Installation instructions for contractors PYROMAT ECO PYROMAT ECO 8/2012 Dispose after installation.
Safety instructions Please follow these safety instructions closely to prevent accidents and material losses. Safety instructions explained Danger This symbol warns against the risk of injury.! Please note This symbol warns against the risk of material losses and environmental pollution. ote Details identified by the word "ote" contain additional information. Target group These instructions are exclusively designed for qualified contractors. Work on electrical equipment must only be carried out by a qualified electrician. The Code of Practice of relevant trade associations All current safety regulations as defined by DI, E, DVGW, VDE and all locally applicable standards. a ÖORM, E and ÖVE c SEV, SUVA, SVTI, SWKI and SVGW Working on the system Isolate the system from the power supply and check that it is no longer 'live', e.g. by removing the separate fuse or by means of a main isolator. Safeguard the system against unauthorised reconnection. Regulations Observe the following when working on this system ational installation requirements Legal instructions regarding the prevention of accidents Legal instructions regarding environmental protection 2
Index Safety and liability... 4 Preparing for installation... 6 Installation sequence Fitting the flue gas fan casing... 16 Fitting the flue gas fan... 17 Connecting the boiler on the flue side... 18 Connecting the boiler on the heating water side... 20 Hydraulic connection... 20 Connections... 21 Making the electrical connections... 22 Overview of top connector strip... 22 Overview of bottom connector strip... 23 Plug connections... 24 Power supply... 30 Directives... 30 Fitting the cleaning tool mounting bracket... 31 Commissioning and adjustment... 31 Appendix... 32 Keyword index... 34 3
Safety and liability Application The Pyromat Eco, type PMEA boiler can be used for the following: Central heating via a central heating system DHW heating ote The Pyromat Eco, type PMEA must only be operated by authorised and trained personnel. Any use that differs from or goes beyond this is considered inappropriate. Boiler application limits Life cycle stages Life cycle stages Manufacture Delivery, moving, handling, installation Installation Commissioning Operation Maintenance, repair, decommissioning Dismantling, removal, collection Disposal Responsible/participating personnel External person Manufacturer External person Manufacturer Logistics Electrician/heating contractor External person Electrician/heating contractor System user External person Electrician/heating contractor System user External person System user Electrician/heating contractor Service engineer External person Logistics Electrician/heating contractor Disposal contractor External person Disposal contractor 4
Safety and liability (cont.) Occupational safety Danger Incorrectly executed electrical installations can result in injuries from electrical current and in appliance damage. Connect the power supply and implement all safety measures (e.g. RCD circuit) in accordance with the following regulations: IEC 60364-4-41 VDE regulations [IEE or local regulations] Technical connection requirements of the local power supply utility Danger Contact with 'live' components can lead to serious injury from electric current. Some components on the PCBs will remain 'live' even after the power supply has been switched off. Isolate the system from its power supply (e.g. at a separate MCB/fuse or mains isolator), check that there are no more 'live' currents and safeguard against reconnection. Danger The absence of component earthing can result in serious injury from electrical current and in component damage in the event of an electrical fault. Always reinstate all earth connections. Boiler and pipework must be grounded to the equipotential bonding of the building. Working on the boiler Please note! Prior to commissioning and following repair or maintenance work check that the boiler is in an appropriate condition. Wear appropriate protective clothing (e.g. safety boots) in compliance with applicable regulations on accident prevention and in line with trade association recommendations. ote In addition to the control circuit, there may be several power circuits. Prior to removing the boiler covers, wait at least 4 min. to permit the voltage to decay. 5
Preparing for installation Unloading and transportation ote Before unloading, have the recipient check the consignment for possible damage. ote down any damage on the delivery note and notify the haulage contractor.! Please note Jolting movements can damage the combustion chamber lining. Ensure the boiler is not subjected to excessive jolting movements during handling and installation. ote The pre-installed lifting eye can be used to transport the boiler. The boiler can be moved inside its packaging subject to the physical space allowing such handling. Wherever possible, transport the boiler to the installation location with the shipping protection fitted. Only transport the boiler with fitted shipping feet on a pallet truck. 6
Preparing for installation (cont.) Wall clearances b a c > d 7
Preparing for installation (cont.) Pyromat ECO... 35-65 61 81 101 151 a mm 200 400 400 400 400 b mm 600 730 730 730 730 c mm 600 800 800 800 800 d mm 800 800 800 800 800! Please note Boiler damage resulting from incorrect installation. Position the boiler level and directly on the floor. ever use any plinths/supports. ote The specified wall clearances are required for installation and maintenance work. Requirements to be met by installation area Avoid air contamination through halogenated hydrocarbons (e.g. as contained in sprays, paints, solvents and cleaning agents) Avoid very dusty conditions Avoid high levels of humidity Prevent frost and ensure good ventilation Max. room temperature of 40 C Weights Data on weights excluding fan installed Wood boiler for logs up to 0.5 m long: Pyromat Eco 35 45 55 65 Shipping weight kg 750 760 920 935 Wood boiler for logs up to 1 m long: Pyromat Eco 61 81 101 151 Shipping weight kg 1300 1320 1680 1720 8
Preparing for installation (cont.) Remove all loose components from the boiler interior 1. 2. 3. 4. 1. Open the hopper door. 2. Remove all loose components from the hopper interior. 4. Remove ash box and all loose components. 3. Open ash door. 9
Preparing for installation (cont.) Components inside the boiler hopper: in case of Pyromat Eco 35-65: Fan and casing ready installed in case of Pyromat Eco 61-151: Fan housing Fan Buffer cylinder control valve Cleaning tool Also delivered with the boiler: Set of technical documentation comprising the following: Installation and service instructions Operating instructions Set of turbulator rods (subject to boiler output) Boiler output label Components in the boiler ash box: Sight glass 3 sensor wells for buffer temperature sensors Mounting bracket for cleaning tool 10
Preparing for installation (cont.) Fitting the sight glass 2. 3. 1. 1. Open ash chamber door and remove sight glass from ash box. 3. Insert sight glass. 2. Undo lifting eye. 11
Preparing for installation (cont.) Removing the shipping feet Danger Risk of injury due to slipping and tipping of boiler. Ensure the trolley jack is in a stable position before removing the shipping feet. Take the boiler weight into account. Only use appropriate tools and equipment. Only use a square timber that can bear the weight of the boiler to raise and lower it.! Please note Damage to the boiler and installation location due to slipping and/or tipping of the boiler. Ensure the trolley jack is in a stable position before removing the shipping feet. Take the boiler weight into account. Only use appropriate tools and equipment. Only use a square timber that can bear the weight of the boiler to raise and lower it. ote Use a trolley jack to remove the shipping feet. Removing the rear shipping feet 1. 3. 4. 2. 12
Preparing for installation (cont.) 1. Remove the Lambda probe from the casing. Push square timber as far as it will go into the boiler's flue outlet. 3. Remove rear transport feet. 4. Lower boiler slowly with trolley jack. 2. Position the trolley jack against the square timber. Lift the boiler. Removing the front shipping feet 1. 2. 4. 5. 3. 1. Open chamber door at the front of the boiler. 2. Push square timber as far as it will go into the hopper chamber. 3. Lift the boiler with the trolley jack. 4. Remove front transport feet. 5. Lower boiler slowly with trolley jack. 13
Preparing for installation (cont.) Mounting the turbulator set (if available) The boiler turbulator set consists of turbulators with corresponding mounting brackets. 2. 3. 1. 4. 1. Release the cleaning cover of the heat exchanger via the mushroomshaped handle. 2. Open the cleaning cover. 3. Hook mounting brackets into turbulators. 14 4. Introduce turbulators on the mounting brackets into the heat exchanger pipes. 5. Close cleaning cover and lock in place.
Preparing for installation (cont.) Affixing the boiler output label CE A A Boiler type plate 1. Remove boiler output label from its packaging. 2. ote Ensure that the surface of the type plate to which the label is to be affixed is free of dust and grease. Affix the label to the boiler type plate (A). 15
Fitting the flue gas fan casing 1. ote The fan and housing is supplied ready assembled for the wood boiler for logs up to 0.5 m long (Pyromat Eco 35, 45, 55 and 65). 1. Secure the casing with fan on the protruding flue outlet using the screws. 2. Fit the Lambda probe. 3. Fit and connect the flue gas temperature sensor. 4. Push plugs ag, a-ö and a-öa onto the connector strip on the back of the boiler. 16
Fitting the flue gas fan ote This installation step is not required for wood boilers for logs up to 0.5 m long (Pyromat Eco 35, 45, 55 and 65). 1. 2. 1. Push fan onto the casing and secure with wing nuts. 3. Tighten wing nuts. 2. Cable conduit only for Pyromat Eco 61, 81, 101 and 151. Fit cable conduit with winged screw. 17
Connecting the boiler on the flue side ote We recommend you install a flexible connection piece in the flue. This prevents transmission of sound produced by the induced draught fan. ever grout the flue pipe into the chimney. ote ever fit any secondary air device (draught stabiliser). A B A Thermal insulation B Flexible flue adaptor 18
Connecting the boiler on the flue side (cont.) 1. Install the flue pipe rising to the chimney (preferably 45 ). Max. flue pipe length: 3000 mm. Flue pipe (internal diameter) 40-100 kw 7 200 mm 120-170 kw 7 250 mm 2. The entire flue pipe with cleaning apertures must be gas-tight. 3. Thermally insulate the flue pipe with at least 30 mm thick insulation. ote If you expect condensate to form inside the chimney, we recommend you push the flue several centimetres into the chimney, ensuring the required minimum cross-section of the chimney is maintained. 19
Connecting the boiler on the heating water side Hydraulic connection A B C F X X X X G E D H K A Boiler return B Boiler flow C Thermally activated safety valve, safety heat exchanger installed in the boiler D Sensor, thermally activated safety valve E Valve, thermally activated safety valve F Shut-off valve G Particle filter H Check valve K Pressure reducer 20
Connecting the boiler on the heating water side (cont.) Connections ECO 33 to 55 and 65 ECO 61 to 151 Flow D 32 40 R 1¼ 1½ Return D 32 40 R 1¼ 1½ Cold water supply *1 D 15 15 On-site R ½ ½ Cold water outlet On-site R ¾ ¾ *1 Fixed metal pipe, 2.5 to 4 bar 21
Overview of top connector strip 23 22 21 L3 PE L2 L1 PE L1 PE L1 L1 PE L2 PE L1 B4 S3 T2 T1 145 182 29 179 40 181 9 M Making the electrical connections CA 13 14 11 Y2 Y1 1~ 12 11 12 230V/50Hz 6A Y2 Y1 Pt1000 Pt1000 Pt1000 A B C D E F G A Plug avg : KM BUS B Plug a;s : Boiler control valve C Plug sl : Boiler circuit pump D Plug aml : Enabling additional boilers or oil/gas burner (with safety chain example) E Plug fö : Power supply F Plug a;a : Buffer cylinder control valve G Plug ) : Buffer temperature sensors PTS (from left to right: bottom, centre, top) 22
Overview of bottom connector strip 23 22 21 23 22 21 23 22 21 23 22 21 T1 T2 S3 PE L1 1 146 15 100A Making the electrical connections (cont.) 50A 100 M 1~ Pt1000 Pt1000 A B C D E A Plug! : Outside temperature sensor B Plug avh C Plug ag and a-öa : Flue gas temperature sensor and hall sensor D Plug göa : External fault message E Plug a-ö : Flue gas fan 23
Making the electrical connections (cont.) Plug connections Connect plug avg: KM BUS for extension kits 145 KM- BUS 23 22 21 Assignment Function Additional information 23 KM BUS + 22 KM BUS - Recommended cable type: H05VV-F2X 0.75 mm² H05R-F2X 0.75 mm² For extension kit installation: Min. and max. diameter (strain relief): 6.5-8.3 mm Extension kit installation instructions For adjustment at the extension kit and the connection of sensors at the extension kit: Service section of these instructions Plug aml: Connecting the oil/gas burner enable signal ote Should an oil/gas burner be used in the boiler, make connections as described in the following: Alternatively an additional heat source can be connected to plug aml. 24
Making the electrical connections (cont.) A 179 PE 12 11 12 14 11 13 L1 max. 2 A A Example of a safety chain Connector PE L1 Implement the safety chain A in accordance with current regulations. Description eutral conductor Earth Phase conductor 230 V, max. 2 A ote The door contact switch for the charge cover and the burner withdrawal facility switch are part of the standard delivery of the optional burner withdrawal facility. Plug aml: Connecting an additional boiler enable signal ote If an additional heat source is employed, make all connections as described in the following: Alternatively an oil/gas burner may be connected to plug aml (see previous diagram). 25
Making the electrical connections (cont.) 179 A PE L1 L1 A Boiler enable Connector PE L1 Recommended cable type: H05VV-F2X 1.5 mm² H05R-F2X 1.5 mm² Description eutral conductor Earth Phase conductor 230 V, max. 2 A Min. and max. diameter (strain relief): 6.5-8.3 mm Plug fö: Connecting the power supply 40 L1 230V/50Hz 6A PE 26
Making the electrical connections (cont.) Assignment Function Additional information L1 230 V AC / 50 Hz max. backup fuse 6 A PE Backup fuse on site: 6 A Recommended cable type: H05VV-F3G 1.5 mm² H05R-F3G 1.5 mm² Min. and max. diameter (strain relief): 6.5-8.3 mm Plug a;a: Connecting a buffer cylinder control valve 181 L2 Y2 Y1 PE L1 Valve connection Connector Colour Description blue eutral conductor Y2 L2 white Actuating signal CLOSE (230 V AC) Y1 L1 black Actuating signal OPE (230 V AC) Recommended cable type: H05VV-F4G 0.75 mm² H05R-F4G 0.75 mm² Min. and max. diameter (strain relief): 9.0-11.5 mm 27
Making the electrical connections (cont.) Plug ): Connecting the buffer temperature sensors 9 A B B4 S3 T2 T1 C A Buffer temperature sensor PTS, bottom (Pt1000) B Buffer temperature sensor PTS, centre (Pt1000) C Buffer temperature sensor PTS, top (Pt1000) Assignment Function Additional information T1 Top buffer temperature sensor PTS Pt1000 T2 Centre buffer temperature sensor PTS Pt1000 S3 Bottom buffer temperature sensor PTS Pt1000 B4 GD (for all 3 sensors) Recommended cable type: H05VV-F5G 0.75 mm² H05R-F5G 0.75 mm² Min. and max. diameter (strain relief): 7.5-10.5 mm 28
Making the electrical connections (cont.) Plug!: Connecting the outside temperature sensor 1 23 A 22 21 A Pt1000 Assignment Function Additional information 22 Outside temperature sensor Pt1000 21 Outside temperature sensor GD Recommended cable type: H05VV-F2X 0.75 mm² H05R-F2X 0.75 mm² Min. and max. diameter (strain relief): 6.5-8.3 mm 29
Making the electrical connections (cont.) Plug göa: Connecting the central fault message 50A A T1 L T2 S3 A Signalling device (e.g. horn) Assignment Function Additional information T2 Fault message (common contact) floating contact S3 Fault message max. 250 V, 4 A Recommended cable type: H05VV-F2X 1.5 mm² H05R-F2X 1.5 mm² Min. and max. diameter (strain relief): 6.5-8.3 mm Power supply Directives Regulations Carry out the power supply connection and all earthing measures (i.e. RCD circuit) in accordance with IEC 364, the requirements of your local power supply utility and VDE [or local regulations]. Protect the power cable to the control unit with an appropriate fuse/mcb. Mains isolator requirements For combustion equipment to DI VDE 0116, the mains isolator installed on site must comply with the requirements of DI VDE 0116 "section 6" [or local regulations]. 30
Power supply (cont.) Fit the mains isolator outside the installation room; it must be able to isolate all non-earthed conductors simultaneously with at least 3 mm contact separation. Fitting the cleaning tool mounting bracket Fit the cleaning tool mounting bracket on the wall near the boiler. Commissioning and adjustment Boiler service instructions 31
Appendix Plugs already connected in the delivered condition Plug a;s : Boiler control valve 182 L3 PE Y2 Y1 L2 L1 Connector Colour Description blue eutral conductor L2 white Actuating signal CLOSE (230 V AC) L1 black Actuating signal OPE (230 V AC) Plug sl: Boiler circuit pump 29 M 1~ PE L1 32
Appendix (cont.) Plug ag flue gas temperature sensor and a ÖA hall sensor 15 23 A 22 21 23 22 21 B C D 100A A Pt1000 Terminal on plug a-öa Cable 21 Hall sensor D (red) 22 Hall sensor C (white) 23 Hall sensor B (black) Plug a Ö: Flue gas fan 100 M 1~ PE L1 33
Keyword index C Connection On the flue side...18 On the heating water side...20 E Electrical connections...22 M Mains isolator...30 P Power supply...30 34
35
36 Viessmann Werke GmbH&Co KG D-35107 Allendorf Telephone: +49 6452 70-0 Fax: +49 6452 70-2780 www.viessmann.com Köb Holzheizsysteme GmbH Flotzbachstrasse 33 A-6922 Wolfurt Telefon: +43 (0)5574 6770-0 Telefax: +43 (0)5574 65707 www.kob.cc Subject to technical modifications.