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Installation and operation

1. m serpentine tube G 74 inlet and outlet Flue outlet diameter mm 150 The firewood parameters as main recommended fuel type for combined wood gasification hot water boiler from series 3Fera are presented in Table 3 3 Table 3 3 Recommended fuel parameters dry firewood Parameter Dimension Value Fuel type Firewood Moisture 96 lt 2096 Minimum fuel caloricity minimum calorific value MJ kg 213 9 kWh kg gt 3 9 Table 3 4 represents the parameters for wood pellets as type of fuel for hot water boilers from series 3Fera 3Fera 25 35 45 Table 3 4 Wood pellets parameters Parameter Dimension Value Diameter of the granules mm 6 8 Recommended fuel caloricity net calorific value MJ kg gt 17 2 kWh kg 24 7 Wood pellets category according to standard EN 14961 2 ENplus A1 ENplus A2 ENplus B Wood pellets category according to the appliance manufacturing company categorization A AB B BC C CD E EF Moisture Max 8 10 The parameters for dry calibrated wood chips as type of fuel for hot water boilers from series 3Fera are presented in Table 3 5 Table 3 5 Dry calibrated wood chips parameters Parameter Notation Dimension Value Typical size of dry calibrated wood chips P mm 20 Moisture W 96 lt 10 Ash content A 96 lt 1 5 Bulk densit
2. MANUAL FOR OPERATION OF COMBINED WOOD GASIFICATION HOT WATER BOILER UTILIZING WOOD LOGS WOOD PELLETS AND DRY CALIBRATED WOOD CHIPS FROM SERIES 3Fera 25 35 45 http www greenecotherm eu Manufacturer ZMM Haskovo PLC Address 67 Saedinenie 6300 Haskovo Bulgaria Telephone 359 800 15 145 Fax 359 38 603070 e mail greenecotherm erato bg home page www greenecotherm eu The manufacturing company thanks you for the contribution of your choice The manufacturing company provides this manual in help to the team that will install adjust and service this system as well as to the customer that will operate it The manufacturing company requires that the technicians performing the above presented procedures has passed training course for the activities performed with the product User manual for operation and installation of combined wood gasification hot water boiler operating with wood logs wood pellets and dry calibrated wood chips from series 3Fera 25 35 45 Edition 21 12 2012 05 44 00 3Fera 25 35 45 2 page 1 INFORMATION RELATED TO THE USERS SAFETY sss 4 2 DESRIPTION AND ADVANTAGES OF COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES S FERA 5 3 TECHNICAL DATA FOR COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES FERA i Iis asso eerie o inh rea Ce EE ye a pde p baa E Ta ea nae Rag
3. 7 4 CONSTRUCTION DESCRIPTION OF COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES FERA uuu a idera ana pa Pea ea 10 5 MOUNTING AND INSTALLATION OF THE BOILER sssseeseseeeneeerenn nennen 17 6 INITIALIZATION OF THE APPLIANCE IN OPERATION essere 23 6 1 GENERAL REQUIREMENTS ABOUT THE USED FUEL ener 23 6 2 GENERAL REQUIEMENTS DURING OPERATION OF THE HEATING INSTALLATION 23 6 3 INITILIZATION OF HOT WATER BOILER FROM SERIES IN OPERATION 24 6 3 1 ADJUSTMENT OF THE FIRING AIR FLOW RATE THERMO REGULATION VALVE 25 6 3 2 INTERFACE CONTROL PANEL OF HOT WATER BOILER FROM SERIES 26 6 3 8 BOILER POWER SUPPLY u 27 6 3 4 BOILER SWTICH ON ku ere eoe eee u era 28 6 4 CHANGING THE BOILER OPERATION PARAMETERS 30 6 5 PARAMETERS FOR ADJUSTMENT OF THE BOILER OPERATION 32 6 5 1 OPERATION OF THE BOILER WITH FUEL MANUAL REFUELING WITH FIREWOOD 32 6 5 2 OPERATION OF THE BOILER IN COMBINED MODE AUTOMATED FEEDING WITH WOOD PELLETS OR DRY CALIBRATED WOOD CHIPS 34 6 6 ADJUSTMENT OF THE BOILER HEATING OUTPUT sese 36 6 6 1 OPERATION MODE DURING FIREWOOD UTILIZATION
4. eene 36 6 6 2 BOILER OPERATION IN COMBINED MODE nnns 37 6 7 STOPPING THE BOILER QOPERA TION a nennen enne 38 6 7 1 BOILER EMERGENCY SHUT DOWN 39 6 8 BOILER SHUT DOWN A u eite Heide eas nu Hee Qu Dn ee 39 6 9 BOILER CEEANING m iha k W Sua clea ele eden 39 6 10 USER INTRODUCTION WITH THE SERVICING AND ADJUSTMENT PROCEDURES OF THE BOILER E 41 6 11 SAFETY AND UNPREDICTED RISKS nennen enn enne 41 6 12 ACTIVITIES AFTER THE APPLIANCE LIFE CYCLE EXPIRY 42 7 FAILURES AND TROUBLESHOOTING l n 43 8 WIRING DIAGRAM OF THE APPLIANCE n n 45 9 WARRANTY CONDITIONS nn nnns 47 25 35 45 3 CONTENT 1 INFORMATION RELATED TO THE USERS SAFETY The manual book for operation of combined wood gasification hot water boiler from series is designated for users and authorized servicing specialists The user must know that All activities related to the heating installation must be performed only by authorized installers which have acquired legal rights for such activities from the local authorities All activities related to the electrical installation must be p
5. 3Fera 25 35 45 46 Figure 8 2 Schematic wiring diagram of the appliance control board 9 WARRANTY CONDITIONS The warranty period of combined wood gasification hot water boiler from series starts considered from the date of completing and stamping its warranty card THE PRODUCT WARRANTY IS NOT VALID in the following situations Damages over the appliance caused by improper storage transport and or unloading which are not organized by the manufacturing company Failures caused by natural disasters earthquakes fire floods and others The requirements for installation operation and periodical maintenance presented in the current manual book are not observed Attempts for removing any defect performed by the buyer or other unauthorized persons Changes over the appliance construction Incorrect heating calculations and project design for mounting and installation of the boiler Failures for which the manufacturing company is not responsible which are not under its control Malfunctions and damages which are not caused by the boiler itself but have led to failure in its construction Every warranty repair must be written in the product warranty card The warranty period is interrupted for the period of time from the date of registering the warranty claim up to removal of the failure The warranty period of the product is 24 twenty four months The warranty is valid only when the purchase in
6. assigned temperature value High heating output of the boiler It is necessary to decrease the fuel quantity or the firewood refuel frequency of the boiler 3 Overheating of the boiler Lack of heating load or incorrect adjustment of the boiler heating output or the operation of the heating installation Correct operation inspections must be performed over the heating installation and eventually adjustment of the operation parameters to be performed by specialist After cooling of the appliance and removing the problem source the emergency thermostat must be deactivated remove its protection cover press the button and put the cover back and after that the boiler can be started again 4 The flame is dark and the chimney smokes dark Low quality fuel moisture more than 20 Fuel replacement is required whit such that corresponds to the required parameters Improper adjustment of the appliance parameters Adjustment of the appliance air distribution is required 5 Presence of unburned fuel in the fuel chamber Inefficient fuel burning Adjustment of the firing air distribution is required 6 High flue gas temperature if a thermometer is Dirty heat exchanging surfaces Cleaning of the boiler s heat exchanging surfaces is required 3Fera 25 35 45 43 installed 7 Condensation of the water vapors over the combustion chamber heated s
7. installation of additional flue gas extraction fan and or change of the chimney thermostat 11 Another not presented Consultation with and or failures intervention of servicing technician is required 3Fera 25 35 45 44 8 WIRING DIAGRAM OF THE APPLIANCE The wiring diagrams for connecting combined wood gasification boiler from series 3Fera are presented on Figure 8 1 and Figure 8 2 Figure 8 1 Schematic wiring diagram for connecting the appliance to the main power supply Motors thermostat plates 2 220V Overheat 3Fera 25 35 45 45 sensor presence of burning process input flame sensor I3 Start I6 Manual ignition amp only wood gasification combine process POWER SUPPLY UNIT I8 sensor pellets level capacitive sensor POWER STEP PS 1AC 24DC 0 5 Ll 1 T A emergency thermostat alarm thermostat H O SUPPLY UNIT PHOENIX CONTACT 220V T W operation thermostat boiler thermostat 24 V St 24V St T R room thermostat GERMANY 2 3 24 V St m TR SB2 Capacitve Oo D 6 E 8 Sensor TW P option L1 1 220Vac 7 D 24 V St 24V St PROCESS CONTROL 1 SB1 Start SB2 Manual ignition amp only pyrolisis combine process 220Vac 220 2 4 24V St Alarm Manual External pellet transport auger ignition Flue gas Fe g a I amp 2 OK extraction option air fan
8. is stopped from operation entire cleaning of the ash residues over the heat exchanging surfaces of the boiler must be performed because the ash has corrosive influence over the steel surfaces which decreases the appliance life At the end of the heating season it is necessary to perform not m only cleaning but also prophylaxis by specialized servicing company which evaluates the boiler condition and may take further measures for repairs and parts replacement The prophylaxis provides availability for inspectional checks and evaluation of the appliance and also to perform measures for replacement of defective and worn modules or components Observance of these procedures provide longer life and reliable operation of the boiler 6 7 1 BOILER EMERGENCY SHUT DOWN During the boiler operation emergency situations are possible to occur exceed of its tolerable operation temperature this is followed by activation of the emergency thermostat which activates if the boiler is overheated and also the Emergency overheating indication lamp positioned on the boiler s control panel lights It is necessary to take measures for removing the reason for overheating and for gradual cooling After the boiler cools down its emergency thermostat cap has to be removed and the button inside has to be pressed by using sharp tool in order to switch it on again and finally the protection cap must be placed back in primary position The boiler must be in
9. manufacturing company method A AB B BC C CD E EF Dry calibrated wood chips category according to standard EN 14961 1 Annex 2 P16 M10 0 7 Firewood consumption at kg h 7 9 11 1 14 2 nominal heating output Wood pellets consumption kg h 56 78 10 1 at nominal heating output Dry calibrated wood chips consumption at nominal kg h 6 1 8 6 11 0 heating output Sce at nominal 93 0 93 0 93 0 eating output Wastes from the fuel ash The quantity depends on the fuel ash content burning The dimensions and technical parameters of combined hot water boiler from series 3Fera are presented in Table 3 2 3Fera 25 35 45 Table 3 2 Dimensions and technical parameters of combined hot water boiler from series SFera Parameter Dimension Value Boiler model 3Fera 25 3Fera 35 3Fera 45 Weight kg 418 438 485 Fuel chamber volume 120 160 160 Water volume 126 150 200 Overall size of the boiler WxHxL mm 800x1100x1150 800x1100x1250 800x1200x1250 Max operating pressure bar 2 0 Recommended operation water 80 85 temperature Minimum temperature of the inlet C 60 water Chimney draught Pa 18 24 Supply voltage 50Hz 230V Expansion tank type in the _ Opened or closed installation Environment protection index IP20 IP20 IP20 Connection Inlet outlet water li G 11 2 inks pipes Drain pipe G 1 2
10. mounted and a wall must be at least 400 mm 3Fera 25 35 45 17 o The minimum distance from the left and right sides of the reserve fuel transport auger to a wall must be at least 500 mm in order to ensure free access to its manhole cover and to the boiler rear side as well o The minimum free area above the fuel transport auger must be at least 600 mm in order to ensure easy access for servicing of its control components and to its gear cover After the boiler has been positioned at its designated place the following activities for its equipment and preparation must be completed Mounting and positioning of the fireclay component in the boilers combustion chamber Figure 5 1 and Figure 5 2 Figure 5 1 Directional fireclay made component which must be positioned in the boiler s combustion chamber Figure 5 2 Picture of correctly positioned directing fireclay made component mounted in the boiler s combustion chamber 3Fera 25 35 45 18 Installation of the firing air flow rate thermo regulation valve Figure 5 3 Figure 5 3 Thermo regulating valve for the firing air flow rate adjustment The thermo regulation valve for the firing air flow rate is mounted and is linked with a chain which moves the flap for regulation of the boiler air intake Installation of the safety temperature valve that supplies water for emergency cooling of the boiler in case the circulations water
11. of the upper limit of the circulations water temperature hermo manometer serves for indication of the circulations water temperature and pressure Operation mode switch operation as normal wood gasification boiler or as combined operation with firewood and after its complete burning the system automatically switches to reserve fuel operation Controller module for management of the boiler operation serves for boiler management according to preliminary installed program Alarm overheating serves for indication of the emergency thermostat activation due to exceeding of the emergency temperature of the water in the boiler overheating Controller alarm interference during operation serves for indication of failure alarm and emergency situations Ignition OK indicates operation and lights in presence of burning process 3Fera 25 35 45 26 An interface panel with connectors is mounted on the back side of the combined wood gasification hot water boiler from series 3Fera Figure 6 2 Figure 6 2 Interface panel with connectors of hot water boiler from series 3Fera Interface panel components and their functions Flue gas extraction fan connector for plugging the flue gas extraction fan External auger option connector for plugging additional auger Combined fuel transport auger option connector for plugging the auger Switch POWER serves for centra
12. restart the appliance and the alarm will reset automatically 6 5 PARAMETERS FOR ADJUSTMENT OF THE BOILER OPERATION 6 5 1 OPERATION OF THE BOILER WITH FUEL MANUAL REFUELING WITH FIREWOOD For this operation mode the switch POWER must be ON The mode switcher is in wood logs gasification mode pyrolisys then the switch START must be on the flue gas extraction fan starts to operate the wood logs must be fired manually The lighting of the green lamp after period of time when the flue gasses reach certain temperature is a signal that stable burning process is achieved The boiler operation thermostat has to be positioned between 65 C 80 C and the contact from the room thermostat has to be closed If a room thermostat is not installed its connector must be left in the interface panel d plug with a brindle the brindle is factory installed and has to be removed if a room thermostat will be installed The firing air flow rate is essential about the boiler operation mode and its efficiency when the air quantity is less than the optimum this insufficiency leads to incomplete fuel combustion and also to separation of health harmful substances in the flue gasses one of the harmful emissions is the carbon oxygen When the air consumption is higher than the optimum it leads to cooling of the burning zone and again to incomplete fuel combustion Therefore the necessary air quantity has to be supplied to the boiler The
13. temperature has been exceeded above the limits The temperature safety valve s sensor has to be screwed in a muff positioned at the upper part of the boiler heat exchanger The temperature safety valve s operation module must be screwed in one of the two ends depending on the installation availability of the emergency cooling boiler tube serpentine Figure 5 4 The inlet side of the temperature safety valve must be linked to the water supply pipeline that supplies fresh clean water or to another source of clean water under pressure The outlet side of the emergency cooling boiler tube serpentine must be linked to a drain pipe so the outlet water can easily and safely flow to the sewers 3Fera 25 35 45 19 Figure 5 4 View of the boiler with shown ends of the emergency cooling boiler tube Serpentine Emergency cooling boiler tube input output The inlet and outlet pipelines of the heating installation must be connected to the relevant boiler muffs Figure 5 5 Figure 5 5 View of the boiler with shown muffs for connecting to the heating installation and its outlet to the chimney Positioning of the boiler in compliance with the requirements for connecting to the electrical supply network the appliance must be positioned so free access to the socket box is guaranteed 230V 50Hz 3Fera 25 35 45 20 The completion of the installation works and the hot test of the boiler mu
14. that if the boiler has been operated more continues without attendance of the 3Fera 25 35 45 24 servicing personal the firewood in the fuel chamber may overarch and eventually to block the fire nozzle inlet which reflects the burning process and decreases the boiler heating output Therefore it is recommended to stir the fuel in the chamber the coals also periodically and to clean the nozzle orifice by using specialized tool rabble by observing the personal safety measures Such actions will improve the burning and wood gasification processes 6 3 1 ADJUSTMENT OF THE FIRING AIR FLOW RATE THERMO REGULATION VALVE The thermo regulation valve for adjustment of the air quantity needed for effective burning process must be adjusted when the boiler operates at nominal heating output The thermo regulation valve serves for adjustment of the air quantity needed for achievement of effective burning process This valve also serves as protection from overheating The valve indicates the circulations water temperature in the boiler by changing the position of a lever from its construction When the water temperature is low the lever opens the air regulation flap and when the temperature starts to increase the lever moves and partially closes the flap i e the TRV does not need outer energy source for operation The position of the firing air flap moved by the thermo regulation valve can be checked visually The thermo regulat
15. In case of necessity the system can be refilled toped up with water but only when the boiler is in cold condition This is necessary in order to prevent the steel made heat exchanger of the boiler from damages caused by thermal stresses by the intake of cold water In case the boiler and the heating installation will not be operated for long period of time and there is possibility of local circulations water freezing then it is recommended to drain the water out of the system It is also good to know that the presence of water in the heating installation and the boiler protects the steel surfaces from contact with the air oxygen and respectively from corrosion 3Fera 25 35 45 23 6 3 INITILIZATION OF HOT WATER BOILER FROM SERIES 3Fera IN OPERATION The following requirements must be observed during initialization of combined wood gasification hot water boiler from series 3Fera The boiler servicing handling must be performed in compliance with the maintenance and operation manual The boiler must be serviced handled only by adult people which are well familiar with the operation manual of the appliance A Presence of children near the boiler is not allowed intervention over the boiler operation which may lead to danger for the servicing personal health or other indirectly related persons is not allowed Incase easy flammable gasses may penetrate come in the boiler room also during repairs which can b
16. adjustment of the burning process is performed by adjustment of the firing air flow rate and its distribution The firing air is sucked to the fuel chamber and to the combustion nozzle by the flue gas extraction fan This air is distributed through a manifold where it is being preheated and then transferred to the fuel chamber this is the so called primary air and the combustion nozzle the so called secondary air The adjustment of the primary and secondary air distribution ratio is performed by a regulation flap positioned over the firing air flap inlet The primary air which is sucked to the fuel chamber is used for the wood gasification process The secondary air is used for burning of the combustible volatile gasses separated from the wood gasification process and transferred through the boiler s nozzle The firing air distribution ratio adjustment can be performed by changing the position of the primary air regulation flap and also by the common air quantity regulation flap consummated for the burning process A small movement of the flap significantly affects the primary air quantity i e the adjustment is very sensible Therefore every change of the firing air adjustment must be performed very carefully and to wait enough time at least 30 minutes so the change influences the boiler operation mode If fuel with higher moistureis used the primary air has to be increased by opening the primary air flap gradually step by step wh
17. ciency This may also lead to condensation of the water vapor which is final product from the fuel combustion Continues operation of the appliance with heating output below the minimum as presented in the boiler specification is not recommended because such operation modes are not efficient and economic and may also create conditions of excessive harmful and hazard chemicals separation mainly carbon oxide which might endanger the people s life and also to decrease the appliance resource tars which condensate over the heat exchanging surfaces and cause corrosion In nominal heating output operation the boiler has to be refueled periodically by performing the following procedure Wait for around 5 10 seconds after that open the fuel chamber door It should be opened on stages First open it slightly to get a small gap through which the surrounding air can flow in but do not allow extraction of flue gasses out of the door After that open the fuel chamber door completely and refuel with firewood The refueling should be performed carefully keep the skin from burning or and intake of gas It is recommended to work with personal safety equipment The firewood has to be loaded in the chamber parallel and longitudinal to the firing nozzle so the chamber volume is filled to maximum Before loading the new fuel it is recommended to mix the burning remains 3Fera 25 35 45 36 around the nozzle in order to ensure free gas flow through it
18. door lower boiler door and quick assessment of the flame color After that the door must be closed The flame coming down from the nozzle must reach the directing fireclay component positioned on the bottom of the combustion chamber The flame color at optimal burning process process realized with low excess air and minimum harmful emissions concentration in the flue gasses mainly carbon oxygen CO nitro oxygen NO and unburned carbon hydrogen is deep yellow with bluish blue areas In case the flame is Deep red this shows insufficient secondary air it is necessary to increase the secondary air flow rate by opening the flap Bright yellow or with small length this is indication for excessive secondary air and its flow rate has to be decreased by gradual closing of the common air regulation flap driven by the chain of the thermo regulation valve Flame with low intensity slow flame indicates that the primary air flow rate has to be increased the primary air regulation flap has to be opened gradually Smoke in the flame indicates insufficient secondary air and increased production of combustible gasses and tars Therefore it is necessary to decrease the primary and increase the secondary air flow rates after waiting for a period of time this is performed by closing the primary air regulation flap move its shaft gradually towards the boiler Criterion for optimal combustion is the conditio
19. e accompanied by separation of gas for example coating with flammable paints and materials flooring the boiler must be shut down from operation During the boiler operation it must be periodically checked by the servicing handling personal the user user must not perform repairs over the appliance In case of failure during the boiler operation the solution can be found in the troubleshooting table presented in this manual or eventually to ask for assistance by servicing company changes over the boiler construction and electrical installation are strictly forbidden Usage of unspecified for the boiler fuel is forbidden Increasing the boiler heating output over its nominal output and also its overheating are forbidden Positioning of easy flammable materials near or next to the boiler at distance shorter than the safe is forbidden ash residues from the burning process must be collected in fireproof containers with covers and after cooling to ambient temperature they must be dumped at proper for the purpose places During the ash removing from the boiler presence of flammable materials at distance less than 1500 mm from the appliance is not allowed The ash from firewood utilization can be used for soil fertilization After every heating season the boiler and the chimney to which it is connected must be cleaned from the ash soot and tar deposits The period length of burning depends on the operat
20. e the heating output and the operation mode of the appliance for the relevant fuel wood pellets or dry calibrated wood chips If the fuel type is changed the parameters T4 C1 and T7 should be changed too 3Fera 25 35 45 35 6 6 ADJUSTMENT OF THE BOILER HEATING OUTPUT 6 6 1 OPERATION MODE DURING FIREWOOD UTILIZATION After completion of the boiler starting process the fuel is successfully fired stable process of fuel gasification is monitored and stable fuel burning process in the combustion chamber the boiler has heated the circulations water and the heating installation is equally tempered it can be accepted that the appliance is in nominal operation mode In such mode the burning process and other control elements can be adjusted In such mode the circulations water temperature in the boiler must be in its operating range from 65 to 85 C It has to be rendered into account that the boiler refueling is manual and is required periodically which might lead to slight imbalance change of its operation parameters as well as to the heating system in dependence on the refueling frequency and the fuel quantity If a circulations pump is used for transferring the heat energy from to boiler to the heating installation the reverse water temperature cooled water from the system should not be lower than 60 C because it is possible to cool down the flue gasses in the boilers heat exchanger and to decrease significantly its effi
21. erformed only by electricians The initialization of the appliance in operation including visual check of the heating installation adjustment and boiler start up must be performed by certified technician authorized by the manufacturing company representatives Please observe the following rules during installation initial start up adjustment and operation initialization of combined wood gasification hot water boiler from series 3Fera All legal provisions related to the safety techniques Environment protection provisions Installation initial start up and adjustment provisions The harmonized EU provisions applicable in the relevant country Please strictly observe the presented safety instructions in order to avoid risks and harms to people properties as well as to environment polluting Please pay attention to the following symbols from the current manual book 3Fera 25 35 45 4 2 DESRIPTION AND ADVANTAGES OF COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES 3 Fera The steel made combined wood gasification hot water boilers from series 3Fera are designated for heating and or providing hot domestic water of single family houses offices business buildings and others The boiler represents welded steel construction optimized for high efficiency and economic operation and also for easy servicing and cleaning The reliable steel made construction of the boiler is specially designed for firing o
22. es SFera with shown flue gas and ash directions WteTeTaYuTeTaY wv sig 2 i Me F 3Fera 25 35 45 13 Figure 4 5 Overall sizes of combined wood gasification hot water boiler from series 3Fera 800 1223 1221 Exploded view of the combined fuel transport auger offered as an option used for feeding combined wood gasification hot water boilers from series 3Fera operating with reserve fuel wood pellets or dry calibrated wood chips is presented on Figure 4 6 3Fera 25 35 45 14 Figure 4 6 Exploded view of combined fuel transport auger 1 Cover 7 Pipe 2 Chain gear auger 8 Auger Screw 3 Chain gear flap 9 Shut down device 4 Chain tensioner 10 Moving cover 5 Sectioned dozing flap 11 Motor gear 6 Body Figure 4 7 presents the dimensions of combined fuel transport auger for feeding of combined hot water boilers from series 3Fera with wood pellets or dry calibrated wood chips 3Fera 25 35 45 15 Figure 4 7 Dimensions of combined fuel transport auger 125 25 35 45 16 5 MOUNTING AND INSTALLATION OF THE BOILER The following requirements must be observed during the mounting and installation of combined wood gasification hot water boiler from series 3Fera The room designated for the boiler installation must provide constant air intake which is needed for the burning pr
23. f dry wood with moistureup to 20 and for other type reserve fuel wood pellets or dry calibrated wood chips by fuel gasification with maximum efficiency economic operation and easy servicing Its manual initial firing and the automatic switching to reserve type of fuel provide comfort approaching the electrical heating diesel fuel or natural gas heating The generated heat energy is acquired by the boiler body heat exchanging surfaces and is transferred to the heat carrier in most cases circulations water in the heating installation or to the hot domestic water system The appliance can utilize the following types of fuels Firewood with the following parameters o Clean firewood Usage of materials with improper impurities as paint lacquer coatings organic or non organic substances is not applicable o The firewood logs length must correspond to the boiler fuel chamber depth o Thecross cut diameter of the firewood must be D lt 200mm o The fuel moisturemust be W lt 20 Wood pellets with diameter 6 8 mm category ENplus A1 ENplus A2 and ENplus B according to standard EN 14961 2 2010 or category A AB B BC C CD E EF according to the methodic developed and used by the appliance manufacturing company Dry calibrated wood chippings with main fraction size P 20mm moisture W s10 0 and ash content A S2 0 This fuel must correspond to the requirements of standard OENORM M7133 G30 W10 ash class A1 or A2 Acc
24. ich will ensure optimal wood gasification process The adjustment of the boiler heating output parameters must be performed by trained user personal and in order to achieve it a gas analyzer should be used The primary air flow rate which can be adjusted by changing the flap position determines the quantity of air needed for maintaining the wood gasification process of the fuel loaded in the upper boiler chamber The flap is used to regulate the intensity of wood gas separation and respectively its adjustment partially reflects the boiler heating output 3Fera 25 35 45 32 The secondary air flow rate can be changed by changing the primary air flap position By opening it the primary air flow rate increases and the secondary air decreases The air is transferred through the preheating box then through the nozzle orifices and mixes with the combustible gasses separated from the wood gasification which results in optimum combustion and production of heat energy The total air quantity sucked by the boiler is determined by the flap position driven by the thermo regulation valve The valve changes the common air regulation flap position its tilt by chain The burning process adjustment must be performed by trained specialist and gas analyzing device For primary adjustment of the burning process it is necessary to perform visual evaluation of the flame color it is performed by slightly opening of the combustion chamber
25. iod it reaches high values which leads to clogging of the chimney pipelines and sensible decrease of the chimney draught 3Fera 25 35 45 40 Figure 6 7 Cleaning of the boiler s tube bundle and fire grate 1 Inlet for cleaning of the boiler s tube bundle 2 Fire grate The tube bundle cleaning has to be performed with steel brush by carrying it through the top opening to the bottom of the tract At the end after the cleaning the ash residues have to be scraped out from the boiler s tube bundle bottom zone 6 10 USER INTRODUCTION TO THE SERVICING AND ADJUSTMENT PROCEDURES OF THE BOILER The user must be well introduced to The appliance operation manual How to operate the appliance How to adjust and regulate the boiler The methodic for servicing handling of the boiler How to clean the combustion and fuel chambers How to clean the boiler s tube bundle 6 11 SAFETY AND UNPREDICTED RISKS Risks related to the appliance usage The combined wood gasification hot water boiler from series 3Fera is designed and manufactured in compliance with the major safety European standards and directives 3Fera 25 35 45 41 Danger conditions may occur in the following situations The combined wood gasification hot water boiler from series 3Fera has been improperly used appliance is installed by unqualified personal The instructions for safe usage presented in this manual are not obse
26. ion mode and also on the used firewood quality The resinous wood with medium and low quality may lead to excessive tar contamination of the fuel chamber The fresh wood material which is not dried to the required parameters has low caloricity and respectively leads to increased fuel consumption compared to the nominal consumption and also to sensibly lower boiler heating output This type of fuel may also lead to excessive contamination of tar deposits and corrosion of the heated surfaces The combined wood gasification hot water boiler from series 3Fera is appliance with manual loading of the primary fuel firewood Its heating output depends not only by the fuel characteristics mostly its water content but also by the operating mode Practically effective wood gasification process in such type of boilers can be achieved if the circulations water in the boiler heat exchanger is over 60 C Therefore such conditions must be provided during its operation If the circulations water temperature is lower it leads to decreased intensity of burning gas separation from the wood and also to condensation of these gasses over the heat exchanger unit walls This is highly unpleasant process with regards to the boiler life time because the tar condensation have corrosive influence and this process leads to decreasing the boiler walls thickness respectively its life time in other words it leads to leaks from the heat exchanger unit The practice show
27. ion valve adjustment can be performed by the following method The boiler operates until the circulation water reaches 80 C indicated by the thermo manometer gauge positioned on the front control panel of the boiler The handle position of the thermo regulation valve must be adjusted to temperature value equal to the boiler circulations water The chain has to be adjusted which connects the TRV lever with air regulation flap by moving its hook so the flap is opened but to position limited by the screw that provides the minimum clearance of the flap The chain must be stretched f it is necessary to adjust the minimum firing air flap opening clearance as it can be performed by the adjusting screw 3Fera 25 35 45 25 6 3 2 INTERFACE CONTROL PANEL OF HOT WATER BOILER FROM SERIES 3Fera The management of combined hot water boilers from series 3Fera can be performed by its interface control panel equipped with controlling and managing devices and with interface panel with connectors Figure 6 1 represents the interface controller front panel for management of hot water boilers from series 3Fera Figure 6 1 Interface control panel with controlling and managing devices for hot water boiler from series Interface panel components and their functions START serves for submitting START STOP command to the control module Operation boiler thermostat is used for assignment
28. l boiler ON and OFF switching Emergency thermostat serves for overheating protection of the boiler Factory adjusted to close when the boiler water temperature exceeds 95 C Room thermostat connector for plugging a room thermostat to the boiler Power supply connector for plugging the boiler to the main electrical supply eno po c 6 3 3 BOILER POWER SUPPLY The boiler must be connected to electrical power supply installation by observing the safety technique rules Before the manual firing of the initial firewood in the fuel chamber of the boiler it is necessary to check the boilers components modules functionality which provide its reliable operation and to the heating system s also o Flue gas extraction fan o Firing air flap o Position and condition of the directing fireclay made component located in the boiler combustion chamber 3Fera 25 35 45 27 o Thermo regulation valve for adjustment of the firing air flow rate and also its adjustment Managing and indication devices functionality thermostats thermo manometer Doors sealing Circulations pump if installed in the heating installation Combined fuel transport auger O OQ O O The fuel chamber has to be loaded with small quantity of firewood sticks dry sticks branch timber wood splinters by forming a pile over the nozzle zone positioned in the lower part of the fuel chamber It is recommended that the total weight of the wood
29. n of the directing fireclay component mounted in the boiler s combustion chamber its surface must be white to light grey color the ash deposits quantity should be relatively little without presence of unburned particles coals and others or dark colored wooden particles The burning process adjustment can be also evaluated by monitoring the smoke color exhausted from the chimney to which the boiler is connected If the smoke is dark it means that the secondary air is not enough or the fuel moistureis high The chimney smoke is usually visible as mainly the sun lights break through it due to the smoke gas higher temperature compared to the environment In other cases when the temperature is below 10 C it is possible to monitor 3Fera 25 35 45 33 condensation of the water vapors in the flue gasses which is visualized as white smoke coming out from the chimney 6 5 2 OPERATION OF THE BOILER IN COMBINED MODE AUTOMATED FEEDING WITH WOOD PELLETS OR DRY CALIBRATED WOOD CHIPS The main parameters which take part in the adjustment of combined wood gasification hot water boilers from series 3Fera are presented in Table 6 1 Parameters change should be performed only by authorized technicians which are well familiar with the appliance operating processes 3Fera 25 35 45 34 Table 6 1 Main operation parameters determining the appliance heating output in combined fuel feeding mode Parameter Description 3Fe
30. n the range of 65 C 80 C in order to prevent the appliance from low temperature corrosion 3Fera 25 35 45 29 6 4 CHANGING THE BOILER OPERATION PARAMETERS Outside view of the boiler s interface panel control module is presented on Figure 6 3 Figure 6 3 Outside view and notation of the control module buttons 5 dea In the next lines is presented the algorithm for visualization and relevant change only if necessary of parameters from the customer allowed access group 1 Press the green button e marked as Menu OK on the controller A list of menus appears 2 With buttons arrow up V or down A from the menu choose the option PARAMETER 3 Arrow up A must be pressed several times until reaching the desired timer for T4 or T6 these are the parameters defining the appliance heating output 4 With button arrow right f choose the field in which the time is marked the value of the chosen parameter the digits start blinking i e they expect change 5 With button arrow down V or up A the value can be changed Note If the buttons arrow down V or up A are hold continues the values start to change quicker 6 After adjusting the desired time the button Menu OK must be pressed 7 the control module display appears message CONFIRM CHANGES By the arrows down V or up A position the mark over Yes or No Choose Yes by pressing the green but
31. ocess and for good ventilation Installation of the boiler in living premises including corridors is not allowed The boiler connection to the heating installation must be performed only by qualified technician The installation and maintenance of solid fuel hot water boilers must be performed by specialized companies which have acquired legal rights for performing such activities The combined hot water boiler from series can be connected to the heating system with opened or closed expansion tank which has to be calculated during the installation project development The combined hot water boiler from series 3Fera is connected to the heating system with OPENED or CLOSED expansion tank type In case the system is with closed type expansion type a safety pressure valve must be installed which opens if the boiler operation pressure exceeds 0 25MPa This valve must be certified according to PED 97 23 Before initialization of the boiler in operation the entire heating installation must be filled with water and air freed eliminate the air The boiler servicing handling must be performed only by adult persons which are well familiar with the appliance operation manual During the boiler transportation precaution measures must be taken against damage or braking of the fireclay component which is positioned in the boiler s combustion chamber The boiler installation requires preliminary developed project c
32. omplying with the acting norms and prescriptions For the heating system BDS EN 303 5 2000 Central heating hot water boilers part 5 hot water solid fuel boilers with maximum nominal heating output up to 300 kW terminology requirements tests and notation For the chimney Fire safety prescriptions For the electrical supply system BDS EN 60 335 1 1997 Safety of domestic electrical appliances The opened area for supplying the boiler room with fresh air must be at least 0 04 m The positioning of the boiler for easy manipulation without combined fuel transport auger which is offered as an option must comply with o The boiler must be positioned over inflammable pad with minimum height of 50 mm o The minimum distance for manipulation in front of the boiler must be 1000 mm o The minimum allowed distance between the boiler rear side and a wall must not be less than 400 mm o The minimum distance between the boiler left and right side to a wall must be 500 mm in order to ensure free access to its side cover panels and its rear side o The minimum distance of the free area over the boiler must be at least 600 mm in order to ensure easy access to its control components and cleaning of the convection pipeline Positioning of the boiler and the combined fuel transport auger for feeding of reserve fuel o The minimum allowed distance between the rear side of the hopper storage container in which the fuel transport auger is
33. on to the heating output of hot water boiler 3Fera 45 Tanvironment AT Ratio T4 T6 Heating output Seconds Wood 5 Wood Dry Wood E pellets calibrated pellets calibrated pellets calibrated wood chips wood chips wood chips 15 85 0 200 0513 30 77 10 30 0 150 0385 23 58 ose 23 59 24 0 20 0084 0218 13 33 15 15 35 0 253 0660 38 99 45 15 fe Tooms average temperature in the heated premises C Tenvironment environment temperature C AT Trooms environment temperature load C The parameter values defining the boiler s heating output are determined in operation with fuel that comply with the requirements presented in the boiler s technical data table In case the fuel is from another type size or water content then these parameters have to be changed by observing the adjustment requirements presented above At the same time other parameters may need adjustment for example the values of parameters T4 C1 and T7 6 7 STOPPING THE BOILER OPERATION The boiler operation can be stopped by the switch START In presence of glowing embers the boiler operation can be restored by switching on the same switch In case there are no more glowing embers in the fuel chamber that can ignite the new loaded fuel then it is necessary to fire the boiler manually 3Fera 25 35 45 38 In case the boiler
34. ording to the European standard for solid bio fuels EN 14961 1 2010 Annex 2 P16 M10 0 7 or A1 5 BD200 The standard equipment of combined hot water wood gasification boiler from series 3Fera includes Hot water wood gasification boiler from series 3Fera 1 unit Directing fireclay made component for the combustion chamber 1 pc Thermo regulation valve for the firing air flow rate 1 pc Steel made cleaning brush 1 pc Steel made cleaning scraper 1 pc User manual book for installation and operation of wood gasification hot water boiler utilizing firewood wood pellets and dry calibrated wood chips 25 35 and 3Fera 45 1 pc The appliance consists of Steel made heat exchanging unit for heating of the heat carrier Flue gas extraction fan for extracting the flue gasses out of the boiler Refueling chamber Fireclay combustion chamber Convective heat exchanging module tube bundle in which the firing air is preheated Control board for monitoring and controlling of the appliance 3Fera 25 35 45 5 Mineral wool heat isolation The appliance is equipped with Thermo manometer temperature pressure gauge for monitoring the operation parameters of the circulations water Thermostat for controlling the flue gas extraction fan operation Thermostat for indication of the boiler operation mode and the necessity for cleaning it is offered optionally Emergency
35. particles used for initial firing should be around 5kg The nozzle should be monitored in order to prevent its blocking which may disrupt the wood gas flow through it after firing of the wood material 6 3 4 BOILER SWITCH ON Before switching on the boiler it is necessary to check if the fireclay component is positioned correctly in the boiler s combustion chamber centered and backed to the rear wall The combined wood gasification boilers from series 3Fera operate in two different modes Operation with firewood Combined operation mode The desired operation mode of the boiler can be chosen with the mode switch firewood mode combined mode from the boiler s interface control panel In firewood mode the process starts by manual firing of the wood logs and by pressing the switch Start in position Firewood In Combine mode the process starts by manual firing of the wood logs and by pressing the switch Start in Firewood position After the green indication lamp lights that registers a burning process the mode switcher has to be switched to Combine mode After complete burning of the wood logs the system automatically switches to reserve fuel operation If after that it is necessary to operate with wood logs again the mode switcher must be positioned in Firewood mode After good inflammation of the wood logs the mode switcher can be positioned in Combine mode again and
36. pliance it is recommended to adjust it according to the heat consumption which will be covered The heating output which is necessary for providing constant heat comfort in the premises can be considered as lineal function from the temperature load AT the difference between the average rooms temperatures and the environment temperature Therefore a periodical adjustment of the appliance operation parameters should be performed in case of necessity The formulation of the below presented data is based on average rooms temperature of the heated premises T ooms 20 C The T4 parameter value is determined in condition that the value of parameter T6 is constant Table 6 2 Adjustment of the parameters T4 and T6 in relation to the heating output of hot water boiler 3Fera 25 Tenvironment AT Ratio T4 T6 T4 Heating output Sens Seconds Wood Dry Wood Dry Wood Dry C C pellets calibrated pellets calibrated pellets calibrated wood chips wood chips wood chips 25 is o 2 005 ore os 20 3Fera 25 35 45 37 Table 6 3 Adjustment of the parameters T4 and T6 in relation to the heating output of hot water boiler 3Fera 35 Tanvironient AT Ratio T4 T6 Heating output MEL Dry Wood Dry pellets calibrated pellets calibrated pellets calibrated wood chips wood wood chips 8 je HI 0 20 0062 0159 09 24 n Table 6 4 Adjustment of the parameters T4 and T6 in relati
37. quality of the used fuel directly influences the ash residues quantity and respectively the necessity for cleaning 3Fera 25 35 45 39 Before cleaning the appliance must be shut down and cooled to room temperature for prevention of skin burns The ash must not contain glowing coals which can cause fire Before complete cleaning of the appliance it is recommended to switch off its power supply The cleaning of the boiler from the accumulated ash resulting from the wood utilization has to be performed periodically which ensures its high efficiency and reliability The cleaning of the combustion chamber and the fire grate is mandatory before every firing and refueling and or on several days depending on the utilized fuel quantity and the boiler operation mode The tools for cleaning the ash residues from the boiler are presented on Figure 6 6 Figure 6 6 Tools scraper and brush for cleaning the ash residues from the boiler Cleaning of the heat exchanger tube bundle is recommended on a 1 month period by rendering in account the boiler operation mode and the utilized fuel quantity Figure 6 7 The practice shows that significant part around 30 40 from the mineral mass ash is carried away by the flue gasses this leads to fine particles depositing on the boiler s tube bundle and also on the flue gas extraction fan s operation wheel At first sight this quantity looks relatively little but for longer per
38. quids according to standard BDS 15207 81 During the heating season it is necessary to keep constant water quantity in the heating system Refilling with water should be performed carefully in order to prevent access of air to the system The circulations water must be used only for its designation It is not allowed to drain the water out of the boiler or the system except in case of repairs In case the heating installation is designed with closed expansion tank then the following should be taken into account the heating systems with closed expansion tank are systems operating under pressure and do not allow direct contact between the circulations water and the surrounding atmosphere Therefore such systems are not endangered by intake of air from the atmosphere Such systems are under pressure and it must be controlled so they can function without failures not only the exceeded pressure is dangerous because the mechanical components loads increase and the possibility for defects increases but also the pressure decrease could lead to the system improper functioning even to absorb air from the environment Therefore it is necessary to keep constant pressure of the water in the heating system The circulations water must be used only for its designation It is not allowed to drain the water out of the boiler or the System except in case of repairs It is recommended to check the water pressure the heating system on every 14 days
39. ra 25 3Fera 35 3Fera 45 Pellets Chips Pellets Chips Pellets Chips T4 impuls in RUN Period of time for fuel feeding in operation mode sec 2 1 5 5 3 7 7 3 8 9 9 T6 Pause in RUN Period of time for fuel feeding pause in operation mode sec 15 15 15 15 15 15 A1 Flame OK Registered flame This parameter could be locked protected 1 3 1 3 1 3 1 3 A2 NO good flame Unstable flame This parameter could be locked 0 9 0 9 0 9 0 9 0 9 0 9 C1 Number of cycles before cleaning Number of cycles before afterburning pause self cleaning 100 250 100 250 100 250 T2 Ignition pellet impuls Impulse fuel for ignition sec T3 Ignition pellet pause Pause fuel for ignition sec 20 20 20 20 20 20 T7 Limitation in pilot flame Time limiting for feeding in smoldering mode sec 05 0 7 0 7 0 7 TA No feeed for cleaning Holds fuel feeding during self cleaning sec 200 200 200 200 200 200 TC Delay flame OK Time delay when a flame is registered sec 60 60 60 60 60 60 TD NO good flame Time delay when there is no flame sec 30 30 30 30 30 30 The values of the presented parameters 4 and T6 are most frequently changed they determin
40. roduct life cycle its extermination has to be performed in protective for the environment way Its modules must be disassembled and transferred to second raw material redemption stations by observing the principles for separate collection of wastes 3Fera 25 35 45 42 7 FAILURES AND TROUBLESHOOTING Table 7 1 Description of the possible boiler operation failures and their troubleshooting No Failure Reason Troubleshooting 1 Low temperature in the heated premises Insufficient heating output It is necessary to decrease the time between two refuels or and to increase the firweood quantity Heating output adjustment of the boiler is required Check the fuel moisture and if necessary replace it with drier Low temperature assigned to the operating thermostat of the boiler It is necessary to increase the operating thermostat assigned temperature value the maximum recommended is up to 90 C Low temperature assigned to the room thermostat if connected It is necessary to increase the room thermostat assigned temperature value 2 High temperature the heated premises High temperature assigned to the operating thermostat of the boiler It is necessary to decrease the operating thermostat assigned temperature value the minimum recommended is down to 60 C High temperature assigned to the room thermostat if connected It is necessary to decrease the room thermostat
41. rved Unpredicted risks The appliance is designed and manufactured in compliance with the acting safety standards Although all possible risks resulting by its improper usage are preliminary considered it is possible that the following situations may occur Risks of burning caused by the high temperature from the burning process in the combustion chamber and or access in its chamber door while cleaning the burning zone or unburned material while stirring up the fuel in the fuel chamber while servicing handling of the boiler and contact with heated surfaces Risks of electrical shock from indirect contact The boiler is connected to the electrical network and the control modules are positioned in the control board equipped with the necessary safety devices protecting against overload and short circuit The appliance ground connection is mandatory and must be performed by an authorized technician Risks of finger injuring during works of opening closing and cleaning It is recommended to use proper personal safety equipment Risk of strangulation in case of insufficient chimney draught clogging of the convection line of the boiler or improper sealing of the flue pipeline Also fine ash dust which teases the respiratory tract of the cleaning person could be absorbed while cleaning the ash residues it is recommended to use protection mask 6 12 ACTIVITIES AFTER THE APPLIANCE LIFE CYCLE PERIOD EXPIRY After expiry of the p
42. s box also serves for preheating of the firing air before it is led to the burning zone The inlet section of the box is equipped with a flap which is controlled by thermo regulation valve TRV The TRV is linked to it by a chain and its function is to partially close the air inlet section when the circulations water temperature increases The water inlet muff is threaded inside see Table 3 2 for its size and is positioned on the boiler s low left back side The water outlet muff is threaded inside see Table 3 2 for its size and is positioned on the left top back side of the boiler By these muffs the boiler connects to the heating system The draining muff is with inside threading see Table 3 2 for its size It must be equipped with draining cock Emergency unloading boiler tube serpentine which serves for cooling of the circulations water in the boiler body when the temperature exceeds the highest limits This boiler tube is with outside thread G3 4 Flue outlet with external diameter 150 mm positioned in the top back side of the boiler after the convection pipeline of the boiler and is used for cooling of the flue gasses and preheating of the firing air Steel made heat exchanger and its cover which are isolated with mineral wool that serves for limiting of the heat losses transfer to the surrounding environment Fuel chamber and combustion chamber cast iron doors which provide excellent isolation and sealing of the boiler
43. s opening by using scraper tool or another suitable tool to clean the nozzle opening Close the fuel chamber door and the ignition air flap Observe the following rules when adding fuel in the fuel chamber The refueling should be performed with preliminary prepared fuel so it happens quickly in order to prevent flue gas extraction to the boiler room when the door is opened Place the fuel longitudinal parallel to the chamber s nozzle by preventing its orifice from blocking by wood pieces The door must be fully closed after refueling Do not allow its blocking by wood pieces n case the chamber is loaded with mixed wood type the larger and wetter pieces have to be positioned in the middle of the chamber and the smaller and drier particles logs have to be placed on its periphery Such arrangement prevents the forming of the so called overhanging of the fuel over the nozzle When the circulations water temperature in the boiler is heated up to the assigned operation temperature defined by the boiler s operation thermostat the flue gas extraction fan switches off and the boiler transits to stand by mode by which the fuel is not consumed so intensively One part of the fuel is still consumed in order to keep the wood glowing During stand by mode the heating output is around 1096 from the boiler nominal output 6 6 2 BOILER OPERATION IN COMBINED MODE For optimal reliable and efficient operation of the ap
44. series 3 Fera to a heating installation together with heat accumulator and water mixing valve as presented on Figure 5 6 3Fera 25 35 45 21 Figure 5 6 Recommended hydraulic diagram for connecting hot water boiler from series 3 Fera to heating installation heat accumulation tank and water mixing valve 24 23 3 4 lll VAS F 7 p oan vata retis Domestic hot X water Y ra I 1 uer 15 4 5 6 2222 7 16 9 10 r 10 Va 13 Mi g y p55 aM From heating system Tap water Table 5 2 Identification of the components marked on Figure 5 6 No Identification No Identification 1 Hot water boiler from series 11 Ball valve 3Fera 12 Water filter 2 Safety valve 13 Temperature valve TV 3 Boiler hot domestic water 14 Retaining valve 4 Retaining valve 15 Contact thermostat 5 Circulations pump 1 16 Heat accumulator 6 Safety valve 17 Automatic water refilling device 7 Opened or closed expansion 18 Filling and draining cock tank 22 Air free device with flap 8 Ball valve 23 Safety valve 9 Three way mixing valve 24 Retaining flap 10 Circulations pump 2 3Fera 25 35 45 22 6 INITIALIZATION OF THE APPLIANCE IN OPERATION The combined wood gasification hot water boilers from series 3Fera must be initiated in operation only by specialized company a
45. so on this is cycle process and is limited only by the necessity for cleaning If necessary the boiler can operate only with one fuel type If the appliance has been adjusted to Combine mode but the electrical supply was interrupted the system continues with complete burning of the remaining fuel and after that it automatically switches to reserve fuel When the boilers thermostat assigned temperature has been reached or when the room thermostat switches off afterburning smoldering follows In operation with reserve fuel the boiler keeps smoldering mode by periodical fuel feeding which keeps it glowing After the water temperature drops or the system receive operation signal by the room thermostat it follows with inflammation and operation in normal mode 3Fera 25 35 45 28 If there is no glowing fuel in the boiler s fuel chamber it is necessary to perform initial manual firing of the fuel For the purpose small quantity of wood should be loaded and fired During the boiler initial start up the reserve fuel transport auger wood pellets or dry calibrated wood chips must be filled with fuel Such filling is continues process and continues until the fuel starts to drop in the boiler s fuel chamber The boiler must be started after the feeding auger has been filled with reserve fuel this is a mandatory primary condition for operation in combine mode It is not recommended to operate the appliance wi
46. spected and its condition evaluated it is recommended to be performed by specialist After inspection and insurance that the boiler condition is operational and there are no damages on its construction which might lead to dangerous situations it can be restored to operation again It is recommended to approach its restoring in operation carefully slow heating by monitoring and inspecting its body for leaks or other unusual events The burning process in the fuel chamber must not be stopped by forced extinguishing without water or other extinguishing liquids because it may lead to irreversible damages to the heat exchanger or to the firing nozzle It is recommended to cool the appliance down to safe temperatures and after that to make inspection and evaluation of its condition 6 8 BOILER SHUT DOWN The boiler shutting down is a step by step process First the fuel feeding must be stopped After complete burning of the fuel and the glowing coals and after the boiler cools down it must be shut down by pressing the switch POWER which is positioned on the rear interface panel with managing connectors It is also recommended to clean the appliance from the ash deposits It is forbidden to shut down the boiler by the key POWER during operation 6 9 BOILER CLEANING For maintaining highly efficient and reliable operation it is necessary to clean the boiler from the ash deposits Not only the quantity but also the
47. st be noted in its warranty card It is mandatory to fill all fields with the required information heating installation and the boiler have to be filled with circulations liquid in most cases with fresh water The water used for filling the boiler and the heating installation must be transparent without color without deposits oils and aggressive chemical impurities The hardness of the water must comply with the tolerable norms presented in the next table In case the used water parameters do not correspond to those presented in the table then water with suitable characteristics should be used or chemical treatment must be performed Table 5 1 represents the heating system water parameters which must comply with the requirements of standard BDS 15207 81 Table 5 1 Parameters of suitable water for the heating installation Parameter Dimension Value Overall hardness mg eq kg 30 Oxygen content mg kg 100 Oil and heavy oil products mg kg 3 Overall hardness mg kg 50 Salts content mg kg 6000 Total alkalinity mg kg 30 pH 8 0 9 5 Content of free CO mg kg Not allowed In case the boiler is connected to heating installations where the water is in contact with copper for example copper pipes the pH hydrogen exponent value must not exceed 10 The manufacturing company recommends the following hydraulic diagram for connecting a combined wood gasification hot water boiler from
48. th its doors opened on the fuel and combustion chambers It is not recommended to operate the appliance with an auger that is power supplied by external from the boiler s plug The auger power supply from external plug is allowed only during its initial filling with fuel as the boiler must be switched off until the auger has been filled i e do not allow uncontrolled combustion For initial start of the appliance the upper chamber must be filled with initial fuel quantity detailed description is presented in the manual After that the initial quantity has to be fired manually and after stabilization of the burning process the following activities have to be performed in dependence on the used fuel Firewood fill the fuel chamber completely and switch to automatic mode Switch to automatic fuel feeding mode wood pellets or dry calibrate wood chips The fuel transport auger must be filled with fuel If it does not feed fuel to the boiler s upper chamber at the first attempt then restart of the appliance is required E E The boiler operates by preliminary installed algorithm Its software is password protected against unauthorized access For the user respectively well familiar with the presented manual book are allowed only a group of parameters for control and adjustment The boiler s water operation thermostat 0 90 C has to be adjusted on the desired temperature It is recommended to be withi
49. thermostat for protecting the appliance from overheating Boiler tube serpentine for emergency cooling of the boiler in case of exceeding its operation temperature Combined fuel feeding auger for dry calibrated wood chips P20 EN 14961 2 moisture up to 10 and for wood pellets with diameter 6 8 mm It suits all boiler models and is offered as an optional equipment Advantages of the boiler Availability for usage of reserve fuel after completion of the firewood burning wood pellets or dry calibrated wood chips which provides INDEPENDENT operation mode High efficiency Eff coef 93 during utilization of the three fuel types which guarantees exclusively economic operation and low costs for heating Easy servicing handling thanks to its wide door and availability for firing of wood logs with diameter up to 20 cm maximum length 50 cm and moisture up to 20 Combustion chamber equipped with high quality ceramics which guarantees maximum efficient burning process Cleaning mechanism for the heat exchanger tube bundle ensuring stable efficiency Thanks to the firing air flow rate thermo regulation valve maximum fuel utilization and economic operation of the boiler are guaranteed Reliable and safe operation thanks to its stainless unloading serpentine and compliance with the requirements of EN303 5 standard Availability for adjustment of the heating output within wide range The boiler is factory equipped with flue gas extrac
50. tion fan Possibility for monitoring of the processes in the combustion chamber through the doors monitoring glasses Components by reputable European manufacturers If a thermostat mixing group Laddomat is added the life length of the appliance will be longer and the fuel economy will be higher up to 2095 The boiler is ecological with low harmful emissions levels below the strictest requirements of the European standards operation temperatures during heating of water from accumulation tank and G LADDOMAT is thermostat mixing group which assists for quicker reaching to implements the process of temperature stratification 3Fera 25 35 45 6 3 TECHNICAL DATA FOR COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES 3 Fera The heating technical data of combined wood gasification hot water boiler from series 3Fera utilizing firewood wood pellets and dry calibrated wood chips are presented in Table 3 1 Table 3 1 Heating technical data of combined wood gasification hot water boiler from series SFera Parameter Dimension Value Boiler model 3Fera 25 3Fera 35 3Fera 45 Nominal output kW 25 35 45 Heating output operation kW 9 25 11 35 15 45 Used fuel chips Firewood wood pellets dry calibrated wood Wood pellets categories according to standard EN 14961 2 ENplus A1 ENplus A2 ENplus B Wood pellets categories according to the appliance
51. ton marked as Menu OK to confirm the change or choose No to cancel the change of settings 3Fera 25 35 45 30 8 Press the green button marked Menu OK on the control board one more time to exit the parameters menu The control module display shows normal operation mode RUN PASSWORD CLEAR 0 5 0000 5 maxmum attempts for entering SHIFT OK EXIT the password It is necessary to exit this mode The method is presented on the screen press together the buttons SHIFT and OK by pressing SHIFT and without releasing it also press the button OK Submenu appears which can be exited by pressing the button arrow left lt 4 Another easier method is by switching off and on the main power supply by using the switch POWER Figure 6 5 Information appearing on the control module display after reaching the limit of attempts for entering the password respectively transition to the service menu PASSWORD CLEAR ERROR 5 5 gt gt gt 30 MINUTES The message on the control module screen means that it is necessary to wait for period of 30 minutes as the appliance remains switched on After expiry of this period 30 minutes the above presented procedure must be performed it is necessary to press together the buttons SHIFT 3Fera 25 35 45 31 and OK On the control module screen appears a submenu which can be exited by pressing button arrow left 4 Another method is to wait at least 30 minutes and to
52. urfaces Low temperature of the inlet water Adjustment of the circulations pump thermostat is required The recommended temperature for operation start of the circulations pump is minimum 65 C 8 Presence of smoke in the boiler room after certain operation period Insufficient chimney draught It is required to heat the chimney in order to provide conditions for reliable operation The chimney condition has to be evaluated by expert whether it has the needed height outlet section area isolation and configuration to be performed by specialist The chimney is dirty or clogged with ash Clean the chimney The flue pipeline is dirty or clogged with ash Clean the flue pipeline Inefficient sealing of the doors by the heat resistant sealing ropes Replacement of the sealing ropes is required to be performed by specialist 9 Abnormal heating of the wood pellets dry calibrated wood chips combined transport auger Insufficient chimney draught or dirty appliance boiler Cleaning of the boiler eventually the chimney is required Possible solution is installation of additional flue gas extraction fan and or change of the chimney 10 Heating of the wood pellets or dry calibrated wood chips transport auger and activation of the emergency Low chimney draught or dirty appliance boiler Cleaning of the boiler eventually the chimney is required Possible solution is
53. uthorized to perform such activities 6 1 GENERAL REQUIREMENTS ABOUT THE USED FUEL n order to achieve complete burning it is necessary to use only dry fuel with characteristics that comply with the fuel requirements The manufacturing company recommends storing of the fuel in dry and ventilated premises or under roof where it will be protected from moistening Storing the fuel next to the boiler or at distance less than 500 mm is forbidden The recommended distance by the manufacturing company is minimum 1000 mm It is better to store the fuel in a neighbor premise The fire safety requirements must be observed during the boiler installation and the fuel storing It is recommended to keep fire extinguisher at near and safe place 6 2 GENERAL REQUIEMENTS DURING OPERATION OF THE HEATING INSTALLATION In case the heating installation is designed with opened expansion tank then the following should be taken into account the heating installations with opened expansion tank provide direct contact between the heating circulations water and the surrounding atmosphere During the heating season the water in the expansion tank absorbs oxygen through their contact surface which increases the corrosive action of the circulations liquid over the steel surfaces and circulations liquid water vaporization could be noticed also For the system refilling must be used only water that complies with the usage requirements of circulations li
54. voice and original warranty card are presented 3Fera 25 35 45 47
55. volume Outside decoration covers that are made from steel and are coated with quality color paint Combined fuel transport auger it is offered as additional option for feeding of the combined hot water boilers from series 3Fera with wood pellets or dry calibrated chips General view of combined wood gasification hot water boiler from series 3Fera utilizing firewood wood pellets and dry calibrated chips is presented in Figure 4 1 3Fera 25 35 45 10 Figure 4 1 General view of combined wood gasification hot water boiler from series 3Fera Figure 4 2 represents front view of the combined hot water boiler from series Rear side view of the boiler from series is presented in Figure 4 3 3Fera 25 35 45 11 Figure 4 2 Front view of combined wood gasification hot water boiler from series 3Fera Primary air valve 1 Primary air valve 2 Total air valve Secondary air valve Ash cleaning cover Reserve fuel inlet Emergency cooling boiler tube input output NOOR WD 3Fera 25 35 45 12 Cross section view of combined wood gasification hot water boiler from series 3Fera with shown flue gas and ash directions is presented in Figure 4 4 The overall sizes of combined wood gasification hot water boiler from series 3Fera are presented on Figure 4 5 Figure 4 4 Cross section view of combined wood gasification hot water boiler from seri
56. y BD kg m 200 Recommended fuel caloricity net Q MJ kg gt 16 0 calorific value net kWh kg 24 4 Dry calibrated wood chips parameters according to standard EN 14962 1 I LIAMA The combined wood gasification hot water boilers from series 3Fera are not designated for utilization of every solid fuel type including coal and cokes 3Fera 25 35 45 4 CONSTRUCTION DESCRIPTION OF COMBINED WOOD GASIFICATION HOT WATER BOILER FROM SERIES 3 Fera The combined wood gasification hot water boiler from series 3Fera consists of the following main components and modules Heat exchanger which presents welded steel plate construction In the upper part of the boiler is formed the fuel loading chamber in which the substances volatile from the wood In the lower part of the heat exchanger is formed a combustion chamber in which the combustion nozzle and the fireclay lining of the combustion chamber are formed The fireclay made combustion nozzle positioned in the refueling chamber lower part provides conditions for effective substances volatile the burning gasses separated during the fuel gasification and their burning Fireclay made directing elements mounted in the combustion chamber providing optimum combustion and assist for complete fuel burning Flue gasses extraction fan installed in the back side of the boiler Air distribution box which is used for adjusting the primary air flow rate by a flap Thi

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