PYROTEC Technical guide
PYROTEC
Grate combustion 390 to 1250 kW
Technical guide
PYROTEC GRATE COMBUSTION
Fully automatic wood boiler
for the combustion of woodchips, pellets, shavings and mixed
wood
5822 511 GB
05/2010
Index
1.
Principles of wood combustion
1. 1 Principles of pellet combustion for generating heat ....................................................
■ What are wood pellets? ..........................................................................................
■ Fuel requirements ...................................................................................................
■ Forms of delivery ....................................................................................................
1. 2 Principles of woodchip combustion for generating heat .............................................
■ What are woodchips? .............................................................................................
■ Fuel requirements ...................................................................................................
1. 3 Minimum wood fuel requirements ...............................................................................
■ Content ...................................................................................................................
■ Non-wood biomass fuels .........................................................................................
■ Wood fuel regulations and standards .....................................................................
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6
2.
PYROTEC
2. 1 Product description .....................................................................................................
■ Benefits at a glance ................................................................................................
■ Delivered condition .................................................................................................
2. 2 Specification ...............................................................................................................
■ Specification ............................................................................................................
7
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8
3.
Control unit
3. 1 Specification for Pyrocontrol .......................................................................................
■ Functions ................................................................................................................
■ Operation: ...............................................................................................................
■ Standard delivery: ...................................................................................................
3. 2 Accessories for Pyrocontrol ........................................................................................
■ External drive control ..............................................................................................
■ Control of external drive with light barrier ...............................................................
3. 3 Accessories for Pyrocontrol output management .......................................................
■ Cylinder management 5 sensors (QM) ...................................................................
■ External requirement on/off .....................................................................................
■ Operating message zero volt ..................................................................................
■ Output signals 0-10 V .............................................................................................
■ Requirement, additional heat source KP0 ..............................................................
■ Requirement, additional heat source KP1 ..............................................................
3. 4 Accessories for Pyrocontrol remote transfer ...............................................................
■ Fault message device, analogue with battery .........................................................
■ Export of operating data ..........................................................................................
■ Visualisation, externally via modem (connected with cable) ...................................
■ Visualisation, internal ..............................................................................................
■ Data line to internal visualisation ............................................................................
3. 5 Mastercontrol for two-boiler systems ..........................................................................
■ Information on the Mastercontrol ............................................................................
3. 6 Accessories for Mastercontrol ....................................................................................
■ Heat meter signal ....................................................................................................
■ Requirement, additional heat source KP0 ..............................................................
■ Requirement, additional heat source KP1 ..............................................................
■ Fault message device, analogue with battery .........................................................
■ Export of operating data ..........................................................................................
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4.
Heating water buffer cylinder
4. 1 Specification, buffer cylinder ....................................................................................... 23
5.
Installation accessories
5. 1 Boiler accessories .......................................................................................................
■ Flue gas recirculation ..............................................................................................
■ Insulation, flue gas recirculation line .......................................................................
■ Displacer rods .........................................................................................................
■ Automatic ignition system .......................................................................................
5. 2 Boiler safety equipment ..............................................................................................
■ Thermally activated safety valve 100 °C .................................................................
■ Thermally activated safety valve 50-120 °C ...........................................................
■ Thermally activated extinguishing valve ½”, 50-90 °C ............................................
■ Supply screw conveyor two-level ............................................................................
5. 3 Accessories, heat distribution .....................................................................................
■ Motor three-way valve ............................................................................................
■ Pumps .....................................................................................................................
5. 4 Accessories, flue system ............................................................................................
■ Flue gas dust extractor 240/800 .............................................................................
■ Accessories, cleaning pneumatic ............................................................................
■ Price reduction net compressed air on site ............................................................
2
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30
PYROTEC
5822 511 GB
Index
Index (cont.)
Design information
5822 511 GB
6.
PYROTEC
5. 5 Accessories, ash removal ...........................................................................................
■ External container ...................................................................................................
■ Extension of ascending screw conveyor .................................................................
■ Extension of combustion chamber screw conveyor ................................................
31
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33
6. 1 System design ............................................................................................................
■ Selection of rated output .........................................................................................
■ Flow temperatures ..................................................................................................
■ Safety temperatures ................................................................................................
6. 2 Delivery .......................................................................................................................
6. 3 Handling ......................................................................................................................
6. 4 Installation ...................................................................................................................
■ Requirements for boiler room .................................................................................
■ Requirements of Sample Combustion Order ..........................................................
■ Combustion air supply ............................................................................................
■ Minimum clearances ...............................................................................................
6. 5 Water connection ........................................................................................................
■ Heating connections ...............................................................................................
■ Boiler circuit and shunt pumps ................................................................................
■ Safety equipment to DIN EN 12828 ........................................................................
■ System examples ....................................................................................................
6. 6 Electrical installation ...................................................................................................
■ Positioning of the programming module and control panel .....................................
6. 7 Safety equipment ........................................................................................................
■ Expansion ...............................................................................................................
■ Extinguishing facilities .............................................................................................
■ Extinguishing water container .................................................................................
■ Extinguishing facility with cold water supply ...........................................................
■ Back burning protection, boiler system ...................................................................
■ Prevention of combustion chamber overfilling ........................................................
■ Reignition protection ...............................................................................................
■ Back burning protection, fuel supply (RSE) ............................................................
■ Shut-off gate valve ..................................................................................................
■ Rotary lock valve .....................................................................................................
■ Dual rotary lock valve with pressure compensation ................................................
■ Low water indicator .................................................................................................
■ Maximum pressure limiter .......................................................................................
■ Minimum pressure limiter ........................................................................................
■ Safety valve ............................................................................................................
■ Expansion vessel ....................................................................................................
6. 8 Fire protection .............................................................................................................
■ Fire protection, fuel store ........................................................................................
6. 9 Commissioning ...........................................................................................................
■ Fuel for commissioning ...........................................................................................
■ Filling the heating system .......................................................................................
6.10 Fuel .............................................................................................................................
■ Suitable fuels ..........................................................................................................
6.11 Fuel discharge by means of screw conveyor ..............................................................
■ Discharge conveyor, pellet, D = 120 mm ................................................................
■ Drive, discharge conveyor, pellets ..........................................................................
6.12 Fuel discharge by means of agitators .........................................................................
■ Spring core discharge AF .......................................................................................
■ Discharge screw AF to spring core discharge ........................................................
■ Horizontal discharge AH .........................................................................................
■ Discharge screw AH for horizontal discharge .........................................................
■ Protective panel AH for bunker ...............................................................................
■ Cover panel AH for pellets ......................................................................................
6.13 Fuel discharge by means of funnel discharge ............................................................
■ Funnel discharge ....................................................................................................
■ Additional outlet flange ............................................................................................
■ Funnel, large ..........................................................................................................
6.14 Fuel discharge by means of a push floor (sizing) .......................................................
■ Number and length of the pushrods with a maximum dumping height ...................
■ Specification for the pushrod drives ........................................................................
■ Forces on the building .............................................................................................
■ Slot discharge, for pulling ........................................................................................
■ Centre discharge .....................................................................................................
■ Slot discharge with fill function ................................................................................
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3
Index (cont.)
8.
4
Appendix
Keyword index
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7. 1 Sizing the expansion vessel .......................................................................................
■ Selection example ...................................................................................................
7. 2 General information regarding low pressure hot water boilers with safety temperatures
of up to 110 ºC ............................................................................................................
7. 3 Pipe connections ........................................................................................................
7. 4 Electrical installation ...................................................................................................
7. 5 Operating instructions .................................................................................................
7. 6 Flue system ................................................................................................................
7. 7 Checks as part of the Building Regulations approval process ....................................
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.............................................................................................................................................. 85
PYROTEC
5822 511 GB
7.
6.15 Fuel discharge by means of push floor (accessory) ...................................................
■ Pushrod drive, individual .........................................................................................
■ Weld base, pushrod drive, individual ......................................................................
■ Pushrod drive, twin ................................................................................................
■ Weld base, pushrod drive, twin ...............................................................................
■ Weld base, bunker ..................................................................................................
■ Pushrod ...................................................................................................................
■ Hydraulic drive, AS individual .................................................................................
■ Hydraulic drive, AS twin ..........................................................................................
■ Push floor screw conveyor D = 190 mm .................................................................
■ Push floor screw conveyor D = 250 mm .................................................................
■ Drive, push floor screw conveyor, standard ............................................................
■ Drive, push floor screw conveyor, higher-power .....................................................
■ Cover, push floor screw conveyor ...........................................................................
6.16 Charging the boiler with fuel .......................................................................................
■ Trough screw conveyor ...........................................................................................
■ Drive, trough screw conveyor, standard .................................................................
■ Pipe screw conveyor ...............................................................................................
■ Drive, pipe screw conveyor, pellets ........................................................................
■ Drive, pipe screw conveyor, standard .....................................................................
■ Drive, pipe screw conveyor, high-power .................................................................
6.17 Fuel storage in on-site pellet store (sizing) .................................................................
■ Sizing the pellet storage room ................................................................................
■ Pellet storage room design and required system components ...............................
■ Additional safety instructions for pellet stores .........................................................
■ Protective boards with Z profiles .............................................................................
■ Fill connector and return air connector ...................................................................
6.18 Fuel storage in on-site pellet store (accessories) .......................................................
■ Deflector 1.42 x 1.25 m ...........................................................................................
■ Blast pipe, straight ..................................................................................................
■ Blast pipe with 45° bend ........................................................................................
■ Extension, blast pipe, straight .................................................................................
■ 45° bend for blow line .............................................................................................
6.19 Fuel storage in on-site bunker (accessories) ..............................................................
■ Silo cover, manual FDM 2.9/1.3 m ..........................................................................
■ Bunker cover hydraulic FDH ...................................................................................
■ Fall protection grille 120 for FDH ...........................................................................
■ Fall protection grille 200 for FDH ...........................................................................
■ Bunker cover, movable FDB ...................................................................................
■ Fall protection grille, 120 for FDB ...........................................................................
■ Fall protection grille, 200 for FDB ..........................................................................
■ Shaker motor for fall protection grille ......................................................................
■ Hydraulic drive, bunker charging cover, ASH .........................................................
■ Cover drives for hydraulic drive, ASH ....................................................................
■ Silo filling screw conveyor FS 300 ..........................................................................
■ Drive, silo filling screw conveyor ............................................................................
6.20 Back burning protection ..............................................................................................
■ Rotary lock valve .....................................................................................................
■ Shut-off gate valve MA 220 .....................................................................................
■ Downpipe L = 1.0 m ................................................................................................
■ Special adaptor .......................................................................................................
6.21 Connection on the flue gas side .................................................................................
■ Chimney ..................................................................................................................
■ Flue pipe .................................................................................................................
6.22 Sound insulation .........................................................................................................
■ Braces .....................................................................................................................
Principles of wood combustion
1.1 Principles of pellet combustion for generating heat
What are wood pellets?
Wood pellets are made from 100% natural wood residues. This raw material is waste matter created by the wood industry in large volumes
through planing or sawing. Wood remnants are compressed under high pressure and formed into pellets, i.e. pressed into a cylindrical shape.
The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage conditions.
Perfect and effective combustion can only be ensured under these conditions.
Fuel requirements
For combustion in the PYROTEC, use pellets with a diameter of 6 mm,
a length from 5 to 30 mm (20 % up to 45 mm) with a maximum residual
moisture content of 10 %.
The wood pellets used for combustion in the PYROTEC must comply
with the requirements of DINplus or ÖNORM M 7135.
Demand
Abrasion resistance
Raw density
Water content
Ash content
Net calorific value
Sulphur content
Chlorine content
Nitrogen content
Compression additive
Ext. production control
DINplus
%
kg/dm3
%
%
MJ/kg
kWh/kg
%
%
%
%
≤ 2.3
≥ 1.12
≤ 10
≤ 0.5
≥ 18
≥5
≤ 0.04
≤ 0.02
≤ 0.3
≤2
yes
Ö-NORM
M 7135
≤ 2.3
≥ 1.12
≤ 10
≤ 0.5
≥ 18
≥5
≤ 0.04
≤ 0.02
≤ 0.3
≤2
–
Quality characteristics
High quality pellets:
■ smooth shiny surface
■ uniform length
■ low proportion of dust
■ sink in water
Low quality pellets:
■ cracked rough surface
■ severely varying length
■ high proportion of dust
■ float in water
Forms of delivery
In their loose form, pellets are transported by silo tanker and blown into
the storage room via a hose system.
Careful handling of pellets enables a low proportion of dust, perfect
boiler charging and a constant wood boiler output.
1.2 Principles of woodchip combustion for generating heat
What are woodchips?
Woodchips are made from 100% natural wood from forests and plantations. This raw material comes in the form of trunks or branches. The
wood is then processed with high speed cutting tools in accordance
with ÖNORM M 7133.
The raw material is stored and transported in completely dry conditions. The system user should also ensure completely dry storage
conditions. Perfect and effective combustion can only be ensured
under these conditions.
Fuel requirements
For combustion in the PYROTEC, use woodchips with a maximum
percentage of coarse chippings of 20%, a maximum cross-section of
5 cm² and a maximum length of 12 cm (5 % with max. 16 cm). The
water content of the woodchips may be max. 50 % (W50).
Bulk density S (kg/m³, water content W (%), size G (mm) as per ÖNORM M 7133
S 200
W20
G30/50
Soft natural woodchips from forest thinnings
S 250
W20 to W35
G30/50
Soft natural woodchips from forest thinnings
S 300
W20 to W35
G30/50
Soft/hard natural woodchips from forest thinnings
S 300
W35 to W50
G30/50
Soft natural woodchips from forest thinnings
S 350
W20 to W35
G30/50
Hard natural woodchips from forest thinnings
S 350
W35 to W50
G30/50
Soft/hard natural woodchips from forest thinnings
S 350
W50 to W60
G30/50
Soft natural woodchips from forest thinnings
S 400
W35 to W50
G30/50
Hard natural woodchips from forest thinnings
S 400
W50 to W60
G30/50
Soft/hard natural woodchips from forest thinnings
5822 511 GB
Quality characteristics
■ Max. 5 % outliers
■ Smooth surfaces
Good woodchips:
■ As per ÖNORM M 7133
■ Size up to G30 or G50
PYROTEC
5
1
Principles of wood combustion (cont.)
Poor woodchips:
■ Frayed surface
■ More than 5 % outliers
■ Coarse percentage higher than 20 %
■ Greater than G50
1
1.3 Minimum wood fuel requirements
Content
When procuring wood for combustion, it is important to ensure that
foreign matter (e.g. stones, metal parts, brick fragments, plastics, etc.)
is avoided. These change the composition of the charge and therefore
the critical parameters of the combustion process.
The values must not exceed or fall below the following limits (per kg of
dry fuel) for the non-combustible contents (ash at an analysis temperature of 815 °C):
Limit
Chlorine Cl
Sulphur S
Total Cl, S
Ash content total
Alkali oxides in the ash (K2O and Na2O)
SB starting of ash sintering
mg/kg
mg/kg
mg/kg
g/kg
g/kg
°C
A consequence of exceeding the above limits is a shortened combustion chamber and wood boiler service life. This also means that the
maintenance work is increased and the servicing intervals are shortened.
max. 300
max. 1000
max. 1000
max. 15.0
max. 1.0
min. 1000
Comparison with natural wood from forest
thinnings
10
120
130
5.0
0.35
approx. 1200
The proportion of dust-like and fine-grain materials should also be
minimised (in accordance with ÖNORM M 7133).
Non-wood biomass fuels
Non-wood biomass fuels, such as needles, leaves, grain, straw, husks,
fruit kernels, etc., are generally unsuitable as a fuel for trouble-free
operation and therefore not permissible.
In some cases, the fuel properties (essential composition, ash sintering point, etc.) differ considerably from those of wood. Combustion in
a PYROTEC can lead to impairment of the combustion characteristics
and to greater stress on the fireclay lining and the heat exchanger surfaces. Warranty claims can therefore only be asserted when using
permissible fuels.
Wood fuel regulations and standards
1.BImSchV in the revised version dated 22.03.2010
FAV dated 18.11.1997 "Ordinance for Combustion Systems" § 3.(1) 3. Solid fuels
Clean air regulations LRV dated 16.12.1985 (as at 28.03.2000)
Woodchips for energy purposes (1998)
Boilers for solid fuels, table 8 "Test fuels"
Solid biofuels
5822 511 GB
Germany
Austria
Switzerland
ÖNORM M 7133
EN 303-5
CEN/TS 14961
6
PYROTEC
PYROTEC
2.1 Product description
A
B
C
D
E
F
G
H
K
L
M
The PYROTEC grate combustion has been specially developed for the
automatic combustion of dry and moist wood fuels (waste wood, wood
pellets or woodchips from forest thinnings up to max. W50). It combines the benefits of underfeed combustion with the advantages of
grate combustion to optimum effect. The PYROTEC grate combustion
is particularly impressive thanks to its maximum efficiency and perfect
combustion in all load stages. The horizontal heat exchanger with
pneumatic cleaning is ideal for the use of fuels with a high fine percentage.
3-pass boiler (3 bar or 6 bar)
External grate with primary air 2
Safety heat exchanger
Secondary air
Ignition fan
Supply screw conveyor with separating barrier
Combustion retort with internal grate and primary air 1
Removal of ash
Combustion chamber door
Moving infeed grate
Pneumatic heat exchanger cleaning
2
The ash is removed automatically from the combustion base and
transported into a standard container. Efficiency of over 90 % enables
maximum seasonal efficiency in modulating operating mode. The use
of a PYROTEC grate combustion as a base load boiler is practical in
terms of a building heat load of 300 kW. Combination with a solar
thermal system is also easily possible. The PYROTEC grate combustion is tested and permissible to EN 303-5. It is produced in accordance
with the Machinery Directive and has a CE designation. It is also subject to ongoing monitoring by the TÜV.
Benefits at a glance
■ High efficiency thanks to proven combustion technology, 3-pass
heat exchanger, modulating output control and regulated primary
and secondary air supply
■ Easy service thanks to fully automatic ash removal and optional
pneumatic cleaning system
■ Highly developed safety devices ensure a safe and reliable operation
■ Optimum system output is the result of manufacture and delivery of
all system components from a single source
■ Automatic ignition device prevents having to maintain the incandescent bed and saves fuel (option – only for fuels with water content
below 40 %)
■ Individual planning of your system by our team of experts
■ Excellent output control from 30 to 100 %
Delivered condition
Preassembled steel boiler for wood pellets and woodchips according
to DINplus and ÖNORM M7135.
With integral return temperature raising facility, combustion chamber
door, ash doors, ash boxes, cleaning device.
1 supply screw conveyor with separating barrier, incl. extinguishing
valve with dirt trap
1 Pyrocontrol programming unit
1 flue gas fan
1 extinguishing water container with holder
1 automatic ignition system
1 secondary air device (draught stabiliser); for the installation in the
flue pipe
5822 511 GB
Pyrocontrol
■ Programming unit
■ Update-compatible software
■ Data line 10 m
■ Control panel
■ Infrared light barrier for level monitoring, separating barrier, supply
screw conveyor
■ Safety limit switch on inspection cover of supply screw conveyor
■ Contact sensor PT-100 at the supply screw conveyor
■ Infrared light barriers for level monitoring of the fuel in the combustion chamber
■ Zirconium dioxide probe with measured value transducer
■ Flue gas temperature sensor PT-100
■ Return temperature sensor KTY
■ Boiler water temperature sensor KTY
■ High limit safety cut-out
■ Underpressure sensor
■ Sensor KTY with sensor well
■ Overpressure limiter
■ Light barrier ash removal
■ Limit switch, combustion chamber door
PYROTEC
7
PYROTEC (cont.)
2.2 Specification
Specification
Output with woodchips W 45*3
Heating data
Content on hot gas side
Permissible shutdown temperature of the high
limit safety cut-out
Minimum return temperature
Grate ash container capacity
Ash container capacity, flue gas dust extractor
Boiler water content
Water-side pressure drop (diff. 15 K)
Permiss. operating pressure
Test pressure
Maximum operating pressure
Heating surface
CE designation
Boiler class to DIN EN 303-5
Overall dimensions
Total length
Total width (boiler)
Total width (boiler with supply screw conveyor)
Total height (boiler)
Total height (boiler with induced draught fan)
Weight
Boiler
Combustion block
Displacer rods
Flue gas fan
Supply screw conveyor
Total dry weight
Total wet weight
Max. power consumption
Ignition unit
Electrical connections (total)
During heating operation
Supply screw conveyor
Primary air fan 1
Primary air fan 2
Secondary air fan
Flue gas fan
Grate drive
Electrical power consumption with QN
Electrical power consumption with Qmin
Boiler connections
Boiler flow and return
Extinguishing water connection
Boiler drain and fill valve
Safety heat exchanger
Sensor well for TS
PYROTEC grate combustion
530
720
950
7423 675
7423 676
7423 677
390
7423 674
1250
7423 678
kW
kW
kW
390
390
97
530
530
132
720
720
180
950
950
238
1250
1250
312
kW
380
515
700
920
1210
l
°C
1540
100
2280
100
2830
100
4050
100
5210
100
°C
l
l
l
mbar
65
240
240
1150
13
65
240
240
1444
23
65
240
240
1861
43
65
240
240
1943
26
65
240
240
2482
45
7.8
6
42.50
7.8
6
55.50
7.8
6
74.80
7.8
6
91.00
bar
bar
m2
7.8
6
26.32
CE
CE
3
CE
CE
CE
3
3
3
3
mm
mm
mm
mm
mm
4370
1274
2382
2378
3186
4870
1247
2382
2536
3186
5257
1380
2488
2834
3378
5447
1612
2852
3035
3452
5992
1612
2852
3230
3717
kg
kg
kg
kg
kg
kg
kg
1680
2970
394
60
153
5230
6380
2707
4238
394
62
153
7554
8998
3291
4953
394
78
153
8869
10730
4874
5779
538
82
190
11463
13406
5563
6520
538
107
190
12919
15400
W
W
W
W
W
W
W
W
W
W
W
1600
5410
2880
1100
140
1600
7020
3570
1500
300
1600
8120
4560
1500
300
1600
9350
5170
2200
480
1600
11150
6790
2200
480
DN
R
R
R
R
900
900
900
900
900
900
1100
120
2880
2340
1500
1100
120
3570
2900
1500
2200
120
4560
3710
1850
2200
120
5170
4150
1850
4000
120
6790
5470
100
¾
1½
4x½
½
100
¾
1½
4x½
½
100
¾
1½
8 x½
2x½
125
¾
1½
8x½
2x½
125
¾
1½
8x½
2x½
5822 511 GB
2
Trade name
Rated output
Part no.:
Output data
Rated output
Continuous output*1
Minimum output Qmin*2
Levelled output as base load boiler in continuous operation with pneumatic cleaning
Q ≥ Qmin: Output operation modulating control (variable output control)
Q ≤ Qmin: Low load with ON Qmin/ OFF (Stop and Go operation)
*3 Wet fuels: > W45 further limitation-related output, efficiency and control characteristics
*1
*2
8
PYROTEC
PYROTEC (cont.)
5822 511 GB
Trade name
Rated output
Part no.:
Flue gas*4
Average temperature (gross*5)
Mean flue gas temperature with QN*6
Mean flue gas temperature with Qmin
Mass flow rate
QN; W5; O2 8 %
QW35; W45; O2 10 %
Flow rate
QN; W5; O2 8 %; 150 °C
QW35; W45; O2 10 %; 150 °C
CO2 content in the flue gas
Flue outlet
Required draught (at full load)
Efficiency
At full load*7
At partial load
390
7423 674
PYROTEC grate combustion
530
720
950
7423 675
7423 676
7423 677
1250
7423 678
°C
160
160
160
160
160
°C
120
120
120
120
120
g/s
g/s
219
303
297
412
404
560
532
736
700
968
m3/s
m3/s
%
7 mm
Pa
0.26
0.37
14.7
350
0
0.36
0.50
14.7
350
0
0.48
0.67
14.7
350
0
0.63
0.88
14.7
400
0
0.83
1.15
14.7
450
0
91
90
91
90
91
90
91
90
91
90
%
%
Values for calculating the size of the flue system to DIN EN 13384, based on 12.0% CO2.
Actual flue gas temperature as average gross value as per EN 304 at 20 °C combustion air temperature.
*6 Flue gas temperature: Reduction possible by inserting displacer rods (QN-20 °C; Qmin - 10 °C).
*7 For dry fuels (W5-W20) without recirculation, lower.
For PYROTEC 720–1250 without displacer rods, lower.
*4
*5
PYROTEC
9
2
PYROTEC (cont.)
c
678
d
KR
KV
l
k
m
a
b
2
f
h
e
n
800
470
g
q.
p
940
o
KR Boiler return
KV Boiler flow
kW
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
390
2378
2328
4370
2060
577
1200
2405
1086
803
453
2077
308
1274
1263
530
2536
2486
4870
2560
577
1200
2905
1086
803
453
2331
308
1274
1417
720
2834
2784
5257
2562
577
1200
2993
1380
803
453
2491
308
1380
1413
950
3035
2981
5447
2562
657
1275
2861
1612
929
479
2444
440
1612
1317
1250
3230
3176
5992
3107
657
1275
3406
1612
929
479
2639
440
1612
1566
5822 511 GB
Dimensions
Rated output
a
b
c
d
e
f
g
h
k
l
m
n
o
p
10
PYROTEC
PYROTEC (cont.)
D
B
C
E
H
K
G
960
A
F
2
L
220
M
a
b
A
B
C
D
E
F
G
H
K
L
M
Boiler drain and fill valve
Boiler return
Return temperature sensor
Drive, ash removal
High limit safety cut-out
Safety heat exchanger
Dimensions
Rated output
a
b
kW
mm
mm
Primary air fan 1
Boiler water temperature sensor
Boiler flow
Secondary air fan
Supply screw conveyor
390
3282
3800
KR
530
3782
4300
720
3877
4434
950
3835
4392
1250
4380
4937
KV
B
C
A
D
E
F
K
H
G
L
M
N
V
U
T
O
5822 511 GB
S
KV Boiler flow
KR Boiler return
A Removal of ash
PYROTEC
R
Q
P
B Cleaning cover, heat exchanger
C Combustion chamber temperature sensor
D Overpressure limiter
11
PYROTEC (cont.)
E
F
G
H
K
L
M
N
Light barrier, incandescence
Ignition unit
Cleaning cover, combustion retort
Cleaning cover, external grate
Light barrier ash removal
Boiler door
Cleaning, pneumatic
Combustion chamber door
O
P
Q
R
S
T
U
V
Limit switch, combustion chamber door
Primary air fan 2
Drive, infeed grate
Contact sensor, supply screw conveyor
Limit switch, maintenance cover
Light barrier, supply screw conveyor
Extinguishing water connection
Boiler drain and fill valve
5822 511 GB
2
12
PYROTEC
Control unit
3.1 Specification for Pyrocontrol
Programmable logic control (PLC) for the PYROTEC boiler system
incl. the control of equipment for fuel charging according to the articles
listed separately. Modulating matching of the boiler output to heat consumption is carried out.
Rated output range
Part no.
kW
The control circuit of combustion optimisation with a Lambda probe
overlaps the output control circuit. With regard to fire protection and
personal safety, the highest possible quality criteria are fulfilled.
390
7423 692
530
7423 693
720
7423 694
950
7423 695
1250
7423 696
Functions
■ Output control circuit with modulating output operation (25-100 %)
■ Air-controlled by means of variable speed ventilation fan subject to
flow temperature
■ Exact fuel supply via the supply screw conveyor from dosing container with separating barrier
■ Level monitored top up of dosing container
■ Limitation and distribution of the fuel in the combustion chamber
■ Emissions optimised control circuit with fine tuning of the fuel/air
mixture using the Lambda probe
■ The pressure control unit ensures a constant underpressure in the
combustion chamber.
■ Limitation of the combustion chamber temperature with corresponding variation of air ratio for protection of the fireproof lining
■ Keeping up the return temperature through the boiler ensures a long
boiler service life
■ Protection to avoid:
– Excessive temperature
– Burn-back
– Opening of the combustion chamber door
– Opening of a charging cover
– Pressure in the combustion chamber
■ Zero volt output (fault message)
Operation:
Operation is carried out via a 8” touch-screen module. All operating
data can be shown on the display. The set values of all important
parameters can be entered easily. Fault messages are displayed in
plain text and output in the sequence of occurrence.
Programming module:
For operating the heating system.
The 8” touch-screen module integrated in the control panel door enables visualisation and graphical evaluation via the system.
Übersicht
Status: Level 0
Zeit:
05.10.07 10:45:01
Text:
Warnung Feuerrauntüre offen
Aus
26,4 °C
25,9 °C
21,0 %
27,0 °C
30,0
°C 26,6
°C
26,2 °C
KOB
PYROTEC
0,0
°C
0,0
°C
26,4 °C
27,0 °C
Analyse
Archiv
Kessel Ein
Kessel Aus
Sperren
5822 511 GB
Einstellungen
PYROTEC
13
3
Control unit (cont.)
Standard delivery:
■ Sensors and switches at the combustion block and in the flue outlet
(installation on site):
– Combustion chamber temperature sensor NiCrNi
– Infrared light barriers, level monitoring, fuel in combustion chamber
– Zirconium dioxide probe with measured value transducer (Lambda
probe)
– Flue gas temperature sensor PT-100
– Underpressure sensor
– Overpressure limiter
■ Sensors and switches installed at top of boiler:
– Boiler water temperature sensor PT-1000 in connector flow
– Return temperature sensor PT-1000 in connector return
– High limit safety cut-out
5822 511 GB
3
■ Control panel loose; surface powder-coated. Version as per ÖVE/
VDE directives fully wired to terminal strips, fed 3 x 400 V 50 Hz;
control voltage 230 V or 24 V;
– Freely programmable control unit, CE tested
– Motor overload relay for all drives according to the separate price
item
– Inverter for fan motors
– Motor overload relay for boiler pump
■ In the control panel door:
– 4-pole main isolator
– 8” touch-screen, 640 x 480 mm
– Documentation incl. fixed wiring diagram, terminal connection diagram with cable designation, operating and maintenance instructions, and installation instructions in a plan wallet
■ Sensors and switches installed at the supply screw conveyor:
– Infrared light barrier, level monitoring, separating barrier, supply
screw conveyor
– Safety limit switch on inspection cover of supply screw conveyor
– Contact sensor PT-100 at the supply screw conveyor
14
PYROTEC
Control unit (cont.)
3.2 Accessories for Pyrocontrol
External drive control
Part no. 7387 802
Control of an external conveyor drive or a rotary lock valve without
reversing. The motors are protected against overload and switched off
early in the case of a pressing risk.
Standard delivery
■ Motor overload relay/contactor combination for drive motor fully integrated in control panel.
■ Input in control panel for safety limit switch at maintenance cover
■ Output in control panel for external conveyor drive
Note
The customer is resopnsible for the delivery and installation of the
safety switch of the external conveyor drive.
Note
Only with defined limited material supply (upstream supply screw conveyor). The electrical output data of the existing conveyor device (kW,
Ampere, Volts) must be given.
Control of external drive with light barrier
Part no. 7387 816
Control of an external conveyor drive without reversing, with interruption of the upstream charging where there is a risk of overfilling in the
inlet by means of an integral light barrier. The motors are protected
against overload and switched off early in the case of a pressing
risk.
■ Output in control panel for external conveyor drive
■ Infrared light barrier installed at the supply screw conveyor inlet
Standard delivery
■ Motor overload relay/contactor combination for drive motor fully integrated in control panel.
■ Input in control panel for safety limit switch at maintenance cover
Note
The electrical output data of the existing conveyor device (kW,
Ampere, Volts) must be given.
5822 511 GB
Note
For the control of a supply screw conveyor with external motor downstream of the external discharge.
PYROTEC
15
3
Control unit (cont.)
3.3 Accessories for Pyrocontrol output management
Cylinder management 5 sensors (QM)
Part no. 7387 809
Modulating output operation is optimised with the use of a DHW cylinder. Short term heat demand peaks are also covered. The temperature sensors record the heating of the cylinder. The specification for
the charging level of the cylinder is weather-compensated and carried
out via the external sensor. The combustion output is matched to the
charging level of the cylinder.
Standard delivery:
■ 5 additional sensors PT-1000 with sensor well 1/2" x 280 mm
■ 1 weather sensor PT-1000
External requirement on/off
Part no. 7387 986
Input for automatic switching on/off of the system via external zero volt
N/O contact.
Operating message zero volt
Part no. 7387 987
Issue of the operating condition "Load operation" (zero volt output) to
higher control technology.
Output signals 0-10 V
Part no. 7387 835
Issue of boiler output as voltage signal and connection preparation to
receive a maximum limit of the boiler output included in standard delivery.
■ Issue of the output signals.
■ Receipt and processing of an external output restriction.
■ Receipt and processing of an external output restriction.
– Incandescent bed
– Output operation
Note
Note: The installation of "Output signals 0 – 10 V" downstream of QM
wood heating plants is possible irrespective of additional control modules to be used.
Requirement, additional heat source KP0
Part no. 7387 973
Function
The additional heat source supplies, individually or jointly with the
boiler, heat to the cylinder, which is designed as a low loss header.
Taking into consideration the inertia of the boiler, control is carried out
so that the additional heat source covers the peak load and the boiler
covers the base load. In the operating phase of the additional heat
source, the boiler pump is operating and the motorised shut-off device
is open.
Standard delivery:
■ Sub-menu on touch-screen
■ Motor protection, boiler circuit pump, additional heat source
■ Control of motor, shut-off device
■ Zero volt contact for the control of the burner
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low
loss header - system sensor)
Note
The electrical output data of the on-site boiler pump (kW, Ampere,
Volts) must be given.
5822 511 GB
3
Note
For external requirement, an automatic ignition system is necessary
16
PYROTEC
Control unit (cont.)
Requirement, additional heat source KP1
Part no. 7387 905
Function
The additional heat source supplies, individually or jointly with the
boiler, heat to the cylinder. This is designed as a low loss header.
Taking into consideration the inertia of the boiler, control is carried out
so that the additional heat source covers the peak load and the boiler
covers the base load. In the operating phase of the additional heat
source, the boiler pump is operating and the control unit of the boiler
mixer is enabled.
Standard delivery:
■ Sub-menu on touch-screen
■ Motor protection, boiler circuit pump, additional heat source
■ Control of motor, shut-off device
■ Zero volt contact for the control of the burner
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return
of additional heat source)
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low
loss header - system sensor)
3
Pt1000
5822 511 GB
Note
The electrical output data of the on-site boiler pump (kW, Ampere,
Volts) must be given.
PYROTEC
17
Control unit (cont.)
3.4 Accessories for Pyrocontrol remote transfer
Fault message device, analogue with battery
Part no. 7387 840
Transmission of fault messages of boiler system either as SMS on a
mobile or as a fax. Four different text messages are possible, as the
fault message modem has four independent digital inputs.
To be carried out on the customer side:
■ Electrical connection of the phone line to the modem
■ Configuration in accordance with the documentation
Standard delivery:
■ Analogue modem in control panel
■ Battery station (also works in the event of a power failure)
Export of operating data
Standard delivery:
■ Interface at the control panel
■ Software module
■ MOD BUS report (Baud rate 9600)
Note
Additional fault message device, analogue with battery station
[ECO-SME / 7387994] possible
Additional visualisation, wired [ECO-SVD] or wireless [ECO-SVG /
7388003], not possible
Visualisation, externally via modem (connected with cable)
Part no. 7387 997
Package for the transmission of relevant data to an EDP workstation
(internal and/or external) for the visualisation, remote maintenance
and operating data archiving of the PYROTEC boiler system. Hardware and software are integrated into the Pyrocontrol control unit. All
selectable parameters can be changed from the EDP workstation.
Standard delivery:
■ Industrial PC with interfaces for screen, keyboard and PC mouse for
EDP – workstation close to boiler room
■ Analogue modem in control panel
■ Windows operating system, remote maintenance software pcAnywhere and visualisation/archiving software installed and tested on
the industrial PC.
Images on the screen:
■ Cross-section image of boiler, 3D with display fields
■ Installation scheme for heat source with display fields
■ Table of parameters (with change option)
To be carried out by customer:
■ It is the responsibility of the customer to organise the EDP workstation for remote maintenance together with modem, and installation
of pcAnywhere and modem independently.
Note
Additional fault message device, analogue with battery station [ECOSME / 7387994] possible
Also, export of operating data [ECO-SED / 7388038] not possible
Visualisation, internal
Part no. 7387 902
With a data line (max. 30 m) to the PC, all data is fed via the serial
interface RS 232 at the programming module to the PC. The current
operating data for the boiler system is shown visually on a function
screen with all options for inputting values and functions and reading
out the operating conditions (exception "Start boiler"). All operating
data is archived cyclically and can be evaluated graphically in an
extremely simple way. PC and data line are not included in the price.
Standard delivery:
■ CD with visualisation software and installation instructions
Note
Requirements for on-site PC:
Operating system Windows 98 / 2000 / XP
Free hard disk memory at least 50 MB
At least 128 MB RAM
Per boiler 1 free serial interface
Note
The PC and data line are not included in the price.
Data line to internal visualisation
Part no. 7379 404
Data line comprising:
18
■ D-SUB connector for connection between programming module and
data line, soldered
■ 30 m data line 3–pole (cut to length as required on site)
■ D-SUB connector with threaded fittings 9–pole for connection to the
PC
PYROTEC
5822 511 GB
3
Part no. 7387 890
Issue of relevant boiler system operating data and fault messages as
ASCII dataset via serial interface to higher control technology on the
customer side. All selectable parameters can be changed by higher
control technology if this is planned by control technology.
Control unit (cont.)
3.5 Mastercontrol for two-boiler systems
The Mastercontrol optimises the entire heat generation of two biomass
boilers (PYROTEC dual system) incl. control of an oil, gas or electric
boiler as a redundancy and/or as a peak load boiler.
Trade name
Boiler combination
Boiler
Part no.:
Mastercontrol for
A
Boiler 1
Pyrotec
7387 863
Boiler 2
Pyrotec
B
Boiler 1
Pyrotec
7387 848
Boiler 2
Pyrotec
Information on the Mastercontrol
Function
■ Heat management:
Optimum division of the required heating output between the two
biomass boilers with the main load on the lead boiler and the remainder load on the lag boiler via a defaulted output value. The defaulted
output is calculated in accordance with QM wood heating stations in
line with the required set temperature in the common low loss
header. Automatic switchover of the two boilers between the lead
boiler and the lag boiler is possible. This ensures an even boiler load
over a long operating time (e.g. weekly changeover).
■ Charging:
If fuel for the two biomass boilers is taken from a common fuel store,
charging is controlled up to fuel distribution by the Mastercontrol.
■ Operating data archiving:
Relevant operating data of the past 31 days is stored in a ring buffer
and can easily be displayed in graph form on the Mastercontrol
touch-screen.
■ Contactor/overload relay combinations for all common charging
drives (3 x 400 V) according to separate price items
■ Ethernet interface (network connection) on touch panel
■ Zero volt output (fault message)
■ 10“ touch-screen
■ 4-pole main isolator
■ Documentation incl. fixed wiring diagram
■ Terminal connection diagram with cable designation in plan wallet
■ Cylinder management 5 sensors (QM)
■ 5 sensors PT-1000 with sensor well 1/2" x 280 mm
■ 1 weather sensor PT-1000
■ Defaulted output value for both biomass boilers for further processing in the subordinate boiler control units via CAN-BUS
Operation:
Operation is carried out via a 10“ touch-screen integrated in the control
panel.
Visualisation with the touch-screen
■ Operating data archive
■ Display and archiving of the relevant
■ operating data of both wood boiler systems and the Mastercontrol
■ Easy operation of the wood boiler systems at the touch-screen of the
Mastercontrol
■ Installation scheme for heat source with display fields
■ Table of parameters (with parameter setting options)
■ Fault history
5822 511 GB
Standard delivery:
■ Control panel:
Surface powder coated in RAL 7035 (grey) texture. Version as per
ÖVE/VDE directives fully wired to terminal strips, fed 3 x 400 V 50
Hz; control voltage 230 V or 24 V
■ Freely programmable control unit, CE-tested, program and real time
clock are battery backed
Note
Remote maintenance with PC or network, water-side and electrical
installation is the responsibility of the customer.
PYROTEC
19
3
Control unit (cont.)
Schematic diagram
A
T
M
B
M
M
PYROCONTROL
PYROCONTROL
2
1
PYROTEC 1
T
B28.1
PYROTEC 2
MASTERCONTROL
T
B28.2
C
T
B28.3
T
B28.4
3
T
B28.5
D
PYROCONTROL
PYROCONTROL
1
2
1
(ECOTRONIC)
2
G
E
MASTERCONTROL
F
Additional heat source
Flow consumers
Cylinder as low loss header
Return consumers
E Charging exclusively boiler 1 in control unit boiler 1
F Charging exclusively boiler 2 in control unit boiler 2
G Common charging, control unit modules
5822 511 GB
A
B
C
D
20
PYROTEC
Control unit (cont.)
3.6 Accessories for Mastercontrol
Heat meter signal
Part no. 7387 975
Function
With this analogue input (0-10 V signal), the external heat meter can
be read into the Mastercontrol. The current values can be displayed.
The heat meter data is archived in the visualisation.
Requirement, additional heat source KP0
Part no. 7387 973
Function
The additional heat source supplies, individually or jointly with the
boiler, heat to the cylinder, which is designed as a low loss header.
Taking into consideration the inertia of the boiler, control is carried out
so that the additional heat source covers the peak load and the boiler
covers the base load. In the operating phase of the additional heat
source, the boiler pump is operating and the motorised shut-off device
is open. It is generally used when integrating an electric boiler.
3
Standard delivery:
■ Sub-menu on touch-screen
■ Contactor and overload relay, boiler circuit pump, additional heat
source
■ Control of motor, shut-off device
■ Zero volt contact for the control of the burner
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low
loss header - system sensor)
Note
The electrical output data of the on-site boiler pump (kW, Ampere,
Volts) must be given.
Requirement, additional heat source KP1
Part no. 7387 905
Function
The additional heat source supplies, individually or jointly with the
boiler, heat to the cylinder. This is designed as a low loss header.
Taking into consideration the inertia of the boiler, control is carried out
so that the additional heat source covers the peak load and the boiler
covers the base load. In the operating phase of the additional heat
source, the boiler pump is operating and the control unit of the boiler
mixer is enabled. It is generally used when integrating oil or gas boilers.
5822 511 GB
Standard delivery:
■ Sub-menu on touch-screen
■ Contactor and overload relay, boiler circuit pump, additional heat
source
■ Control of motor, shut-off device
■ Zero volt contact for the control of the burner
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation, return
of additional heat source)
■ Sensor PT-1000 incl. sensor well ½” x 280 mm (installation in low
loss header - system sensor)
Pt1000
Note
The electrical output data of the on-site boiler pump (kW, Ampere,
Volts) must be given.
PYROTEC
21
Control unit (cont.)
Fault message device, analogue with battery
Part no. 7387 840
Transmits the boiler system fault messages as a phone message. The
fault message must be acknowledged. Four different text messages
are possible, as the fault modem has four independent digital inputs.
To be carried out on the customer side:
■ Electrical connection of the phone line to the modem
■ Configuration in accordance with the documentation
Standard delivery:
■ Analogue modem in control panel
■ Battery station (also works in event of a power failure)
Export of operating data
Part no. 7387 890
Issue of relevant operating data and fault messages of the boiler system via MOD-BUS as ASCII dataset via a serial interface to higher
control technology on the customer side. All selectable parameters can
be changed by higher control technology if this is planned by control
technology.
Standard delivery:
■ Interface at the control panel
■ Software module
■ MOD BUS report (Baud rate 9600)
5822 511 GB
3
Note
■ Additional fault message device, analogue with battery station possible, part no. 7387 840
■ Additional visualisation, wired (part no. 7387 997) or wireless (7387
874) possible
22
PYROTEC
Heating water buffer cylinder
4.1 Specification, buffer cylinder
Note
Specification and information on request.
5822 511 GB
4
PYROTEC
23
Installation accessories
5.1 Boiler accessories
Flue gas recirculation
Standard delivery:
■ Inlet line made from heat-resistant steel, from flue outlet to inlet
adaptor
■ Inlet adaptor, supply air, with motorised cover
■ Recirculation fan in heat-resistant version
■ Supply line for gas mixture incl. covers for the combustion block
(internal and external grates)
■ Software module in the control unit
Note
The primary air fans do not apply.
Rated output
Part no.
kW
390
7388 043
530
7387 418
720
7387 982
950
7387 837
1250
7387 881
Insulation, flue gas recirculation line
High temperature resistant insulation 35 mm thick made from mineral
wool with aluminium lamination and side adhesive strips for straight
elements of the gas recirculation line. Incl. adhesive strips made from
aluminium foil for the faces.
Note
This is the responsibility of the customer as part of the general insulation work on flue gas and heating pipes.
Displacer rods
The installation of the displacer rods in the heat exchangers results in
a better heat transfer and therefore a considerable reduction in flue
gas temperature. Use is only recommended when particularly low flue
gas temperatures are required and when used as a base load boiler.
Rated output
Part no.
390
-
530
-
720
7387 419
950
7387 921
1250
Note
In the boilers Pyrotec 390 and Pyrotec 530, boiler pipes NW40 are
used. For this reason, the flow velocity of the flue gas in these boilers
is higher. No displacer rods are therefore provided for these boilers.
Automatic ignition system
Part no. 7387 420
The heating element is electronically protected against overload, eliminating the need for visual heating element monitoring. It reliably achieves the specified maximum temperatures.
Function
If the combustion chamber is filled accordingly with fuel, the ignition
process is triggered.
The fuel is ignited by means of hot air. If ignition is successful, the
ignition system cuts out.
The fan of the ignition system runs on for approx. 1 minute. This cools
the heating element and supplies the combustion chamber with fresh
air.
Automatic ignition only functions with a water content in the fuel of max.
W40.
Specification
Ignition system
Operating voltage
Pressure
Weight
Length
Width
Height
Diameter, blast tube Ø
Connection, pressure
compensation line
Max. temp.
Length, connection line
Connected load
V / Hz
Pa
kg
mm
mm
mm
mm
mm
°C
mm
kW
230/50
2800
1.1
335
85
85
31.5
38
650
2000
1.4
Note
In conjunction with the Mastercontrol, the automatic ignition system is
essential.
5822 511 GB
5
kW
24
PYROTEC
Installation accessories (cont.)
5.2 Boiler safety equipment
Thermally activated safety valve 100 °C
Part no. 7387 405
Standard version for response temperature fixed approx. 100° C, connection R ¾
Standard delivery:
■ Thermally activated safety valve incl. sensor well
Note
We recommend the thermally activated safety valve. Even if there is
no need to use it in accordance with the local safety regulations.
Thermally activated safety valve 50-120 °C
Part no. 7387 406
Special version for response temperature of 120 ° C, connection R
¾
Note
Replacement for art. no. K-TS-131; only use with manufacturer declaration
Standard delivery:
■ Thermally activated safety valve incl. sensor well
Thermally activated extinguishing valve ½”, 50-90 °C
Part no. 7387 521
Thermally opening extinguishing valve with adjustable opening temperature for on-site connection to a pressurised water line or an extinguishing water container.
Standard delivery:
■ Extinguishing valve Danfoss AVTA, adjustable 50-90 °C with dirt trap
Supply screw conveyor two-level
Part no. 7387 804
Version with two-level supply screw conveyor for optional optimised
operation for shavings/chippings (high level) on the one side and for
pellets (low level) on the other
Standard delivery:
■ Geared motor, supply screw conveyor, pole-changing 750/
300 rpm
■ Starttec for geared motor, pole-changing
■ Software module in the control unit
5822 511 GB
5
PYROTEC
25
Installation accessories (cont.)
5.3 Accessories, heat distribution
Motor three-way valve
Designation
Motor three-way valve, VBF 21.80/SQL 33 (ZH-3-80)
Motor three-way valve, VBF 21.100/SQL 33 (ZH-3-100)
Motor three-way valve, VBF 21.125/SQL 33 (ZH-3-125)
Rated output
Type
390 and 530 kW
720 kW
950 and 1250 kW
ZH-3-80
ZH-3-100
ZH-3-125
Part no.
7388 260
7388 165
7388 053
DN [mm]
Kvs [m3/h]
80
100
125
Servomotor 230
V
100 SQL 33
160 SQL 33
550 SQL 33
Incl. complete fitting
Mating flanges, gaskets
Mating flanges, gaskets
Mating flanges, gaskets
Note
No individual issue: delivery only as part of an overall system
Pumps
Rated output
Designation
Part no.
390 kW
Wilo TOP-S 50/7 DM
(ZPS-506-4)
Wilo TOP-S 65/10 DM
(ZPS-656-4)
Wilo TOP-S 80/7 DM
(ZPS-806-4)
Wilo TOP-S 80/10 DM
(ZPS-8012-4)
Wilo IL 100/145-1,1/4
(ZPS-1060-4)
7338 271
50
7388 221
65
7388 224
80
7388 131
80
7388 202
100
530 kW
720 kW
950 kW
1250 kW
DN
mm
Voltage
V
Output
Output
Incl. complete
W
fitting
m3/h / mWS
400
245-625
28.0/7.0 Mating flanges,
gaskets
400
400-960
42.0/9.0 Mating flanges,
gaskets
400
320-880
30/4.5 Mating flanges,
gaskets
400
710-1500
30/6.0 Mating flanges,
gaskets
400
1100
40/5.7 Mating flanges,
gaskets
Note
We reserve the right to select the pump manufacturers and types.
Delivery only as part of an overall system.
5822 511 GB
5
26
PYROTEC
Installation accessories (cont.)
5.4 Accessories, flue system
Flue gas dust extractor 240/800
The flue gas dust extractor minimises dust emissions and is designed
as a multi-cyclone with axial function. The dust extractor is fully insulated and has three covers for cleaning.
The crude gas space is cleaned via the side cleaning cover. The clean
gas space is cleaned via the upper or back cleaning cover (unused fan
connection).
The ash box has a carriage and is connected to the dust extractor with
quick-action fasteners. It can easily be pulled out for emptying. The fan
can be installed either on the side or top.
Standard delivery:
■ 1 flue gas dust extractor 240 or 800
■ 1 ash container with a hopper volume of 240 or 800 litres
Note
Additional ash containers must be ordered separately.
Note
The flue gas dust extractor is required for fuels with an increased fine
percentage. (Fine percentage > 4 %)
Flue gas dust extractor 240
Rated
output
Volume of ash box
Part no.
Flue gas dust extractor 800
Rated output
Volume of ash box
Part no.
kW
kW
l
390
530
720
950
1250
240
7423 679
240
7423 680
240
7423 681
240
7423 682
240
7423 683
390
800
7423 684
530
800
7423 685
720
800
7423 686
950
800
7423 687
1250
800
7423 688
Ash container 240 l, reserve
Ash container 800 l, reserve
Part no. 7387 993
Part no. 7387 783
5822 511 GB
5
PYROTEC
27
< 200
Installation accessories (cont.)
øa
A
B
c
h
d
E
m
f
b
g
øa
G
F
C
e
450
g
l
D
k
240 l
n
n
800 l
1200
940
19,19 mm
1200
940
1200
940
5
< 200
Positioning in 4x 90° possible. (Removal, ash container.)
C Dust extractor (axial cyclone)
D Ash station
5822 511 GB
A Flue gas fan (with variable rotation)
■ Either top or side
■ Unused connection as cleaning cover, clean gas space
B Cleaning cover (crude gas space)
28
PYROTEC
Installation accessories (cont.)
Dimensions
Rated output
Volume
Part no.
Weight with flue gas fan
Dimensions
a
b
c
d
e
f
g
h
k
l
m
n
Dimensions
Rated output
Volume
Part no.
Weight with flue gas fan
Dimensions
a
b
c
d
e
f
g
h
k
l
m
n
kW
l
390
240
7423 679
500
530
240
7423 680
500
720
240
7423 681
517
950
240
7423 682
535
1250
240
7423 683
559
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
350
447
2359
3186
1330
1256
600
2080
1670
620
1260
1330
350
447
2359
3186
1330
1256
600
2359
1670
620
1260
1330
350
461
2491
3378
1462
1256
660
2491
1730
620
1260
1462
400
579
2444
3452
1462
1300
690
2446
2083
620
1020
1462
450
579
2639
3717
1657
1300
760
2641
2153
620
1020
1657
kW
l
390
800
7423 684
641
530
800
7423 685
641
720
800
7423 686
691
950
800
7423 687
709
1250
800
7423 688
749
350
447
2359
3186
1330
1256
600
2080
1670
620
1260
1330
350
447
2359
3186
1330
1256
600
2080
1670
620
1260
1330
350
461
2491
3378
1462
1256
660
2491
1730
620
1260
1462
400
579
2444
3452
1462
1300
690
2446
2083
620
1020
1462
450
579
2639
3717
1657
1300
760
2641
2153
620
1020
1657
kg
kg
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
mm
Accessories, cleaning pneumatic
The whole tubular heat exchanger is cleaned with periodic blasts of
compressed air during operation. The process of cleaning itself is carried out in consecutive blasting of the individual sections. The ash is
removed from the heat exchanger pipes by means of an extremely
short but strong pressure pulse. The loosened particles are carried in
the gas flow to the dust extractor, where they are largely separated
out. The device is integrated in the boiler door. The compressor should
preferably be installed where possible in a cool place in the boiler
room.
Function of the control unit:
The number of cleaning processes within a unit of time (e.g. per hour)
is matched according to the boiler load. An individual, complete cleaning process comprises a sequence of pressure pulses across all sections of the heat exchanger.
5822 511 GB
Standard delivery:
■ Nozzle part integrated in the flue gas collector; incl. connectors with
heat deflection discs
■ Compressed air distributor with container and valves; with heatresistant hoses connected to the nozzle part
Specification
Rated output
Part no:
Number of zones/valves
Size of valves
Max. air consumption under full load
Additional weight (at the boiler)
PYROTEC
kW
pce
l/h
kg
■ Compressor (rotation compressor) for utility applications
– Supply output 160 l/min
– Container 90 l
– Pressure max. 10 bar
– Motor 1.5 kW
– 1450 rpm
– 3 x 400 V
– Incl. pressure regulator and pressure switch
– Sound power level 68 dBA
■ Compressed air hose up to max. 4.0 m length
■ Valves fully wired on terminal strip
■ Software module in the control unit
To be carried out on the customer side:
■ Provision of a socket 400 V / 16A
■ Connector for compressor 400 V / 16A
390
7423 689
8
6/4”
3500
78
530
7423 689
8
6/4”
3500
78
720
7423 690
6/4”
4400
86
950
7423 691
5
6/4”
5300
104
1250
7423 691
6
6/4”
5300
104
29
5
Installation accessories (cont.)
Price reduction net compressed air on site
Part no. 7388 288
This eliminates the need for the compressor listed in the item "Cleaning
pneumatic". The compressor provided by the customer must supply at
least the specific quantity and quality of the air and has an adjustable
pressure regulator and protection against the hose breaking (e.g. runtime limiter).
The compressor must meet the following minimum requirements:
■ Compressor (rotation compressor) for utility applications
– Supply output 160 l/min
– Container 90 l
– Pressure max.10 bar
– Motor 1.5 kW
– 1450 rpm
– 3 x 400 V
– incl. pressure regulator and pressure switch
– Sound power level 68 dBA
5822 511 GB
5
30
PYROTEC
Installation accessories (cont.)
5.5 Accessories, ash removal
External container
Complete screw conveyor ash removal from the ash chamber into an
external movable zinc-plated ash box. The level in the ash trough is
monitored by means of the light barrier. If a certain level is exceeded,
a certain quantity of ash is fed into the container. In this way, the ash
can anneal in the ash trough under the combustion system and only
cool, annealed ash is fed into the container in normal operation. For
cleaning purposes, the ash removal can be switched to continuous
operation in the event of a boiler standstill.
Standard delivery:
■ Combustion chamber conveyor made from heat-resistant steel
■ Ascending ash conveyor as a pipe conveyor with direct transfer from
the ash removal conveyor
Drive via geared conveyor motor
■ Connection station with mobile ash container
■ Control of the conveyor drives
■ Infrared light barrier, level monitoring, ash in combustion chamber
A
B
C
D
5
5822 511 GB
Connection station with mobile ash container can be installed in each
case at 90°. It is possible to select the direction in which the ash container is pulled out.
PYROTEC
31
Installation accessories (cont.)
22,07 mm
30,27 mm
8,74 mm
16,14 mm
2459
1096
742
98
2106
25,93 mm
9,13
1,20mm
mm
1793
9,13 mm
742
710
1311
Ash removal into an external container with a hopper volume of 240 l
Ash container hopper volume
Part no.
l
240
7387 415
22,07 mm
16,00 mm
21,03 mm
2459
1330
16,37 mm
30,27 mm
2337
28,77 mm
95
1210
14,77 mm
1200
1299
1708
Ash removal in external container 800 l
Ash box hopper volume
Part no.
l
800
7387 953
Extension of ascending screw conveyor
Part no. 7387 826
Note
Per metre
Max. 2 m permissible
32
5822 511 GB
5
14,89
1,17mm
mm
1793
PYROTEC
Installation accessories (cont.)
Extension of combustion chamber screw conveyor
Part no. 7388 037
Note
Per metre
Design information
6.1 System design
Selection of rated output
Select the wood boiler according to the required heat load. The Pyrotec
should be planned as a base load boiler and always operated in conjunction with a buffer cylinder (management). The correct system
design point therefore does not depend on the nominal load specification (i.e. the building heat load) but rather on the required duration
of use (length of the heating period, heat demand).
Note
In places more than 1800 metres above sea level, the project enquiry
must include information about the exact geographical location (altitude and address of the location).
Flow temperatures
To minimise distribution losses, we recommend that you size the heat
distribution system and the DHW heating to a max. flow temperature
of 70 ºC.
For wood boilers supplied with a boiler control unit, the max. boiler
water temperature is limited to 85 ºC. The flow temperature may be
increased by adjusting the control thermostat.
Safety temperatures
The boilers comply with EN 303 and DIN 4702, and all are CE-designated and can be used in sealed heating systems as per EN 12828.
■ Permissible flow temperatures (= safety temperatures):
Up to 110 ºC
To EN 12953: up to 120 ºC
■ Max. possible flow temperature:
Approx. 15 K below the safety temperature
■ High limit safety cut-out of the boiler control unit:
Delivered condition 110 ºC
Adjustable to 100 ºC
6.2 Delivery
KÖB delivers to the site. The system is unloaded on site.
A special crane is required on site for unloading.
The personnel carrying out transportation must be aware of any accident hazards. These hazards are to be prevented by suitable countermeasures.
Only lift the boiler when it is completely empty (water, fuel, ash).
To lift the combustion base, lifting eyes should be screwed to the points
provided. After unloading, the lifting eyes must be removed.
The heat exchanger is lifted by the lifting eyes provided for this purpose, placed on the combustion base and then secured to it with
screws.
6.3 Handling
Our experts can undertake the handling and installation on prepared
foundations upon request (chargeable option).
Recommended minimum clearances to walls for installation and maintenance work must be observed.
An anti-vibration boiler support should be provided if anti-vibration
measures are required.
5822 511 GB
The combustion base has four eyes that must be screwed in before
lifting. Lifting gear can be attached to these eyes.
The heat exchanger of the PYROTEC has two lifting eyes to which
lifting gear may be attached.
A special crane (on site) is required to lift the combustion block and
heat exchanger.
PYROTEC
33
6
Design information (cont.)
A
B
2°°
33,,547
20
45°
B
A Lifting eyes
(screw in before lifting)
B Lifting eyes (heat exchanger)
6.4 Installation
Requirements for boiler room
■ Avoid air contamination through halogenated hydrocarbons (e.g. as
in sprays, paints, solvents and cleaning agents)
■ Avoid very dusty conditions
■ Avoid high levels of humidity
■ Prevent frost damage and ensure good ventilation
In rooms where air contamination through halogenated hydrocarbons can occur, install the boilers and flue gas/water heat exchangers
only if adequate measures can be taken to provide a supply of uncontaminated combustion air.
If these instructions are not observed, any consequential losses
directly related to any of these causes are excluded from our warranty.
If in doubt, please contact us.
5822 511 GB
6
A separate dry boiler room must be provided for the system. No combustible materials should be stored in the boiler room. The wood boiler
may only be installed on a fire and temperature-resistant floor. No
temperature-sensitive pipes or lines should be routed through the floor
under the boiler. The load bearing capacity of the boiler room floor
should be sized to the system weight plus the water fill volume and the
fuel. Floor load bearing capacity in the area of the boiler supporting
surface 2000 kg/m².
The minimum clearances from walls and the ceiling according to the
measurement sheet, which are required for cleaning and maintenance, must be observed. An adequate fresh air supply directly from
outside into the boiler room must be ensured. If a boiler room is narrow
and/or internal, forced ventilation is required. The temperature in the
boiler room when operating the system must not exceed +40 °C
(measurement point: in boiler proximity approx. 1 m away from boiler).
The temperature in the boiler room when operating the system must
not fall below +10 °C (measurement point: inner side of external
wall).
34
PYROTEC
250
250
d
e
b
< 400
a
< 400
250
250
4,36 mm
Design information (cont.)
< 400
c
Hatched surface
Floor in heat-resistant version
Surface medium grey Boiler supporting surface
Foundation properties
Trade name
Rated output
Part no:
a
b
c
d
e
kW
mm
mm
mm
mm
mm
PYROTEC grate combustion
530
720
950
7423 675
7423 767
7423 677
1026
1112
1360
1826
1912
2160
4721
4912
5096
1260
1400
1630
3061
3112
3066
390
7423 674
1026
1826
4221
1260
2561
1250
7423 678
1360
2160
5641
1630
3611
Requirements of Sample Combustion Order
The installation room must meet the standards laid down by the "Fire
Regulations" of the respective country. Observe the Building Regulations and Fire Regulations of the respective country of installation.
Provide a sign adjacent to the emergency stop switch with the inscription "EMERGENCY STOP SWITCH - COMBUSTION".
Emergency stop switch
The burner, the fuel supply equipment and the burner control units
must be able to be switched OFF at any time by an emergency stop
switch installed outside the installation room.
6
Combustion air supply
For open flue combustion equipment with a total rated output in excess
of 35 kW, the fresh ventilation is deemed to have been verified if the
combustion equipment is located in areas which provide an aperture
or duct leading outdoors.
At 35 kW rated output, the cross-section of the aperture must be at
least 150 cm2. For every kilowatt rated output in excess of 35 kW, the
aperture must be 2 cm2 larger than stated above.
Pipes must be sized to provide equivalent flow rates. The required
cross-section may be split over a maximum of 2 apertures or pipes.
A
5822 511 GB
A = 150 cm² + 2
cm²
x (Σ²n – 35 kW)
kW
Σ²n = total of all rated outputs in kW
PYROTEC
35
Design information (cont.)
Never close or obstruct combustion air apertures and lines. Use special safety measures to ensure that the combustion equipment can
only be operated when the aperture is open.
The required cross-section must not be blocked by any closure or
grille.
26,39 mm
> 800
Minimum clearances
10,20 mm
>a
> 880
12,25 mm
> 500
14,68 mm
6
Dimensions and clearances
Trade name
Rated output
Part no:
a
kW
mm
390
7423 674
1350
PYROTEC grate combustion
530
720
950
7423 675
7423 676
7423 677
1850
1800
1600
1250
7423 678
2100
6.5 Water connection
Existing systems
Flush the heating system thoroughly before connecting the boiler to
an existing heating system, to remove dirt and sludge residues.
Otherwise, these dirt and sludge residues would be deposited in the
boiler and could lead to local overheating, noise and corrosion. Boiler
damage caused by such deposits is excluded from our warranty.
Where necessary, install dirt traps.
36
Connections on the heating water side
it is the customer's responsibility to ensure that there is a water supply
independent of the power supply. This (redundant) version guarantees
that the boiler is reliably cooled in the event of a power failure via the
thermally activated safety valve. We also refer to the standards and
regulations listed in this document.
PYROTEC
5822 511 GB
Heating connections
Design information (cont.)
Connect all heat consumers or heating circuits to the boiler flow and
return connectors. Never make any connections to the safety flow or
to other connections.
We recommend you install shut-off valves into the heating flow and
return lines, so that the entire water content will not have to be drained,
should work be required on the boiler or heating circuits.
Easy installation
For safety temperatures up to 110 ºC, the boiler requires no intermediate flow piece for the connection of safety equipment.
All connections required for the various pieces of equipment, e.g. for
water level or pressure limiters, are provided on the boiler.
Boiler circuit and shunt pumps
In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C.
The boiler has variable output control. This requires a constant boiler
flow rate of the water to be heated. The boiler circuit with boiler pump
and boiler mixer should therefore be installed in accordance with the
design recommendations.
The sizing of the boiler circuit should be carried out in such a way that
the temperature differential between the flow and return is 15 °C or
smaller. The control of the boiler pump and boiler control valve is integrated in the control unit supplied.
Safety equipment to DIN EN 12828
Installation of the safety equipment of the heating system should be
carried out by the authorised heating installer.
EN 12828 applies to the design of DHW heating systems with safety
temperatures up to max. 110 ºC.
This standard contains safety requirements laid down for boilers and
boiler systems.
■ A low water indicator is not required, except in attic heating centres
(water level limiter available as an accessory).
■ Thermometer and pressure gauge.
■ Sealed expansion vessel.
■ A safety valve at the highest point of the boiler or a pipe connected
to the boiler. The pipework between the boiler and the safety valve
must not be able to be shut off. Pumps, fittings or restrictions must
not be present in this pipework. The blow-off line should be constructed so as to prevent the possibility of increases in pressure. Any
expelled heating water must be able to be drained off safely. Arrange
the outlet of the blow-off line so that any water expelled from the
safety valve can be safely observed and drained off.
System examples
General information
■ In order to reliably prevent boiler corrosion caused by flue gas condensation, the boiler return temperature must never be below 65 °C.
A boiler circuit pump with boiler mixer should be provided in accordance with the system scheme.
■ The sizing of the boiler circuit should be carried out in such a way
that the temperature differential between the flow and return is 15
°C or smaller.
■ Integrating heat consumers
■ The expansion vessel must be connected to the boiler without shutoff devices via the boiler flow.
5822 511 GB
6
PYROTEC
37
Design information (cont.)
--B28.4--
--B28.5---B28.5--
C
G
3
--B28.2--
--B28.3--
--B28.2--
Sizing recommendation for systems with sealed expansion, cylinder circuit if required
2
--B28.5--
--B28.3--
D
2
1
2
1
2
B
H
--B28.1--
3
3
--B28.1--
1
A
3
F
E
--B28.1--
--M20--
5822 511 GB
KW
M
WW
1
L
--Y20--
P
6
Example
A
B
38
Additional heat source
1 cylinder as low loss header (5 sensors)
C
Distributor, heat consumer
PYROTEC
Design information (cont.)
D
E
F
G
H
L
M
Buffer cylinder
More than 1 buffer cylinder as low loss header
(5 sensors)
Buffer cylinder 2
Buffer cylinder 1
Low loss header
Possible with large water volume in mains
TS131
(2 pce from Pyrotec 720)
Sizing recommendation
Trade name
Rated output
Boiler circuit
Thermally activated safety valve TS-131
Required water flow rate at 2.5 bar
Cylinder capacity
Supply line ZLg
Supply line ZLv
Drain line ALv
Safety valve type SV 68 M
Safety line SL
kW
pce
l/h
l
R
R
R
R
Additional heat source controlled with a directional control valve
for
- Oil/gas boiler
- Electric heater
P With additional heat source, dual mode
- Oil, gas, electric
M20 Boiler pump
Y20 Boiler mixer
KW Cold water supply min. 2.5 bar, max. 3.5 bar
390
NW 80
1
1637
3200
¾
¾
¾
1¼
NW 50
PYROTEC grate combustion
530
720
950
NW 80
NW 100
NW 125
1
2
2
2224
3020
3986
4300
5800
7600
¾
1
1
¾
¾
¾
¾
¾
¾
1½
1½
2x 1½
NW 65
NW 80
2x NW 65
1250
NW 125
2
5246
10000
1¼
¾
¾
2x 1½
2x NW 80
6.6 Electrical installation
This should be carried out in accordance with the wiring diagram. In
the vicinity of hot parts (flue gas fan, flue pipe), cables must be routed
in steel pipes for temperature protection with appropriate clearances.
The cable entries for the motors and equipment should be dust-proof
and provided with strain relief.
Positioning of the programming module and control panel
The programming module should be installed by the electrical company responsible for installation in a place that is easily accessible for
operation. Optimal positioning of the control panel can minimise cable
lengths and therefore reduce costs. The location of the programming
module and control panel should be selected so that negative influence
caused by thermal radiation (boiler front panel, boiler back panel with
flue gas collector and flue gas fan, as well as flue pipe) and exposure
to dust during cleaning is minimised.
The ambient temperature of the control panel (approx. 10 cm away
from the control panel) when operating the system must not exceed
40 °C. In case of doubt, the control panel should preferably be located
outside the boiler room near to the boiler room door.
Note
The regulations of the local power supply utility must be observed.
6.7 Safety equipment
Expansion
The required expansion vessels should be selected according to the
system-specific circumstances (pressure, water content, etc.).
6
In the case of sealed expansion, the pre-charge pressure of the expansion vessel should be equal to the max. system height plus 0.2 bar.
Extinguishing facilities
In accordance with TRVB 118, the container should be equipped with
fill level monitoring. The boiler automatically switches off in case of a
water shortage. In the case of excessive temperature, the supply
screw conveyor safety is flooded, but to a limited extent.
5822 511 GB
A water extinguishing facility is required on the supply screw conveyor.
This facility is intended to reliably prevent burn-back in the event of a
fault (e.g. power failure).
For safety reasons and in order to avoid damage caused by flooding,
it is not advisable to connect the extinguishing facility directly to the
water mains. This extinguishing facility is equipped with an extinguishing water container 25 l with float switch and an adjustable Danfos
extinguishing valve.
PYROTEC
39
Design information (cont.)
Extinguishing water container
Part no. 7387 785
C Material supply
D Combustion
A
Note
Part of the boiler.
B
< 500
C
Note
■ Adjustment, valve, Danfos AVTA 15 50–90 °C
3 corresponds to 80 C°.
■ Lines should be secured in metal pipes (½“).
■ The cold water supply must not be able to be isolated without the aid
of a tool.
D
17,34 mm
A N25 fill level monitoring
B Extinguishing water container 25 l
Extinguishing facility with cold water supply
Part no. 7388 521
KW
KW
6
A
B
A
B
A Combustion
B Dosing container with separating barrier
KW Cold water supply DN 15 ½“ min. 2.0 bar, max. 3.0 bar
Note
Alternative or additional safety equipment. A shut-off gate valve is
required as standard for an unpressurised material store or a rotary
lock valve for a material store with overpressure or underpressure
(charging with fan, e.g. wood processing operations).
5822 511 GB
Note
■ Lines should be secured in metal pipes (½“).
■ The cold water supply must not be able to be isolated without the aid
of a tool.
Back burning protection, boiler system
The boiler system back burning protection is part of the standard delivery.
40
PYROTEC
Design information (cont.)
Prevention of combustion chamber overfilling
In accordance with TRVB 118, a fill level monitor should be installed
to prevent overfilling of the combustion chamber. The boiler has two
light barriers for incandescence monitoring. A sensor directly on the
insert pipe is used to detect any sign of a burn-back risk and to counteract this early on by means of a short-term output increase (increasing in material feed).
As a result, any prescribed protection device does not come into effect
and normal operation is maintained with regard to the greatest possible
heat supply reliability.
Reignition protection
In accordance with TRVB 118, reignition protection is prescribed for
all systems over 150 kW. If a spark detection and extinguishing facility
is not used, TRD 414 prescribes a constantly available separating
barrier (TRD 414 relates primarily to waste wood from the preparation
and distribution of wood and wood materials). There are simpler ways
of achieving this for woodchips from the forestry and sawmill sector.
The boiler is equipped with a separating barrier and is operated permanently with underpressure. The boiler is then equipped with reignition protection in accordance with both TRVB 118 and TRD 414.
Back burning protection, fuel supply (RSE)
Additional "material transportation back burning protection" depends
on the relevant requirements (location, size of the fuel store, material,
pressure, regulations) and is a separate item from the standard delivery ordered from KÖB Holzfeuerungen GmbH.
For this boiler, we recommend installing a rotary lock valve. In addition
to the back burning protection, the penetration of infiltrating air via the
supply screw conveyor is also prevented.
Shut-off gate valve
The shut-off gate valve is permissible in all unpressurised fuel stores
and is considered suitable back burning protection in accordance with
TRVB 118 (test certificate BV 2979/89).
Rotary lock valve
If the wood remnants are introduced with fans in fuel storage rooms,
due to the pressure load, at least one rotary lock valve is required to
reduce pressure between the fuel store and the boiler. The rotary lock
valve is suitable for reducing pressure and at the same time is considered suitable back burning protection in accordance with TRVB 118
(test certificate BV 2979/89).
■ Max. permissible overpressure in the fuel store: + 500 Pa
■ Max. permissible underpressure in the fuel store: + 0 Pa
Dual rotary lock valve with pressure compensation
If, due to special circumstances, mechanically generated underpressure or extremely high overpressure can be expected in the fuel store,
then in accordance with the relevant project plan, two rotary lock valves
with a pressure compensation to outside should be installed in the
material transport path.
The maximum pressures that can be expected are to be confirmed by
the supplier of the chip extraction system. Leaks may occur in the
rotary lock valve under the silo discharge system as a result of wearing
of the sealing elements or due to larger pieces of wood that cannot be
transported. Such leaks may allow the back flow of low temperature
carbonisation gases from the combustion system into the silo.
Between the rotary lock valve and the silo discharge system, a flue gas
alarm should be installed, which, when responding, switches off the
system causing the silo underpressure.
■ Max. permissible overpressure in the fuel store: + 3000 Pa
■ Max. permissible underpressure in the fuel store: - 3000 Pa
6
Low water indicator
EN 12828 specifies that boilers must be equipped with a low water
indicator (water level limiter). Tests have verified that the burner will
be automatically switched OFF in the event of water shortage due to
a leak in the heating system and oil burner operation, before the boiler
or the flue system reach unacceptably high temperatures.
5822 511 GB
Maximum pressure limiter
If the rated output of the wood boiler is more than 300 kW, a maximum
pressure limit is required for each boiler in a system.
PYROTEC
For installation purposes, the wood boilers have a R½ connector on
top of the boiler.
41
Design information (cont.)
Minimum pressure limiter
Recommended for flow temperatures in excess of 100 ºC. One
required per multi boiler system.
Safety valve
Equip the boilers to EN 12828 with a type-tested safety valve. For all
other operating conditions, this must be identified in accordance with
TRD 721 with "D/G/H":
The pipework between the boiler and the safety valve must not be able
to be shut off. Pumps, fittings or restrictions must not be present in this
pipework.
Expansion vessel
For boilers above 300 kW, install an expansion vessel with blow-off
and drain line near the safety valve. In order to prevent a risk caused
by escaping steam, the blow-off line must be routed to the outside.
The blow-off line on the safety valve should be constructed so as to
prevent the possibility of increases in pressure. Arrange the outlet of
the drain line so that any water expelled by the safety valve can be
safely observed and drained off.
Replacement, expansion vessel
An additional expansion vessel and blow-off line are not required if a
second high limit safety cut-out and a second maximum pressure limiter are installed.
6.8 Fire protection
The fire safety regulations for wood combustion systems vary depending on the country.
The regulations valid for the relevant installation location must be
observed.
Fire protection, fuel store
The measures necessary for this are not part of the standard delivery
from KÖB Holzheizsysteme GmbH.
Note
In this regard, the conditions of the local planning office must be fulfilled
by the operator.
6.9 Commissioning
Initial commissioning of a newly installed system may only be carried
out by KÖB Holzheizsyteme GmbH or another contractor trained and
authorised by KÖB. Prior to commissioning, the system must be filled
with water, fuel must be stored for the commissioning and the installation must be monitored.
Fuel for commissioning
Rated output
390 kW
530 kW
720 kW
950 kW
1250 kW
Quantity of the fuel to be stored
approx. 2500 kg
approx. 3000 kg
approx. 4000 kg
approx. 5300 kg
approx. 6800 kg
Filling the heating system
Usually, the system is initially filled with raw water without chemical
treatment. This must be filtered and be free of suspended solids. Particular attention should be paid to careful ventilation during filling. In
the case of difficult water conditions (high hardness, etc.) and/or large
water volumes, VDI directive 2035 "Prevention of damage through
corrosion and scaling in hot water heating systems" must be observed.
Measures recommended by the directive for water treatment should
be carried out.
42
Note
The fill pressure of the cold hydraulic seal should be approx. 0.1 bar
higher than the pre-charge pressure of the sealed expansion vessel.
However, it must not exceed a maximum of 3 bar.
5822 511 GB
6
As the boiler system is cold and residual moisture is also extracted
from the refractory concrete during commissioning, the fuel for commissioning must be at least air dry. The heat-up process should be
carried out in the first three hours with low output. In order to check the
function of the silo discharge system, not too much fuel should be
stored so that, in the event of a fault, the discharge system can be
quickly released to remedy the cause. For commissioning, dry fuel with
a max. water content of 20 % (W20) should be stored. The quantity
corresponds to consumption of approx. 10 – 24 full operating hours.
PYROTEC
Design information (cont.)
6.10 Fuel
The PYROTEC grate combustion has been specially developed for the
automatic combustion of dry and moist wood fuels (waste wood, wood
pellets or woodchips from forest thinnings up to max. W50). It combines the benefits of underfeed combustion with the advantages of
grate combustion to optimum effect.
Suitable fuels
The Pyrotec is suitable for the following dry to moist wood fuels in
accordance with ÖNORM M 7133:
Note
The following are unsuitable types of fuel: Fossil fuels and those containing sulphur, such as anthracite and coke, as well as plastics, grain,
straw, material soaked in flammable liquids and waste wood treated
with plastics or wood preservatives.
Bulk density S (kg/m³)
S 130
S 200
S 200
S 250
S 250
S 300
S 300
S 350
S 350
S 400
S 130
S 200
S 250
S 350
S 650
S 650
Water content W (%)
W10 to W20
W20 to W35
W20
W20 to W35
W35 to W50
W20 to W35
W35 to W50
W20 to W35
W35 to W50
W35 to W50
< W15
< W15
< W15
< W15
< W10
< W10
Size G (mm)
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
G30/50
Fuel
Natural sawdust
Natural sawdust
Soft natural woodchips from forest thinnings
Soft natural woodchips from forest thinnings
Natural sawdust
Soft/hard natural woodchips from forest thinnings
Soft natural woodchips from forest thinnings
Hard natural woodchips from forest thinnings
Soft/hard natural woodchips from forest thinnings
Hard natural woodchips from forest thinnings
Dry, mixed shavings, chippings from waste wood
Dry, mixed shavings, chippings from waste wood
Dry, mixed shavings, chippings from waste wood
Briquettes from waste wood D 40 to 60 mm
Standardised natural pellets D 6 to 10 mm
Standardised natural pellets D 11 to 15 mm
6.11 Fuel discharge by means of screw conveyor
Discharge conveyor, pellet, D = 120 mm
Part no. 7837 954
As pellet transportation from a rectangular room with the possibility of
filling from the top. The pellets trickle via a tilted intermediate floor into
the conveyor channel. The supply screw conveyor found inside this
channel transports the pellets to the outlet.
Standard delivery:
■ Discharge conveyor for pellets according to project drawing
Note
Price given per m; total length in m = length of conveyor channel
6
Note
For increases of 0° to 8°; exclusively for pellets; boiler output up to
max. 1250 kW
To be carried out on the customer side:
Delivery and installation of the intermediate floor (preferably made of
wood) incl. static calculation and sizing. The forces resulting from the
weight of the combustion material (approx. 650 kg/m3) should be
transferred to the silo floor and not through the discharge conveyor.
Observe this when constructing the intermediate floor.
mm
mm
mm
D=120 mm
7837 954
< 9250
> 750
< 10000
5822 511 GB
Specification
Pellet discharge conveyor
Part no.
a
b
c
PYROTEC
43
Design information (cont.)
24,36 mm
7,53 mm
5,92 mm 77,60 mm
a
<200
b
c
3,28 mm
<30
0-8°
3,10 mm
8,02°
250
<110
5,15 mm
c
A
180x180
102,15 mm
c
260
500
540
~ 500 166
130
12,13
3,84mm
mm
23,07 mm
14,79
14,03
mm
4,96
mmmm
B
1,48 mm
50
C-C
2,
09
m
9,79
6,21
mm
mm m
D
D
201
24
10,20 mm
24,31 mm
40,28 mm
115
274
454
A Possible outlet into a bunker
B Optional drive left or right
< 30
75
6,65 mm
58
45°
45°
6
66
24
110
8,8720,67
mm mm
C
C Intermediate floor
D Intermediate floor with anti-vibration measure
Part no. 7387 998
The system is driven via a spur geared motor and chain in a dust-proof
chain guard. The geared motors are sized at the factory.
44
Standard delivery:
■ Drive unit
■ Spur geared motor matched to boiler size and pump rate
PYROTEC
5822 511 GB
Drive, discharge conveyor, pellets
Design information (cont.)
■ Control of spur geared motor 3 x 400 V according to boiler control
unit
■ Inspection cover with safety limit switch and sealed outlet
6.12 Fuel discharge by means of agitators
Spring core discharge AF
Part no. 7387 964 for spring core discharge 3.5 m
Part no. 7387 977 for spring core discharge 4.5 m
Silo or bunker discharge with bottom agitator in lightweight version,
especially for smaller bunker volumes and/or lower boiler outputs. The
fuel supply is carried out via a bottom agitator with two leaf spring arms,
which fills a screw channel let into the floor (or intermediate floor). If
the silo is full, the leaf spring arms move to the cover disk. Drive is via
a geared conveyor motor to the discharge screw and via an angular
gear to the agitator. The spring core discharge is suitable for round,
square and rectangular rooms.
Standard delivery:
Spring core discharge according to the project drawing
■ Bottom agitator with two leaf spring arms
■ Drive unit with geared conveyor motor 3 x 400 V
■ Control according to boiler control unit with enabling by the following
conveyor device; speed/output:
Project-related and subject to boiler output and fuel
Specification
Spring core discharge AF
Part no.
a
Max. length of discharge screw
b
Discharge circuit
c
Boiler output at angle of inclination
Torque at shaft
Pellets S 650
Woodchips from forest S 200
Shavings
Maximum fill level
Pellets S 650
Woodchips from forest S 200
■ Light barrier for monitoring the fill level at the end of the sealed screw
channel
■ Outlet with inspection cover and safety limit switch
To be carried out on the customer side:
■ Installation of an intermediate floor required (preferably wooden
boards)
Note
1. Discharge screw must be ordered for this!
2. Speed/output of the drives: Sizing by KÖB design department.
m
m
Nm
kW
kW
kW
m
m
AF 3.5 m
7387 964
6
3.5
0°
450
540
300
220
AF 4.5 m
7387 977
6
4.5
15°
450
540
220
150
2.7
5.0
2.7
5.0
5822 511 GB
6
PYROTEC
45
Design information (cont.)
11,00 mm
Sizing
52,24 mm 4,14 mm
72,64 mm 11,89 mm
24,75 mm
170
ø 150
b
< 6000
320
480
80
361
205
9,93
2,20mm
mm
13,20
8,80
mmmm
22,00 mm
140
ø 110
500
250
øa
3,85 mm
5,42 mm
6,88 mm
13,75 mm
300
8,25 mm
385
275
700
440
C
3,03 mm
18,93 mm
10,59 mm
7,56 mm
900
160
A
400
> 42
4,40 mm
4,40 mm
B
> 250
8,25
1,16mm
mm
øa
800
m
m
5
8
,
73 m
47,24 m
0
E
F
c
160
6
4,47 mm
D
< 600
d
G
D
E
F
G
Shavings
Remainder
Pellets
Base (height adjustable)
5822 511 GB
A Second leaf spring
B Installation opening
(seal with fire-retardant panel)
C Rotational direction
46
PYROTEC
Design information (cont.)
Note
1. Installation position, horizontal:
preferably in concrete with recess for screw conveyor and central
gear
2. Installation position, angled:
exclusively with intermediate floor, preferably made from wood
3. Suitable for woodchips up to G30/50; not suitable for wood briquettes and shredded matter from used or waste wood
4. Sloping installation position reduces the discharge output and the
degree of emptying (by approx. 2.3% per 1 degree slope)
5. Speed/output: Project-related and subject to boiler output and fuel,
sizing by KÖB design department
Discharge screw AF to spring core discharge
Part no. 7388 035
The fuel is moved by the spring core discharge arms into the open
conveyor channel in the silo. Outside the bunker, the screw channel is
sealed.
Note
Article price per m, always round up to whole numbers!
The max. length of the discharge screw AF is 6 m.
Total price = total length a in metres (max. 6 m) x individual price
Standard delivery:
■ Conveyor channel with specially matched discharge screw
Horizontal discharge AH
Part no. 7387 979 for horizontal discharge up to D = 5.0 m
Part no. 7387 854 for horizontal discharge up to D = 6.5 m
Horizontal discharge with bottom agitator in heavy version, especially
for larger bunker volumes and/or high boiler outputs. The two agitator
arms each comprise one or two (depending on size) articulated arm(s)
and an externally fitted leaf spring package. The agitator is driven subject to the fill level of the discharge screw (control via light barrier).
The discharge screw itself is enabled independently of the agitator by
a separate drive unit according to the boiler requirement. The result is
trouble-free operation and a long service life. When using pellets, a
cover panel is required over the screw channel. Maximum fill level and
maximum slope must be observed.
Standard delivery:
Horizontal discharge according to the project drawing
■ Bottom agitator with two arms and external drive with shaft routed to
inside
■ Drive for bottom agitator 3 x 400 V, with geared conveyor motor and
torque support; control according to boiler control unit with enabling
of discharge screw
m
kg
Nm
Nm
To be carried out on the customer side:
■ Installation of an intermediate floor required (preferably made from
wooden boards)
Note
1. Discharge screw (part no.: 7387 603) must also be ordered!
2. Speed/output of the drives: Sizing by KÖB design department.
6
AH up to 5 m
7837 979
3.8
4.5
480
480
~2900
~800
~2900
~800
5.0
480
~2900
~800
AH up to 6 m
7837 854
5.0
5.5
500
500
~2900
~800
~2900
~800
6.0
500
~2900
~800
5822 511 GB
Specification
Horizontal discharge AH
Part no.
Discharge circuit f
Weight excluding conveyor channel
Torque of the drives
A
B
■ Drive unit for discharge screw with spur geared motor 3 x 400 V and
chain drive; control according to boiler control unit with enabling of
the following conveyor device; speed/output: project-related and
subject to boiler output and fuel
■ Light barrier for monitoring the fill level at the end of the sealed screw
channel
■ Outlet with inspection cover and safety limit switch
PYROTEC
47
Design information (cont.)
42,99 mm
øg
4,33 mm
18,03 mm
410
A
B
246
287
ø 1490
3,46 mm
øf
e
2,9629,62
mm mm
a
34,54 mm37,56 mm
14,59 mm
7,29 mm
D
< 200
d
C
c
b
> 10000
A Axis, agitator
B Screw axis
585
C Rotational direction
D Centre, agitator
Sizing the horizontal discharge AH with agitator and discharge screw
a
Min. length of protective panel for bunker walls
b
Sealed channel
c
Open conveyor channel downstream of agitator centre
d
Open conveyor channel upstream of agitator centre max. 2.8 m
e
Wall clearance to centre
f
Discharge circuit from 3.9 to 6.1 m depending on bunker situation
g
Effective scope 0.8 to 0.95 x f
Depending on: fuel, installation position, compression, etc.
5822 511 GB
6
48
PYROTEC
4,85
4,00mm
mm
4,81 mm
Design information (cont.)
76,25 mm
A
B
A
B
> 10000
361
406
A
< 330
3,65 mm
B
< 200
A
B
B
A
a
C
> 1000
0
A
< 200
A-A
B-B
287
A
46
=
< 300
< 170
=
< 330
> 725
F
< 600
E
D
6
G
D
1,52 mm
E
C
30
C-C
K
H
< 330
1260
1360
H
0,96 mm
C
13,59 mm
14,67 mm
50
33,67 mm
L1 + 200
C
630
630
5822 511 GB
1260
PYROTEC
49
Design information (cont.)
A
B
C
Installation position, horizontal (version 1)
Installation position, sloping (version 2)
Finished floor, concrete-lined (concrete block out for recessed
installation)
A Finished floor
B Seal installation opening with fire-retardant panel
C Height adjustable base
D
E
F
G
H
K
Fuel-specific limits
Maximum fill level
Pellets S 650
Briquettes S 350
Woodchips from forest S
250
Boiler output max.
Pellets S 650
Briquettes S 350
Woodchips from forest S
250
a
Pellets S 650
Briquettes S 350
Woodchips from forest S
250
Note
For pellets, the cover panels part no. 7387 895 are required.
m
m
m
Axis, screw conveyor
Axis, agitator
Sub-structure
Building floor
Centre, agitator
Concrete block out (for recessed installation)
4.5
6.0
8.0
kW
kW
kW
2000
720
720
Angle of inclination max.
6°
0°
15°
Discharge screw AH for horizontal discharge
Part no. 7387 603
The fuel is moved by the horizontal discharge agitator arms into the
conveyor channel, which is open across the entire bunker length. Outside the bunker, the screw channel is sealed.
Standard delivery:
■ Conveyor channel running through the entire system with specially
matched discharge screw
Note
Article price per m
The max. length is 10 m. Total price:
Total length L in m (max. 10) x individual price
Protective panel AH for bunker
Part no. 7387 985
Metal cover to protect against damage to the bunker wall caused by
the agitator arms. Mounting on the internal wall of the silo.
Cover panel AH for pellets
Part no. 7387 895
Metal cover of the open screw conveyor area to reduce the inlet cross
section.
Standard delivery:
■ Cover panel, painted
Length and number matched to the project
■ Screws
Note
Observe the following when changing the fuel:
1. Changeover from woodchips from forest thinnings to pellets:
Before filling the silo with woodchips from forest thinnings, remove
the cover panels from the discharge screw.
2. Changeover from pellets to woodchips from forest thinnings:
The discharge system is to be extended by means of cover panels.
5822 511 GB
6
Standard delivery:
■ Protective panel, painted
Length and number matched to the project
■ Rawl plugs and screws
50
PYROTEC
Design information (cont.)
6.13 Fuel discharge by means of funnel discharge
Funnel discharge
Material discharge for round silos is carried out with an agitator integrated in the discharge casing. In its centre, the discharge screw is
driven via a solid universal joint. When the silo is full, the screw conveyor moves into a vertical position. The funnel limits the angle of the
screw conveyor when the silo is empty. Drive is via a spur geared
conveyor motor to the agitator. In the case of material compression in
the discharge casing, as a result of increased drive power consumption, the supply direction of the screw conveyor is changed automatically for a period set at the factory. This releases the compression,
preventing a fault.
Standard delivery:
■ Funnel discharge as per order data with drive unit 3 x 400 V
■ Automatic control of the drive for the spur geared conveyor motor for
both rotational directions
■ Safety limit switch installed on inspection cover of discharge casing
Version and drives
Funnel discharge
Part no.
Diameter, discharge circuit, max.
Boiler outputs with
Pellets S 650
Woodchips from forest S 200
Shavings S 130
Torque at screw conveyor
m
kW
kW
kW
Nm
AP-11
7837 899
6.0
AP-12
7837 929
7.5
3000
1250
1250
~1500
2500
2500
2500
~3000
øa
øb
95
210
c
6
11,22 mm
8,32 mm
e
320
5822 511 GB
< 600
d
0°
5,15 mm
°
40
40,0
17,94 mm
18,86 mm
6,69 mm
95
< 1,8 x a
2,21 mm
57,48 mm
2,26 mm
PYROTEC
51
Design information (cont.)
Version and drives
Funnel discharge
Part no.
a
b
c
d
e
m
mm
mm
mm
Nm
AP-11
AP-12
AP-Z02*8
7387 899
6.0
2205
708
282
431
7387 929
7.5
3005
1030
310
469
7388 042
7.5
3005
1030
-
Additional outlet flange
Part no. 7388 520
Additional connection option for supply equipment to discharge casing
for twin-boiler system.
Funnel, large
Part no. 7388 042
Surcharge for a funnel diameter of 3000 mm.
Note
In the case of funnel discharge AP-12, a funnel diameter of 3000 mm
is required.
6.14 Fuel discharge by means of a push floor (sizing)
Number and length of the pushrods with a maximum dumping height
Special version as individual rod with a width of up to 3.00 m possible
on request.
Max. permissible dumping height and length of the pushrods in S200
Trade name
Type
AS-2.50
Part no.:
7387 992
Dumping height with length:
12
m
3.1
10
m
3.9
8
m
5.3
6
m
7.5
6
Max. permissible dumping height and length of the pushrods in S350
Trade name
Type
AS-2.50
Part no.:
7387 992
Dumping height with length:
10
m
2.6
8
m
3.4
6
m
4.9
Max. permissible dumping height and length of the pushrods in S450
Trade name
Type
AS-2.50
Part no.:
7387 992
Dumping height with length:
10
m
2.1
8
m
2.7
6
m
3.8
*8
52
AS-2.25
7387 995
Pushrod
AS-2.0
7387 836
AS-1.75
7387 956
AS-1.5
7387 989
3.6
4.6
6.1
8.6
4.1
5.3
7.0
9.8
4.9
6.3
8.4
12.3
5.8
7.4
9.8
14.9
AS-2.25
7387 995
Pushrod
AS-2.0
7387 836
AS-1.75
7387 956
AS-1.5
7387 989
3.0
4.0
5.6
3.5
4.55
6.4
4.1
5.4
8.0
4.8
6.4
9.7
AS-2.25
7387 995
Pushrod
AS-2.0
7387 836
AS-1.75
7387 956
AS-1.5
7387 989
2.4
3.1
4.4
2.7
3.6
5.0
3.2
4.2
6.2
3.8
5.0
7.5
5822 511 GB
Applies to pushrods for pushrod drive (AS) individual and for the pushrod with discharge function of the AS-twin (standard version). Permissible dumping heights below are maximum values and should not be
exceeded.
Option for article AP-11. Required for AP- 12.
PYROTEC
Design information (cont.)
Max. permissible dumping height and length of the pushrods in S650
Trade name
Type
AS-2.50
Part no.:
7387 992
Dumping height with length:
12
m
1.5
10
m
1.9
8
m
2.6
6
m
3.7
AS-2.25
7387 995
Pushrod
AS-2.0
7387 836
AS-1.75
7387 956
AS-1.5
7387 989
1.8
2.3
3.0
4.3
2.0
2.6
3.5
4.9
2.4
3.1
4.2
6.1
2.9
3.7
4.9
7.4
Specification for the pushrod drives
Trade name
Type
Part no.:
Piston diameter
Piston rod diameter
Lift
Test pressure
Pressure force at 190 bar FZD
Tensile force at 190 bar FZZ
Length from centre of cylinder - piston boss
mm
mm
mm
bar
kN
kN
mm
Individual standard
7387 978
180
90
600
240
484
362
Type K
1080
Pushrod drive
Twin standard
7387 915
180
90
600
240
484
362
Type L
1230
Heavy
Version
On request
220
110
800
240
722
542
1575
Forces on the building
In the case of pushrod drives for discharge push floors with several
pushrods, the hydraulic cylinders have pipes laid in opposite flow
directions, i.e. the first cylinder pulls, the second cylinder pushes, the
third cylinder pulls, etc. The cylinder with the lowest pressure drops
generally moves first into the end position, then the next one.
When all cylinders are in the end position, the oil pressure increases
up to the response pressure for the pressure diverter valve (set to 190
bar at the factory) and this switches to the opposite direction.
5822 511 GB
6
FG1 Maximum tensile force on the weld base of the bunker upwards
per metre length
FS Total standard forces on the front panel (slot discharge)
PYROTEC
FR Total standard forces on the back panel
FR1 Standard force of a pushrod on the back panel
FS1 Standard force of a pushrod on the front panel
53
Design information (cont.)
FZD Maximum pressure force on the weld base for the pushrod
drive
FZZ Maximum tensile force on the weld base for the pushrod drive
Number of pushrods
FS
FR
1
1x FS1
1x FR1
mm
mm
Standard version
AS-001/2
Heavy version
Y article
2
1x FS1
1x FR1
3
2x FS1
110
FS1
160 kN
FR1
130 kN
FZZ
362 kN
FZD
484 kN
FG1
12 kN
FM1
100 kN
Z
125 mm
240 kN
195 kN
542 kN
722 kN
15 kN
150 kN
150 mm
Slot discharge, for pulling
The drawing below is a general arrangement and should not be used
for construction design. A project-related drawing must be produced
for construction design.
Specification
Slot discharge, for pulling
a
b
c
d
e
f
mm
mm
mm
mm
mm
Note
Only KÖB original weld bases are permissible for the pushrod drive.
Screw
D = 190 mm
650
380
350
For max. dumping height, see page 52
> 3200
1500-2500
Screw
D = 250 mm
700
430
400
For max. dumping height, see page 52
> 3200
1500-2500
5822 511 GB
6
54
PYROTEC
Design information (cont.)
a
500
B
7,92 mm
A
125
5,54
1,98mm
mm
10,29 mm
c
6,02 mm
0,89
19,48
mm
9,50
mmmm
27,72 mm
95,02 mm
b
1230
50
600
> 1750
(4000 - 12000)
0,48 mm
d
50 - 150
C
FS1
A
f
> 150
A
K
FR1
A
> 100
FZD
e
49,44 mm
FZZ
> 100
15,84 mm
E
C
D
1500 - 2500
D
1500 - 2500
F
1,19 mm
0,79
mm19,68
19,80
mm0,79
mm
mm
42,36 mm
A-A
H
G
5822 511 GB
Required order data for the above example:
Position
Part no.
Quantity
7387 978
2
A
7387 924
1
B
7387 952
2
C
7387 830
2
D
E
Corresp. to length
2
F
See pricelist
Corresp. to dimensions
1
G
See pricelist
7387 904
1
H
Corresponding boiler output
1
K
See pricelist
Unit
pce
pce
pce
pce
6
pce
Designation
Pushrod drive AS individual with hydraulic cylinder type L
Cover for push floor screw conveyor (optional)
Weld base, AS individual
Weld base, bunker
Hydraulic compartment
Pushrod (incl. stop wedges)
pce
Push floor screw conveyor
pce
pce
Version and drive, AQ standard
Hydraulic drive, ASH individual
Centre discharge
The drawing below is a general arrangement and should not be used
for construction design. A project-related drawing must be produced
for construction design.
PYROTEC
Note
Use only KÖB original weld bases for the pushrod drive!
55
Design information (cont.)
Specification
Centre discharge
12,67 mm
800
500
FM1
a
5,54 mm
250
A
125
2,09 mm
mm
Screw
D = 250 mm
400
360
For max. dumping height, see page 52
In the middle third of the silo length
> 3200
8,07 mm
mm
mm
3,96 mm
a
b
c
d
e
Screw
D = 190 mm
350
270
For max. dumping height, see page 52
In the middle third of the silo length
> 3200
0,84
17,10
mm
9,50
mmmm
4,28 mm
33,26 mm
95,02 mm
50
1080
600
+10
b 0
> 2100
C
0,43 mm
50 - 150
A-A
B
E
1500 - 2500
K
D
1,30 mm
0,79
19,69
mm19,73
mm1,58
mm
mm
43,16 mm
d
15,84 mm
0,51 mm
46,86 mm
50 - 150
c
(5000 - 12000)
6
H
F
A
5822 511 GB
G
1500 - 2500
> 150
e
A
56
PYROTEC
Design information (cont.)
Required order data for the above example:
Position
Quantity
2
A
2
B
C
1
D
4
E
1
F
G
1
H
2
K
Unit
pce
pce
pce
pce
pce
pce
pce
Designation
Pushrod drive AS individual with hydraulic cylinder type K
Weld base, bunker
Cover, centre discharge
Push floor screw conveyor
Pushrod (incl. stop wedges)
Version and drive, AQ standard
Hydraulic compartment
Hydraulic drive, ASH individual
Weld base, AS individual
Slot discharge with fill function
The drawing below is a general arrangement and should not be used
for construction design. A project-related drawing must be produced
for construction design.
Specification
Slot discharge with fill function
a
b
c
d
e
f
Note
Use only KÖB original weld bases for the pushrod drive!
mm
mm
mm
Screw
D = 190 mm
650
380
350
mm
> 3200
Screw
D = 250 mm
700
430
400
Charging chute
For max. dumping height, see page 52
> 3200
5822 511 GB
6
PYROTEC
57
Design information (cont.)
9,71 mm
235
500
230
5,86 mm
3,57
mm
16,78
9,32
mmmm
b
c
125
2,04 mm
5,44
mm
3,57
mm
a
7,70 mm
B
A
1080
600
1,90 mm
15,53 mm
>46,60
3000mm
230
d
e
15,53 mm
0,50 mm
46,60 mm 46,60 mm
93,20 mm
A-A
50 - 150
C
< 8000
< 12000
FZZ
FS1
> 100
FR1
> 150
A
g
1500 - 2500
f
A
G
FZD
3,03
0,54 mm
mm
390
E
5822 511 GB
F
50 - 150
> 100
49,60 mm
H
1,16 mm
6
D
1500 - 2500
C
19,42
9,42
mm
0,78
mm
0,78
mm1mm
41,55 mm
(< 20000)
58
PYROTEC
Design information (cont.)
Required order data for the above example:
Position
Quantity
2
A
1
B
2
C
2
D
1
E
1
F
1
G
2
H
Unit
pce
pce
pce
pce
pce
pce
pce
pce
Designation
Pushrod drive AS twin with hydraulic cylinder type K
Cover for push floor screw conveyor (optional)
Weld base, bunker
Pushrod (incl. stop wedges)
Push floor screw conveyor
Version and drive, AQ standard
Hydraulic drive, ASH twin
Weld base, AS twin
6.15 Fuel discharge by means of push floor (accessory)
Pushrod drive, individual
Part no. 7387 978
With hydraulic cylinders, pushrods to which transport wedges are
attached, are moved forwards and backwards. Stop wedges are fixed
to the floor between the transport wedges. As a result of this movement, the wood fuel is dispensed from the bunker and fed into the
trough of the push floor screw conveyor.
Standard delivery:
■ Mount with hinge lug connection for the cylinder
■ Hydraulic cylinder with 2 HP ball valves and 2 hydraulic hoses
■ Pushrod up to bunker wall with hinge lug connection
■ Material for complete hydraulic pipework
Weld base, pushrod drive, individual
Part no. 7387 952
Solid steel structure for installation in concrete to secure the pushrod
drive. The structure has been load tested and permanently withstands
the dynamic stress. A prerequisite for this is the prescribed embedding
in concrete.
Standard delivery:
■ 1 weld base per pushrod drive
To be carried out on the customer side:
■ Location, positioning and connecting of the weld base with the iron
reinforcement on the customer side
■ Embedding the weld base in concrete
■ Static calculation and sizing of the iron reinforcement on the customer side
Note
Only KÖB original weld bases are permissible!
Pushrod drive, twin
Part no. 7387 915
With hydraulic cylinders, pushrods to which transport wedges are
attached, are moved forwards and backwards. Stop wedges are fixed
to the floor between the transport wedges.
In the case of a twin pushrod drive, each longitudinal section of the
bunker is moved with two pushrods working independently of one
another.
■ Charging pushrod for quick removal of the fuel filled at the bunker
end in the direction of the bunker centre.
■ Discharge pushrod for the dispensed discharge of the wood fuel into
the trough of the push floor screw conveyor.
The two pushrod drives are located one above the other and are supported by a joint mount.
Standard delivery:
■ Mount for two cylinders with a hinge lug connection
■ Two hydraulic cylinders with 2 HP ball valves and 2 hydraulic hoses
■ Discharge pushrod up to bunker wall with hinge lug connection
■ Charging pushrod up to start of level charging function with hinge
lug connection
■ Material for complete hydraulic pipework
Weld base, pushrod drive, twin
Part no. 7387 916
Solid steel structure for installation in concrete to secure the pushrod
drive. The structure has been load tested. If embedding in concrete
has been carried out in accordance with the regulations, the weld base
permanently withstands dynamic stress.
Standard delivery:
■ 1 weld base per pushrod drive
To be carried out on the customer side:
■ Location, positioning and connecting of the weld base with the iron
reinforcement on the customer side
■ Embedding the weld base in concrete
■ Static calculation and sizing of the iron reinforcement on the customer side
Note
Only KÖB original weld bases are permissible!
5822 511 GB
Weld base, bunker
Part no. 7387 830
Steel profiles for welding the pushrod guide elements and the trough
of the push floor screw conveyor. The weld base in the bunker is also
the slide rail for the pushrod.
PYROTEC
Standard delivery:
■ Rolled profiles UNP 240 with anchoring irons per pushrod over the
entire length
■ Angle profiles 50/50/5 with anchoring irons over the entire width
(push floor screw conveyor)
59
6
Design information (cont.)
To be carried out on the customer side:
■ Manufacturing the concrete floor
■ Installation of the profiles level with the concrete floor (max. deviation
of 5 mm to 10 m)
Note
Article price per m
Total price is calculated as follows:
For pushrod drive, individual: (pushrod drives in pce x length of bunker
in m) + (1 x width of bunker in m) x article price
For pushrod drive, twin: (pushrod drives in pce x length of bunker in
m) + (2 x width of bunker in m) x article price
Pushrod
Pushrod in solid structure with crosswise transport wedges, side connection profiles, stop wedges and guide elements.
Length x width of the pushrod gives the floor area moved with the
transport wedges.
Note
Number width transport wedge in m; article price per m;
Total price: Length in m x article price (for max. length, see table 3)
Standard delivery:
■ Pushrod split into rod, transport wedges and guide elements (welding during installation)
■ Stop wedges incl. fixing materials
Specification
Pushrod
Part no.
Width
m
B 1.50
7837 989
1.50
B 1.75
7387 956
1.75
B 2.00
7387 836
2.00
B 2.25
7387 995
2.25
B 2.50
7837 992
2.50
Hydraulic drive, AS individual
6
■ Control:
According to the boiler control unit, fuse protected with temperature
and level switch in the oil container
Use of the hydraulic drives for various push floors (drives plus rods)*9
Hydraulic drive, AS individual
Rated output of the boiler/s
kW
Part no.
kW
Output, gear pump*10
Supply volume
l/min
Stage 1
Draught
bar
Stage 1
Supply volume
l/min
Stage 2
Draught
bar
Stage 2
Oil content
l
pce
Max. number of pushrods*11
*9
V9
100-720
7387 912
4
9
V18
750-1250
7387 901
4
9
V40
1250-2500
7387 806
7.5
20
200
200
200
-
18
40
-
100
100
30
3
55
3(4)
80
3(4)
Additional equipment for driving hydraulically controlled silo covers possible.
*10 Information on function: with a 2-stage gear pump, the pump runs in standard mode at stage 2, which means that the pushrods move quickly.
Only when the pressure drop is increased (e.g. in the case of a forward movement of the discharge pushrod with a high fill level) does the
pump switch to stage 1.
*11 Values in brackets: option only in coordination with project management at the factory.
60
PYROTEC
5822 511 GB
Hydraulic drive to actuate single pushrod drives with discharge function. When the required fill level of the push floor screw conveyor is
reached, the discharge function is switched off.
■ Hydraulic drive comprising:
– Gear pump 3 x 400 V
– Oil container
– Non-return valve
– Pressure limit valve
– Pressure diverter valve
– Return filter
– Oil level indicator
– Pressure gauge
– Shut-off valve
– Oil filling
– Hydraulic hoses
– Wall mounting brackets
Design information (cont.)
Hydraulic drive, AS twin
Hydraulic drive to activate twin pushrod drives with discharge and fill
function. When the required fill level of the push floor screw conveyor
is reached, the discharge function is switched off. If there is free space
above the discharge push floor to accommodate top-up fuel, the top
and back pushrod carries out the fill function. When the fuel is required
by the heating system, the fill function is interrupted and switched to
the discharge function of the bottom and front pushrod.
■ Hydraulic drive comprising:
– Gear pump 3 x 400 V
– Oil container
– 4/2-way solenoid valve
– Non-return valve
– pressure limiting valve
– Pressure diverter valve
– Return filter
– Oil level indicator
– Pressure gauge
– Shut-off valve
– Oil filling
– Hydraulic hoses
– Wall mounting brackets
■ 2 infrared light barriers for level monitoring, bunker
■ Control of discharge function:
according to the boiler control unit, fuse protected with temperature
and level switch in the oil container
■ Control of fill function:
According to the light barrier enabling in the bunker
Use of the hydraulic drives for various push floors (drives plus rods)*12
Hydraulic drive, AS twin
Rated output of the boiler/s
Part no.
Output, gear pump*13
Supply volume
Stage 1
Draught
Stage 1
Supply volume
Stage 2
Draught
Stage 2
Oil content
Max. number of pushrods*14
V18
100-1250
7387 812
4
9
V40
1250-2500
7387 969
7.5
20
200
200
18
40
bar
100
100
l
pce
55
3(4)
80
3(4)
kW
kW
l/min
bar
l/min
Push floor screw conveyor D = 190 mm
Part no. 7387 811
In order to transport the discharged fuel away from the pushrods, the
push floor screw conveyor extends over the entire push floor width as
an open trough screw conveyor. For further transportation, the push
floor screw conveyor, depending on the transfer situation, is designed
in the sealed version as a trough or pipe.
Standard delivery:
■ Push floor screw conveyor according to the project drawing
6
Note
Article price per m
Push floor screw conveyor D = 250 mm
5822 511 GB
Part no. 7387 887
In order to transport the discharged fuel away from the pushrods, the
push floor screw conveyor extends over the entire push floor width as
an open trough screw conveyor. For further transportation, the push
floor screw conveyor, depending on the transfer situation, is designed
in the sealed version as a trough or pipe.
*12 Additional
Standard delivery:
■ Push floor screw conveyor according to the project drawing
Note
Article price per m
equipment for driving hydraulically controlled silo covers possible.
*13 Information on function: with a 2-stage gear pump, the pump runs in standard mode at stage 2, which means that the pushrods move quickly.
Only when the pressure drop is increased (e.g. in the case of a forward movement of the discharge pushrod with a high fill level) does the
pump switch to stage 1.
*14 Values in brackets: option only in coordination with project management at the factory.
PYROTEC
61
Design information (cont.)
Drive, push floor screw conveyor, standard
Part no. 7387 925
Standard version for push floor screw conveyor with pulling drive and
discharge into a drop section. The system is driven via a spur geared
motor and chain in a dust-proof chain guard.
Drive, push floor screw conveyor, standard
Part no.
Torque at screw conveyor
Push floor screw conveyor
Function, push floor screw conveyor
Max. length, push floor screw conveyor
Max. boiler output with woodchips
Standard delivery:
■ Drive unit with spur geared motor 400 V and chain drive
■ Light barrier across the entire open area for monitoring the fill level
(overfill protection)
■ Discharge with inspection cover, safety limit switch and downpipe/
adaptor for the following conveyor device (not required in pushing
version)
Nm
Type
m
kW
~800
AQ-L150
Pulling
10
300
7837 925
~800
AQ-L150
Pushing
8
300
~800
AQ-L190
Pulling
10
1250
Drive, push floor screw conveyor, higher-power
Part no. 7387 880
Special, powerful version of the push floor screw conveyor for more
difficult applications (high pump rate and/or pushing function). The
system is driven via a more powerful version of a spur geared motor,
bearing and chain in a dust-proof chain guard.
Drive, push floor screw conveyor, higher-power
Part no.
Torque at screw conveyor
Push floor screw conveyor
Function, push floor screw conveyor
Max. length, push floor screw conveyor
Max. boiler output with chippings
Standard delivery:
■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 400 V and chain drive; matching
and control on project basis;
■ Light barrier across the entire open area for monitoring the fill level
(overfill protection)
■ Discharge with inspection cover, safety limit switch and downpipe/
adaptor for the following conveyor device (not required in pushing
version)
Nm
Type
m
kW
~1200
AQ-L190
Pulling
10
1500
7837 880
~1200
AQ-L250
Pushing
8
2500
~1200
AQ-L250
Pulling
10
2500
Cover, push floor screw conveyor
Note
Article price per m;
Total price: Length A in m x article price [A = width of bunker]
Standard delivery:
■ Cover of the push floor screw conveyor with wall mounting bracket
and hinge according to project drawing
■ Limit switch for emergency stop of the push floor and the push floor
screw conveyor when opening the cover
6.16 Charging the boiler with fuel
Trough screw conveyor
Part no. 7387 941 for trough screw conveyor D = 150 mm
Part no. 7387 873 for trough screw conveyor D = 190 mm
Part no. 7387 955 for trough screw conveyor D = 250 mm
The trough screw conveyor is an extremely reliable means of transportation for all granulated wood fuels. Observe the restriction in the
angle of inclination.
Standard delivery:
■ Trough screw conveyor according to the project drawing
Note
Article price per m; total price; length L in m x article price
5822 511 GB
6
Part no. 7387 924
Cover for the open trough of the push floor screw conveyor and the
bunker slot. The cover is fitted to the front bunker panel and can be
opened via a hinge. It helps to protect maintenance personnel against
contact.
62
PYROTEC
Design information (cont.)
500
2 mm
5,10 m1m4,5 176
A-A
000
m
58,32 m < 10
e
5,51 mm
g
A
f
a/b
2,32 mm80
6,38 mm
a
A
l
15,67 mm
3,77 mm
7,54 mm
k
A
7,54 mme
500
h
mm
13,77 mm 4,82
14,51166
mm
~ 500
b
7,31 mm
2,32 mm80
5,80 mm
d
c
8,30° c
A
8,12 mm
1,11
mmmm
> 6,40
30
50
m
1,47 m
0
8,75 mm 30
m
4,53 m
166
7,54 mm
B
A Drive (optionally on the l.h. or r.h. side)
B Inspection clearance
Trade name
Type
Part no:
a
b
c (woodchips from forest thinnings)
c (pellets)
d
e
f
g
h
k
l
mm
mm
mm
mm
mm
mm
mm
mm
mm
Trough screw conveyor
MF 150
MF 190
7387 941
7387 873
180x180
220x220
7180
7200
20°
20°
45°
45°
140
280
220
260
216
256
150
190
130
130
260
260
540
540
MF 250
7387 955
280x280
7200
20°
45°
380
352
317
250
154
350
665
Drive, trough screw conveyor, standard
Proven version for the trough screw conveyor with pulling drive and
discharge into a drop section. The system is driven via a spur geared
motor and chain in a dust-proof chain guard.
5822 511 GB
Trade name
Part no:
Torque at screw conveyor
Diameter, screw conveyor
Function
Max. length
Max. boiler output (pellets)
Max. boiler output (woodchips from forest thinnings)
Nm
mm
m
kW
kW
Standard delivery:
■ Drive unit with spur geared motor 3 x 400 V and chain drive
■ Inlet with light barrier for monitoring the fill level (overfill protection)
■ Discharge with inspection cover, safety limit switch and downpipe/
adaptor for the following conveyor device
Drive, trough screw conveyor
7387 984
~800
~800
7150
7190
Pulling
Pulling
10
10
2000
3200
600
1500
~800
7250
Pulling
8
2500
Pipe screw conveyor
Part no. 7387 990 for pipe screw conveyor D = 120 mm
Part no. 7387 962 for pipe screw conveyor D = 190 mm
Part no. 7387 928 for pipe screw conveyor D = 250 mm
PYROTEC
63
6
Design information (cont.)
The pipe screw conveyor is ideal for conveying pourable wood fuels
and/or in the case of steep ascending inclines.
Note
Article price per m
Total price: Length L in m x article price
Standard delivery:
■ Pipe screw conveyor according to the project drawing
Trade name
Part no:
Diameter of the screw conveyor max.
Trade name
Type
Part no:
a
b
c
d
Angle of inclination max. with pushing screw conveyor
e
Angle of inclination max. with pulling screw conveyor
e
f
g
h
k
l
mm
7387 990
120
Pipe screw conveyor
7387 962
190
7387 928
250
mm
mm
mm
mm
MR-L120
7387 990
140
150x150
140
120
Pipe screw conveyor
MR-L190
7387 962
280
220x220
220
190
MR-L250
7387 928
380
280x280
324
250
mm
-
90°
90°
mm
mm
mm
mm
mm
mm
65°
7150
140
540
130
260
65°
7200
280
540
130
260
65°
7200
380
665
154
350
5822 511 GB
6
64
PYROTEC
m
3,77 mm
m
12,26
4,35
12,92
mm
mmmm
Design information (cont.)
13,90 mm
3,36
10,55
mm
mm
m
m
a
500
l
A
m
m
25
0
6,
23
m
8
08
7°
16
f
e
4,
2
46,
m
c
k
~ 500
<
d
2,58 mm
b
h
166
10
00
0
g
94
,
51 mm 2,56 mm
5,99
a
4,61 mm
30
g
9,
00
2
10
<
m
1,94 mm 7
6,
9
m
8
m
m
5,25
m mm
m
f
D
E
58°
29
2
C
e
16
b
3,
7
45,
4,60 mm
4,
55
c
5,
d
0
m
m
35
5
B
A Drive (optionally on the l.h. or r.h. side)
B Distributing container
C Distributing screw conveyor
6
D Pipe screw conveyor, vertical, pushing
E Pipe screw conveyor, horizontal, pushing
Drive, pipe screw conveyor, pellets
5822 511 GB
Part no. 7387 931
Simple version of the pipe screw conveyor MR 120 with pulling drive
and only permissible for pellets. The system is driven via a spur geared
motor and chain in a dust-proof chain guard.
Trade name
Type
Part no:
Diameter of the screw conveyor max.
Torque at screw conveyor
Function
Length of the screw conveyor max.
Boiler output max.
PYROTEC
Standard delivery:
■ Drive unit with spur geared motor 3 x 400 V and chain drive
■ Inlet/discharge in simple version for pellets; incl. downpipe/adaptor
for the following conveyor device
mm
Nm
m
kW
Drive, pipe screw conveyor, pellets
MR-11
7387 931
120
~800
Pulling
10
1200
65
Design information (cont.)
Drive, pipe screw conveyor, standard
Part no. 7387 843
Standard version for pipe screw conveyor with pulling drive and discharge into a drop section. The system is driven via a spur geared
motor and chain in a dust-proof chain guard. For MR 150 and exclusively with pellets, it is also possible as a pushing version.
Trade name
Type
Part no:
Diameter of the screw conveyor max.
Torque at screw conveyor
Function
Length of the screw conveyor max.
Boiler output max. when using:
Pellets
Woodchips from forest thinnings
Standard delivery:
■ Drive unit with spur geared motor 3 x 400 V and chain drive
■ Inlet with light barrier for monitoring the fill level (overfill protection)
■ Discharge with inspection cover, safety limit switch and downpipe/
adaptor for the following conveyor device (not required in pushing
version)
Drive, pipe screw conveyor, standard
MR-12
7387 843
150
150
~800
~800
Pulling
Pushing
10
8
mm
Nm
m
kW
kW
200
300
1200
-
190
~800
Pulling
10
3200
1250
Drive, pipe screw conveyor, high-power
Part no. 7387 963
Special, powerful version of the pipe screw conveyor for more difficult
applications (high pump rate and/or pushing function). The system is
driven via a more powerful version of a spur geared motor, bearing
and chain in a dust-proof chain guard.
Trade name
Type
Part no:
Diameter of the screw conveyor max.
Torque at screw conveyor
Function
Length of the screw conveyor max.
Boiler output max. when using:
Woodchips from forest thinnings
Standard delivery:
■ Drive unit in powerful version and additional axial bearing with pushing function with spur geared motor 3 x 400 V and chain drive
■ Inlet with light barrier for monitoring the fill level
■ Discharge with inspection cover, safety limit switch and downpipe/
adaptor for the following conveyor device (not required in pushing
version)
Drive, pipe screw conveyor, high-power
MR-13
7387 963
190
250
~1100
~1100
Pulling
Pushing
10
8
mm
Nm
m
kW
1500
2500
250
~1100
Pulling
10
2500
6.17 Fuel storage in on-site pellet store (sizing)
Sizing the pellet storage room
The storage room should be more rectangular than square and should
be of a size which allows an annual quantity of fuel to be stored. The
size of the storage room depends on the heating load of the building.
The floor area should, however, not be less than 2 x 3 m.
The required size of the storage room for the annual fuel volume in
m3 (incl. empty space) is calculated by multiplying the building heating
load (in kW) by a factor of 0.9 (m3/kW).
Example:
Heating load of the building 150 kW
150 kW x 0.9 (m3/kW) = 135 m3
Available space (storage room less unusable area due to sloping
floors) = 135 m3 x 2/3 +135 m3 = 225 m3
Amount of pellets = 225 m3 x 650 kg/m3
= 146250 kg/m3 ≈ 147 t
Storage room size = 135 m3/ 2.3 m (room height)
= 59 m2 floor area
In order to store the annual fuel quantity, a room size of 7 m x 8.5 m
is sufficient.
Stored amount of energy = 58500 kg x 5 kWh/kg = 292 500 kWh
5822 511 GB
6
66
PYROTEC
Design information (cont.)
200 mm
A
B
C
≥ 500 mm
D
40°
G
A
B
C
D
E
F
E Empty space
F Discharge system
G Available volume = ⅔ of the room
Fill connector
Return air connector
Air space
Slanted floor
Pellet storage room design and required system components
A
B
C
D
≥ 100
6
K
H
G
E < 9250
5822 511 GB
F
A
B
C
D
E
<10000
Protective boards at the entrance to the storage room
Supply area, screw supply system
Deflector
Discharge to supply screw conveyor
Min./max. length of the discharge area
PYROTEC
F
G
H
K
Max. storage room length
Return air connector
Fill connector
Slanted panel to compensate for the lengths of the storage room/
supply area
67
Design information (cont.)
■ The pellet storage room must be dry, as pellets will swell up markedly
if exposed to moisture. This leads to substantial difficulties in delivering the fuel to the boiler.
■ The pellet storage room must be of solid, leak-proof construction, as
loading pellets into the room creates dust and the pellets will exert
high pressure against the walls.
■ Doors or access hatches into the pellet storage room must open
outwards and must be sealed against dust egress (with an all-round
seal). From a pellet amount in excess of 6.5 tonnes, doors must be
self-closing and fire-retardant T30.
■ Fit protective boards on the inside of the door opening, so that pellets
do not push against the door (see page 68).
■ Avoid electrical installation in the pellet storage room. Essential
electrical installations must be of explosion-proof type – in accordance with current regulations.
■ a In Austria, surrounding walls and separating ceilings in the storage room must be designed in accordance with fire resistance class
F90, and doors or access hatches in accordance with T30. Observe
the fire regulations to TRVB H118 and the respective legal requirements.
■ Avoid the installation of water pipes inside the storage room because
of condensation and the risk of burst pipes.
■ Pellet storage rooms should be equipped with a delivery H and a
return air connector G with a coupling 4” DW100 (fire hose connector) with extension hoses leading into the pellet storage room.
Pipes should be metal (not plastic), should be connected to the
brickwork and should be earthed.
■ Fit a deflector C opposite the fill connector to protect the pellets and
the brickwork.
■ The pellet storage room must be free from foreign bodies (small
stones, wood particles, etc.).
■ The wall outlet for the room discharge from the storage room should
be fire-proofed (e.g. rendered).
The screw conveyor system may be up to max. 10 m long.
Additional safety instructions for pellet stores
To operate the pellet store, we also recommend observing the following safety instructions:
1 Access by unauthorised persons is not permitted, and doors must
be kept sealed
2 Smoking, fires and other sources of ignition are prohibited
3 Risk to life due to odourless carbon monoxide (CO) and a lack of
oxygen
4 Before entering, ensure sufficient ventilation is in place - keep
door open when entering
5 Entry into the storage room is only permitted with the supervision
of a person standing outside the storage room
6 Risk of injury caused by moving parts
7 Ensure filling is carried out under the conditions stipulated by the
heating installer and pellet supplier
8 Protect the pellets from moisture
Protective boards with Z profiles
A
B
A
Z brackets are available as accessories for the installation of the protective boards.
Never install Z brackets up to the ceiling, to facilitate the (future)
removal or addition of protective boards.
6
C
A Z profile (length 2000 mm)
B Protective board (30 mm thick; on-site)
C Door towards the storage room
Fill connector and return air connector
68
Earthing
The connectors must be earthed in order to prevent static loads during
the filling process. Generally the connection of each pipe element to
the bonding of the building earth is recommended. At the very least,
connect each pipe element securely to the brickwork, either by setting
the pipe into the brickwork (without thermal insulation) or via pipe clips
set into the brickwork.
5822 511 GB
Arrange the connectors so that no overpressure is created in the pellet
storage room during the filling process. Keep the return connector
unrestricted, even when the maximum filling level in the storage room
has been reached (see page 67). The connectors should be located
as high as possible inside the storage room to enable it to be filled to
its maximum. To prevent pellets hitting the ceiling, the fill connector
should be at least 20 cm below the ceiling (fit protective boards if the
ceiling is plastered). The connectors should be located along the narrow side of the storage room. Pellets are blown approx. 4 - 5 m with
straight fill connectors. Where a 2 x 45° bend fitting is located before
the entry into the storage room, fit a straight pipe of at least 0.5 m length
on the other side to protrude into the storage room. This enables the
pellets to reach the required filling velocity and therefore the necessary
"blow-in" depth.
PYROTEC
Design information (cont.)
Connector length and location
The length of the fill connector is subject to the distance from the return
air connector. Connectors may be spaced out < 500 mm if both connectors are set into a cellar window.
Internal pellet storage room
If the fill and return air connectors must be routed through an adjacent
room, clad both with a fire-resistant material compliant with class F 90
(rockwool, or similar). Earth each extension piece via pipe clips. Plastic
pipes should not be used as extension pieces.
≥ 500
~ 100
If connectors must be located on the long side of the storage room, we
recommend alternating the filling between the connectors. This
ensures more efficient filling. In any case both connectors should be
earthed. A deflector should be installed opposite both connectors.
Connector clearance ≥500 mm
A Fill connector
B Return air connector
A
A
B
C
D
C
D
Connector
Fire resistant cladding (F 90)
Extension pipe
Pipe clip
< 500
≥ 500
B
~ 100
Connector clearance < 500 mm
A Fill connector
B Return air connector
6
≥200 mm
B
A
approx. 100 mm
B
A
5822 511 GB
Alternating filling
A Deflector
B Fill and return air connector
PYROTEC
69
Design information (cont.)
Connector installation options
Setting into brickwork
The connector is bricked into the opening without thermal insulation.
A Fill connector
B Wall outlet Ø 150 mm
Wall installation with screws
The connector is secured to the outside wall with screws and is earthed
via a pipe clip.
C Pipe clip for earthing
D Wall outlet Ø 110 mm
C
BA
D
A Fill connector
B Screws
Window installation with screws
A plate is set into the window opening. The connector is fitted through
the plate, secured with screws and earthed via a pipe clip.
C Pipe clip for earthing
D Outlet Ø 110 mm
E Window aperture
C
D
E
BA
A Fill connector
B Screws
5822 511 GB
6
70
PYROTEC
Design information (cont.)
Installation into a lighting duct
Connectors may be installed through a wall or through a window opening. The shortened fill and return connectors are inserted in a 45 º
bend. The bend is inserted into an extension pipe routed through the
wall or the window opening.
C Extension pipe
D Wall outlet Ø 110 mm
or
Outlet Ø 110 mm
E 45º bend
B
A
E
C
D
A Fill connector
B Pipe clip for earthing
6.18 Fuel storage in on-site pellet store (accessories)
Deflector 1.42 x 1.25 m
Part no. 7388 188
The deflector comprises 4.0 mm thick chipboard with a fabric lining for
high strength.
Install the deflector B at a clearance of at least 100 mm from the wall
opposite the fill connector. This deflector protects the pellets as well
as the brickwork or the rendering/plaster.
Pieces of plaster/render or wall that have been prised off can hinder
the pellet supply and the ash removal from the boiler combustion
chamber.
A
B
C
Standard delivery
■ Deflector 1.4 x 1.25 m
■ Section anchor with snap link for fastening
≥200 mm
6
A Fill connector
B Deflector (1000 x 1200 mm)
C Fill width approx. 4 - 5 m
Blast pipe, straight
Part no. 7388 213
■ Zinc-plated steel pipe with male thread M 107 x 2.0
■ Dummy coupling with imprint and padlock
Standard delivery:
■ Blow-in connector with Storz coupling 4”
■ Mounting flange 200 x 200 x 2 mm
Blast pipe with 45° bend
5822 511 GB
Part no. 7388 154
■ Zinc-plated steel pipe with male thread M 107 x 2.0
■ Dummy coupling with imprint and padlock
Standard delivery:
■ Blow-in connector with Storz coupling 4”
■ Mounting flange 200 x 200 x 2 mm
PYROTEC
71
Design information (cont.)
Extension, blast pipe, straight
Part no. 7388 056
Standard delivery:
■ Extension DN 100, length 700 mm, zinc-plated
■ Union nut for fitting
■ Clip for fastening
45° bend for blow line
Part no. 7388 052
Standard delivery:
■ Zinc-plated bend DN 100
■ Union nut for fitting
6.19 Fuel storage in on-site bunker (accessories)
Silo cover, manual FDM 2.9/1.3 m
Part no. 7387 782
Cover for secure sealing of openings for wood fuel delivery. The cover
is controlled manually with leg springs as an opening aid. The opening
has a fall protection grille to prevent anyone falling in when the cover
is open.
Note
For the filling process (opening, filling, closing), the local regulations
on accident prevention must be observed (e.g. enclosure, safety of
personnel)
■ Cover
– Surface, aluminium button plate
– Watertight, welded
■ Leg springs as opening aid
To be carried out on the customer side:
■ Creating the ceiling recess with concrete collar
■ Seal between cover frame and supporting surface, concrete collar
■ Padlock to protect against incorrect operation
Standard delivery:
■ Steel supporting structure
– Permissible load 250 kg/m²
– Sand-blasted
– Primed with zinc dust and painted
■ Welded fall protection grille with rod clearance 150 mm
5822 511 GB
6
72
PYROTEC
Design information (cont.)
A All-round seal (not included in standard delivery)
B Rod clearance, fall protection grille
C Secured with 10 x screws
6
Bunker cover hydraulic FDH
Cover for secure sealing of openings for wood fuel delivery. The cover
is controlled manually using a hydraulic cylinder. The silo cover is prevented from falling shut in the event of a hose break.
■ Hydraulic cylinder with hinge lug connection, pipe break protection,
mount, hydraulic hoses 1 m long
■ Rubber apron to deflect chippings on the hinge side
Note
For the filling process (opening, filling, closing), the local regulations
on accident prevention must be observed (e.g. enclosure, safety of
personnel). Where wind is strong (greater than 10 m/s), the cover must
not be opened.
To be carried out on the customer side:
■ Creating the ceiling recess with concrete collar
■ Seal between cover frame and supporting surface, concrete collar
5822 511 GB
Standard delivery:
■ Supporting structure: permissible load 250 kg/m² made from steel,
sand-blasted, primed with zinc dust and painted
■ Cover surface: Aluminium button plate, watertight, welded
PYROTEC
73
A
h
40,55 mm
Design information (cont.)
B
62,77 mm
C
g
Specification
Type*15
Part no.
Opening length x width
a
c
Dimensions, concrete collar
b
d
e
Dimensions, cover, external
f
g
h
Number of hydraulic cylinders
Weights, cover
*15 Type
74
FDH 4.0/2.4
7388 011
FDH 5.5/2.4
7387 903
FDH 7.0/2.4
7387 834
FDH 8.5/2.4
7387 884
mm
mm
4020
2400
5520
2400
7020
2400
8520
2400
mm
mm
mm
4420
2800
250
5920
2800
250
7420
2800
250
8920
2800
250
mm
mm
mm
pce
kg
3025
4500
2924
1
1029
3025
6000
2924
1
1231
3025
7500
2924
1
1516
3025
9000
2924
2
1823
5822 511 GB
6
A Fall protection grille (optional)
B Rubber apron
C All-round seal, required, not included in standard delivery
Recommendation: Kemperol combi roof seals
7.0/2.4 and 8.5/2.4 with covered expansion joint for heat expansion
PYROTEC
Design information (cont.)
Fall protection grille 120 for FDH
Fall protection grille for corresponding bunker cover in several elements to prevent anyone falling in when the cover is open. Each element is prepared for installation of a shaker motor (shaker motor at an
additional charge).
Specification
Fall protection grille, type 120 for
Part no.
Quantity
Weight per pce
pce
kg
Standard delivery:
■ Support profile for installation in ceiling recess
■ Fall protection grille in several elements, mesh size: 200 x 120 mm
FDH 4.0/2.4
7387 914
2
117
FDH 5.5/2.4
7387 817
2
161
FDH 7.0/2.4
7388 014
3
133/141
FDH 8.5/2.4
7387 922
4
124/120
Fall protection grille 200 for FDH
Fall protection grille to prevent anyone falling in when the cover is
open. Suitable for corresponding bunker cover in several elements.
Each element is prepared for installation of a shaker motor (shaker
motor at an additional charge).
Specification
Fall protection grille, type 200 for
Part no.
Number of elements
Weight per pce
pce
kg
Standard delivery:
■ Support profile for installation in ceiling recess
■ Fall protection grille in several elements, mesh size: 200 x 200 mm
FDH 4.0/2.4
7387 910
2
104
FDH 5.5/2.4
7387 824
2
143
FDH 7.0/2.4
7387 930
3
118/125
FDH 8.5/2.4
7387 983
4
110/106
Bunker cover, movable FDB
Cover for secure sealing of openings let into travel planes for wood
fuel delivery. The surface of the cover is flush with the travel plane.
The sub-structure has a drip channel. The cover is controlled manually
using a hydraulic cylinder. The silo cover is prevented from falling shut
in the event of a hose break.
Standard delivery:
■ Supporting structure:
Perm. wheel load: FDB 3.0/2.0: 7.5 to; FDB 3.8/2.4 and FDB 3.2/3.2:
10.0 to; steel, sand-blasted, primed with zinc dust and painted.
■ Cover surface:
For filling with asphalt or concrete on the customer side.
■ Sub-structure:
Has drip channel and two drain connectors NW 100.
■ Hydraulic cylinder:
With hinge lug connection, pipe break protection, mount and
hydraulic hoses 1 m long
To be carried out on the customer side:
■ If the travel surface is sloping, the water flowing to the cover must
be drained away upstream of the cover frame by means of a drain
channel
■ Drain line for rainwater, channel heating
■ Seal between cover frame and supporting surface of cover frame
■ Filling of the cover surface with a bitumen layer and asphalt or concrete, watertight design (max. permissible own weight of the fill 2200
kg/m3)
5822 511 GB
6
PYROTEC
75
b
,
86
31,972,26
mm mm
39,71 mm
Design information (cont.)
86
08
°
120
°
A
1,90 mm
~ 1730
ø102
C
B
56,10 mm
a
37,68 mm
c
1,87 mm58,53 mm1,87 mm
90
90
(120)
±0,0
f
F
G
90
C
D
H
< 10%
A
B
C
D
76
Filling on customer side (concrete or asphalt)
Channel for rainwater
Rainwater drain (on site)
Threaded fitting
E
F
G
H
Filling level
Fall protection grille (optional)
All-round seal (required) (on site)
Drain channel, running water (on site)
5822 511 GB
6
E
6,78 mm
d
e
290
47,31 mm
1,68 mm
5,30 mm
40,20 mm
C
PYROTEC
Design information (cont.)
Specification
Bunker cover, movable FDB
Part no.
a
b
c
d
e
f
Weight, cover, FDB
Max. permissible wheel load
mm
mm
mm
mm
mm
mm
kg
t
FDB 3.0/2.0 m
7387 850
3000
2110
2000
3150
2530
2150
1520
7.5
FDH 3.8/2.4 m
7387 793
3800
2510
2400
3950
2930
2550
2360
10
FDH 3.2/3.2 m
7387 974
3200
3310
3200
3350
3730
3310
2680
10
Fall protection grille, 120 for FDB
Fall protection grille to prevent anyone falling in when the cover is
open. Suitable for corresponding bunker cover in several elements.
Each element is prepared for installation of a shaker motor (shaker
motor for additional charge).
Specification
Fall protection grille, type 120 for
Part no.
Number of elements
Weight per pce
Standard delivery:
■ Support profile for installation in ceiling recess
■ Fall protection grille in several elements
■ Mesh size:
200 x 120 mm
pce
kg
FDB 3.0/2.0 m
7387 889
2
130
FDH 3.8/2.4 m
7388 016
2
205
FDH 3.2/3.2 m
7387 868
2
230
Fall protection grille, 200 for FDB
Fall protection grille to prevent anyone falling in when the cover is
open. Suitable for corresponding bunker cover in several elements.
Each element is prepared for installation of a shaker motor (shaker
motor for additional charge).
Standard delivery:
■ Support profile for installation in ceiling recess
■ Fall protection grille in several elements
■ Mesh size:
200 x 200 mm
Specification
Fall protection grille, type 200 for
Part no.
Weight per pce
pce
kg
FDB 3.0/2.0 m
7387 798
2
120
FDH 3.8/2.4 m
7387 801
2
180
FDH 3.2/3.2 m
7388 019
2
210
Shaker motor for fall protection grille
Part no. 7387 810
The shaker motor sets the fall protection grille in an oscillating motion.
This prevents the delivered fuel from bridging the fall protection grille
and therefore ensures a steady material flow during filling.
Standard delivery:
■ Shaker motor, 3 x 400 V incl. control, thermal protection and installation material
■ Key switch
To be carried out on the customer side:
■ Electrical connection of shaker motor and key switch
Note
One shaker motor is required per fall protection grille element. In addition, when using shaker motors, a large control panel must be included
in the plans.
Hydraulic drive, bunker charging cover, ASH
Standard delivery:
■ Hydraulic drive comprising:
– Gear pump 4 l/min incl. motor 1.5 kW 3 x 400 V
– Oil container 12 l, non-return valve
– pressure limiting valve
– Pressure diverter valve
– Return filter
– Oil level indicator
– Pressure gauge
– Shut-off valve
– Oil filling
5822 511 GB
Part no. 7388 856
The hydraulic drive is used exclusively for actuating a bunker cover,
which is opened hydraulically. The cover is opened by the hydraulic
cylinder when the key switch button is pressed. When the key switch
button is released, the load holding valve fixes the cover in position.
PYROTEC
77
6
Design information (cont.)
– Hydraulic hoses
– Wall mounting brackets
■ Control:
– According to the boiler control unit, fuse protected with temperature and level switch in the oil container
■ Key switch button OPEN/OFF/CLOSED for installation of a locking
cylinder on the customer side (installation close to cover)
Note
Application in the case of silo discharge systems without hydraulic
activation (AF, AG, AP, external discharge)
Cover drives for hydraulic drive, ASH
Type
Part no.
ASH 1
7388 010
ASH 2
7387 913
ASH 3
7387 897
The auxiliary equipment for the hydraulic drive ASH of the pushrod
discharge for activating hydraulically opening bunker covers. The covers are opened by the hydraulic cylinder when the key switch button
is pressed. When the key switch button is released, the load holding
valve fixes the cover in position.
Control:
According to the boiler control unit
One key switch button OPEN/OFF/CLOSED per cover for installation
of a locking cylinder on the customer side
(installation close to bunker cover so that the motion process can be
monitored).
Standard delivery:
■ 1 valve block per cover, each equipped with:
– 2 solenoid valves
– 1 load holding valve
– 2 non-return throttle valves
Silo filling screw conveyor FS 300
Part no. 7387 808
Supply screw conveyor in open version for filling a fuel store located
inside a building from an external tipping trough. Generally, at least
two silo filling screw conveyors are required. The silo filling screw conveyors are routed through the fuel store in such a way so as to maximise filling.
Standard delivery:
■ Silo filling screw conveyor according to order data
■ Mounting brackets for wall mounting
■ Duct for routing through a wall
Note
Price per m:
Total length = wall inner up to end of screw conveyor in drop area (silo
cover)
Note
The load bearing capacity of the walls must be verified on site by a
structural engineer!
Drive, silo filling screw conveyor
Part no. 7387 898
The drive is located inside the building but outside the fuel store. This
means that the silo filling screw conveyor has a pulling effect. For
safety reasons, the key switch button must be located close to the
tipping trough. The operator must permanently monitor the filling process from outside. Releasing the button stops the screw conveyor
immediately.
Standard delivery:
■ Drive unit, silo filling screw conveyor
■ Spur geared motor with matched torque and pump rate, 3 x 400 V
■ Control of screw drive according to boiler control unit
■ Key switch button ON/OFF for installation of a locking cylinder on
the customer side (installation close to cover).
5822 511 GB
6
Note
Screw conveyor length with drive unit max. 10 m
78
PYROTEC
Design information (cont.)
1,54
mm
mm
10,19
mm
2,58
10
0,
13
°
<1
500
mm
>1
000
0
mm
< 1500
A
ø300
13,51 mm
2860
36
18
2,31 mm
12,
59,
22,06 mm
> 10°
< 800
8,72°
0°
10
A-A
200
1300
9,59 mm
350
A
6.20 Back burning protection
Rotary lock valve
5822 511 GB
Standard delivery:
■ Rotary lock valve according to order data
■ Control of spur geared motor for both rotational directions according
to boiler control unit
6
Note
Rotary lock valve 190 for supply system D 120 mm
Rotary lock valve 260 for supply system D 150 mm and D 190 mm
a
7,86 mm
d
øb
13,24 mm
10,67 mm
Rotary lock valve for fire protected separation of combustion system
and fuel store with overpressure or underpressure, and with simultaneous material transportation for installation in a drop section. The
rotary valve is made entirely from steel and is permissible as a fire
protection between the combustion system and woodchip silos in
wood processing operations with overpressure or underpressure. The
drive device is a spur geared motor with sprung torque support. If the
woodchips are extremely coarse, briefly running the system in reverse
avoids jamming.
Fire protection: RSE according to TRVB and VKF
Max. permissible overpressure in the fuel store: + 500 Pa
Max. permissible underpressure in the fuel store: ± 0 Pa
27,93 mm
7,86 mm
14,00 mm
c
e
f
Positioning:
■ Directly above the supply screw conveyor
■ Exception for funnel discharge: directly at the casing
PYROTEC
79
Design information (cont.)
Trade name
Type
Part no:
a
b
c
d (Di)
e (Da)
e (Di)
e (Da)
f
Output, drive
Drive speed
Rotary lock valve
MZ 190
MZ 260
7387 967
7387 422
260
330
7193
7264
662
709
150
202
200
250
150
202
200
250
274
346
0.75
0.75
252
25
mm
mm
mm
mm
mm
mm
mm
mm
kW
rpm
Shut-off gate valve MA 220
350
34
B
13,91 mm
287
220x220
240
12,36 mm
Standard delivery:
■ Shut-off gate valve according to order data
■ Control of shut-off gate valve according to boiler control unit
■ Spring return motor (torque 30 Nm)
A
158
Part no. 7388 020
Fire protected appliance for installation in a drop section, for mechanical separation of the combustion system and unpressurised fuel store.
The shut-off gate valve opens automatically and closes with zero volts
via a spring balancer in the event of burnout, risk of burn-back or power
failure.
Material: Steel/brass
Drive: Spring return motor, fire protection: RSE according to TRVB and
VKF
230
605
410
785
230
1015
6
A Shut-off gate valve closed
B Shut-off gate valve open
Downpipe L = 1.0 m
Part no. 7387 942
Connection of a drop section between the discharge system or conveyor device and an onward conveyor device by means of a downpipe.
Note
The length of the downpipe is 1 m.
Design (diameter, profile) of the downpipe is matched to the relevant
project at the factory.
Special adaptor
Note
Design (diameter, profile) of the special adaptor is matched to the relevant project at the factory.
5822 511 GB
Part no. 7387 939
Connection of a drop section between the external discharge system
and an onward conveyor device by means of a special adaptor.
80
PYROTEC
Design information (cont.)
6.21 Connection on the flue gas side
Chimney
The system is equipped with a flue gas fan and therefore combustion
equipment without draught requirement. The chimney sizing should be
carried out in the same way for combustion equipment with a pressurejet oil or gas burner without draught requirement (flue gas temperature
at rated load 160 - 200 °C). The PYROTEC grate combustion has output control in the range of 25 - 100 % of the rated output. This results
in flue gas temperatures in the range of min. 100 °C to max. 250 °C.
In order to avoid a risk of soot contamination, there should be an insulated chimney. The route from the flue gas fan to the chimney should
be as short as possible. 90° bends should be avoided wherever possible. Flue pipes more than 1 m long should be thermally insulated.
The chimney should be connected rising at an angle of 30- 45°. The
flue pipe incl. inlet to the chimney must be gas-tight. For the operation
of the PYROTEC grate combustion in accordance with the regulations,
a draught stabiliser (draught limiter) is required in the chimney.
A chimney compliant with regulations relevant to the rated boiler output
is required for efficient boiler operation.
Provide verification to DIN EN 13384.
Note that in its lower output range, flue gas temperatures below
90 ºC may be generated. Therefore connect the boiler to a moistureresistant chimney (thermal resistance class I to DIN 18160 T1).
If the boiler is not being connected to a moisture-resistant chimney,
carry out a chimney calculation or request a chimney assessment
(values for a chimney calculation, see page 9).
Flue pipe
The induced draught fan may cause vibrations, which can lead to
excessive noise. We therefore recommend connecting the connector
to the chimney with a flexible flue pipe adaptor.
C Lambda probe with measured value transducer
D Flue gas temperature sensor
E Flue gas fan
Observe the following when connecting the flue:
■ Install the flue pipe rising to the chimney (with 45º if possible).
■ Never push the flue pipe too far into the chimney.
■ Ensure the full flue gas path (incl. cleaning aperture) is gas-tight.
■ Do not fit the flue pipe with mortar into the brickwork of the chimney.
Instead, use a flexible flue pipe adaptor. Provide a cleaning aperture.
■ Wall liners to adapt to flue systems by third party manufacturers.
■ Provide the flue with thermal insulation of at least 30 mm thickness.
A
b
5,57 mm
6,90 mmc
d
6,16 mm
6,64 mm 20,54
a mm > 1000
E
A
D
C
B
6
A Draught limiter
B Recirculation
kW
mm
mm
mm
mm
390
7423 674
447
350
450
600
PYROTEC grate combustion
530
720
950
7423 675
7423 676
7423 677
447
461
579
350
350
400
450
450
450
600
660
690
1250
7423 678
579
450
450
760
5822 511 GB
Trade name
Rated output
Part no:
a
b
c
d
PYROTEC
81
Design information (cont.)
6.22 Sound insulation
Braces
To avoid the transmission of structure-borne noise during the operation of the fuel transportation equipment, the braces and the anchors
of the relevant conveyor device are placed on high quality Sylomer
bases (plastic anti-vibration mounts for noise attenuation) or anchored
with a Sylomer support and a fixing plate in the building structure. The
anchors with heavy load anchors are separated from the braces with
Sylomer washers.
Trade name
Type
Part no:
Discharge
conveyor
7419 991
Screw
conveyor
7419 992
Standard delivery:
■ Sylomer washer
■ Sylomer support
■ Sylomer base
■ Fixing plate for the braces of the relevant equipment
Sound insulation, braces
Supply
Spring core
Horizontal
discharge
discharge
7419 995
7419 996
7419 997
Removal of
ash
7419 998
Flue gas
dust extractor
7419 999
Note
■ Depending on the means of fuel transportation, the sound insulation
article should be used once, e.g. 1 AH + 1 sound insulation AH-AS
■ Installation room characteristics relating to the physical building
structure largely determine the transmission of structure-borne noise
in the building. It is important to note that the specified measures do
not offer full sound insulation.
■ Building related measures (brick openings, fire barriers, floating
screeds, etc.) must be coordinated with structural engineers and
architects and are not part of standard delivery and therefore not
within our area of responsibility.
Appendix
7.1 Sizing the expansion vessel
In accordance with EN 12828, water heating systems must be equipped with a diaphragm expansion vessel. The size of the expansion
vessel is subject to the heating system specification and should be
checked in each case.
Vn
litres
25
35
50
80
100
140
200
250
300
400
500
Selection example
Datum:
psv = 3 bar (response pressure of the safety valve)
H
= 13 m (static ceiling of the system)
Q
= 18 kW (rated output of the heat source)
v
= 8.5 l/kW (specific water capacity)
panel radiators 90/70 °C
VPH = 1000 l (volume of buffer cylinder)
The specific water capacity v was determined as follows:
■ Radiators: 13.5 l/kW
■ Panel radiators: 8.5 l/kW
■ Underfloor heating: 20 l/kW
82
Calculation:
VA = Q x v + 1000
VA = 18 kW x 8.5 l/kW + 1000 l
= 1153 l
If possible, when calculating the gas pre-charge pressure, select a
supplement of 0.2 bar:
p0 ≥ H/10 + 0.2 bar
p0 ≥ (13/10 + 0.2 bar) = 1.5 bar
From the table:
With psv = 3 bar, p0 = 1.5 bar, VA = 1153 l
Vn = 250 l (for VA max. 1360 l)
PYROTEC
5822 511 GB
7
Quick selection table for calculating the vessel size Vn
Safety valve
bar
3.0
psv
Pre-charge
bar
1.0
1.5
1.8
pressure
System vollitres
220
—
—
ume VA
340
200
—
510
320
200
840
440
260
1050
540
330
1470
760
460
2100
1090
660
2630
1360
820
3150
1630
990
4200
2180
1320
5250
2720
1650
Appendix (cont.)
Selected:
1 x diaphragm expansion vessel N 250 (from Vitoset pricelist)
■ All details relate to a flow temperature of 90 °C.
■ The tables have allowed for a hydraulic seal to DIN 4807-2.
Conversion factor for flow temperatures other than 90 °C
Flow temperature °C
50
55
60
65
Conversion factor
3.03
2.50
2.13
1.82
Recommendations:
■ Select a sufficiently high safety valve response pressure:
psv ≥ p0 + 1.5 bar
■ For circulation pumps, due to the inlet pressure required, select at
least 0.3 bar above the pre-charge pressure even for attic/roofspace
installations: p0 ≥ 1.5 bar
■ Set the water side filling/starting pressure of vented systems in their
cold state at least 0.3 bar above the pre-charge pressure:
pF ≥ p0 + 0.3 bar
70
1.59
75
1.39
80
1.24
85
1.11
90
1.00
95
0.90
100
0.82
Divide the vessel size found in accordance with the above tables by the conversion factor.
7.2 General information regarding low pressure hot water boilers with safety temperatures
of up to 110 ºC
The pressure equipment (hot water boiler) has been built in accordance with TRD 702 and should be equipped in line with that Directive.
Observe the operating conditions in that Directive. Subject to type, this
boiler meets the following standards regarding its stated rated output
and technical requirements:
■ DIN 4702 or EN 303
■ EN 297
■ EN 483
■ EN 677
(See details on the type plate and the enclosed documentation). During installation and commissioning of these boilers, observe all local
Building Regulations and regulations concerning combustion systems,
as well as the following Standards, Regulations and Directives:
■ DIN 18160-1: Flue system (design versions).
■ DIN 1988: Technical Regulations for Drinking Water Installations
(TRWI).
■ DIN 4753: DHW systems for DHW and process water.
■ EN 12828: Heating systems in buildings – Design of DHW heating
systems.
■ EN 13384: Flue systems – Thermal and flow calculations.
■ TRD 702: Equipment level for steam boiler systems with hot water
boilers class II
■ Also observe EN 12953 with:
– Low pressure hot water boilers with safety temperatures > 110 to
120 ºC.
■ EN 12953-1: Boilers with large water chambers – General information.
■ EN 12953-6: Boilers with large water chambers – Equipment
requirements.
■ EN 12953-7: Boilers with large water chambers – Requirements for
combustion systems for liquid or gaseous fuels for the boiler.
■ EN 12953-8: Boilers with large water chambers – Safety valve
requirements
■ EN 12953-10: Boilers with large water chambers – Feed water and
boiler water requirements
Use of oil combustion
■ DIN 4755: Oil combustion equipment.
■ DIN 4787-1: Atomising oil burner (in excess of 100 kg/h throughput).
■ DIN 51603-1: Liquid fuels; fuel oil EL, minimum requirements.
■ EN 230: Atomising oil burners as mono block version – equipment
for safety, monitoring and control, as well as safety times.
■ EN 267: Pressure-jet oil burner.
■ TRD 411: Oil combustion for steam boilers (where applicable).
Use of gas combustion
■ EN 298: Burner control units for gas burners and boilers with or
without fans.
■ EN 676: Pressure-jet gas burner.
■ DVGW Code of Practice G 260/I and II: Technical rules for gas
quality.
■ DVGW-TRGI 2008: Technical rules for gas installations.
■ TRD 412: Gas combustion for steam boilers (where applicable).
■ TRF 1996: Technical rules for LPG.
7.3 Pipe connections
All pipe connections to the boiler should be made free from stress and
torque.
7
7.4 Electrical installation
Carry out the electrical connection and installation in accordance with
VDE regulations (DIN VDE 0100 and DIN VDE 0116), local regulations
and the technical connection requirements laid down by your electricity
supply company.
■ DIN VDE 0100: Installation of HV systems with rated voltages up to
1000 V.
■ DIN VDE 0116: Electrical equipment for combustion systems.
5822 511 GB
7.5 Operating instructions
According to EN 12828, section 5 and EN 12170/12171, the system
installer must produce operating instructions for the whole system.
PYROTEC
83
Appendix (cont.)
7.6 Flue system
Only flue pipes that meet Building Regulations may be used with condensing systems.
7.7 Checks as part of the Building Regulations approval process
As part of the Building Regulations approval process, condensing
combustion equipment is tested by the flue gas inspector (where applicable) for adherence to Building Regulations and any generally recognised technical rules.
The State Building Regulations, their implementation orders and the
combustion equipment orders, as well as the general building approvals and permits of the higher supervisory authority, in individual
cases, are part of the Building Regulations requirements.
5822 511 GB
7
84
PYROTEC
Keyword index
A
Accessories
■ For control unit......................................................15, 16, 18, 19, 21
■ For the boiler.................................................................................25
Agitators
■ Discharge system.........................................................................45
B
Boiler circuit pump............................................................................37
Boiler room.......................................................................................34
Building Regulation approval process..............................................84
Bunker cover
■ Bunker filling.................................................................................73
■ Movable........................................................................................75
C
Chimney...........................................................................................81
Cleaning pneumatic
■ Accessories...................................................................................29
Combustion air.................................................................................35
Connection on the flue gas side.......................................................81
Content
■ Limits...............................................................................................6
Control unit
■ Accessories.................................................................15, 16, 18, 21
■ Specification, function.............................................................13, 19
■ Standard delivery..........................................................................14
D
Delivered condition.............................................................................7
Delivery............................................................................................33
Design..............................................................................................33
Diaphragm expansion vessel...........................................................82
E
Emergency stop switch....................................................................35
Expansion vessel.......................................................................42, 82
Extinguishing facilities......................................................................39
Extinguishing water container..........................................................40
F
Fall protection grille
■ Bunker filling.................................................................................75
Flow temperature.............................................................................33
Flue pipe..........................................................................................81
Fuel..............................................................................................5, 43
■ Limits...............................................................................................6
L
Low water indicator..........................................................................41
M
Mastercontrol.............................................................................19, 21
Maximum pressure limiter................................................................41
Minimum pressure limiter.................................................................42
Minimum wood fuel requirements......................................................6
O
Output management........................................................................16
P
Pellet storage room design..............................................................67
Positioning........................................................................................33
Pyrocontrol.......................................................................................13
■ Accessories...................................................................................15
■ Functions......................................................................................13
■ Operation......................................................................................13
■ Standard delivery..........................................................................14
R
Requirements for boiler room...........................................................34
S
Safety equipment.......................................................................37, 39
Safety temperature...........................................................................33
Shunt pump......................................................................................37
Sizing the pellet storage room..........................................................66
Sound insulation...............................................................................82
Specification, control unit.................................................................13
Specification - boiler...........................................................................8
Spring core discharge
■ AF.................................................................................................45
T
Two-boiler systems....................................................................19, 21
W
Woodchips.........................................................................................5
■ Quality characteristics.....................................................................5
■ Requirements..................................................................................5
Wood fuel
■ Regulations and standards.............................................................6
Wood pellets......................................................................................5
■ Forms of delivery............................................................................5
■ Quality characteristics.....................................................................5
■ Requirements..................................................................................5
5822 511 GB
H
Halogenated hydrocarbons..............................................................34
Handling...........................................................................................33
Heating connections.........................................................................36
Horizontal discharge
■ AH.................................................................................................47
PYROTEC
85
86
PYROTEC
PYROTEC
87
5822 511 GB
Printed on environmentally friendly,
chlorine-free bleached paper
Viessmann Werke GmbH&Co KG
D-35107 Allendorf
Telephone: +49 6452 70-0
Fax: +49 6452 70-2780
www.viessmann.com
88
Köb Holzheizsysteme GmbH
Flotzbachstrasse 33
A-6922 Wolfurt
Telefon: +43 (0)5574 6770-0
Telefax: +43 (0)5574 65707
www.koeb-holzfeuerungen.com
PYROTEC
5822 511 GB
Subject to technical modifications.
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