyor Infrared light barrier for level monitoring, barrier layer, feed screw conveyor Safety limit switch on inspection cover of feed screw conveyor Pt1000 contact temperature sensor on the feed screw conveyor Limitation of the combustion chamber temperature with corresponding variation of air ratio for protection of the fireproof lining Keeping up the return temperature through the boiler ensures a long boiler service life Protection to prevent the following: Excess temperature Burn-back Opening of the combustion chamber door Opening of a charging cover Pressure in the combustion chamber Potential-free output (fault message) Programming module: For operating the heating system. The touchscreen integrated into the control panel door enables visualisation and graphic evaluation of the system. Sensors and switches on the combustion block of the combustion system and in the flue outlet (installation on site) Combustion chamber temperature sensor NiCrNi Underpressure sensor Overpressure limiter Zirconium dioxide probe with measured value transducer (Lambda probe) Flue gas temperature sensor Sensors and switches installed at top of boiler Flow temperature sensor Return temperature sensor High limit safety cut-out 18 Viesmann VITOFLEX 300-UF

19 Control unit (cont.) 3.2 Ecocontrol accessories External drive switching ctivation of an external conveyor drive or a rotary lock valve without reversing. The motors are protected against overload. Motor overload relay/contactor combination for drive motor fully integrated in control panel Input in control panel for safety limit switch on maintenance cover Output in control panel for external conveyor drive The customer is responsible for delivery and installation of the safety switches of the external conveyor drive. Only with defined limited material supply (upstream screw conveyor). The electrical output data of the existing conveyor device (kw, amps, volts) must be stated. External drive switching with light barrier ctivation of an external conveyor drive without reversing, with interruption of the upstream charging where there is a risk of overfilling in the inlet, by means of an integral light barrier. The motors are protected against overload. Motor overload relay/contactor combination for drive motor fully integrated in control panel Input in control panel for safety limit switch on maintenance cover Output in control panel for external conveyor drive Infrared light barrier installed at the screw conveyor inlet For the activation of a screw conveyor with external motor downstream of the external discharge. The electrical output data of the existing conveyor device (kw, amps, volts) must be stated. 3 VITOFLEX 300-UF Viesmann 19

20 Control unit (cont.) 3.3 ccessories for Ecocontrol output management Cylinder management, 5 sensors Modulating output operation is optimised with the use of a buffer cylinder. Short term heat demand peaks are also covered. The temperature sensors record the heating of the heating water buffer cylinder. Specification of the charging level of the heating water buffer cylinder is weather-compensated and carried out via the outside temperature sensor. The combustion heat output is matched to the charging level of the heating water buffer cylinder. 5 additional Pt1000 sensors with sensor well 1/2" x 280 mm 1 Pt1000 outside temperature sensor External demand ON/OFF Input for automatically switching the system on/off via an external floating N/O contact For external demand, an automatic ignition system is required. 3 Operating message potential-free Issue of the operating condition "Load operation" (potential-free output) to a higher ranking control system. Output signals 0-10 V Issue of boiler output as voltage signal and a connection preparation to receive a maximum boiler output limit included in standard delivery. Issue of the output signals Receipt and processing of an external output restriction 0-3 V... Ember retention V... Output operation The installation of "Output signals 0 10 V" according to QM Holzheizwerke is possible irrespective of additional control modules to be used. The boiler can only be connected externally via "external demand ON/OFF". This should be ordered separately. Demand for an additional heat source (peak load heat source) Function: With the "enable signal" (floating contact), an on-site peak load heat source (oil or gas boiler) is activated when the flow temperature falls below a certain value. The temperature of start and stop points can be selected freely on the controller. The controller and control unit for the oil or gas burner is not included in the standard delivery. Floating contact Software 20 Viesmann VITOFLEX 300-UF

21 Control unit (cont.) 3.4 ccessories for Ecocontrol remote transfer Fault message device, analogue with battery Transmission of boiler system text messages either by SMS to a mobile or by fax. 4 different text messages are possible, as the fault message modem has 4 independent digital inputs. To be carried out by the customer: Modem installation and electrical connection of the phone line to the modem Configuration in accordance with the documentation nalogue modem for wall mounting Rechargeable battery pack (also works in the event of a power failure) Exporting operating data via Modbus TCP/IP Output of relevant boiler system operating data and fault messages via Ethernet to an on-site, higher ranking control system. On request, the flow temperature can be specified by the on-site, higher ranking control system. The number of data points depends on the supplied system. Ethernet interface in the control panel Software module Modbus TCP/IP 3 VITOFLEX 300-UF Viesmann 21

22 3 Control unit (cont.) 3.5 Mastercontrol for two-boiler systems The Mastercontrol optimises the entire heat generation of two solid fuel Vitoflex series boilers incl. control of an oil, gas or electric boiler as a redundancy and/or as a peak load boiler. Function Heat management: Operation Operation is via a touchscreen integrated into the control panel. Standard delivery Control panel Powder-coated surface Version as per ÖVE/VDE guidelines, fully wired to terminal strips Supply V, 50 Hz, control voltage 230 V or 24 V Freely programmable control unit, program and real time clock have battery backup Contactor/motor overload relay combinations for all common charging drives (3 x 400 V) according to separate price items Potential-free output (fault message) Touchscreen 4-pole mains isolator Documentation incl. fixed wiring diagram, terminal connection diagram with cable designation in the guide folder Visualisation with the touchscreen Operating data archive Display and archiving of relevant operating data for both solid fuel boiler systems and the Mastercontrol Simple operation of the solid fuel boiler systems on the Mastercontrol touchscreen Optimum division of the required heating output between the two solid fuel boilers with the main load on the lead boiler and the remaining load on the lag boiler with a default output value. The default output value is calculated in accordance with QM Holzheizwerke in line with the required set temperature in the common low loss header. utomatic changeover possible between the lead boiler and the lag boiler. This ensures an even boiler load over a long operating time (e.g. weekly changeover). Charging: If fuel for the two solid fuel boilers is taken from a common fuel store, charging is controlled up to fuel distribution by the Mastercontrol. Operating data archiving: Relevant operating data from the last 31 days is stored in a ring buffer. This data can easily be displayed graphically on the Mastercontrol touchscreen. Sensors Cylinder management 5 sensors (QM) 5 Pt1000 sensors with sensor well 1/2" x 280 mm 1 Pt1000 outside temperature sensor Default output value for both biomass boilers for further processing in the subordinate boiler control units via CN BUS Water-side and electrical installation on site. Installation scheme for heat source with display fields Table of parameters (with parameter setting options) Fault history 22 Viesmann VITOFLEX 300-UF

23 Control unit (cont.) 3.6 ccessories for Mastercontrol Heat meter signal Function: With this analogue input (0-10 V signal), the external heat meter can be read into the Mastercontrol. The current values can be displayed on the screen. The heat meter data is archived in the visualisation. dditional heat source demand Function: The additional heat source delivers the heat to the heating water buffer cylinder either separately or jointly with the solid fuel boiler. This heating water buffer cylinder is designed as a low loss header. In parallel operation of the two boilers, the additional heat source covers the peak load. Due to its inertia, the solid fuel boiler is used to cover the base load. Demand is signalled by issuing a command via the floating contact. 3 Submenu on touchscreen Floating contact for enabling an additional heat source Fault message device, analogue with battery Transmits the boiler system text messages as a phone message. The fault message must be acknowledged. 4 different voice messages are possible, as the fault modem has 4 independent digital inputs. To be carried out by the customer: Electrical connection of the phone line to the modem Configuration in accordance with the documentation nalogue modem for wall mounting Rechargeable battery pack (also works in the event of a power failure) Exporting Mastercontrol operating data Output of relevant boiler system operating data and fault messages via Modbus as SCII data set via serial interface to an on-site, higher ranking control system. ll adjustable parameters can be changed by the higher ranking control system if the control system has provision for this. Option of additional fault message device, analogue with rechargeable battery pack, for part no., see pricelist Option of additional hardwired visualisation - for part no., see pricelist RS232 interface on the programming panel Software module Modbus protocol (Baud rate 9600) VITOFLEX 300-UF Viesmann 23

24 Control unit (cont.) Mastercontrol external visualisation (hardwired) Pack for the transmission of relevant data to an EDP workstation (internal and/or external) for visualisation, remote maintenance and operating data archiving of the boiler system. Hardware and software are integrated into the Mastercontrol control unit. ll adjustable parameters can be changed from the EDP workstation. Industrial PC with interfaces for screen, keyboard and PC mouse for EDP workstation close to boiler room Windows operating system, remote maintenance software and visualisation/archiving software installed and tested on the industrial PC Images on the screen: Overview of the 2 solid fuel boilers Overview of heating water buffer cylinder Cross-sectional image of boiler, 3D with display fields Installation scheme for heat source with display fields Table of parameters (with change option) To be carried out by the customer: EDP workstation for remote maintenance, installation of remote maintenance software Option of additional fault message device, analogue with rechargeable battery pack, for part no., see pricelist The following is required for "Mastercontrol external visualisation (hardwired)": 2 network cables (on site) for connecting the boiler control units to the Mastercontrol 3 24 Viesmann VITOFLEX 300-UF

25 Heating water buffer cylinder 4.1 Buffer cylinder specification Specification and information on request 4 VITOFLEX 300-UF Viesmann 25

26 Installation accessories 5.1 Boiler accessories Flue gas recirculation Inlet line made from heat-resistant steel, from flue outlet to inlet adaptor Inlet adaptor, supply air, with motorised cover Recirculation fan in heat-resistant design Supply line for gas mixture incl. dampers to the combustion block (internal and external grates) Software module in the controller Flue gas recirculation line insulation This is the responsibility of the customer as part of the general insulation work on flue gas and heating pipes. Displacer rods Installation of the displacer rods in the heat exchangers results in better heat transfer and therefore a considerable reduction in flue gas temperature. Use is only recommended when particularly low flue gas temperatures are required and when used as a base load boiler. In 390 and 530 kw boilers, DN40 boiler pipes are used. s a result, the flow velocity of the flue gas is higher and there is no need for displacer rods in these boilers. 5 utomatic ignition system The heating element is electronically protected against overload, eliminating the need for visual heating element monitoring. It reliably achieves the specified maximum temperatures. Function: If the combustion chamber is filled accordingly with fuel, the ignition process is triggered. The fuel is ignited with hot air. If ignition is successful, the ignition system switches off. The fan of the ignition system runs on for approx. 1 minute. This cools the heating element and supplies the combustion chamber with outdoor air. utomatic ignition only works when the moisture content in the fuel is no higher than M40. Specification Ignition system Operating voltage V/Hz 230/50 Pressure Pa 2800 Weight kg 1.1 Length mm 335 Width mm 85 Height mm 85 Flame tube diameter mm 31.5 Max. temperature C 650 Length, connecting lead mm 2000 Connected load kw 1.4 In conjunction with the Mastercontrol, the automatic ignition system is essential. Feed screw conveyor, 2-stage Version with two-stage feed screw conveyor for optional optimised operation for shavings/woodchips (high level) on the one side and for wood pellets (low level) on the other Feed screw conveyor geared motor, pole-changing (drive speed of the geared motor: 750/3000 rpm) Motor starter for geared motor, pole-changing Software module in the controller Pneumatic cleaning The whole tubular heat exchanger is cleaned with periodic blasts of compressed air during operation. The process of cleaning itself is carried out in consecutive blasting of the individual sections. sh is removed from the heat exchanger pipes by means of a very short but extremely intensive pressure pulse. The loosened particles are carried in the gas flow to the dust extractor, where they are separated out. The device is integrated in the boiler door. The compressor should be installed in a cool place in the boiler room. Function of the control unit: The number of cleaning processes within a unit of time (e.g. per hour) is matched to the boiler load. n individual, complete cleaning process comprises a sequence of pressure pulses across all sections of the heat exchanger. Nozzle part integrated in the boiler door, incl. connectors with heat dissipation discs Compressed air distributor with container and valves; with heatresistant hoses connected to the nozzle part Compressor (rotation compressor) for local applications Supply output 160 l/min Container 90 l Pressure max. 10 bar Motor 1.5 kw 1450 rpm 3 x 400 V Incl. pressure regulator and pressure switch Sound power level 68 db Compressed air hose up to max. 4.0 m in length 26 Viesmann VITOFLEX 300-UF

27 Installation accessories (cont.) Valves fully wired on terminal strip Software module in the controller To be carried out by the customer: Provision of a socket 400 V / 16 Connector for compressor 400 V / 16 Specification Rated heating output kw Number of valves pce Size of valves 6/4" 6/4" 6/4" 6/4" 6/4" Max. air consumption under full load l/h dditional weight (on the boiler) kg VITOFLEX 300-UF Viesmann 27

28 Installation accessories (cont.) 5.2 Boiler safety equipment Thermally activated safety valve 100 C Standard version for fixed response temperature approx. 100 C, connection R ¾ Water feed requirements: Cold water supply DN 15 R 1/2' Permanently connected with a metal pipe Min. 2.5 bar, max. 3.5 bar Drain pipe R 3/4 Thermally activated safety valve incl. sensor well We always recommend using the thermally activated safety valve, even if it is not required by local safety regulations. Thermally activated extinguishing valve C Thermally opening extinguishing valve with adjustable opening temperature for on-site connection to a pressurised water line or an extinguishing water container, connection R ½ Danfoss VT extinguishing valve, adjustable C with dirt trap 5 28 Viesmann VITOFLEX 300-UF