Installation and operation manual for pellet boiler TANGRA HP 30. Manufactured in accordance with standard: - EN Rev.

Transcription

1 Installation and operation manual for pellet boiler TANGRA HP 30 Manufactured in accordance with standard: - EN Rev

2 User manual TANGRA HP30 - Rev

3 Content 1. Introduction Safety GUARANGTEE CONDITIONS Description and construction Technical data Main parts of the boiler TANGRA HP Transport and storage Transport Transport to the technical room Storage Installation Requirements for the technical room Requirements for the chimney Requirements for the heating system Boiler installation Leveling of pellet boiler TANGRA CL Connection to the heating system Electrical power supply Requirements to the pellets Commissioning Filling the installation Initial filling of the auger Set the capacity of the boiler: Set the temperature in the boiler Initial start up of the boiler Setting of the burning process Measure the draught in the chimney Maintenance Cleaning of the combustion chamber Annual maintenance Decommissioning Dismantling and disposal Emergency activities Overheating of the system Smell of flue gases Fire Appendix Wiring diagram User manual - controller Turning on/off the boiler Schemes of the main menu Description of the functions Service menu of the boiler Parameters of the controller User manual TANGRA HP30 - Rev

4 User manual TANGRA HP30 - Rev

5 User manual TANGRA HP30 - Rev

6 Before start any installation, commissioning or service works, please read very carefully this manual! 1. Introduction The pellet boilers, manufactured by TANGRA, are produced in accordance with all applicable Bulgarian and EU requirements. Their installation and usage should be done according to the following instruction. The manufacturer is not responsible for damages due to improper use. This manual is an integral part of the unit. It should be kept in an easy accessible place for the operating personnel. We recommend keeping it near the air handling unit. By installation, dismantling, maintaining or cleaning the unit all safety rules should be strictly observed. The use of personal protective equipment is required! Changes in the construction of the unit and all its components without consulting the manufacturer are unacceptable and could lead to improper work of the unit, damages or incidents. By decommissioning it is important to follow strictly the prescription for environmental protection, as well as to dispose of the units in accordance with local regulation and practices for waste management. Safety symbols The following symbols could be found on the products or in the current instruction: DANGER! Warning! Electricity! Components under voltage! Warning! General warning sign. Attention! Attention! Mandatory use of protective gloves and personal protective equipment! Attention! Please, read this part of the instruction carefully! User manual TANGRA HP30 - Rev

7 2. Safety These pellet boilers are designed according to EN It is forbidden, people without the necessary qualification (especially children) to handle with the pellet boiler or parts of it. The pellet boiler cannot operate in explosive, aggressive or corrosive, dusty or polluted environment. All installation and service activities should be carried out exclusively by trained specialist personnel. The experts carrying out work on the electrical equipment must have as minimum third qualification group. Before carrying out repairs or maintanance on the ventilator sections make sure that the power supply is disconnected and it could not be switched back on unexpectedly by another person. Do not touch hot surface. Contacts with hot parts of the boiler or chimney could lead to seriouse burns and injuries. Mandatory use of protective gloves. Do not open the burning chamber s door during operation. This could lead to injuries, damages or entry of smoke in the room. All the elements that stay under support voltage after turning off the main switch are marked with sign Before carrying out repairs on the electrical board or other elements of the boiler, turn the power supply off. In any case do not touch electrical swiches, circuit-breackes or signal lamps with wet hands. Check regularly the insulation of the cables or duct joints are not damaged. Do not touch terminals in the electrical board or unclad wires, because they might be under pressure. Be very careful when working with voltage over 25V for AC and 35V for DC. When emptying the water content of the boiler, the temperature of the water should not exceed 60 C. For lengthy periods of downtime, the controllers should be in position off. User manual TANGRA HP30 - Rev

8 Installation and maintenance should be carried out by trained and qualified specialists (specialized company). Every action should be certified with a protocol. It is not allowed to use plug-type "Schuko" or other type of connection to the electrical supply. Connection is done with terminal box. Turn on/off the boiler is made from pole circuit breaker located in the power supply board. Turn on/off the boiler from the main supply to the boiler is done with the key that is located on the right of the control panel. This key is single-pola and provides on / off only of the phase conductor. Functionaly turn on / off the boiler is done by pressing the On / Off key, which is located on the control panel. If the power cable of the appliance is damaged, it must be replaced by the manufacturer, its service agent or a similarly qualified person to avoid danger situation. We ecommended once a week to check the combustion chamber and, if necessary, to clean the collected ash with the shovel and pan, included in the package. User manual TANGRA HP30 - Rev

9 3. GUARANGTEE CONDITIONS The MANUFACTURER guarantee correct and flawless work of the unit when the installation and operating instructions are followed and the unit is installed from a certified by the manufacture INSTALLERS. The guarantee starts from the date, when the guarantee card is filled and stamped. The guarantee card should be submitted in three copies, an original for the CLIENT and two copies, saved by the INSTALLER and MANUFACTURER. When the installation is complete the INSTALLER should return a copy of the guarantee card to the MANUFACTURER (in 15 days) THE GUARANTEE IS NOT VALID in case of: Damages on the unit caused by incorrect storage, transportation and loading, or occurred during the installation ; Damages caused by nature disasters (earthquake, fire, flood, etc.); Not following the instructions for installation, operation and maintenance; Repairs from the buyer himself or an unauthorized maintenance company; Changes in the construction of the unit; Units, which capacity is not correctly selected; Damages caused by unexpected factors, for which the manufacturer is not responsible Every warranty repair should be documented in the guarantee card of the client and the installation company, which should inform the manufacturer for the repairs, if some part(s) need(s) to be changed. Guarantee period is interrupted for the period of time from the claim until the repair of the damage. The guarantee period of each unit is 24 (twenty four) months. The guarantee period of hydraulic density of the unit is 60 (sixty) months. The guarantee is valid if the customer presents the original guarantee card and the invoice. 4. Description and construction CL 35 is steel single-thread water pellet boiler equipped with electro pneumatic self-cleaning system. CL 35 is designed especially for heating systems in single family houses, small residential and office buildings, services, workshops etc User manual TANGRA HP30 - Rev

10 The boiler consists of two separate modules boiler body and storage tank for pellets. 4.1 Technical data Paremeter Measure Value HEATING CAPACITY kw EFFICIENCY % 94 WATER VOLUME L 320 VOLUME OF THE PELLET STORAGE TANK kg 250 FLUE GAS CONNECTION mm 150 MINIMUM DRAUGHT IN THE CHIMNEY Pa 20 OVERALL DIMENSIONS OF PELLET BOILER BхLхH mm 710/890/1600 OVERALL DIMENSIONS OF PELLET STORAGE TANK BхLхH mm 710/890/1600 TOTAL WEIGHT kg 320 MAXIMAL PRESSURE OF WATER MPa 0,2 TRIAL OVERPRESSURE MPa 0,4 RECOMMENDED WORKING TEMPERATURE OF WATER C 80/60 MAXIMUM WATER TEMPERATURE C 90 DIMENSIONS OF INLET/OUTLET WATER CONNECTIONS 1¼ DIMENSIONS OF DRAIN CONNECTION ½ INSTALLED ELECTRIC CAPACITY W 550 NOMINAL ELECTRIC CAPACITY W 130 POWER SUPPLY V(AC) 220 (50Hz) PROTECTION IP IP20 User manual TANGRA HP30 - Rev

11 4.2 Main parts of the boiler TANGRA HP fig.1 N Name 1 Connection to the chimney system 2 Connections to the heating system 3 Controller 4 Auger for automatic supply of the burner with fuel 5 Pellet storage tank 6 Compressor 7 Burner 8 Burning chamber User manual TANGRA HP30 - Rev

12 5. Transport and storage 5.1 Transport The units, boiler and storage tank, are supplied separately, mounted on a transport pallet. Loading and uploading are done with motor or electro fork lift or hand lift truck. The transportation of the boiler should be done in a reinforced vertical position in the original packing and transport pallet, in order to avoid transport damage of the level system and the external covers. Задължително е транспортирането на котела и бункера за гориво да се извършва в укрепено вертикално положение. All movements of the unit should be done with suitable equipment. Assembly components weight should be checked prior to transport. All unit components should be inspected for transport damages immediately upon delivery with annotations made on the delivery slip as appropriate. Damages, caused during transport, which are not annotated, cannot be taken into consideration. 5.2 Transport to the technical room Transporting to the technical room should be done by using a pallet truck with the original transport pallet. In the technical room this pallet should be removed and the boiler could be moved on a wheel, mounted on the back side of the boiler. 5.3 Storage The boiler should be stored in appropriate environmental conditions, at temperature from -25 C to +55 C and without high level or relative humidity.. For short periods, less than 24 hours, the temperature could reach up to +70 C. User manual TANGRA HP30 - Rev

13 6. Installation 6.1 Requirements for the technical room The boiler should be installed in a special technical room, which floor and walls are made of non-combustion materials with good ventilation and enough quantity of fresh air for the combustion process. The boiler could work only in premises without high level of humidity. It is not permissible to expose the boiler to dripping or splashing water. In fig.3 are given the required distances for installation. ig.3 f Environmental conditions, that guarantees the correct operation of the boiler: Room temperature from +5 C to +40 C Relative humidity up to 90% (at 20 C), decreasing to 50% at 40 C Degree of environmental pollution - 2 It is forbidden to install the boiler in living rooms, corridors, etc. 6.2 Requirements for the chimney Water heating pellet boiler HP30 should be connected to the insulated system to take the flue gases off. This system should be made of non-combustion materials with minimum diameter ф150mm and minimum under pressure in the chimney 20Pa (when the boiler works). 6.3 Requirements for the heating system The installation of the water heating boiler HP 30 should be done only by qualified specialists, certified as installers by the manufacturer. According to EN should be connected to the following systems: User manual TANGRA HP30 - Rev

14 High-temperature (until 90 o C) closed water heating system with open or closed expansion tank, with maximum working pressure 2bar. When the system is supplied with closed expansion tank, it should be with minimum volume 35 l and pressure safety valve up to 4bar. Low-temperature (until 55 o C) water heating system (under floor heating or fan coil units) closed or opened type. Mixing unit should be installed in order to decrease the temperature of the water after the boiler. It is totally forbidden to install stop and control valves between the boiler, the expansion tank and the balancing valve. The boiler should not work with water temperature under 55 o C. In this case the guarantee is not valid! 6.4 Boiler installation The boiler could be installed directly on the floor, which is made of non-combustion materials or on a previously reinforced foundation with sufficient carrying capacity. fig.4 Leveling scheme User manual TANGRA HP30 - Rev

15 6.4.1 Leveling of pellet boiler TANGRA CL35 Remove the packing of the boiler and the bunker. Place the boiler in the technical room (take into account the dimensions shown in fig.2 (6.1). Level the boiler body using the two front leveling screws (fig.3) and the back leveling screw (fig.4) fig.3 fig. 5 The pellet storage tank is placed on the right side of the boiler body and is leveled in a way, similar to the boiler body. Both units shall be leveled one to another and to fit. fig.6 Both parts are connected with 6 bolts M8 two based in the main plate and 4 in the upper side of the tank. Precise leveling is required. Connect the burner with 4 bolts M8 to the previously installed adapter flange of the boiler. Pull the main power cable with the connector and both pneumatic hoses through the service opening on the left side of the burner. Connect the blue hose to the connection, which is closer to the burner fan (pneumatic hose Ø4 for the flowmeter) and User manual TANGRA HP30 - Rev

16 the other one to the free connection on the receiver (pneumatic hose Ø6 supplying the cleaning system cylinder). Connect the pneumatic hose Ø10 (from compressor) to the bottom side of the receiver. Join the main connector for supply of the boiler and both connector, which supply the compressor and the auger, according to fig.5. Name 1 Auger feeding 2 Compressor power supply 3 Jack from the boiler 4 Compressed air supply Burner bottom view Фиг.5 It is forbidden to install the boiler in the technical room on the transport pallet. The pallet must be removed. 6.5 Connection to the heating system Fig. 8 shows an example of connecting a pellet boiler to a combined heating system with radiators, under floor heating and domestic hot water supply. fig.6 User manual TANGRA HP30 - Rev

17 6.6 Electrical power supply Main wire for electrical power supply - 3х1,5m 2,double insulated. 7. Requirements to the pellets CL 35 is designed to work with wood pellets, with diameter 6-8mm, length 5-30mm and moisture content 5-9%. With his integrated automatic burner cleaning system, as well as the module for forced cleaning of the burner, this boiler is not pretentious about the quality of the pellets. It works with all type of wood pellets intended for domestic usage, according to the ÖNORM M7135, DIN 51731, DIN Plus standards. Regardless of the pellets, which are used, after correct adjustment of the combustion process could be reached efficiency of 90-94% and low emission of greenhouse gases CO, CO 2 and NO X. In case of changing the quality of pellets or the supplier during the exploitation, the parameters of the combustion process should be reset. This should be done only by authorized service organization. There is a possibility to save up to three different setting for different quality of pellets. 8. Commissioning 8.1 Filling the installation Filling the installation, filling with fuel and check the integrity of the unit After the installation of the boiler and its connection to the heating and electrical systems, could proceed to filling of the boiler body and heating installation with water. All types of connections inside and outside the boiler should be visually inspected for leaks. To ensure enough quantity of pellets, which is needed for initial start of the pellet boiler, ½ of the volume of the pellet storage tank should be filled. Verify the position of the ceramic element in the combustion chamber Verify of all electrical connections of the burner and the flexible pipe for compressed air. Scheme for supply the burner and the compressor After inspection turn the supply on, using the main switch. 8.2 Initial filling of the auger Initial filling of the auger is required for the initial start up of the boiler or after the boiler stop due to running out of fuel. Take off the flexible connection for pellets from the burner; From menu Setup choose level [6] (Manual feeding) The initial feeding of the auger with fuel and hold the button Enter, until the main auger is filled with fuel and the flow become stable. User manual TANGRA HP30 - Rev

18 8.3 Set the capacity of the boiler: The capacity of the boiler depends on the quality and the quantity of the fuel supplied in the burner, measured in kg/h. The controller allows 5 levels 1 (minimum capacity), and AUTO (maximum capacity with automatic modulation). Set of the maximum capacity (AUTO level): From menu Power choose Auto; Remove the plug of the main auger of the burner; Press and hold the button on/off, until on the display is On; Wait minimum 60 s.; Place a plastic bag at the end of the flexible connection; Take out the flame sensor; Connect the plug of the main auger to the burner. After 60 s the main auger will turn on; Measure the quantity of pellets, passed through the main auger for 6 min. This quantity, multiplied by 10 gives the amount of fuel in kg/h. Press and hold on/off button, until the display shown Off; Return the flame sensor. After s the boiler will terminate loop of self-cleaning of the burner; Connect the flexible connection for pellets to the burner. If you want to change the capacity in Auto mode (highest capacity), enter in menu Setup, level Parameters, change parameter 18, in proportion with what we want to achieve and repeat, to establish the capacity. Heating capacity, kw Fuel, kg/h Use the same procedure to set level 1 (minimum capacity) by choosing from the Menu parameter 10. The rest of the capacity levels (2,3,4) will be calculated automatically by the controller. We do not recommend capacity under 15kW. Note: The correct choice of boiler capacity is of a great importance for the trouble-free and flawless work of the unit. Before setting the maximum and minimum capacities, please check what is the total necessary capacity of the building (according to the project). Please, pay attention if the boiler will be used only for heating or for heating and domestic hot water. It is forbidden the value of the lower capacity (level 1)to be lower than the necessary capacity of the building. Otherwise, the boiler will work without pauses and will not commit a self cleaning cycles which could cause blocking or stopping of the burner. User manual TANGRA HP30 - Rev

19 If the boiler shall work without modulation, set the same values for parameter 1 and AUTO. 8.4 Set the temperature in the boiler From menu Temperature set the water temperature in the boiler. When the boiler reaches this temperature, it will turn automatically in modulation mode and after 5 о С will turn off. Example: set 65 о С water temperature, the boiler will slowly decrease its capacity and when it reaches 70 о С turn off. Automatic start up - when the boiler reached the temperature (cooling of the water in the boiler) to Тwater=Тset Parameter 50, the boiler will start automatically the ignition procedure. Example: if set temperature is Т set =65 о С, and parameter 50=10 о С, the boiler will start automatically the ignition if temperature Т1=55 о С 8.5 Initial start up of the boiler When we are sure, that all connections are correctly installed, the quantity of fuel for the lowest and highest capacity are checked and there is enough draught in the chimney, we can start the boiler from on/off button. From menu Power, set Auto. When the boiler starts, the control light, placed next to the start button, blinking. That means that the boiler is in ignition mode. When appeared a stable flame (3-10min), the boiler turn into working mode and the lamp light up permanently. The boiler works at maximum capacity until it reaches the maximum set temperature (Т given ), after that it starts modulating the capacity from the upper to the lower capacity and it stops when reaching Т given +5 C. 8.6 Setting of the burning process Mandatory setting of the burning process with gas analyzer, measuring CO, O 2, ʎ and the temperature of the flue gases. Measuring the parameters of the flue gases is done after the water temperature reached at least 50 C and the boiler is not in modulation, is start or stop mode. Achieving optimal burning is done by changing the fresh air quantity, using parameter 28 (air quanity at maximum capacity) and 24 (air quantity at minimum capacity). Recommended values for parameters 28 and 24 are given in 13.5 Parameters of the controller Recommanded readings of the gas analyser: СО 100 ppm; O 2 4-8%; λ = ; T flue gases 180 о С. 8.7 Measure the draught in the chimney When the boiler is not working, measure with suitable device (gas analyzer, differential manometer) the draught at the end of the chimney, using probe M12. The draught should not be less than 15 Pa. The operation of the boiler with less draught than 15Pa could lead to overheating or fire in the burner. User manual TANGRA HP30 - Rev

20 9. Maintenance 9.1 Cleaning of the combustion chamber Accumulation of ash depends mainly of the quality of the pellets and operation hours of the boiler. The boiler is supplied with tray and blades to collect the ashes. We recommend once a week to check the amount of ash, collected at the bottom of the combustion chamber and if necessary to clean it. 9.2 Annual maintenance This should be done once a year or after 5 tones of pellets are burned. The annual maintenance should be done by authorized organization. This includes testing of the systems and general cleaning of the burner, combustion chamber, pipes and upper flue gas chamber. Annual maintenance is a compulsory part in connection with warranty service. In case of rejection, incorrect work, alarm messages on the display you should contact your service provider and follow his instruction. You can also receive additional help and instructions from the manufacturer using the contacts mentioned on the last page. 10. Decommissioning When decommissioning a unit, the following activities are to be carried out: When dismantling a unit, all components, which are under voltage, must be switched off. The unit must be fully disconnected from the electrical network. The water tank must be drained. Blown the coils with pressure air to secure that no fluid is left, otherwise the water can freeze, when the temperature is low. Follow the instruction when transport, lifting, loading and uploading the unit. If you can handle this alone, please, contact the manufacturer 10.1 Dismantling and disposal After the lifetime of the unit is run out, it must be professionally dismantled. Prior to dismantling, it must be ensured that all energy lines (electrical and all media) are switched off. No lines should remain supplied with voltage, temperature or other energy. All components are to be disposed or recycled in accordance to national regulations. 11. Emergency activities In case of rejection, incorrect work, alarm messages on the display you should contact your service provider and follow his instruction. You can also receive additional help and instructions from the manufacturer using the contacts mentioned on the last page. User manual TANGRA HP30 - Rev

21 11.1 Overheating of the system If the boiler temperature exceed the maximum, proceed as follows. Turn off the main power supply of the boiler Keep all doors of the boiler closed Open all valves, switch on all pumps Leave the technical room and close the door Open all available radiator thermostat valves If the temperature does not drop, please contact the your installer or the manufacturer (find contacts on the last page) Smell of flue gases Flue gases could cause fatal poisoning. In case you smell a flue gases: 11.3 Fire Turn off the power supply of the boiler Keep all the doors of the boiler closed. Ventilate the room, where the boiler is installed Leave the room and close all close the doors of the living rooms In case of fire, there is risk of burns and explosion! Turn off the power supply of the boiler Use fire extinguisher Observe all fire safety regulations of the country, where the boiler is installed. User manual TANGRA HP30 - Rev

22 12. Appendix 12.1 Wiring diagram User manual TANGRA HP30 - Rev

23 13. User manual - controller 13.1 Turning on/off the boiler To turn on/off the power supply, please use the button, placed on the right side of the controller. Power supply ON OFF button (Disconnect the boiler from the power supply ) Emergency stop button should be used only in case of accident. This button is unipolar and provides switching on/off of the phase conductor. Turn the boiler off using the emergency stop button can affect the operation of the unit and it is not recommended by the manufacturer! Switching on/off the boiler is done by holding the On/OFF button. This button ensures functional start up of the boiler and it is not intended to disconnect the boiler from the power supply. TANGRA capacitive touch keyboard (fig.10) is designed for intuitive use. fig. 10 Important: Keep the keyboard clean. Any contamination could send signal for pressed button. At the top of TANGRA keyboard are located indicators for various alarms and menus. User manual TANGRA HP30 - Rev

24 The display shows the set or current values for the currently selected menu option. With buttons you can navigate through the menu and control the operation of TANGRA controller. Refer to the Table on next page for descriptions of the buttons. It is possible to activate keyboard sound signal. The following sound alarms are available: Short high tone: sounds when navigating the menu and editing the settings; Long low tone: sound in case of invalid operation (wrong button pressed); Long high tone: in case of alert, this tone sounds with the user defined loudness, and in case of an error, this tone sound with 100% loudness User manual TANGRA HP30 - Rev

25 13.2 Schemes of the main menu User manual TANGRA HP30 - Rev

26 13.3 Description of the functions User manual TANGRA HP30 - Rev

27 User manual TANGRA HP30 - Rev

28 13.4 Service menu of the boiler 16 Possible errors: Е001-Keyboard error; E004 Motherboard communication error; E108 security switch error; E110 NTC1 error temperature sensor; E111 TC1 error temperature flue gas; E115 User manual TANGRA HP30 - Rev

29 13.5 Parameters of the controller SWV1.4HP30/2014 Nº parameter Description Measure Limits of acceptable values Recommended values 0 Maximum wait time for successful firing in ignition phase. minutes Time for flame stabilization s Operation time of the auger in flame stabilization phase ( The pause in the auger operation is fixed on 20 seconds). 10 = 1 s Operation time of the auger at minimum capacity level 1 working dose at power level 1 18 Operation time of the auger at minimum capacity level AUTO working dose at power level AUTO 19 Air quantity in Fire down phase After Fire down phase is executed, the fan works at full speed for time, set by parameter =max. 22 Air quantity in Ignition phase Air quantity in flame stabilization phase Air quantity at minimum capacity (level 1) Air quantity at maximum capacity (level AUTO) Temperature difference between T given and T current, by reaching of which o C the controller starts fire up. Example: if Т1=65 о С and parameter 50=10 о С, the boiler will restart at Т1=55 о С. 51 T given required water temperature in the boiler. When T given is o C reached, the controller starts smooth reduction of burner power from level 5 down to level1 and at [T given +5 o C] the burner is switched off. Example: if T1 is set to 65 o C, the boiler will stop completely at 70 o C. 55 Gasses modulation start temperature - flue gasses temperature threshold, when the controller begins to decrease the burning power, independently from the water temperature in boiler. o C Maximum temperature of the gases: If the flue gasses temperature is higher than [PAR57*2], the Alarm Gasses is activated and the controller switches the system off Time between two blow cleanings. minutes Blow cleaning period. s Air quantity during blow cleaning period Water pump turn on temperature. o C Water pump turn off temperature. MUST BE lower than PAR67 value. o C Start Up phase duration. s Light level of the flame sensor present detection level - Defines the sensor input for valid flame detection User manual TANGRA HP30 - Rev

30 79 Minimum light level of the flame sensor, after that there is no flame Time delay before OFF detected - Defines the time during which flame sensor detects value under param. 79 before the burner to be stopped and blow cleaning started. 82 Minimal air quantity entering at the burner under which alarm is activated (stuffed chimney, fan failure etc.) s Time delay before triggering pressure error - Defines the time for air s quantity to be under param Time to service warning level - Defines the Time to service due time. weeks Time to purge after the flame sensor is under parameter 79. s Freeze protection o C User manual TANGRA HP30 - Rev

31 User manual TANGRA HP30 - Rev

32 User manual TANGRA HP30 - Rev