Veto Stoker Boilers User Manual

VSB20132803EN1.0
Veto Stoker Boilers
30, 60, 75, 80, 100, 120, 150, 220 kW
User Manual
Installation, Operation, and Service
Retailer:
Keep this manual.
1
Contents
1.
Introduction .................................................................................................................... 4
1.1.
Contact information ................................................................................................. 4
1.2.
Type plate information ............................................................................................ 5
1.3.
Warranty ................................................................................................................. 6
1.3.1.
Deficiencies in delivery and return of warranty parts ........................................ 7
1.3.2.
Processing of warranty matters ........................................................................ 7
1.4.
Product markings .................................................................................................... 8
1.5.
Product documentation ......................................................................................... 11
1.6.
Version history ...................................................................................................... 11
1.7.
Document conventions ......................................................................................... 12
1.7.1.
Symbols ......................................................................................................... 12
1.7.1.
Other document conventions ......................................................................... 12
2.
General safety and warnings........................................................................................ 14
3.
Product description ...................................................................................................... 16
3.1.
Product variants .................................................................................................... 16
3.2.
Optional accessories............................................................................................. 17
4.
Technical data ............................................................................................................. 18
5.
Installation.................................................................................................................... 20
5.1.
Boiler room requirements ...................................................................................... 21
5.2.
Chimney requirements .......................................................................................... 22
5.3.
Checking the device.............................................................................................. 23
5.4.
Boiler connections................................................................................................. 24
5.5.
Installing venting ................................................................................................... 27
5.6.
Installing plumbing ................................................................................................ 27
5.6.1.
Connecting the boiler directly to the heating network ..................................... 28
5.6.2.
Connecting the boiler to the heating network through boiler connections ....... 29
5.6.3.
Connecting the boiler to a water accumulator ................................................ 30
5.7.
6.
Electrical installation ............................................................................................. 32
Commissioning ............................................................................................................ 34
6.1.
Before taking the boiler into use ............................................................................ 34
6.1.1.
7.
Preparing the heating network for use ........................................................... 35
Operation ..................................................................................................................... 36
7.1.
Heating with a solid fuel burner ............................................................................. 37
2
7.2.
8.
Taking the boiler temporarily out of use ................................................................ 37
Emergency situations ................................................................................................... 38
8.1.
Fire in the boiler room ........................................................................................... 38
8.2.
Chimney fire.......................................................................................................... 38
8.3.
Boiler is overheating ............................................................................................. 38
8.4.
Overpressure in the boiler ..................................................................................... 38
9.
Service ......................................................................................................................... 40
9.1.
Service schedule .................................................................................................. 41
9.2.
Preparing for service ............................................................................................. 41
9.3.
Emptying the ash box ........................................................................................... 41
9.4.
Removing ashes from the boiler’s convection parts .............................................. 42
9.4.1.
9.5.
Disposal of ashes .......................................................................................... 42
Sweeping .............................................................................................................. 43
9.5.1.
Sweeping the fire surface and convection parts ............................................. 43
9.5.2.
Sweeping the chimney ................................................................................... 44
9.6.
Checking the boiler door gasket ............................................................................ 44
9.6.1.
Adjusting the boiler door gasket ..................................................................... 44
9.6.2.
Changing the boiler door gasket .................................................................... 44
9.7.
Removing pitch ..................................................................................................... 44
9.8.
Checking the relief valve ....................................................................................... 45
9.9.
Testing the safety devices..................................................................................... 45
10.
Troubleshooting........................................................................................................ 46
10.1.
Boiler water is boiling......................................................................................... 46
10.2.
Solid fuel burner does not start .......................................................................... 46
10.3.
System does not produce heat even though the boiler is warm ......................... 47
10.4.
Water not sufficiently warm ............................................................................... 47
10.5.
Smoky flame ..................................................................................................... 48
10.6.
Weak draft in the flue......................................................................................... 48
11.
Device components and spare parts ........................................................................ 50
12.
Disposal of the boiler ................................................................................................ 60
13.
Glossary ................................................................................................................... 62
3
1. Introduction
You have made a good choice in purchasing a Veto stoker boiler. The boiler together with a
Veto burner offers a pure, economic, efficient, and near-emission-free way of burning
renewable energy sources approved by the manufacturer. By avoiding using fossil fuels, you
can considerably diminish the burden on the environment and prevent global warming.
This manual is for using the Veto stoker boiler. To gain the best possible benefit of the
device, read this instruction manual carefully before installing, connecting or using the
device. If all the instructions are followed, the device provides a long-lasting, economic, and
faultless performance. Only use this manual with the device it was delivered with.
The instructions, descriptions and technical information are based on the latest knowledge
on the structure of the boiler at the moment this instruction manual is created. We constantly
develop our products further, and we therefore reserve the right to make any alterations
without prior notice.
Improper use of the product can result in serious injury. To
avoid injury, read and carefully follow all instructions provided
in this manual before installing, operating, or servicing the
device.
The instructions provided in this manual are
recommendations. Laws and regulations of local authorities
override our recommendations.
1.1.
Contact information
4
1.2.
Type plate information
Write down the information from the type plate for easy reference. You need the information
when, for example, ordering spare parts or claiming warranty.
Figure 1 Type plate location
1
1
Location of the type plate in all 30-220 kW boilers
Table 1 Type plate information
Model
Manufacturing year
Serial number
5
1.3.
Warranty
The manufacturer Veljekset Ala-Talkkari Oy grants a warranty for the products that it
manufactures and markets. The user is liable for damage resulting from use of the
equipment for any purpose other than that for which it was designed.
The warranty period is one year from the date of delivery (EU countries: The device has a
warranty that complies with the legislation in the country of use).
The warranty for parts changed under the warranty continues until the end of the original
warranty period.
The prerequisite for warranty is observation of the installation, use, service and safety
instructions for the device.
Continuation of the warranty for the device requires the use of original spare parts or those
approved by the manufacturer. Service and any repairs performed during the warranty
period must be assigned to a service company approved by the manufacturer.
Compensation for service during warranty period can also be claimed if:
•
•
•
The service visit is unnecessary (the reason is not covered by the warranty).
The manufacturer’s instructions concerning installation, use and care have not been
observed.
Corrective measures were not taken immediately upon observation of the fault.
The warranty covers:
•
Manufacturing and raw material defects in products manufactured by Veljekset AlaTalkkari Oy.
The warranty does not cover:
•
•
•
•
Defects or damage caused by:
o Natural wear (spring agitator springs, feeding screw, grates, blades, feet, etc.)
o Misuse of the product or use in violation of the instructions
o Neglect of service in accordance with the instruction manual
o Change work or repairs made without the manufacturer's consent
o Other manufacturers’ control devices or programs
o Safety equipment that deviates from that delivered or is installed contrary to
the instructions
o External factors
Breakage of parts preventing overloading
Indirect costs or down time, or the resulting financial losses
Work or travel costs unless separately agreed in advance with the manufacturer
6
1.3.1. Deficiencies in delivery and return of warranty parts
•
•
•
•
•
Deficiencies in delivery must be reported within seven (7) days of the delivery.
Broken warranty parts must be returned to the plant for a warranty inspection
(include a warranty report).
A part to replace the broken part can be delivered prior to warranty processing.
An invoice for returned warranty parts that do not meet the terms of the warranty can
be sent after warranty processing.
The client can be charged for parts that are not returned upon request.
1.3.2. Processing of warranty matters
•
•
•
The retailer is the primary contact channel in warranty matters and problem
situations.
The retailer handles processing of the matters with the manufacturer.
The retailer must be provided with the following information: brand, model and
purchasing date for the device and the serial number of the device from the type
plate.
Warranty compensation is subject to determination of the cause of the damage and
agreement with the manufacturer concerning the repair prior to initiating any repair work.
7
1.4.
Product markings
Pay attention to the warning and information stickers:
they help you to avoid risks.
Figure 2 Product marking locations
8
Table 2 Product markings on the device
Item
Product marking
1
Risk of carbon monoxide
poisoning and fire
Leaving covers or hatches open
leads to immediate risk of fire
when device is in operation.
Hazardous voltage will cause
severe injury or death.
Turn off power. Wait 15 min
before service. Although control
unit is dead, supply voltage from
frequency converter remains.
Close covers and hatches
airtight.Ventilate properly before
entering fuel bin.
Always work in pairs. When
entering fuel bin have a person
outside fuel bin to secure your
safety.
Read manual before using
device.
Failure to follow instructions
could result in death, serious
injury or damaged device.
Moving parts can crush and cut.
Blower impeller rotates.
Keep fingers away from rotating
impeller. Switch off control unit
before servicing.
Moving parts can crush and cut.
Feeding screw under lid starts
rotating without warning.
Switch off power before
opening lid.
Bin lid may suddenly close
due to strong wind or weakened
gas springs.
During maintenance ensure lid
stays open in all conditions.
Risk of burn and fire
Device is hot and remains hot
after switch-off.
Do not cover burner head. Keep it
clean. Be cautious in boiler room.
Moving parts can crush and cut.
Hot water in boiler
Burner runs intermittently and
starts without warning. Even when
device is switched off springs may
have potential energy.
When pressure rises hot water
may discharge through relief
valve.
Do not enter fuel bin while
power is on.
Inhalation hazard
Air born particulates
Dust mask required during
sweeping boiler and working in
silo. Protect device from dust.
Be careful near relief valve’s
downpipe. Do not let cold water
inside hot boiler.
Do not step on motor.
Motor surface is slippery.
Motor may get damaged.
9
Item
Product marking
2
Risk of carbon monoxide
poisoning and fire
Leaving covers or hatches open
leads to immediate risk of fire
when device is in operation.
Close covers and hatches
airtight.Ventilate properly before
entering fuel bin.
Always work in pairs. When
entering fuel bin have a person
outside fuel bin to secure your
safety.
3
Risk of burn and fire
Device is hot and remains hot
after switch-off.
Do not cover burner head. Keep it
clean. Be cautious in boiler room.
4
Inhalation hazard
Air born particulates
Dust mask required during
sweeping boiler and working in
silo. Protect device from dust.
10
1.5.
Product documentation
Table 3 Related product documentation
Manual name
Control unit
A•T Log-1 and A•T Log-2 Control Unit User Manual
Lambda 5S control unit
Burners
VetoMat User Manual
Veto ChipMatic User Manual
Veto 6 User Manual
Veto 8 User Manual
Veto Spring Agitator User Manual
Other
TA control Unit Data Sheet
Ash Screw Data Sheet
Rotary Feeder Data Sheet
VetoMat Transport and Storage
ChipMatic Transport and Storage
Veto 6 Transport and Storage
Veto 8 Transport and Storage
Boiler Transport and Storage
Veto Spring Agitator Transport and Storage
Veto Burner Head 160, 240, 360, 480, 640, 800 and 990 kW User
Manual
Veto Burner Head 160, 240, 360, 480, 640, 800 and 990 kW
Transport and Storage
Veto Air
Other manufacturers’ documentation
Frequency converter user manual 1.5 kW
Frequency converter user manual 2.2 kW
Boiler Thermostat User Manual
BVTS User Manual
Dry-boil Protection Centre User Manual
1.6.
Identification
ATL20132803EU1.0
039 028 06_LAMBDA
5S GB_v8
VMB20132803EU1.0
VCM20132803EU1.0
V6T20132803EU1.0
V8T20132803EU1.0
VST20132803EU1.0
TAC20132803EU1.0
ASD20132803EU1.0
RFD20132803EU1.0
VMT20121221US1.0
CMT20121221US1.0
V6T20130328US2.0
V8T20130328US2.0
SBT20121221US1.0
VST20121221US1.0
VBR20130328EN1.0
VBT20121221US1.0
VAIR2V20012012GB
ATV312HU15N4
ATV312HU22N4
1282/B-07/01
IC.PI.500.E4.72520B4081
D17016Ds
Version history
Table 4 Document version history
Version
1.0
Date
28.03.2013
Changes
First version
11
1.7.
Document conventions
1.7.1. Symbols
Table 5 Symbols used in this document
Symbol
Explanation
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate injury.
Indicates special information to the reader, but
not related to personal injury.
1.7.1. Other document conventions
Table 6 Document conventions
Item
Italics
Convention
Indicates a reference within
this document.
Example
Refer to 1.7.1. Document
conventions.
12
13
2.
General safety and warnings
These general safety instructions help you to avoid dangerous situations when installing,
operating or servicing the device. Important safety instructions are also presented in the
beginning of each section.
Do not make any alterations to the original device design. Any
alterations to the product may result in serious hazard to
people, property or environment.
Installation and service of the device must only be performed
by an authorized professional installer following all the
requirements of the authority having jurisdiction over the
installation.
Incorrect installation, operation, and service of this device
could result in severe personal injury, death, or substantial
property damage from fire, carbon monoxide poisoning, soot
or explosion.
Risk of fire! Fuel remains on the floor may catch fire from a
spark, and fire may spread to the structure of the building.
Keep the boiler room tidy.
Risk of fire! Do not use the boiler room as a general storage
space due to fire hazard.
Risk of carbon monoxide poisoning! When using the device,
always ensure that the service doors are completely shut to
prevent hot chimney gas from entering the boiler room.
The boiler must only be used together with a Veto burner
device and a control unit.
Risk of burn! The service doors are always hotter than the rest
of the boiler surface. Also some of the pipes are hot. Always
be cautious in the boiler room.
Risk of carbon monoxide poisoning and fire! Keep ash in a
metal container.
Ashes or fuel may contain constituents causing allergic
reactions.
• Use appropriate protective equipment such as
respiration protector when handling ashes or fuel.
• Use clothes and gloves made of infusible materials
when servicing the boiler.
14
15
3.
Product description
Veto stoker boiler is an effective, economical, easy to use and environmentally friendly
central heating boiler.
Veto stoker boiler is designed to be used with a control unit and a stoker burner using solid
fuel, such as chips, pellets and briquets as a heating source.
The boiler delivery includes:
•
•
•
•
•
Gauge for boiler water temperature
System pressure gauge
Cleaning rake for removing soot and ash from flue gas circulations and fire surfaces
Lifting lug for lifting the boiler
User manual
The delivered gauges are not calibrated.
3.1.
Product variants
Boiler outputs are achievable as defined in the 14961-4 standard. The chip class is
A1, piece size P31.5 and moisture M25.
∆t must be 20°C. Minimum furnace underpressure of 15Pa.
∆t = temperature difference between output water and return water.
•
The power capacity of the boilers ranges from 30 kW to 220 kW:
o
o
o
o
o
o
o
o
•
Veto 30 (30 kW)
Veto 60 (60 kW)
Veto 75 (75 kW)
Veto 80 (80 kW)
Veto 100 (100 kW)
Veto 120 (120 kW)
Veto 150 (150 kW)
Veto 220 (220 kW)
The water coil is only available for 30, 60, 80 and 100 kW stoker boilers.
16
If a particularly large amount of hot water is needed, it is possible to install two
water coils side by side in the boiler. Available for 60, 80 and 100 kW boilers.
The burner can be installed to enter the boiler on the front, or from the right or the left
side.
o
•
The handedness of the service doors and the side for the feedthrough connection for the burner is selected when the product
is ordered and cannot be changed afterwards.
3.2.
Optional accessories
Accessories that can be ordered separately:
•
•
•
•
•
•
•
•
Four-way mixing valve for adjusting the water circulation
Ash screw for removing ash automatically from the boiler at appropriate intervals
Veto Air
Flue gas cleaner (150 and 220 kW)
Lambda control
Electric resistance (30, 60, 80, and 100 kW boilers)
Veto XL control unit
Flue gas blower (underpressure control)
17
4.
Technical data
Table 7 Requirements for flues, chimney, compensation air holes, and chimney gas
Height of the chimney
(from floor level)
Recommended chimney
size Ø mm (in)
30 kW
5m
60, 75, 80 kW
6m
100 kW
7m
120, 150 kW
8m
220 kW
14 m1
30, 60, 75, 80, 100 kW
Ø 200
120, 150 kW
Ø 250
220 kW
Ø 330
Area of the brick chimney (30-120 kW)
ca. 300 cm²;
160–180 mm x 160–180 mm
Area of the brick chimney (150, 220)
200-300 x 200-300 mm
Diameter of the insulated steel chimney
Ø 180–300 mm
Size of the compensation air hole of the boiler
room
Temperature of
Brick chimney
chimney gas
Steel chimney
1.5 x chimney size
Chimney gas
connector, width x
height
1
min. 150ºC
min. 120ºC
30 kW
Ø168 mm
60, 75, 80 kW
Ø168 mm
100, 120 kW
Ø194 mm
150 kW
Ø240 mm
220 kW
Ø300 mm
Flue gas cleaner and a 6-meter chimney are recommended.
18
Table 8 Technical data for boiler
100 kW
120 kW
150 kW
220 kW
Water
volume
l
80 kW
width x
length x
height
mm
75 kW
Boiler
60 kW
Weight kg
30 kW
Power (using a solid fuel burner)
520
685
675
770
880
865
1050
1650
625x
1160x
1406
725x
1190x
1425
725x
1190x
1425
725x
1190x
1620
825x
1340x
1630
825x
1340x
1630
825x
1605x
1830
1075x
1875x
1850
270
340
290
410
475
385
460
850
Productive
capacity of
the water
coil
Chamber
length x
width x
height
mm
35 l/min
480x
400x
690
455x
500x
690
-
455x
500x
940
35 l/min
455x
500x
850
600x
600x
900
-
600x
600x
1100
800x
600x
1150
800x
850x
1150
Table 9 Flue gas connection’s location
Flue gas connection’s location
Chimney height
Left
Back
Right
30 kW
-
x
-
60, 75, 80 kW
x
x
x
100 kW
x
x
x
120 kW
x
x
x
150 kW
220 kW
x
-
x
-
19
5.
Installation
Installation of the device must only be performed by an
authorized professional installer following all the requirements
of the authority having jurisdiction over the installation.
Incorrect installation of this boiler could result in severe
personal injury, death, or substantial property damage from
fire, carbon monoxide poisoning, soot or explosion.
Incorrect installation may cause premature wearing of the
boiler, a fire hazard, or a danger of explosion.
Risk of explosion! An expansion tank, a relief valve and a
pressure gauge must always be included in the boiler
installation.
• The volume of the expansion tank must be at least 5%
of the total water content of the system (boiler water
content + water network content).
• The expansion tank must be directly connected to the
boiler. No valves or the like are allowed between the
expansion tank and the boiler.
• An open expansion tank must be installed to the
highest point of the heating system whereas a
membrane expansion tank should be installed to the
boiler room.
• The boiler room temperature must be kept above the
freezing point. The expansion tank must not ever
freeze.
• The maximum pressure of the boiler systems is 1.5 bar
(21.76 psi).
• The maximum temperature of the boiler water is
100°C.
During installation, always follow official regulations, statutes,
and installation instructions.
Hazardous voltage! Only an authorized electrician shall
perform electric installations.
20
5.1.
Boiler room requirements
The boiler must be installed indoors.
Clean the boiler room before bringing the boiler in. An unclean
space is hazardous when moving the heavy boiler on its place.
The minimum requirements for the boiler room are:
•
•
•
The boiler room must be built of incombustible materials and according to the
national, regional and local regulations.
The temperature of the boiler room must always remain above the freezing point 0°C.
The boiler room must be dimensioned keeping in mind the installation, use and
service of the devices included in the planned system.
The figure indicates the recommended minimum space in the boiler room.
Figure 3 Recommended minimum distances in a boiler room
A
B
C
D
800 mm
500 mm
1000 mm
2000 mm with Vetomat
21
•
•
•
The size of the compensation air hole in the boiler room must be 1.5 x size of the
chimney.
The connections to the water network and the radiator system must be available.
It is recommended that the boiler room is equipped with a water faucet and a drain
made of cast iron.
It may be necessary to run boiling water into the drain. Boiling
water melts drains made of plastic.
•
Adequate fire fighting equipment must be available.
The manufacturer recommends 2 x 6 kg extinguishers near the boiler room. If they
are stored inside the boiler room, they may be hard to reach in case of fire.
Risk of burn! In case of fire, do not enter the boiler room without
protective clothing or a smothering blanket.
5.2.
Chimney requirements
Risk of carbon monoxide poisoning! The chimney must be
reserved for this heating equipment only.
The minimum requirements for the chimney are:
•
•
•
The chimney must be constructed according to the national, regional and local
regulations, and the chimney manufacturer instructions.
The flue must include a sweeping door and an explosion relief door.
The height and the diameter of the chimney must be according to the chimney
requirements presented in 4 Technical data.
Horizontal flue must be avoided. If this is not possible, a
maximum of 1 m of horizontal flue can be used.
• Install the horizontal flue so that it slopes a little upward.
• The 1 m of horizontal flue can be compensated by
adding 2 m into the chimney height.
• The horizontal flue must be isolated so that the
temperature on the outer surface of the flue and
chimney does not exceed 80°C.
22
If a steel chimney is in use, it must be:
•
•
Acid-proof.
Isolated so that the temperature on the outer surface of the flue does not exceed
80°C.
Risk of fire! Do not store anything on or near the chimney or the
flue.
It is recommended to have a damper in the chimney. The damper makes it possible to
regulate the draft.
5.3.
•
Checking the device
Check that the boiler delivery includes all the parts that it is supposed to.
See 3 Product description.
The boiler and the cleaning rake are fastened to the pallet.
•
Check that the boiler is in good condition when delivered.
o
o
o
o
Doors are not damaged.
Gaskets are in place and intact.
Gauges are intact.
The pipes of the water coil (if included in the delivery)should be straight.
If a listed part is missing or there are damages in the delivery, contact your retailer.
23
5.4.
Boiler connections
The boiler must be directly connected to the expansion tank and the relief valve. There
should not be any valves between them. The figure shows the connections of a standard
boiler.
Figure 4 Boiler 30 kW
1
4
5
6
3
7
2
1
2
3
4
5
6
7
Mixing valve connection
1½-inch output water connection and expansion connection
2-inch return water connection
1½-inch return water connection
Boiler temperature gauge and pressure gauge
¾ inch thermostat connection
¾-inch drain valve
24
Figure 5 Boiler 60-120 kW
3
1
2
3
4
5
6
7
8
Mixing valve connection
2-inch return water connection
2-inch output water connection
Drain valve connection
¾-inch discharging boiler connection
Boiler temperature gauge and pressure gauge
1-inch feeding and expansion connection
2-inch electric resistance
25
Figure 6 Boiler 150-220 kW
1
2
3
4
5
6
7
8
¾-inch thermostat connection
1-inch thermostat connection
1-inch feeding and expansion connection
DN 65 connection, output water
Drain valve connection
2-inch discharging boiler connection
DN 65 connection, return water
2-inch output water connection
The input side and output side of the mixing valve and water coil are marked on the boiler by
colored signs (input side by a blue sign). Cold water is always conveyed into the more
central area inside the water tank of the boiler. This is why the connector of the input side
continues as a straight pipe line into the boiler.
26
5.5.
Installing venting
Installation of the device must only be performed by an
authorized professional installer following all the requirements
of the authority having jurisdiction over the installation.
Risk of fire and carbon monoxide poisoning! The chimney and
the boiler must be connected airtight.
Risk of fire! Overpressurized boiler causes backfire.
There must always be underpressure in the combustion
chamber.
•
5.6.
Check the set of flues to ensure that they do not contain any blockages. Remove the
eventual blockages.
Installing plumbing
The plumbing must include an automatic deaerator.
•
Water is added through topping-up valves (two valves) so that the system is full of
water.
Installation of the device must only be performed by an
authorized professional plumber following all the requirements
of the authority having jurisdiction over the installation.
•
•
•
The boiler does not include any piping.
The connections to the water network and the radiator system must be available in
the boiler room.
The system must have a pressure gauge. The maximum pressure of the boiler can
be found from the type plate.
Do not install a valve or the like in the pipe between the boiler
and the deaerator valve.
Do not try to adjust the deaerator valve yourself.
27
5.6.1. Connecting the boiler directly to the heating network
The volume of the expansion tank(s) must be at least 5% of the
total water content of the system (boiler water content + water
network content).
The figure is a sketch diagram; the connection between the
boiler and the network varies from case to case.
Figure 7 Connecting boiler (100 kW) directly to the heating network
1
2
3
4
5
6
7
8
9
Filling valve
Expansion tank
Relief valve
Automatic deaerator
Thermometer
Shut-off valve (shut off with a tool)
Water pump
Four-way valve
Drain valve
28
A temperature gauge is installed in the output and return water pipe. The function of the
boiler thermostat can be checked and adjusted by an output water gauge.
5.6.2. Connecting the boiler to the heating network through boiler
connections
The volume of the expansion tank(s) must be at least 5% of the
total water content of the system (boiler water content + water
network content).
The figure is a skeleton diagram; the connection between the
boiler and the network varies from case to case.
Figure 8 Connecting the boiler through boiler connections
1
2
3
4
5
6
7
8
9
Water pump
Thermostatic mixing valve
Thermostat
Filling valve
Drain connection
Automatic deaerator
Three-way valve
Relief valve
Expansion tank
29
5.6.3. Connecting the boiler to a water accumulator
The figure is a sketch diagram; the connection between the
boiler and the network varies from case to case.
Figure 9 Connection to a water accumulator
1
2
3
4
5
6
7
8
9
10
11
12
Shut-off valve (shut off with a tool)
Thermostatic mixing valve
Thermostats
Accumulator pump
Pump’s control thermostat
Expansion tank
Drain valve
Relief valve
Automatic deaerator
Water coil
Water accumulator
Electric resistances
30
The water accumulator is connected to the connector on top of the boiler. This means that
the water in the hottest part of the boiler is conveyed to the water accumulator.
The pipes between the boiler and the water accumulator (exit and return pipe, diameter DN
65) must be connected by a mixing valve, which regulates the heat of the water returning to
the boiler to a temperature of 70ºC. This means that the water does not flow from the boiler
into the water accumulator until the temperature of the boiler reaches 80–85ºC.
If the water returning to the boiler is colder than 70ºC, it is
possible that the temperature in the lower parts of the
convection parts falls below the dew point. As a result, the
draft becomes weaker, the boiler operates at partial capacity,
and pitch starts to collect in the boiler.
Depending on the capacity of the water accumulator, the right pump must be selected.
Table 10 Selecting the right pump
Water capacity l
Veto 30
Veto 60
Veto 75
Veto 80
Veto 100
Veto 120
Veto 150
Veto 220
270
340
290
410
475
385
460
850
Water coil
x
x
x
x
Minimum flow with nominal output
∆t = 10°C l/s
∆t = 20°C l/s
0.72
0.36
1.44
0.71
1.80
0.90
1.92
0.96
2.40
1.20
2.88
1.44
3.60
1.80
5.27
2.64
The volume of the expansion tank(s) must be at least 5% of the
total water content of the system (boiler water content + water
network content).
An open expansion tank is an economic and practical alternative.
•
•
An open expansion tank must be insulated. The expansion tank or the pipes leading
to it must not ever freeze.
The open expansion tank must be installed to the highest point of the heating
system.
31
5.7.
Electrical installation
During installation, always follow national, regional and local
regulations, statutes, and installation instructions.
Hazardous voltage! Only an authorized electrician shall
perform electric installations.
The connection diagram is delivered with the control unit.
When installing an automatic controlling system (mixing valve) use the instructions provided
by the supplier.
32
33
6.
Commissioning
Risk of explosion! Make sure that the boiler is full of water. If the
boiler is not full of water and it is taken into use, the boiler
thermostat does not register the water temperature, which can
cause an explosion.
Risk of carbon monoxide poisoning! There might come some
smoke into the boiler room because the boiler water is cold and
the chimney draft is poor.
When the device is lighted for the first time, some water may
condensate on the fire surfaces and dribble to the ash chamber.
Water in the ash chamber does not mean that the boiler leaks.
6.1.
Before taking the boiler into use
If the brick chimney is new, let it dry properly on a slow fire.
Risk of carbon monoxide poisoning and fire! Ensure that the
connection between the boiler and the chimney is airtight.
An authorized professional (for example a plumber) should
with the end user check the boiler before taking it to actual
use.
Before taking the boiler into actual use, an authorized professional checks that:
•
•
•
•
•
•
•
•
•
•
•
•
•
The relief valve functions correctly.
The pressure in the expansion tank is correct. The prepressure is adjusted case by
case.
The expansion tank is at least 5% of the whole mass of water in the system.
The expansion tank or the pipes leading to it are not subject to freezing.
The open expansion tank must be installed to the highest point of the heating
system.
There are no valves between the boiler and the expansion tank.
The pumps are operating and the flow direction is correct.
The pipe sizes are large enough.
The connections are leak-proof.
The BVTS sensor is adjusted and tested.
The water tank is filled and tested.
The boiler thermostat is installed correctly.
A boiler with a water coil has a mixing valve to limit the service water temperature.
40-60°C is recommended.
34
•
•
•
•
•
•
The flue gas flows freely.
All the doors of the boiler are closed.
The boiler is filled with water.
The safety devices are tested.
The shut-off valves between the water accumulator and the boiler are open.
Valves are open.
6.1.1. Preparing the heating network for use
Risk of explosion! The pressure must not exceed the structure
pressure of the weakest component. The structure pressure of
the boiler is 1.5 bar (21.76 psi).
1. Fill the heating network with water.
o
o
o
Remove air through the relief valve when filling the system.
Ensure that the boiler is full of water and the air is removed from the system.
Ensure that the deaerator valve opens at the correct pressure in relation to
the weakest component of the network.
2. Reduce the pressure of the network for example through the drain valve of the boiler
so that the pressure is the same as the prepressure of the expansion tank.
3. To remove the air that has dissolved in water, heat the boiler until the boiler water
reaches the temperature of 85ºC.
The control unit alarms if the temperature of the boiler water
exceeds 100ºC.
The system must have a pressure gauge. The maximum pressure of the boiler can be found
from the type plate.
The return water temperature can be checked from the return water gauge.
The water always cools in the heating network.
35
7.
Operation
Incorrect operation of this boiler could result in severe
personal injury, death, or substantial property damage from
fire, carbon monoxide poisoning, soot or explosion.
The boiler must only be used together with a Veto burner
device and a control unit.
Only burn solid, renewable fuels accepted by the
manufacturer.
The figure shows the connections of a standard boiler.
Figure 10 Boiler 30-120 kW
1
2
3
4
5
6
7
Lid of the convection part
Burner head connection
Service hatch of the convection part
Combustion chamber ash box hatch
Mixing valve
Boiler temperature gauge and pressure gauge
Combustion chamber service door with an inspection opening
36
Figure 11 Boiler 150-220 kW
1
2
3
4
5
6
Convection part lid
Burner head connection
Convection part service hatch
Furnace ash box hatch
Combustion chamber service door with an inspection opening
Boiler temperature gauge and pressure gauge
7.1.
Heating with a solid fuel burner
For instructions, see the user manual of the burner and the control unit.
7.2.
•
•
•
Taking the boiler temporarily out of use
Empty the ash box.
Sweep the fire surfaces.
Close the chimney damper.
Refer to the service chapter for more information.
37
8.
Emergency situations
Adequate fire-fighting equipment must be available. The manufacturer recommends 2 x 6 kg
dry chemical extinguishers near the boiler room. If they are stored inside the boiler room,
they may be hard to reach in case of fire.
8.1.
Fire in the boiler room
Risk of burn! In case of fire, do not enter the boiler room without
protective clothing or a smothering blanket.
1. Switch off the power from the main switch that is located near the exit of the boiler
room.
2. Always call the emergency number.
8.2.
•
8.3.
Chimney fire
Always call the emergency number.
Boiler is overheating
Risk of explosion! Do not let cold water inside a hot boiler. It
can cause an explosion. The water expands when overheated
and the pressure rises in the boiler.
Boiling water will melt plastic drains. The boiler room should
be equipped with a drain made of cast iron.
1. Shut down the burner.
2. Use the water coil to remove hot water from the boiler.
3. After the boiler has cooled down, check that there is enough water in the boiler.
8.4.
Overpressure in the boiler
Risk of burn! Be careful when the relief valve opens.
•
If the relief valve is broken, carefully let some water flow from the emptying tap.
38
39
9.
Service
Service of the device must only be performed by an
authorized professional following all the requirements of the
authority having jurisdiction over the action.
Risk of burn! Before servicing, turn the operating switch to the
0 position and turn off the main switch. Let the boiler cool
down sufficiently.
Risk of carbon monoxide poisoning! Service the boiler only
when it is cold and contains no hot ashes. In case fire is still
burning or there are embers left in the boiler when service
measures are started, carbon monoxide spreads from the
open service doors to the boiler room.
Risk of carbon monoxide poisoning and fire! Do not collect
ash in a plastic or cardboard box. Ashes containing embers
develop carbon monoxide and cause fire hazard even when
collected in a container made of incombustible materials.
Ashes or fuel may contain constituents causing allergic
reactions.
• Use appropriate protective equipment, especially
respirator mask, when handling ashes or fuel.
• Use clothes and gloves made of infusible materials
when servicing the boiler.
40
9.1.
Service schedule
Check the general boiler operation.
Check the pressure.
Check the temperature.
Empty the ash box.
Empty ash from the convection parts.
Sweep the fire and convection parts.
Check the condition of the gaskets.
Sweep the flue.
Sweep the chimney.
Check the safety devices.
Yearly
Monthly
Bi-weekly
Weekly
Daily
Table 11 Service schedule
x
x
x
x
x
x
x
x
x
x
Follow also the local authorities’ rules for servicing.
9.2.
Preparing for service
1. Burn all the fuel inside the burner.
2. Switch the burner off.
3. Let the burner and the boiler cool down.
Tools needed for service:
•
9.3.
Cleaning rake
Emptying the ash box
When taking the device in use, check the amount of ash every day. Different fuel types
produce different amount of ashes. Later, empty the ash box once a week.
1. Open the combustion chamber ash box hatch.
2. Take out the ash box.
The ash box can be heavy.
3. Place the ashes in a metal container with a tight-fitting lid.
41
4. Clean the area underneath and around the ash box.
5. Return the ash box to its place.
9.4.
Removing ashes from the boiler’s convection parts
1. Remove ashes from the upper parts of the convection parts.
•
•
Check and sweep the convection parts through the service doors on the top
of the boiler.
Light soot can be removed by using the cleaning rake and a sweeping brush.
2. Remove ashes from the lower parts of the convection surfaces.
•
•
•
Remove the ash box.
Sweep the lower part of the boiler right up to the flue connection.
Sweep the convection surfaces.
When sweeping, be careful not to cause damage to the
temperature sensor that is located in the flue connection.
9.4.1. Disposal of ashes
•
•
Place the ashes in a metal container with a tight-fitting lid.
Place the closed container of ashes on a incombustible floor or on the ground, well
away from all combustible materials, pending final disposal.
For final disposal of ashes, follow the local recommendations.
42
9.5.
Sweeping
Always follow national, regional and local regulations for
sweeping, and use professional services for sweeping the
chimney even if the regulations do not require this.
Ashes or fuel may contain constituents causing allergic
reactions.
• Use appropriate protective equipment such as
respiration protector when handling ashes or fuel.
• Use clothes and gloves made of infusible materials
when servicing the boiler.
Make sure that the boiler room is well-ventilated when
sweeping.
Risk of fire! After sweeping, make sure that the service doors
and the ash box are properly in place.
After sweeping always remove the ash from the as box.
Soot collects on the convection surfaces more quickly than on
the fire surfaces of the combustion chamber.
The fire surfaces of the combustion chamber and the convection parts must be swept
regularly.
If the boiler temperature is kept low or if the fuel used is too moist it starts to collect dirt and
soot.
Moisture and soot caused by the low boiler temperature prevent the heat from transferring to
the boiler water and thus reduce the efficiency of the boiler.
9.5.1. Sweeping the fire surface and convection parts
If the flue gas temperature rises 50°C over a clean boiler’s given value, the boiler must be
swept.
1.
2.
3.
4.
Turn the operating switch on the control unit to BLOWER position.
Let the blower operate 30 min so that the device cools down.
Turn off the main switch.
Open the convection parts’ hatches one at a time. When you are done with one
convection part, close the hatch before opening another.
The draft of the chimney is concentrated on the hatch that is open. Ash, soot and flue
gases do not spread to the boiler room when opening the hatches one by one.
5. Sweep the surfaces.
6. Remove the ash from the ash box.
43
9.5.2. Sweeping the chimney
Always follow national, regional and local regulations for
sweeping, and use professional services even if the
regulations do not require this.
Risk of fire! After sweeping, make sure that the service doors
and the ash box are properly in place.
Check and sweep the convection parts through the holes on top of the boiler. Remove light
soot by using a rake and a sweeping brush.
9.6.
•
Checking the boiler door gasket
Check the boiler door gaskets every two weeks.
9.6.1. Adjusting the boiler door gasket
The gaskets installed in the boiler doors in the factory will yield a little at first during use. The
door must then be readjusted in order to make it tight again.
If the adjustment range of the adjusting screw is not sufficient, remove the filling door and
turn the hinges slightly backwards.
9.6.2. Changing the boiler door gasket
1. Cut the new gasket according to the old one.
The gasket is made of glass fiber braided cord that is available in hardware stores.
2. Clean the gripping surface.
3. Use close contact glue to attach the new gasket.
4. Close the lid and let the glue dry.
9.7.
•
Removing pitch
Remove pitch-like dirt using chemical cleansers. These and the instructions for their
use are available at your local hardware store.
44
9.8.
Checking the relief valve
It is possible that the relief valve installed in the heating network gets stuck. This leads to
excessive rise of the system pressure. Therefore, check the function of the relief valve 2–3
times a year.
•
9.9.
Test the relief valve by manually opening the valve. The water should flow through.
Testing the safety devices
Make sure that:
•
•
•
•
•
•
•
•
•
•
•
•
•
•
The relief valve functions correctly.
The pressure in the expansion tank is correct. The prepressure is adjusted case by
case.
The expansion tank is at least 5% of the whole mass of water in the system.
The expansion tank or the pipes leading to it are not subject to freezing.
The open expansion tank must be installed to the highest point of the heating
system.
There are no valves between the boiler and the expansion tank.
The pumps are operating and the flow direction is correct.
The pipe sizes are large enough.
The connections are leak-proof.
The BVTS sensor is adjusted and tested.
The water tank is filled and tested.
The boiler thermostat is installed correctly.
A boiler with a water coil has a mixing valve to limit the service water temperature.
40-60°C is recommended.
The safety devices are tested.
45
10. Troubleshooting
10.1. Boiler water is boiling
Possible cause
Solution
Faulty adjustment of the burner.
Adjust the relation between the stand-by fire
and the interpulse time or the settings of the
overheating protector (changeable).
The boiler thermostat is broken.
Change the boiler thermostat.
The fuel type has been changed, for
example from chips to pellets.
Adjust the feeding values according to the
feeding table.
The set temperature for the boiler
Adjust the boiler thermostat temperature to
thermostat is too high (when the boiler 80°C or less.
is on operating condition work time).
The pause time is too short (when the Adjust the operating condition pause time
boiler is on operating condition pause longer.
time).
10.2. Solid fuel burner does not start
Possible cause
Solution
The overheating protector of the boiler Push the reset button if the temperature has
thermostat has gone off when the
fallen sufficiently low.
temperature has risen too high during
burning of wood.
An alarm is active.
Check the control unit for alarm messages
and follow the instructions there.
46
10.3. System does not produce heat even though the boiler is
warm
Possible cause
Solution
There is not enough water in the
boiler.
Risk of explosion! Do not let
cold water inside a hot
boiler. It can cause an
explosion. The water
expands when overheated
and the pressure rises in the
boiler.
When the boiler water is
near boiling point, turn off
the device and let it cool
down completely. Add water.
The circulation water pump does not
rotate.
Find the cause of the malfunction of the pump. Fix
it or have it fixed.
There is air in the heating network.
Bleed the air from the heating network.
The possible valve between the boiler Open the valve.
and the piping reduces or prevents the
circulation of water.
The thermostat of the water
accumulator pump is broken.
Replace the thermostat.
10.4. Tap water not sufficiently warm
Possible cause
Solution
The water coil is connected the wrong The coil must be reconnected by a plumber.
way round.
The boiler or the water accumulator is Heat more.
not warm enough.
A lot of water has been taken out
lately.
Wait until the water becomes warm.
Mixing valve is jammed.
Change the valve.
Water piping is clogged.
Check the condition of the piping.
47
10.5. Smoky flame
Possible cause
Solution
Faulty adjustment of burner or its fire
jet is cold.
Let the fire jet become warm or readjust.
The moisture content of the fuel is too Change the fuel.
high; no sufficient increase in the
calorific value.
The temperature of the boiler is low
for too long.
Faulty connection of the water accumulator.
See 5.6 Installing plumbing.
The burner does not get air.
Clean the burner and the blower according to the
user manual.
Readjust the feeding and blowing intervals
according to the feeding table.
10.6. Weak draft in the flue
Possible cause
Solution
The junction between the boiler and
the flue is not airtight.
Seal it up using for example mineral wool.
There is a blockage in the flue outlet.
Open the blockage.
The sweeping door in the flue is left
open.
Close it tightly.
Moist and cold chimney.
Burn paper in order to warm up the chimney.
There is partial vacuum in the building Shut the doors and other holes (from which the
and the flow of air in the flue goes in
suction comes) in the boiler room.
the wrong direction.
The moisture content of the fuel is too Change the fuel or add dry fuel.
high.
The boiler is situated far from the
chimney, the aggregate is too long in
the horizontal plane.
The flue must be made to rise slightly.
48
49
11. Device components and spare parts
Figure 12 Veto 30 spare parts
50
Table 12 Veto 30 spare parts
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
Name
Knob
Lid
Wool cover
Wool cover gasket
Lifting eye nut M16
Mixing valve
Mixing valve gasket
Pressure gauge and thermometer
Ash box hatch
Ash box hatch, ash screw
Handle
Cover plate
Water coil
Water coil inlet
Water coil gasket
Water coil flange gasket
Water coil cover with holes
Included in no. 13
Service door, left
Service door, right
Ash box door, right
Ash box door, left
Ash box hatch, ash screw
Ash box hatch, blind
Ash box hatch
Gasket, small service door
Ash box (30-100 kW)
Ash box hatch (30 kW), right
Item
68536
47334
47318
47327
74801
68540
68541
68335
47325
35003
34604
47368
42954-1
68361-2
68271
68270
41938-1
68361-1
35514
35496
35025
35085
35425
35436
47387
48581
48106
35025
51
Figure 13 Veto 60, 80, 100 spare parts
3
23
4
5
9
6
1
2
10
14
15
16
17
18 19
11
20
22
13
12
5
8
22
21
52
Table 13 Veto 60, 80, 100 spare parts
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
Name
Mixing valve
Mixing valve bottom gasket
Knob
Lid, 60/80 kW
Lid, 100 kW
Wool cover
Wool cover
Wool cover
Ash box hatch, right
Ash box hatch, left
Ash box hatch, ash screw
Ash box hatch, blind
Ash box hatch
Lifting eye nut M16
Pressure gauge and thermometer
Cover plate
Ash box hatch, blind
Ash box hatch, ash screw
Service door, right
Water coil
Water coil inlet
Water coil gasket
Water coil flange gasket
Water coil cover with holes
Included in no. 15
Service door, left
Service door, right
Ash box (30-100 kW)
Wool cover
Lid, 60/80 kW
Lid, 100 kW
Item
68541
68541
68536
36663
36680
47318
47936
47935
35025
35085
35425
35436
47387
74801
68335
47368
47325
35003
35025
42954-1
68361-2
68271
68270
4-1938-1
68361
35514
35496
48106
48581
36657
36681
53
Figure 14 Veto 75 and 120 spare parts
1
2
17
3
4
9
5
6
7
8
10
11
13
12
14
15
16
54
Table 14 Veto 75 and 120 spare parts
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Name
Knob
Lid, 75 kW
Lid, 120 kW
Wool cover
Wool cover
Mixing valve
Mixing valve bottom gasket
Pressure gauge and thermometer
Wool cover
Lifting eye nut M16
Service door, left
Service door, right
Handle
Ash box hatch short
Ash box hatch, ash screw
Service door, right
Wool cover
Ash box hatch, right
Ash box hatch, left
Ash box hatch, ash screw
Ash box hatch, blind
Ash box hatch
Ash box (30-100 kW)
Lid, 75 kW
Lid, 120 kW
Item
68536
36663
36680
47936
47935
68541
68541
68335
48581
74801
35514
35496
34604
47325
35003
35025
47318
35025
35085
35425
35436
47387
48106
36657
36681
55
Figure 15 Veto 150 spare parts
4
11
3
1
2
9
8
7
10
5
6
6
5
56
Table 15 Veto 150 spare parts
No.
1
2
3
4
5
6
7
8
9
10
11
Name
Wool cover
Wool cover
Lid
Knob
Ash box hatch
Ash box hatch, blind
Ash box hatch
Wool cover
Service door, right
Service door, right
Service door, left
Service door, left
Wool cover
Pressure gauge and thermometer
Handle
Lid
Item
48148
48212
36706
68536
35424
35951
36189
48505
35484
34600
34332
35494
45776
68335
34604
36681
57
Figure 16 Veto 220 spare parts
58
Table 16 Veto 220 spare parts
No.
1
2
3
4
5
6
7
8
9
10
11
Name
Wool cover
Lid
Wool cover
Lid
Knob
Wool cover
Ash box hatch
Ash box hatch, blind
Ash box hatch
Wool cover
Service door, right
Service door, right
Service door, left
Service door, left
Pressure gauge and thermometer
Handle
Item
48260
35949
48261
35947
68536
48505
35424
35951
36189
45776
35484
34600
34332
35494
68335
34604
59
12. Disposal of the boiler
When used and serviced properly, the boiler will serve you for a long time. In time it will,
however, become unprofitable to maintain and thereby be disposed of.
The boiler device contains:
•
•
Electronic parts (sensors)
Steel
Deliver the boiler device to a waste treatment plant where it is taken to pieces and the parts
are recycled in an appropriate way.
60
61
13. Glossary
Term
Heating network
Explanation
The network where the heating water flows.
Includes piping, radiators, valves, and a
water accumulator.
Heating system
The heating system includes the heating
network and also a boiler and a feeding
device.
62
63