Bosch boiler with pellet burner Pelet Brenn 2000

Transkript

1 Bosch boiler with pellet burner Pelet Brenn 2000 Bosch Termotechnika s.r.o. Krnov v PRAHA KRNOV MĚSTO ALBRECHTICE

2 Steel boiler with pellet burner Pelet Brenn kw Output 6 till 27 kw For installation with boiler from Bosch production: Dakon DOR F Buderus Logano S111-2 Junkers Supraclass S Bosch Solid 2000 B 2

3 Burner Pelet Brenn kw with solid fuel boiler High efficiency set of boiler and pellet burner Comfortable heat solution tank 195 l (140 kg) heating about 2-4 days w/o filling house about 100m 2, standard insulation Simple setting, easy operation and cleaning Room thermostat connection Suitable for boilers output 20 and 27 kw The most convenient way of heating with solid fuel Pellets wood, A1 by EN 303-5, DIN plus, EN ISO

4 Burner Pelet Brenn kw with solid fuel boiler Set for pellet heating Steel boiler from KrnP Pellet burner with control unit Conversion set for boilers 20,24 Conversion set for boilers 25Max/27, 32, 32D Fuel tank Fuel auger Door for burner installation Bricks of combustion space 4

5 Burner Pelet Brenn kw with solid fuel boiler Steel boiler from Bosch production Dakon DOR F Buderus Logano S111-2 Junkers Supraclass S Bosch Solid 2000 B High efficient vertical flue gas ways Easy cleaning from the top Good equipment included Boiler body from steel sheets EN JRG2 thickness 4-5 mm 5

6 Burner Pelet Brenn kw with solid fuel boiler Pellet burner Pelet Brenn kw, output 6 27 kw Easy and quick installation on boiler doors Electronic controller Automatic regulation of operation STB Time program Heat output setting by object size by heat energy Efficient combustion for all prescribed types of pellets 6

7 Burner Pelet Brenn kw with solid fuel boiler Fuel tank Volume 195 liters / 140 kg of pellets Easy and quick assembly from delivered parts Boiler operation for one filling 3 4 days house about 100 m 2 standard insulation Fuel feeding by auger from the tank bottom Complete emptying of the fuel from the tank 7

8 Burner Pelet Brenn kw with solid fuel boiler Pellet auger Auger principle of fuel feeding Automatic operation of feeding by output power Settable quantity of pellets by burner output Delivery max. 8,4 kg/hour, to set burner output power Adjusting the length of the connecting pipe so that the pellets freely distributed from the feeder to the burner Simple assembly 8

9 Burner Pelet Brenn kw with solid fuel boiler Burner controller ST-717 Separate control box, mounted to fuel tank Control of the fan, feeder, CH and DHW pump Safety thermostat STB Additional modules Output control Flow water sensor or room thermostat Error message on CU display Setting output power maximal temperature of flow water operation mode fan speed pellet volume week time program 9

10 Burner Pelet Brenn kw with solid fuel boiler Bricks in combustion space regulate the flow of flue gas in combustion space High temperature concrete easy installation wear parts Two sizes for boilers 20, 24 25Max/27, 32, 32D 10

11 Burner description 1. Burner body 2. Air channel 3. Internal wall 4. PCB 5. Internal feeder motor 6. Photocell 7. Fan 8. Burner tube 9. Burner holder 10.Grate 11.Internal auger 12.Burner wall 13.Heater 14.Pin 15.Cover 16.Bushing 17. Feeder temp. sensor 11

12 Technical data of boiler with pellet burner Parameter Unit DOR F/S111-2 with Pelet Brenn kw Boiler size Max/27 Nom. output with burner kw kw Min. output with burner kw kw Efficiency at nom. output % % Efficiency at min. output % % Fuel consumption Kg/h Kg/h 4,9 5,5 6,4 Boiler class

13 Technical data Parameter Unit Value Output power kw 13,4 34,1 Fuel consumption kg/h 2,9 7,2 Voltage V/Hz 230/50 El. shield protection - IP X0D Input power W 100 Input power of igniter W 300 Burner weight kg 11 Fuel tank volume ltr/kg 195/140 Pellet dimension (diam./length) mm 6/30 Requested chimney draught Pa 20 13

14 Device dimmension Boiler size A [mm] B [mm] Max/ D

15 Burner installation Unscrew the two screws on the bottom hinge and remove the ash door Remove the cotter pin of grate lever, disconnect lever and grate, remove grate lever Remove rotary grate and front grate 15

16 Burner installation Bricks for boiler size 20, 24 kw ( ) 16

17 Burner installation Bricks for boiler size 25Max/27, 32, 32D kw ( ) 17

18 Burner installation Insert ceramics bricks into the boiler 18

19 Burner installation Install and screw the door for the burner to the boiler Install the burner into door The tube for pellet input install to the burner depend on fuel storage tank position (better on right side from the boiler) 19

20 Burner installation Close the tertian air inlets by covers 20

21 Fuel tank assembly Assemble and set up the fuel tank next to the boiler (right / left) 21

22 Fuel tank assembly Auger tube insert into the tank through a seal ring at the lowest point of fuel tank Fill the tank by pellets 22

23 Burner assembly Fix the CU to front wall of the fuel tank Unscrew the cap under the flow water outlet of the boiler and install well ½" for temperature sensors Insert into the basin and fix temperature sensor STB sensor 23

24 Burner assembly To the burner terminal engage cable from CU 2, 3, 5 pole connectors Cable bushing fix to burner body 24

25 Connection of control unit El. supply Main switch Burner PE / N Buffer sensor bottom Buffer sensor top DHW sensor CH sensor Internal feeder Fan Heater Signal common. Feeder sensor Fan sensor Flame sensor STB 2x RS CH pump DHW pump Main feeder 25

26 Control unit ST-717 Control of boiler operation Fuel feedeing Combustion air Control CH pump DHW pump buffer Additional modules Mixing circuit module (up to 2) GSM module Internet module Roo thermostat Data communication RS On/Off 26

27 Control unit ST-717 Description Big graphic display with all necessary data Control by rotating switch By rotation select item or set value of parameter By pressing confirm selection or set Taste - Stand-by Exit leaving actual menu /item w/o change Actual version of SW ZPID STUB X99 ST-717NK 27

28 Control unit ST-717 function Basic display DHW operation mode, level of the fuel in storage tank Operation mode of the boiler Time, date, roomstat status Temperature of CH system actual requested Fan operation or Temperature of DHW actual requested Feeder run Fan output CH Pump Heater DHW pump 28

29 Control unit ST-717 operation modes Firing Activated by user Filling of the feeder and burner by fuel Ignition by hot air Active until flame is detected Operation Primary operation of the boiler Boiler works on nominal power to achieve requested boiler temperature Then switch to minimal power, the temperature should decrease If temperature decrease by hysterese, boiler switch to maximal power again If requested temperature is exceeded, boiler is switch to Damping mode 29

30 Control unit ST-717 operation modes Dumping Activation By user for boiler switch off At exceed of boiler temperature by 5 C External feeder stops, internal feeder works Fan is running to fuel burn out / flame fade Pump in operation Cleaning procedure by fan Pump are switch off at activation temperature In case of exceeding of boiler temperature start new ignition of the burner ater end of cleaning proces 30

31 Control unit ST-717 Main menu Screen Firing up Fuel tank full Requested boiler temperature Requested DHW temperature Manual operation Internal feeder feeders are off, only fan Parameters for maximal power Parameters for minimal power Week based control of boiler temperature Pump mode Installer settings Service settings Factory settings Software version 31

32 Control unit ST Screen Basic information about status of the boiler Valve statust (additional module is needed) Other screens are without sense for boiler and CU configuration 32

33 Control unit ST-717 Firing up Start by user Filling up of the feeder and burner by the fuel Ignition of the fuel by hot air Finish of this mode in detection of the flame by photo cell, switch to Operation mode Tray full After filling up of the fuel tank is performed this choice On basic screen is shown level of the fuel in tank. This level is calculated from feeder operation. At first the fuel tank has to be calibrated 33

34 Control unit ST-717 Temperatures of CH and DHW Temperature of flow water Requested temperature Setting is possible from basic screen Temperature of DHW Requested temperature od DHW 34

35 Control unit ST-717 Manual mode Feeder On/Off Internal feeder On/Off Fan On/Off Blow force Set of fan power 1 100% CH pump On/Off DHW pump On/Off Heater On/Off Valve 1, Valve 2 if mixing module is used Open / Close / Stop / Pump 35

36 Control unit ST-717 Max. / min. power Maximum power setting of burner parameters for nominal power Minimum power setting of burner parameters for minimal power (30%) Feed time Time of fuel feeding in seconds Feed interval Time when feeder is stop in seconds Feeding period summa of feed time and feed interval Blow force Fan output in % of maximum power Fan starts always on 100% power due to clear from the dust 36

37 Control unit ST-717 Weekly control Week-base regulation regulation of CH and DHW temperatures or/and damping mode every day/hour Daily cycle operation Boiler is damped in requested time Boiler week-based operation DHW week-based operation Temperatures are changed in requested time Mode 1 day /hour control of temperature Mode 1 setting Setting of damping time Setting of temperature change The time is necessary to set 37

38 Control unit ST-717 Pump modes Pump modes House heating DHW pump is off Water heat priority The DHW tank is charged if internal temperature is below requested Parallel pump In case of request to heat up of DHW tank is CH pump in operation as well Summer mode CH pump is off Buffer storage tank for CH water Buffer is charged by CH pump Pump start if Bottom temperature is below set Funkce horního čidla?? 38

39 Control unit ST-717 Installers menu Fitters menu setting of boilers parameters for system Boiler correction parameters of burner Ignition parameters for firing of the burner Ignition function -?? Minimum operation - behavior at req. temperature Tray full / Empty tray calibration of fuel tank Temperature settings Valve1, 2 setting of valve parameters Room regulator type and function of roomstat GSM module setting of GSM control Internet module setting of internet control Clock / Date setting of time Encoder sensitivity sensitivity of rotation switch Langue version set of communication language Display contrast setting of best display readability Factory settings reset of all parameters to factory values 39

40 Control unit ST Boiler Boiler modification of feeders and fan operation Fan coefficient Adjust of the fan speed for best combustion Feeder coefficient min. Feeder coefficient max. Optimal setting of fuel feeding based on caloric value of the fuel For minimal and maximal output 40

41 Control unit ST-717 Ignition parameters Ignition procedure Step 1 Blow-by fan is running for a specified period of time. Step 2 Initial fuel feeding feed for filling up of the burner Step 3 Heater Ignition of the fuel by hot air from the heater Photocell indicate flame in combustion space Step 4 Delay Stabilization of the flame 41

42 Control unit ST-717 Ignition parameters Ignition parameters Internal feeder delay Internal feeder is deactivated after the main feeder Fire sensor threshold Level of flame signal to detect flame end of step 3 Heater delay Max time for ignition detection of the flame Fan speed Fan output for ignition step 3 Fan speed delay Fan output for stabilization step 4 Firing up delay Duration of step 4 Duty time Feeder operation during step 4 Pause time Feeder pause during step 4 42

43 Control unit ST-717 Minimum operation Minimum operation Behavior of the boiler when boiler temperature reached requested value On Boiler is switched to Damp mode Off Boiler is switched to minimal output mode 43

44 Control unit ST-717 Fuel tank calibration Calibration of fuel tank Tray full calibration of fuel tank Before calibration is the tank filled and then carry out this option. Empty tray After consumption of the fuel from the tank this option is made CU now has information about the fuel consumption and can be calculated content of the fuel in the tank based on the operation of the feeder After new filling of the tank is made option Main menu -> Tray full The indication of the fuel amount in the tank appears on the main display or on the controller 44

45 Control unit ST-717 Temperature control Temperature settings Boiler hysteresis If temperature of boiler fall under requested by hysteresis value, boiler switch to maximal operation DHW hysteresis If DHW temperature fall under requested by hysteresis value, the DHW pump charge DHW tank Pump switch on temperature Minimal temperature of flow water when start both pumps 45

46 Control unit ST-717 Valve 1, 2 Registration Input of module number for relevant valve Valve status On/Off of the valve Valve setpoint temp Setting of requested temperature on the valve Opening time Maximum time for full valve opening Single stroke Max. value of valve opening change in case of the change requirement Minimal opening Minimal valve opening Valve type Floor heating mixing circuit Radiators mixing circuit 46

47 Control unit ST-717 Valve 1, 2 Equitherm regulation On/Off Parameters setting for equitherm regulation work. point 1 heating water temperature at outside temperature -20 C work. point 2 heating water temperature at outside temperature 0 C work. point 3 heating water temperature at outside temperature +20 C 47

48 Control unit ST-717 Valve 1, 2 Return inlet protection Protects boiler from to cold return water from heating system On/Off Minimal temperature of return water Maximal temperature of return water Additional sensors Sensors of return water and outside temperature are used from Own unit From second, main unit 48

49 Control unit ST-717 Valve 1, 2 Pump activation Condition of the switch on of valve pump Always sustain operation Never pump is stop Above threshold at min. temperature CH pump activation temp. set of temp. Factory settings Set of valve parameters to factory value Valve removal Valve cancellation 49

50 Control unit ST-717 Room regulator Room regulator On/Off Standard regulator On/Off TECH regulator Data regulator RS Room regulator device Off the room regulator is off CH boiler when the room temperature is reached, the boiler temperature is reduced CH pump when the room temperature is reached, the CH pump off 50

51 Control unit ST-717 Other settings GSM module On/Off of module for mobile control by SMS Internet module Setting of communication parameters Clock Setting of actual time Set date Setting of actual date Langue version Setting of communication language Display contrast Best readability of the display Factory settings Return to producer parameters values 51

52 Control unit ST-717 Service menu Service menu Setting of factory parameters for basic behavior of the boiler Relevant for safety of the boiler Access code 52

53 Control unit ST-717 Service menu Select PID Work Operation control Cleaning period Feeding time min Feeding time max Feeding interval min Feeding interval max Min. fan work Max fan work Fan speed min Fan speed max Power coef. Max Power coef. Min Ignition parameters Underpour time Internal feeder delay Fire sensor threshold Heater delay Fan speed Fan speed delay Duty time Pause time Damping parameters Damping delay Blow force Damping protection Min damping 53

54 Control unit ST-717 Service menu Temperature settings Max exhaust temperature Priority temperature CH pump emergency Anti-freeze temperature Boiler alarm temperature Fire sensor Fan Hall sensor Fan Code Fan min Fan max Fan speed min Fan speed max Growth impulses Lambda First lambda update time Update time Oxygen stroke Fan stroke Sum Min change Max change Lambda 100% Lambda 1% Min boiler temperature Flow Display contrast Factory settings 54

55 Control unit ST

56 Control unit ST

57 Burner operation setting For proper operation of the boiler with pellet burner recommended flue gas temperature C under pressure in the combustion chamber 12 Pa Required quality according to EN ISO A1 diameter 6mm, length 30 mm (DIN plus) Caloric value MJ/kg (4,2 5 kwh/kg) Filling the feeder by pellets Manual mode -> Feeder till auger is filled in by pellets Check delivery of pellets in hour by feeder manual mode Calculate Feeder time and Feeder interval for requested minimal and maximal output power Set fan power to best quality of combustion / emissions Content of CO 2 should be app. 15%, O 2 app. 5%, CO max. 300 ppm Set rest of parameters by central heating configuration 57

58 Flow water temperature [ C] Burner output [step] Boiler with pellet burner Burner operation Start procedure 80 C Step 4 Step 3 Step 2 Step 1 Full output Step 1 Step 2 Step 3 Full output Step 1 58

59 Flow water temperature [ C] Damp sequence Start sequence Fan output [%] Boiler with pellet burner Burner operation Minimum operation Off Achieving water temperature, burner switch to min power Achieving hysteresis, burner switch to max power Temp. don t decrease, burner switch to damp procedure Flame fade Start procedure 85 C 80 C 70 C 100% 50% 30% Max output Min output Feeder stop 59

60 Flow water temperature [ C] Damp sequence Start sequence Damp sequence Fan output [%] Boiler with pellet burner Burner operation Minimum operation On Achieving water temperature, burner switch to damp mode Flame fade Start procedure 80 C 70 C 100% 50% Feeder stop 30% Max output Boiler off 60

61 Flow water temperature [ C] Burner output [step] Boiler with pellet burner Burner operation Damp procedure 80 C Step 4 Step 3 Step 2 Step 1 Full output Step 1 Step 2 Step 3 Full output Step 1 61

62 Quality of pellets Quality of pellets is important pro reliable burner operation Requested quality by EN ISO A1 diameter 6mm, length 30 mm (C1 by EN 303-5), DIN plus heat content MJ/kg It is not allowed to use of vegetable pellets, grains, pellets with high bark content, etc. 62

63 Quality of pellets Production When processing wood there is also unusable waste This waste can be processed into pellets, without any chemical additives They are variously mixed finely ground sawdust and wood chips It is precisely defined moisture of the components The mixture is pressed through a circular form There is no need for chemical additives Lignin acts as a binder, is contained in the wood Such chipsticks of pellets are made 63

64 Quality of pellets 64

65 Quality of pellets the mark of quality Good Certification by DIN CERTCO program Certification Pelletsverbände (PVD, PVA) Certification by ÖNorm 7135 Certification by DIN Bad not certified pellets Attention, unknown volume of ash, corrosion risk! 65

66 Quality of pellets the mark of quality Good How can you recognize a good pellet? Ash content < 0,5-1% (DIN Plus < 0,3%) Lignin content is defined Max. moisture 10-20% v Diameter: 3-6 mm, length: 2-3 cm Made from quality wood Shiny, smooth surface No longitudinal or transverse cracks Low dust content at delivery The same size of pellets Clean water at the test Bad 66

67 Burner setting Delivery of pellets / Output power Control unit Max output Min output Fuel feeding Feeding pause Fan speed 67

68 Fuel delivery setting Amount of the fuel in kg per hour By manually operation of both feeders Boiler output = feeder time / feeding period * fuel amount * caloric value * boiler efficiency Sample of calculation Feeder time = 15 sec Feeder pause = 5 sec Feeding period = = 20 sec Amount of the fuel = 8,4 kg/hour Caloric value = 18 MJ/kg = 5,0 kwh/kg Fuel efficiency = 85% Boiler output = 15/20 * 8,4 * 5,0 * 0,85 = 26,8 kw Fan power by combustion quality CO 2 > 15%, O 2 < 5% 68

69 Before starting the burner Check the mounting of the burner to the boiler door, sealing of doors and other parts Connecting of the boiler to the chimney, combustion air inlet, filling the system with water Connecting of the fuel feeder, connecting of hose without bends, feeling of fuel tank Location and fixing temperature sensors in the basin Set the parameters according to the desired operating mode 69

70 Maintenance Regular cleaning of the burner Clean the grate from the ash or slag (lower quality pellets) Check the resistance of lighter (155 Ohm) Photocell control function (t20), position in burner body (lock) Clean dust from the pellets tank Burner adjustment using a combustion analyzer max. burner power for min. 10 minutes Setting O 2 to 5% (up to 10%) at high O 2 decrease fan power CO in range of ppm output power by fuel amount for lower levels correct fan parameters and amount of fuel 70

71 Alarm messages of CU Message Cause Solution CH sensor fault Boiler sensor faulty Change the boiler sensor DHW sensor falut DHW sensor faulty Change the DHW sensor Boiler temo. too high Too high boiler temperature Cool down and reset the boiler Mosfet temp. too high Fan capacitor faulty or wrong fan Check the fan connection to the burner Firing up alarm No fuel Refuel the fuel tank Check the feeder motors (int/ext) Photo cell faulty Check and replace photo cell Heather faulty Check and replace heather Hall sensor Hall sensor faulty Replace fan Fan faulty Replace fan STB Too high boiler temperature Cool down and reset the boiler STB faulty Replace STB C1 or C2 sensor fault Sensors C1 or C2 (additional Replace sensors pumps) faulty No 50Hz CU problem Replace CU No valve Wrong connection Check the connection communication Error by valve registration Register the valve again 71

72 Problem solving Code Failure Cause Solution A02 Parasitic flame signal Short cut of photoconductor Another light source Photoconductor change Removal this light source A03 STB open Boiler overheating Remove the cause of overheating, heating system, temperature setting A04 Safety feeder thermostat open Bad STB Ignition parameters are wrong clogged flue ways, chimney Bad safety feeder thermostat STB change Check the parameters t03, t04 Check the chimney draught remove of dirty Safety thermostat change 72

73 Problem solving Code Failure Cause Solution F02 Parasitic flame signal Flame signal is detected after end of operation request Post-ventilation finishing F05 Air sensor failure Blocked air sensor tube Check the tube F06 F10 Air sensor disconnected Flow ware sensor failure Bad fan Dirty fan wheel Cable interrupt Sensor damaged Short cut or interrupted sensor Change Clean, change Cable check, sensor change Change sensor Sensor and cable check, change 73

74 Comments For proper operation of the boiler with pellet burner must be inside of the boiler (combustion space, internal flue ways) vacuum. Therefore minimal chimney draught is 20 Pa Before equipment installing must be checked chimney. Setting of required chimney draft can be adjusted by draught regulator If chimney draft is insufficient (chimney can be blocked), safety feeder thermostat can be activated Starting boilers with pellet burner can be done by servicemen which were trained by manufacturer only, after all checks and inspection (flue gas ways) according to local regulations Operation is possible only in accordance with safety requirements, flue gas ways and other legal requirements The installation company that sells / installs equipment is required to ensure all the checks and inspections, educate customers on safe operation of the equipment and give him all the documents (manuals, protocols, review) 74

75 Thank you for attention Marek Lapiš KrnP/QMM-STI TT/SCZ-ASA Robert Bosch GmbH Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce,