Operating manual. Wood pellet boiler. PL M 15 and PL M 25

Transcription

1 Operating manual Wood pellet boiler PL M 15 and PL M 25 November 29, 2007

2 Important! This operating manual contains important information for the operator. The boiler must be professionally installed and operated in order to avoid potential accidents. Familiarize yourself with the contents of this manual before installing and operating the boiler. Be sure to also comply with the regional regulatory provisions; they may differ in full or in part from the requirements named in this manual. In this case, the regulator requirements always have precedence! The master chimney sweep responsible for your region can always provide information. The company KÜNZEL would like to thank you for your trust!

3 1 Operating manual pellet boiler 1.1 Included in delivery The pellet boiler includes: 1 warranty card 1 cleaning brush 15 kg pellets 1.2 Intended use This pellet boiler is approved for use in open and closed warm-water heating systems with a permitted operating pressure of max. 3 bar and a maximum flow temperature of 95 C. The pellet boiler may not be operated without return flow increase. The return flow increase function should be monitored. In systems without buffer storage, a 4-way mixer is sufficient as the return flow increase. This pellet boiler may only be operated with wood pellets made of natural wood (fuels in accordance with section 5a of the German Law BlmSchV). The pellets must comply with DIN-Plus or PVA (Pellet Association of Austria) standards. Other fuels, especially pellets, that contain recycled materials must not be used. Pellets with a diameter of 6 mm or 8 mm are permitted. Please note that pellets that only comply with DIN can have a higher ash ratio and a considerably lower abrasion resistance than pellets in compliance with PVA or DIN-Plus. The low abrasion resistance can lead to a considerably higher dust ratio and thus eventually to the failure of the screw conveyance. Pellets in compliance with DIN are not generally suitable for use in a pellet boiler due to their poor material properties. The cleaning interval specification refers to pellets as per PVA. If different qualities are used, much more frequent cleaning may be required; there is also a risk of increased slag formation in the burner. In the interest of operational safety, we thus do not recommend the use of fuels other than pellets in compliance with DIN-Plus or PVA!!! The boilers delivered by KÜNZEL are stationary devices in compliance with the WEEE guideline. The electrical and electronic components contained in the boilers do not fall under this guideline and are thus also not taken back by KÜNZEL. Please recycle these components along with other solid waste. Do not fill in shavings and dust: Danger of explosion We reserve the right to make technical changes. We are not liable for functional problems resulting from the use of components other than original KÜNZEL components. This applies in particular to controllers and external conveyor equipment from other manufacturers. We also do not accept liability for operating problems resulting from insufficient hydraulics- and/or exhaust systems. 3

4 1.3 The KÜNZEL wood pellet boiler PL-M Layout Figure 1: The PL M (without casing) Figure 2: Behind the ash door 4

5 Figure 3: The burner drawer, pulled out half-way Figure 4: Without burner drawer 5 Burner drawer 11 Plug for the electrical igniter 6 Radiation protection plate 12 Plug for the position indicator switch 7 Downspout for the pellets 13 Plug for the ash removal motor 8 Burner pipe 14 Ash box (approx. 13 liters) 9 Guide pipe for the cables 15 Burner pipe support 10 Burner pot 16 Burner support Burn-back protection The KÜNZEL PL-M pellet boiler is equipped with a rotary lock, which hermetically seals the combustion chamber from the pellet storage area. A rolling over of the flames into the bunker is thus excluded. The use of an ID fan provides additional protection in order to ensure that the flames only burn in the direction of the flue. The function of the fan is constantly monitored by a low-pressure sensor in the combustion chamber. Should the low pressure suddenly cease to exist due to the failure of the fan or the opening of the ash door, the fuel infeed stops immediately. 5

6 1.3.3 The nameplate Figure 5: The nameplate In the case of questions or complaints concerning your boiler, please always specify the six-digit serial number and the year of manufacture. These numbers can be found on the nameplate. The nameplate is located behind the ash door. A welding shield with the boiler number is located directly below this. 1.4 The external pellet filling The PL-M pellet boiler is equipped with a large pellet bunker with attached vacuum conveyor unit. Manual filling (emergency mode) is also possible. We offer different systems for the conveyance from pellet storage areas or sack silos installed on site. Please see our PL planning portfolio or our price list for more information. The vacuum conveyor is controlled via the control panel 606 and the provided MM 600 module. The external bunker filling will be started by the control panel at a time specified by the operator (e.g. 3:00 PM). The filling continues until the bunker is filled or until the maximum filling time set in control panel 606 has elapsed. Determine the time that it takes your filling system to completely fill the bunker up to the full detector. Now set the maximum filling time to be approx. 5 minutes longer than the determined filling time. Be sure to set the filling cycle so that the intermediate bunker is never emptied completely. If the bunker is emptied, the dosing screw is also empty and it takes a few false starts to fill the screw with pellets again (see 1.6.1). The filling of the pellet bunker is now repeated automatically every 24 hours by control panel 606. If the automatic filling device fails, the intermediate bunker can be refilled manually while the system is running (emergency mode). The PL should be switched off before filling the external repository. For this, always perform a burnout (press the STOP button) and make sure that there are no glowing or burning pellets in the burner pot or in the ash box. The external storage space should only be filled under supervision. Moist pellets and/or high dust content can lead to problems in the conveyance flow. 6

7 1.5 The control panel 606 Figure 6: The control panel 606 The control panel 606 comes with its own operating manual. Please read the operating manual if you have questions about operation. The control panel can be removed from the holder towards the front; the connections are then freely accessible. The exact terminal designations can be found in the operating manual for control panel 606. For further orientation, the terminals are also described again on the backside of the control panel. The plugs have different colors and only fit in the associated sockets. If you need to unplug the cable connections, be sure to ensure a secure contact when reconnecting them (don t accidentally clamp on the insulation!). Figure 7: Positioning of the immersion sleeve The middle immersion sleeve is reserved for the boiler sensor of the control panel and the right for the safety temperature limiter (STB). The left immersion sleeve is not occupied and is optionally available for other devices. The control panel is pushed back into the control panel collet until it sits securely on its form pins. 7

8 1.6 Operation Initial startup Startup must only take place after orientation by the local dealer or the KÜNZEL factory service department! Before initial startup, please make sure that the boiler is ready to be operated, i.e. that all electrical and hydraulic connections are correct. Using the illustrations on 1.3 on page 4, please check whether burner parts have shifted during shipping. Lift the red casing cover and open the cleaning cover of the reheating register. Check whether the turbulators are hanging correctly in the reheating register. The cleaning lever can be actuated on the left side of the boiler in order to slightly lift the turbo grill. Attention: The turbo grill can have sharp edges and must thus only be touched with suitable protective gloves. Figure 8: Cleaning cover of the reheating register The PL can be operated if the boiler was connected completely both on the water side as well as electrically to the heating system. The first step is to fill the pellet bunker. Filling takes place manually or via the vacuum unit. The boiler can be operated once the bunker is filled with fuel. Please note that there will be several (futile) start attempts during initial startup because the dosing screw is not yet filled with pellets. If the False start error message appears after startup, restart the boiler using the START button. Repeat this procedure until the boiler has been successfully ignited. The KÜNZEL pellet boiler is equipped with an automatic burner pot ash removal. The ash removal cycle is started after each burnout, but at the latest after the time set in the control panel for the forced ash removal. Please read the control panel operating manual for more information. The control panel is preset with sensible values; it may however sometimes be necessary to modify the cycle times of the screw conveyor. Please see the appendix in chapter 4.1 on page 21 for more information. Please read the control panel operating manual for more information. 8

9 Figure 9: Reheating register PL15 with turbulators Controlling the heating system A buffer storage of approx. 500 liters is always recommended for operating the KÜNZEL pellet boiler. The buffer storage allows longer burner operating time, whereby the pollutant emissions and wear and tear are decreased considerably. Discuss the exact system configuration with your heating installer. If a buffer storage is integrated in the system, the two buffer sensors are attached to the 606 control panel and the boiler is controlled exclusively by the boiler control panel. The start and burnout conditions are set as follows: START: Boiler starts if the temperature in the buffer is above the minimum buffer temperature AND the boiler temperature is below the boiler start temperature. STOPP (BURNOUT): The boiler gets the burnout signal if the temperature in the buffer above and buffer below have exceeded the maximum buffer temperature OR the boiler has reached its target temperature. Please read the control panel operating manual to set the minimum and maximum buffer temperatures. To start the boiler, the control panel just needs to be plugged in and the boiler will then start on its own with the start conveyance of pellets and the subsequent ignition. The ignition process ends again at the end of the ignition period or when the control panel has detected that the pellets have been ignited through a defined increase in the exhaust temperature. The PL will now run at full boiler power until the boiler temperature approaches the set boiler target temperature. Once this has occurred, the PL automatically switches to partial load mode. If the boiler temperature drops back below the threshold value, the PL automatically switches back to full power. If the boiler temperature continues to increase despite partial load and if the set boiler target temperature 9

10 is exceeded, a burnout will be introduced. The boiler stops the fuel infeed and the fire goes out. After the exhaust temperature has fallen below 90 C and the subsequent fan follow-up time has elapsed, the pellet boiler performs an automatic burner pot ash removal cycle. The PL starts again automatically and the operating cycle starts over once the start conditions are fulfilled again. If you want to manually stop the PL, press the STOP button on the display. The buffer and the boiler temperatures are continuously measured during the entire operation and the boiler circulating pump is controlled based on this information. Please see the control panel operating manual for more information Control during operation with an external temperature controller In the standard version, the PL-M is operated without an external temperature controller. Optionally, the heating system can be equipped with a heating electronics system BD 600 controlled by atmospheric conditions. We recommend this special piece of equipment for all systems, in which the PL functions as the single source of heat. The pellet boiler is exclusively controlled via the buffer and the boiler sensors. This ensures that the pellet boiler is not used too frequently. Unnecessary starts are thus avoided. By operating the boiler without buffer storage, the switching on and off of the pellet boiler is controlled exclusively by the boiler start and the boiler target temperature. 2 Maintenance and servicing Like all technical devices, your pellet heating boiler from KÜNZEL must be regularly maintained and serviced. Depending on cleaning activity, different intervals should be maintained. An additional thorough maintenance should be performed before longer periods without use, e.g. the summer break. We recommend concluding a maintenance agreement with your heating technician. 2.1 Monthly cleaning The ash box must be emptied once a month. Turn off the boiler by pressing the STOP button and wait until the boiler has completed the burnout and ash removal cycle and is in STANDBY mode. Actuate the cleaning lever (see Ill. 1) on the side of the boiler a couple of times. The reheating register and the baffle plate in the combustion chamber are thereby cleaned. Protective gloves are recommended for subsequent work. The components in the combustion chamber are dirty and could still be hot. The ash door can now be opened and the ash box [14] can be removed. Be sure not to place the hot ash in a container that contains combustible material or that can burn itself. The burner pot must also be checked at least once a month to ensure reliable operation. Open the ash door when the boiler is turned off. Now separate the plugs of the igniter [11], the ash removal motor [13] and the position indicator switch [12] and flip the guide pipe for the cables [9] forward. Lift the radiation protection plate [6] and pull it forward out of the holder. The burner drawer [5] with the burner pot [10] can now be pulled forward and removed from the boiler. Attention: The burner drawer may still contain hot or glowing ash. Thus, place the burner drawer only on a fire-resistant surface. 10

11 Figure 10: Behind the ash door Figure 11: Rod of the ash removal motor Figure 12: Sliding bottom There is a stripping edge on the bottom of the burner drawer that is connected with the sliding-bottom holder. We recommend setting down the burner drawer so that the burner drawer is not resting on this edge; the removal of the burner pot will otherwise be impeded. The burner pot can then be removed from the burner drawer by lifting it towards the back slightly. The igniter pipe extends slightly into the pot. Please do not pull the pot from the holder in a violent manner as the igniter could be damaged. All openings in the burner pot must be open and incrustations on the burner pot should be removed with a suitable tool. Also remove the ash from the igniter pipe. Remove all ash from the burner drawer. It often suffices to position the open side of the burner drawer downwards diagonally and knock out the ash. If the bottom is so dirty that the air slots are clogged, you can lift it out of the holder and clean it with a wire brush or the like. During reinsertion, you must ensure that the rod of the ash removal motor is hooked in and the sliding bottom sits correctly in its holders. 11

12 Figure 14: Lifting the vacuum turbine Figure 15: Lifting the fine filter Figure 13: Insertion of the burner pot The burner pot is placed back into the burner drawer after thorough cleaning. Make sure that the igniter pipe is inserted through the appropriate hole in the burner pot. The igniter pipe should project approx. 1 to 2 mm into the burner pot. Now push the burner drawer back into its guide. Make sure that the drawer is pushed in all the way up to the stop. The guide pipe for the cables is now placed in its guide and the plugs are reconnected. Don t forget to reinsert the radiation protection plate! First push in the upper edge of the plate and then lower the plate. Check whether the air openings in the door are open and clean them if necessary. The fine filter of the vacuum conveyor should be checked and cleaned depending on the quality of the pellets. To do it, release the clasps and lift the vacuum turbine upwards. The filter is now freely accessible and can be beaten out for cleaning. Do not use cleaning agents or water! To restart the boiler, press START on the control panel. 12

13 2.2 Semiannual cleaning ID fan In order to permanently ensure the reliable functionality of your pellet boiler, it is necessary to clean the ID fan at least twice per year. Attention: Be sure to unplug the power before working on the fan! Figure 16: ID fan The ID fan is contaminated by dust in the exhaust. The dust collects on the blades of the fan wheel and the fan can no longer convey sufficient gas, or there are imbalances that can considerably reduce the service life of the engine mount. The ID fan should be cleaned early if there are strong operating noises during operation. The fan can remain mounted on the smoke connection for cleaning! Only the motor fan wheel unit is removed from the housing. Unplug the fan cable, loosen the screws on the motor flange and now remove the motor with the fan wheel from the housing. The fan wheel is now freely accessible from all sides and can e.g. be cleaned with a brush. Accumulated dust should be vacuumed up from time to time. Also vacuum the housing from the inside! Pressurized air must not be used to clean the fan, since there is a chance that dust will be pressed into the mount. The fan is reinstalled in the reverse order after cleaning. Attention: When the system is first started after cleaning, there may be a lot of dust Combustion chamber Open the ash door and remove the burner drawer as described in Chapter 2.1 on page 10. Then carefully pull the burner pipe [8] upwards and to the left out of its seating and then remove it from the boiler. The end piece of the downspout [7] is then removed from the boiler. The clamping screw of the end piece is loosened for this. The end piece can now be removed from the downspout. Now lift the burner pipe support [15] from its position and remove it from the boiler. In conclusion, lift the burner support [16] from its seating and pull it forward and out of the boiler. Lastly, the ash bowl is removed from the boiler. The rest of the ash can be removed from the boiler with a vacuum. 13

14 Figure 17: Without burner drawer After the thorough cleaning of the combustion chamber, all parts are reinstalled in the boiler in the reverse order Pellet bunker The intermediate bunker should be completely emptied for the semiannual cleaning. If there is an automatic filling device, it should be switched off. The wood flour in the pellet bunker can be removed via the pellet bunker emptying or with a vacuum. Figure 18: Flap for pellet bunker emptying 14

15 2.2.4 Rotary lock The rotary lock should ONLY be cleaned by the factory service department! RISK OF INJURY! Figure 19: Disassembly of the rotary lock We recommend checking and cleaning the rotary lock if necessary before longer period without use (summer break). Perform a burnout (push STOP on the control panel) and then completely unplug the boiler. Open the black casing between the boiler and the bunker and remove the hose end from the rotary lock (1). Loosen the four hexagon screws on the motor (1) and remove the motor towards the front (2). Now check whether the shaft can be turned easily and whether the chambers of the lock are open. If wood flour has collected in the chambers, the rotary lock must be cleaned. It usually suffices to vacuum it out. In the case of difficult deposits, you can disassemble the rotary lock and scrap it out e.g. with a screwdriver. To do this, loosen the hexagon nuts and lift out the rotary lock upwards (3). It can now be cleaned and then assembled in the reverse order. Don t forget the seal between the rotary lock and the downspout. 2.3 Annual cleaning Smoke gas flues In order to achieve the high level of efficiency of the PL, the smoke gas flues should be thoroughly cleaned once per year when heavily contaminated. It is best if this takes place at the beginning of the heating period. For this, remove the red casing cover behind the control panel and open the register cover located below it. The smoke gas flues and the upper dust traps are now open. Clean the dust traps e.g. with a vacuum. Make sure that the exhaust gas sensor is not damaged or displaced. The turbulators must be removed in order to be able to clean the smoke gas flues. Lift the holders for the baffle plate with tongs and hook them in on the lower edge of the upstream flues. The turbulators can now be lifted with the cleaning lever attached to the side of the boiler and can be lifted out of the upstream flues on the round rod. The turbulators are very dirty and have sharp edges; gloves must be worn! 15

16 Figure 20: Heating register The flues are thoroughly cleaned using the provided cleaning brush. It may be necessary to vacuum out the dust trap again after cleaning the flues. The turbulators are then reinstalled, the holders for the baffle plate are hooked in again and the register and the casing cover are reclosed. Now actuate the lever on the left side of the boiler several times to clean of the baffle plate. Then clean the combustion chamber of the brushed off ash as described in the previous chapter Thermomix valve The KÜNZEL Thermomix- valve should be opened and cleaned once per year. All moving parts can be removed after the lines are blocked on the cap site. This enables a light cleaning without having to disassemble the entire valve. The stretch cartridge should be replaced after 5 years for reasons of precaution. Please have this work performed by your heating technician. 16

17 3 What to do in the case of a malfunction Before restarting the boiler after a malfunction, carefully check whether the burner pot is empty. Sensor shortcut Damage to the sensor or the cable Replace sensor Sensor broken Damage to the sensor or the cable Check plug contacts Replace sensor Low-pressure switch open Ash door open Close door Check door seal Cleaning cover is open Close cover Check seal Fan not running Check fan, fan cable and plug Check fuse in control panel Vacuum unit is not working Sensor is dirty Hose is plugged or broken Vacuum unit defective The burner pot is very dirty No fuel available Bunker is empty Refill fuel Turn on or check external day bunker filling Adjust filling duration or filling interval Screw conveyor not conveying Check whether the screw is freely accessible or dust is clogging the screw infeed Check whether the downspout is free Check whether hollow spaces or bridges have formed in the pellet filling Check whether pellets are stuck under the cover of the screw flange 17

18 Check whether the safety temperature limiter (STB) has been triggered Too little fuel is being conveyed Adjust cycle times for full power and partial power False start No fuel available Refill fuel Check external day bunker filling Screw conveyor not conveying Check whether the screw is freely accessible or dust is clogging the screw infeed Check whether the downspout is free Check whether hollow spaces or bridges have formed in the pellet filling Check whether pellets are stuck under the release flap Check whether the safety temperature limiter was triggered Ignition time is too short Adjust ignition time (see setup recommendations in the appendix) Start amount is too small Adjust start amount, adjust follow-up time (see setup recommendations in the appendix) Igniter is not working Check igniter element, cables and plug Initial startup (please read Chapter on page 8) Boiler temperature over 95 o C Insufficient heat intake Check pumps Boiler sensor has insufficient contact in the immersion sleeve Rebend or replace contact spring Boiler sensor is defective Replace sensor Burner pot ash removal open Position indicator switch gives no signal Check cables Check position indicator switch Check whether the bottom is easily accessible Remove ash from the air box Remove ash For questions and problems concerning the KÜNZEL pellet boiler, please contact your heating technician. 18

19 4 Technical information 4.1 Sensor values Low temperature sensor for boiler, buffer, industrial water, supply line, sensor type = KTY81 T in o C R in Ohm Exhaust gas sensor, Sensor type = PT1000 T in o C R in Ohm

20 Figure 21: The PL-M pellet boiler, Boiler and bunker can be separated for shipment 20

21 Figure 22: Pellet boiler without bunker Type PL25M PL15M Combustion capacity kw Nominal heating capacity kw Capacity max. kw Capacity min. kw 9 9 Fuel Wood pellets 1 Permissible boiler temperature o C Achievable boiler temp. o C Permissible excess operating pressure bar 3 3 Weight kg Water content Liters Filling capacity bunker kg Water-side resistance Pa Required delivery pressure Pa 1 1 Exhaust gas mass flow rate b. nominal load kg/s 0,018 0,011 Exhaust gas temperature o C CO 2 % ,4 Smoke gas support diameter mm Efficiency level % 90,8 91,8 Turbulators no mm und 8mm pellets at least in compliance with DIN-PLUS 21

22 22

23 23

24 .