HEATING TECHNIQUE Centrometal d.o.o. Glavna, 006 Macinec, Croatia, tel: +8 0 7 600, fax: +8 0 7 6 TECHNICAL INSTRUCTIONS for installation, use and maintenance of hot water boiler and installation of additional equipment Centrometal d.o.o. shall not be responsible for possible incorrect data caused by printing errors or error made in transcription and all figures and diagrams are for explanatory purposes only and relevant adjustment have to be made at the spot. In any case, it reserves the right to modify its products as deemed to be required and useful without any prior notification. Centrometal d.o.o. Glavna, 006 Macinec, Croatia central tel: +8 0 7 600, fax: +8 0 7 6 service tel: +8 0 7 6, fax: +8 0 7 6 BIOCK P Unit HEATING TECHNIQUE TUBCKPU0/0ENG
Technical data Notes TECHNICAL DATA TYPE BIOCK P Unit BIOCK P Unit 0 BIOCK P Unit 60 BIOCK P Unit 00 Nominal heat output Heat output range Boiler class Required chimney underpressure Water amount in boiler Exhaust gas temperature at nominal heat output Exhaust mass flow at nominal heat output Boiler resistance on water side at nominal output Fuel type Fuel moisture content Fuel size Firebox volume Combustion chamber dimensions Combustion chamber volume Combustion chamber type Required minimum accumulation next to boiler Electrical power input Supply voltage Frequency Current type Boiler dimensions Lenght Width Height (A) (B) (C) Boiler body mass Total mass (boiler with casing and accessories) Max. operating overpressure Test pressure Max. operating temperature Flue gas tube external diameter Flow and return pipe Boiler (male thread) connections Charge/discharge Total boiler dimensions (female thread) Total lenght Total width Total height (D) (E) (F) (kw) (kw) (Pa) (lit.) ( C) (kg/s) (mbar) (%) (l) (l) (lit./kw) (W) (V~) (Hz) (kg) (kg) (bar) (bar) ( C) (R) (R) 7, 0 78 7 8 6 7xx0 0 00 60 80 /" /" 00 00 0 0 8 7 0 67 7x66x60 0, 60 80 /" /" 00 wood chip max. G0 60 060 0 7 x7x687 06, underpressure by EN 0 point.. 0 0 0 ~,, 90 0 670 00 " " 0 0 00 6000 7 7 600x80x60 6, 80 8 00 " " 860 8 Boiler parts BIOCK P Unit Position. Boiler. Wood chip burner. Distribution power box with digital boiler control unit Mass Dimensions (HxLxW) Mass Dimensions (HxLxW) Mass (kg) (kg) (kg) Dimensions (HxLxW) BIOCK P Unit x00x60 760x0x BIOCK P Unit 0 BIOCK P Unit 60 BIOCK P Unit 00 xx60 760x70x8 x0x670 8x80x6 8xx80 88x00x00 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Notes Dimensions and basic parts of the boiler BIOCK P Unit TO(O) DP PLV U STO PLV L ST DP T RP GV OC PVV MI FT BT VT PT OD H C=F MT PP B H RK H DKR A=D TR PL EO OZC G E DV VPZ Legend DP Flue gas tube PLV Inlet line PP Filling / drainage PVV Outlet line MI Microswitch DKR Boiler control unit FT Photocell BT Bimetal thermostat MT Conveyor motor OZC Open for burner cleaning EO Distribution power box PL Burner TO(O) Thermal conductor (heat exchanger) or sensor for thermal conductor U RK Socket of safety thermostat Junction box OCOpen for flue gas tube cleaning RP Open for draught regulator STOTube for temperature sensors mounting not used ST Safety thermostat T DV GV Thermometer Lower boiler door Upper boiler door VPZ Primary air door / open for cleaning TR PT OD VT Conveyor thermal protection connectors Opening for wood chip supply Fan NOTE: WHEN ORDERING IT IS NECESSARY TO CHOOSE INSTALLATION OF THE BURNER ON THE LEFT SIDE ON THEBOILER OR INSTALLATION OF THE BURNER ON THE RIGHT SIDE ON THE BOILER. DIMENSIONS TYPE G mm H mm H mm H mm L mm BIOCK P Unit BIOCK P Unit 0 BIOCK P Unit 60 BIOCK P Unit 00 0 70 80 00 0 0 60 60 80 80 60 60 90 0 08 0 0 8 60 0 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
General, boiler description, delivery state Burner maintenance.0. GENERAL The boiler BIOCK P Unit has a modern construction and design and is made out of the controlled materials of high quality, welded with most modern technology and is approved and tested under EN 0 norm and fulfil all special request for the connection on the installation of a central heating system. Figure. Photocell PHOTOCELL.. BOILER DESCRIPTION The boiler BIOCK P Unit is steel hot water boiler. The combustion chamber has a large heating surface and low combustion chamber resistance. Boiler cleaning is very simple and it is possible to clean it from the front side... DELIVERY STATE Delivery state: Boiler BIOCK P Unit with casing Wood chip burner Junction box with digital boiler control unit Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 9
Burner maintenance Additional equipment, boiler positioning and assembly.. BURNER MAINTENANCE After installation, you should then carry out a routine operational check and clean the burner grates to control the amount of ash generated. This is to get an idea of how often the burner needs to be cleaned and how often the ash should be removed. Ash removal is done as needed, depending on woodchip quality. Be aware of variations in woodchip quality and moisture content, which affects the ash quantity and combustion. To clean the burner, it is also advisable to remove the flame sensor and see if it needs cleaning. There is a coating on the transparent part of the flame sensor which should be cleaned with a glass cleaner. Do not use solvents or flammable substances for cleaning. The burner can not be started without the flame sensor in place and you must not remove the flame guard during operation. A clean furnace increases efficiency, resulting in lesser woodchip consumption. In addition, ash removal is best done whilst reviewing the woodchip burner and the attached equipment.for more detailed service and maintenance work this should only be performed by specially trained personnel. When cleaning the burner, the burner must be turned off. If the burner is work, you must wait when burner be cold. Protectiove gloves mus be used (see Figure 9.). Before cleaning is necessary to insure that the burner is cooled. Burner must be clean on daily basis. Burner is clean trought door for cleaning (OZC). It is necessary to open the door for cleaning (OZC) and remove the ashtray with grate. Grate remove from ashtray and clean it. Ashtray must be cleaned with cleaning brush. Before returning ashtray with grate back into the burner, ash in the burner channel must be cleaned with scraper. When cleaning the burner is necessary to disconnect the photocell (Figure ). Photocell glass is need a good clean. It is recommended with glass cleaner. Figure. Cleaning a grate of wood chip burner.. ADDITIONAL EQUIPMENT Additional equipment for wood chip firing: equipment from scheme or if the boiler connect on the closed heating system equipment from scheme or if the boiler connect on the open heating system On the boiler BIO CK P UNIT it is obligatory to install the chipped wood tank or transporter with stirrer for chipped wood ( if You build the storage for chipped wood near the boiler ). It is possible to install the daily chipped wood tanks with stirrer in capacity of 0, m or 0,6 m or large chipped wood tanks with transporter, motor, gearbox and hydraulic stirrer in capacity of, m, 9 m and m..0. BOILER POSITIONING AND ASSEMBLY Boiler positioning and assembly and building in must be performed by a qualified person. We recommend that boiler is placed on a concrete base having height of 0 to 00 mm above the floor. Boiler room must be frostproof and well ventilated. Boiler has to be positioned so that it can be properly connected to the chimney (see Figure ) and simultaneously, enabling tending of boiler and additional equipment, control during operation, and cleaning and maintenance. WARNING! Flammable items must not be placed on the boiler and within the safety distances shown in Figure... MINIMUM DISTANCE FROM THE ROOM WALLS Figure. Minimum distance from the room walls for BIOCK P Unit min. 00 mm max. 600 mm OZC min. 00 mm min. 000 mm Burner grate Ash tray OZC Door for cleaning min. 00 mm Boiler BIOCK P Wood chip burner Junction box with digital boiler control unit Chimney 8 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Opening for fresh air, connection to chimney Maintenance, boiler maintenance.0. OPENING FOR FRESH AIR Each boiler room must be equipped with an opening for supply of fresh air which is dimensioned in accordance with boiler output. Such opening must be protected with a net or grate. Boiler must not operate in flammable and explosive environment. A = 6,0 Q A opening area in cm Q boiler output in kw.0. CONNECTION TO CHIMNEY Properly dimensioned and built chimney is a precondition for safe boiler operation and heating efficiency. A chimney must be thermally insulated, gastight and smooth. Cleaning door must be made in the lower part of a chimney. Chimney made of bricks must include layers with central insulation layer made of mineral wool. Thickness of thermal insulation should be min. 0 mm of chimneys is built against to interior wall, and min. 0 mm if it is built on the outer side. Internal dimensions of the chimney light diameter depend on chimney height and boiler output and they have to be selected in accordance with diagram shown in Figure. Fuel gas temperature at the chimney exist must be min. 0 C higher than condensation temperature of combustion gases. Selection and building of a chimney must be made by a professional. Required maximum distance from boiler to chimney is 600 mm, and minimum distance is 00 mm. Uptake tube must be installed at an angle 0 (Figure.). In order to prevent condensate from chimney to enter the boiler, uptake tube must be placed 0 mm deeper into chimney. Connecting uptake tube between boiler and chimney must be thermally insulated with a mineral wool layer having thickness of 0 to 0 mm. Figure. Possible ways of connection of boilers BIOCK P to chimney 0mm Thermal insulation Opening for cleaning Thermal insulation Opening for cleaning.0. MAINTENANCE Protective gloves must be used (see Figure 9.)... BOILER MAINTENANCE Every milimeter of soot and dirt on the exchange surfaces of the boiler means approx. % higher fuel consumption. Save fuel clean the boiler at a time. Protective gloves must be used, (Figure 9). Maintenance of boilers BIOCK P Unit Spaces under the grate, firebox and flue gas tubes have should be clean as needed. Flue gas tubes are cleaned through upper door (Figure ), but it is necessary first to remove a lid () located between the middle and upper boiler door (upper lid) and take out turbulators from flue gas tubes (Figure ). After that it is necessary to take out the stainless steel chamber throught upper boiler door and refractory stones trought lower boiler door (Figure ). Before firing, return turbulators, stainless steel chamber, refractory stone and upper lid to its position. On the back side of the boiler there is another opening for cleaning (see page.) through which is possible to remove the material which has been collected during firing as well as during the cleaning process. The hole can be approached by removing M8 screws and covers. Figure. Take out movable lids from combustion chamber BIOCK P Unit 6 6 Upper lid Lower lid Upper boiler door Midlle register Flue gas pipe Lower register min. 00 mm max. 600 mm Possible way of connection of boiler BIOCK P (fireing with wood logs not used) to chimney (recommendation). Possible way of connection of boiler BIOCK P with overpressure burner (wood chip) to chimney. Figure. Take out stainless steel chamber and refractory stone from combustion chamber BIOCK P Unit Upper door Upper lid Lower lid Stainless steel chamber Lower door Grate Refractory stone 6 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 7
Boiler use Selection of a chimney.0. BOILER USE Figure. Chimney dimensioning for boilers BIOCK P Boiler must not be used in flammable and explosive environment. Protective gloves must be used (see Figure 9.). It must not be used by children or disabled persons (either physically or mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product. Check whether the boiler and the entire heating system are filled with water and vented. Check whether safety elements have been correctly installed and in proper working order (see previous points of instructions). Check whether flue gas tube is sealed and thermally insulated. Check whether movable parts are placed to foreseen positions (upper lid, lower lid, turbulators in flue gas tubes grate of burner, ash tray) Figure 8. The grate at the entrance to the boiler firebox through the lower door must be placed in its cradle (Figure 8). Boiler heat output (kw) 0 00 90 80 70 60 0 0 0 0 0 8 0 wood chip fireing Light chimney diameter (cm) 0 6 7 8 9 0 Useful chimney height (m) An example of selection of a chimney: BOILER HEAT OUTPUT 0 kw FUEL WOOD LOGS (not used) OR WOOD CHIP REQUIRED USABLE CHIMNEY HEIGHT H = 9 m REQUIRED CHIMNEY LIGHT DIAMETER 0 cm Usable chimney height chimney height from connection spot of smoke pipe to the chimney top. Light chimney diameter interior chimney diameter. 6 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 7
Boiler installation to central heating system Mounting of the turbulators.0. BOILER INSTALLATION TO CENTRAL HEATING SYSTEM Boiler BIOCK P can be built to closed and open central heating systems. In both cases boiler can be fired with wood logs (not used) or wood chip. Installation has to be made, in according to technical standards, by a professional who will be responsible for proper boiler operation. Before connecting boiler to central heating system, the system has to be flushed to remove impurities remaining after system installation. It prevents boiler overheating, noise within the system, disturbances at a pump and mixing valve. Boiler should always be connected to central heating system by connectors, never by welding. Figure. shows safe distances required for boiler cleaning and maintenance... BOILER INSTALLATION TO CLOSED HEATING SYSTEM In closed heating system (as in example shown in Scheme and ) it is obligatory to build in certified safety valve with opening pressure of, bar and a membrane expansion vessel. Safety valve and expansion vessel must be built in accordance with professional rules and any valve must not be located between safety valve and expansion vessel and boiler. If boiler is connected to the heating system under Diagram., it is recommended that the environment temperature control is made by a ways manual mixing valve, thermostat valves on radioators or room thermostat..0. MOUNTING OF THE TURBULATORS Protective gloves must be used (see Figure 9.). By wood chip firing turbulators must be mounted in the flue gas pipes. To mounting the turbulators is necessary to open upper boiler door, take out upper lid (position, Figure.). Then, insert the turbulators into the flue gas pipes and push to the end (see figure.). After that, back in upper lid. Figure. Mounting of the turbulators Boiler BIOCK P Unit Upper boiler door Flue gas pipe Turbulators Upper lid 8 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Process of opening the boiler door Installation to closed heating system 0.. BOILER DOOR OPENING METHOD Scheme. Installation of boiler BIOCK P to closed heating system Figure 0. Boiler door opening method Connection for safety thermostat ROOM THERMOSTAT GV boiler for fireing with wood chips with mounted safety group and thermal protection Left Right RGV GV DV RGV RDV Upper boiler door Lower boiler door Handles of upper boiler door Handles of lower boiler door Open Closed DV bar way manual mixing valve PROCESS OF OPENING BOILER DOOR: UPPER BOILER DOOR: RDV CAS. Pull the handle of the upper boiler door RGV in direction of the arrow "OPEN"..Open the upper boiler door GV in direction of the arrow "RIGHT". LOWER BOILER DOOR: Lower boiler door allowed to open only when the burner is not working ( OFF is displayed in the upper display or control unit is OFF on main switch (0)).. Pull the handle of the lower boiler door RDV in direction of the arrow "OPEN"..Open the lower boiler door DV in direction of the arrow "RIGHT". PROCESS OF CLOSING BOILER DOOR: VTC Example of the closed system for central heating with the boiler with solid fuel / wood chip fireing, way thermic valve ESBE VTC (maintains minimum temperature of return water into the boiler above 60 C), VTC (maintains minimum temperature of return water into the boiler above 60 C), LTC (maintains minimum temperature of return water into the boiler above 60 C) or Laddomat (maintains minimum temperature of return water into the boiler abov 6 C) and the water accumulator CAS. Temperature regulation in the room is performed by way manual mixing valve. REMARK: If the water accumulator "CAS" is included in the installation of the heating system the regulation of the room temperature is also possible with the thermostatic valves on the radiators or with the room thermostat which control the operation of the system pump of the haeating system, in this case the way mixing valve is not necessary to be install. UPPER BOILER DOOR:. Pull the handle of the upper boiler door RGV in direction of the arrow "OPEN".. Press upper boiler door GV in direction of the arrow "LEFT".. Press the handle of the upper boiler door RGV in direction of the arrow "CLOSE". LOWER BOILER DOOR:. Pull the handle of the lower boiler door RDV in direction of the arrow "OPEN".. Press lower boiler door DV in direction of the arrow "LEFT".. Press the handle of the upper boiler door RDV in direction of the arrow "CLOSE". Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 9
Boiler thermal protection Start up... BOILER THERMAL PROTECTION BIOCK P Unit According to European EN standards, boiler thermal protection must be installed in closed heating system. Boiler is factory prepared for installation of thermal protection. Heat exchanger is built into boiler at factory, and thermal safety valve () is installed according to scheme. In case of any damage of boiler installed in the closed heating system due to its overheating, and boiler or system are not equipped with any thermal protection at all, or do not have properly installed thermal protection, guarantee will not be applied. IMPORTANT: Thermal protection must be connected to the water supply installation of the premises supplied from the water supply line and not from hydrophor. Namely, in case of failure of power supply, boiler could be overheated, and then hydrophor is not able to ensure required water supply. THERMAL FUSE Thermal fuse for boiler BIOCK P Unit consist of a HEAT EXCHANGER () and THERMAL VALVE () (see Scheme.). Installing parts () i () shall be in prepared connections (inner thread "), on the upper back side of the boiler, with the inline. Depending on the cold sanitary water installation, it is possible to select the installation of heat exchangers or thermal valve on the left or right side. INSTALLATION (see Scheme.): screw heat exchanger in the selected sleeve (inner thread "), (left or right depending on which side is connection of water supply ) so that the seals. screw into the remaining sleeve (inner thread ") reduce /" " and in his twist sensor () (external thread /") of thermal valve. connector () (inner thread /") of thermal valve connected to the cold hot water from the municipal water supply, connector () (inner thread /") thermal valve connect to connector (6) (external thread /") of heat exchanger. connection (7) (external thread /") of heat exchanger connect to sewage. Scheme. Installation of thermal protection of boiler installet in the closed heating system * bar Connection for safety thermostat T Thermometer Manual way mixing valve 0.0. START UP Boiler must not be used in flammable and explosive environment. Protective gloves must be used (see Figure 9.). It must not be used by children or disabled persons (either physically or mentally), as well as by person without knowledge or experience, unless they are under control or trained by s person responsible for their safety. Children must be supervised in the vicinity of the product. Check whether the boiler and the entire heating system are filled with water and vented. Check whether safety elements have been correctly installed and in proper working order (see previous points of instructions). Check whether flue gas tube is sealed and thermally insulated. Check whether movable parts are placed to foreseen positions (upper lid, lower lid, turbulators in flue gas tubes grate of burner, ash tray) Figure 8. Check whether stainless steel chamber are properly assembled (Figure 8). Check whether refractory stones are properly assembled (Figure 8). The grate at the entrance to the boiler firebox through the lower door must be placed in its cradle (Figure 8). Figure 8. Movable parts of boiler Upper lid Lower lid Stainless steel chamber Grate Grate Refractory stone Refractory stone Figure 9. Protective gloves Protective gloves are obligatory! FROM WATER SUPPLY SYSTEM CONNECTED TO MUNICIPAL WATER SUPPLY LINE ON SEWAGE 6 7 * Position of thermal valve after installation: (valve head downward) 0 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Safety, burner control, wood chip quality Installation to open heating system 8.8. SAFETY Safety information is based on a risk assessment carried out under the provisions of relevant EU Directives in order to meet the necessary European standards for CE marking. Installation, operation, maintenance and other procedures must be performed only by trained personnel and in accordance with current standards. The boiler room where the wood burning equipment is to be installed must also meet the requirements of the latest edition of the National Board of Housing, Fire Protection section or within the country of installations' current regulatory framework... BOILER INSTALLATION TO OPEN HEATING SYSTEM If boiler is installed in an open central heating system, it is recommended that system is made according to Scheme or a and b. In open system it is necessary to put an open expansion vessel min. 0, m above the height of the highest heating body. If expansion vessel is located in a room without heating, it should be insulated. The system pump could be connected on the inline or back line of the boiler. 8.9. BURNER CONTROL There are three ways to control the burner, firstly by using a regular oil burner type thermostat recorder to start and stop, to achieve a difference of about 6 degrees. Secondly, if you use a temperature sensor instead of a typical oil burner type thermostat, the installer can then achieve a greater difference with operation and get fewer starts and stops. The third option is controlling the combustion by using the accumulator tank, which is an advantage if there is an accumulator tank installed at the same time as the burner. When you mount a sensor in the top of the accumulator tank and a sensor in the bottom of the tank to control the burner, the tank then begins to cool and the burner then stops when the bottom of the tank is hot. The combustion time is then adjustable and can be adjusted according to the customers' requirements. By managing the combustion using an accumulator tank there is also a sensor mounted to detect the temperature within the boiler to control any Laddomat pump. 9.0. WOOD CHIP QUALITY Scheme. Example of installation of boiler BIOCK P in an open heating system OPC TO BOILER ROOM ABOVE THE HIGHEST HEATING BODY Thermometer T The burner is construct for burning wood chips. Centrometal guarantee the equipment for 0 mm maximum size of the woodchips in the wood fibre direction. Larger fractions may malfunction. Changing the quality of wood chips would not be allowed to happen without being notified of equipment manufacturer.. Boiler BIOCK P. Open expansion vessel OPC (V vessel = 0,7 V water in system). way manual mixing valve Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Against flame protection Memory functions, screensaver.. AGAINST FLAME PROTECTION The burner must not be installed without against flame protection. Against flame protection must be connected to the water supply installation of the premises supplied from the water supply line and not from hydrophor. Figure a. Against flame protection with contstantly water supply allowed on pressure of min., bar Noncombustible A Inlet cold water (constantly water supply allowed on pressure of min., bar) 7 6 8.6. MEMORY FUNCTIONS Within BIOCK P Unit control is a useful feature that allows you to store specific settings in the programme. It can be useful if you change woodchip quality often or that you want to select different operating modes. Within the Extras menu, you can scroll to SAVE and LOAD functions. Within the save menu, there are five different memories that can be stored separately from each other. At the back of this manual, it is possible to write in what MEMORY contains and it may be helpful to write down what you have saved in each MEMORY. 8.6.. SAVE SETTINGS When you have an operational setting that you want to save, browse your way through to the OPTION menu and then press OK. You will then enter a menu of different symbols, maneuver to the right or left arrow until you reach the SAVE icon and press OK. Now you can see the five different memories and choose one that is free, and press OK. You will get a dialog box if you want to save. Press the up arrow until you come to YES and confirm by pressing OK. You have now saved the current setting. Remember that if you save to a memory where there is already data on you will overwrite the old. LEGEND: Wood chip burner Wood chip transporter Connection for connection with thermal safety valve Thermal safety valve as Caleffi Sensor of the thermal safety valve 6 Connection inlet to the thermal safety valve 7 Connection outlet from the thermal safety valve 7 Detail A 6 8.6.. LOAD SETTINGS When you want to use a setting that you saved earlier, or go to the setting that the installer did you do the following. Go to Options and press OK, look for the LOAD function and press OK. Browse now through the memory that you want to download and press OK. A dialog box appears if you want to download or not, maneuver so that you get the YES and confirm with OK. Now, this option is enabled. 8.7. SCREENSAVER The option "Screen Saver" appears if the minutes did not press any buttons. Pressing any button on the screen appears a condition in which regulation was located before turning screen saver. Pressing any button on the screen appears a condition in which regulation was located before turning screen saver. Figure 7. Screensaver Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Test mode, error list Against flame protection 8.. TEST MODE Figure b. Against flame protection with water tank Within the menus is a test mode. The test mode is used to manually test most features to ensure that everything works as it should, for example during installation. Pressing the OK button when you are at the icon for the test mode you will then get into submenu, and there you have the features that you can try manually. The features available are: Auger Burner Ash screw Chimney Fans Hydraulic Pump Laddomatpump Fan Primer min. 000 mm 7 6 If you press OK when you for are example within the auger menu, a new picture emerges. Within the right side of the box, you can see the description of what function you have selected and you also see a left arrow and right arrow on the motors that can control the reverse gear. 8.. ERROR LIST The alarm will present within a window of the display with an error code and a brief message about why the alarm has been made. By pressing the OK button, a message is then displayed explaining what the alarm is for and what to do. ERROR LIST: E00: Faulty boiler sensor. Troubleshoot and replace if necessary E0: Tank top sensor error. Troubleshoot and replace if necessary E0: Tank bottom sensor error. Troubleshoot and replace if necessary E0: Flame sensor error. Troubleshoot and replace if necessary E0: Burner door open door. Close and restart E06: Cover screw stores open. Close lid and restart E07: Door open to storage. Close lid and restart E008: Faulty fan. Debug fan and replace if necessary E09: Communication error. Check the cables between the burner and control cabinet E0: Auger motor blocked. Some of the auger motors are blocked. E: Auger motor blocked. Some of the auger motors are blocked. E: Error on startup. Check the flame sensor and igniter E: Error mode. Check if there are woodchips within the container E: Module fault. Check for electrical faults in power cables E: Flue gas exhaust temp too high, clean the boiler E6: Auger temperature. Too high temperature within the auger. Clean the boiler E7: Flue gas sensor error. Check sensor and replace if necessary E8: Burner sensor error. Check sensor and replace if necessary E9: Module fault. Check electrical connections in electrical system E0: Module fault. Check electrical connections in electrical system E: Module fault. Check electrical connections in electrical system E: Module fault. Check electrical connections in electrical system LEGEND: Wood chip burner Wood chip transporter Connection for connection with thermal safety valve Thermal safety valve as Caleffi Sensor of the thermal safety valve 6 Connection inlet to the thermal safety valve 7 Connection outlet from the thermal safety valve 8 Water tank (minimum capacity of 0 liters) 7 Detail A 6 0 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Connection to electrical installations Wood chip burner 6.0. CONNECTION TO ELECTRICAL INSTALLATIONS All electrical works must be performed by a certified professional in accordance with valid national and European standards. A device for switching of all power supply poles must be installed in electrical installation in accordance with the national regulations on electrical installations. Scheme 7. Electrical connection for the boiler BIOCK P Unit 8.0. WOODCHIP BURNER The BIOCK P Unit woodchip burner is a fully functioning burner with ignition and extinguishing operation, in which a flame sensor monitors the combustion process. The woodchip burner is equipped with an integrated auger, controller and control unit with a digital display that can be programmed for different operating options, allowing control of the sensors, woodchips, humidity and more. Adaptations can be made to take into account varying sizes of fuel storage and supply options. Woodchip burner is available in power ratings of kw, 0 kw, 60 kw and 00 kw. External burner enclosure is made of enameled steel combustion chamber consists of a fireproof ceramic. Grids and plates inside the burner are resistant to acid, made of fireproof metal. The air is regulated by digital control over the sensors to control and monitor all operations. connect to the place of control unit safety thermostat L N L 8.. STARTUP AND SHUTDOWN OF THE BURNER By pressing the OK button, a symbol then says START / STOP. Select the up or down arrow on the keypad to set the switch to or 0 mode, press OK button. L L L N Supply 80 V Safety thermostat L L L Tank transporter SAFETY THERMOSTAT (installed in the casing cover) 8 9 0 6 7 8 9 0 6 7 8 6 7 L L L Burner transporter L L L Wood chip tank agitator L N Air ash cleaning L N Accumulation tank pump L N Flue gas fan D D D D 6 A A A A A 6 8.. BURNER STARTUP IGNITION PHASE 8.. OPERATING SETTINGS TO BOILER CONTROL UNIT BOILER CASING COVER SAFETY THERMOSTAT SOCKET PLUG (IN SET) CONNECTION:,,,, network supply 80 V 6, 7 safety thermostat 8, 9, 0, burner transporter,,, wood chip tank agitator A boiler sensor A accumulation tank upper sensor A accumulation tank lower sensor Upon installation, the installer is able to set the all important values, such as the boiler temperature and the feeding rate of woodchips to the burner. But with a change of chip quality, you will need to fine tune the system to obtain an optimal functioning of both the burners and woodchip stores. The Operation position is No. within the menu. To go to the menu, press the ESC button and select Operation settings with the Right or Left arrow and go into the menu with the OK button. Within the dropdown list, there are parameters to change values or turn on or off functions. OPERATING SETTINGS: ) CHOICE OF OPERATION: Allows you to set how you want the burner to be controlled, either by thermostat, boiler temp sensor or accumulator tank control. ) STARTING DOSE: This is the amount of woodchips to be inputted during startup, and to adjust the time that the augers work in seconds. To ensure the right amount of initial dose is correct, the S time must pass and be ready, which then starts the burner and the auger motor and checks that the woodchips fill at least half of the combustion zone, and can be increased or decreased as necessary. ) AFTER THE SELECTED FAN: This allows you to control the time that the fan will operate after the flame has disappeared within the burner. Normally, it shall be adjusted so that all the flames and embers have burned out when the time is up. ) MODULATING: This function is for future use. ) FAN AND AUGER: This setting allows control of the auger conveyor drive and speed regulation of the fan. These can be changed when you change the woodchip quality. When and if you change the fuel feed auger this then determines how much fuel the burner must have. The value of feed is given in % and is factory set at 0 %. D o n o t c h a n g e t h e b u r n e r, a s i t s h o u l d n o r m a l l y b e s e t a t 0 0 %. NOTE: There are various fan types of kw and 0kW compared to 60kW and 00kW and you must adjust the values depending on the size of fuel. For kw and 0kW, the minimum speed is 00 RPM and the 60kW and 00kW the minimum speed is 900 RPM. Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 9
Description list menus and submenus Boiler control unit 8) FLAME SENSOR: It is the flame sensor that allows the GOTFire burner to achieve a fast and smooth startup and heating function. The flame sensor is active throughout the burning process and it takes care of the augers should they not operate or decide whether the ignition element is activated or not. The value of the intensity of the flame sensor function is an Ohm value and is factory set to 0 ohms. Sometimes it is necessary that you adjust this value if using more damp woodchips. NOTE: You may not set the value higher than 60 Ohms. 9) OPENINGS STORES CAP: This is very useful in those cases where the woodchip store has a hydraulic opening filler door. When the door is opened you can then go into the feature opening the hydraulic storage and when you're there start one time circuit for minutes, which makes it possible by using the start button to run the hydraulic pump so that you can open the lid. The burner must be set to OFF in order to access this feature. In the operation of all store's door, you must have full visual control over the store so no pinching can be done. When you then press the button to start the pump, you have minutes to open or close. When five minutes is over, you can not start the pump with the start button then you need to activate the time the circuit again. This function is very good when the user can not open the door if you do not have the key out of the store. 7.0. BOILER CONTROL UNIT The woodchip burner is equipped with a control unit located in a separate control cabinet made of painted sheet metal, and a control panel with display for setting the operating parameters, service, maintenance and alarm systems. The control panel is connected to the controller via the network and at the appropriate positions within the boiler room. The control system has been designed around the connection of wood chip storage systems and conveyors. If any other equipment is connected which has not been delivered by Centrometal, you must contact the dealer first. No warranty applies unless the consent has been given by the dealer. 7.. BASIC ELEMENTS OF BOILER CONTROL UNIT Figure. Basic elements 0) BURNERSELF CLEANING: This function is for future use. ) FILLING AUGERS: At some point your storage may run out of fuel and the augers are empty. This will then sound an alarm that it can not start and this is when this feature is useful. At first boot, the installer can set the time to fill woodchip from the augers. When you go into this feature within the display of a symbol of a store and two transporters, you can then start the feature. Press the OK button and start the augers. NOTE: When using this feature, you must not leave the equipment unattended. It can be only that there has been a gap in the wood chips in the auger and the woodchip flow can be faster than expected. To stop filling you press the ESC key. 6 8 7 9 0 Display OK button to confirm selections ond choices Arrow Up and Down, increase the value and move around within menus Arrow Left and right, move between rows ESC key exit the menu 6 Red alarm lamp 7 Green OK light 8 Green operation lamp 9 USB input 0 Connections to the control cabinet 8 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit
Work operation Description list menus and submenus 7.. WORK OPERATION In Figure 6 shows that some symbols on the screen mean. Review of Operations contains lots of information about which additional equipment is connected to BIOCK P Unit and what happens in real time during the combustion process. In Figure 6 shows what happens when you run the boiler BIOCK P Unit and how this process appears on the display of digital boiler control. Figure 6. Boiler control unit display 7.. DESCRIPTION LIST OFF burner off SO Sleep Mode S Start, starting dose S Start, Only igniter S Start, Fan only S Normal operating mode. S Fuelling down phase 9 7 7.. MENUS AND SUBMENUS There are many useful features within BIOCK P Unit control system, which can be entered through the process mode by pressing the ESC key. Once in the menu mode you can scroll through the menus by pressing the Left or Right Arrow key, and confirming with the OK button to enter the menu. To exit the menu, press the ESC key. When repeatedly pressing the ESC key then returns you then to the process mode. 8 0 LIST OF MENUS: ) OPERATING SETTINGS: Here are the most frequently used functions such as starting dose and flame sensor. )Boiler Symbol: Depending on what kind of operation has been shown either the boiler temperature shows ON / OFF. )Symbol for Laddomatpump: If tank control is selected, the symbol displays an animation when the pump is switched on. )Symbol for storage tanks and tank control selected, the current tank temperature is displayed. )Process step: burning phase is divided into four stages, S, S, S and S and the current status appears here. )Time: the current process time of its operation. 6)Time: how long the process will be in operation 7)Stock: Symbol for hydraulic wood chip stocks. When the hydraulic pump is in operation this symobol flashes the content level. 8)Fan Symbol: The symbol indicates an animation when the fan is in operation, with the fan speed displayed above. 9)Flame symbol: This will show what level is the flame of the burner. If the level is above the setting, it displays an animation of a major blaze. A reduced light indicates the burner has reduced the flame. If there is a very small flame, an animation appears indicating smoke. 0) Primer: When booting up, the drive symbol will flash and when the heating process begins this then disables the ignition element and the symbol stops flashing. )Temperature: overheating protection burner. Breaking strength 0 degrees. )Symbol for the burner: Normally, it must be set to 00%. Animation shows when the screw is in operation. )Symbol for auger feed from the store: Current percentage value is displayed and if the screw is in operation the animation indicates. )Clock: Displaying the current time. ) TEMPERATURE SETTINGS: Here are the settings if you use the boiler or accumulator tank sensor control. ) TEST LOCATION: Here you can manually run functions to ensure that everything works as it should. One can operate the screw conveyors, hydraulic pump and laddomat pump. ) INSTALLATION: This menu is only for the installer. The menu is protected by code. The major changes can then be made such as replacement of engines or other major changes which you may need to contact professional personnel for help. ) EXTRA: This menu contains functions, for example to store a special setting that you have made for a special type of operation to be later reused. There are also settings for date and time, backlight and contrast of the display. There are also settings for frost protection and scheduled operation of the burner. The alarm list is also available here. 6) ERROR LIST: If something is found wrong that then causes a stopping of the system, it is then stored within this list. The last 0 error messages are stored within the memory under date and time. All alarms have a code and the codes can be found within the section under ERRORS AND TROUBLESHOOTING. 7) THE FANS: This function can be used if you have an exhaust fan installed. Normally the system is working under pressure via the chimney, or if you let the boiler run for very long times then the pressure is removed, and you may then want to install an exhaust fan. It can happen if you keep firing against a large storage tank when the burner is on standby for several days (and/or over the summer), that it can be hard to get adequate pressure within the chimney. This phenomenon can also occur when solar panels are being used within the system. To see the current status of the chimney you can see it within the operation mode, which when pressing the right button then allows a symbol of the chimney with a fan to come up. By pressing the left button it is then concealed. 6 Technical instructions BIOCK P Unit Technical instructions BIOCK P Unit 7