woodmaster commercial series

Transcription

WOODMASTER COMMERCIAL SERIES
www.woodmaster.com / Retain this manual / Manual PN: 7994-400
Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750
Rev: 3.0
Table of Contents
General Information�� 2
Reference Standards�� 3
Safety�� 4-5
Technical Features�� 6-13
Fuels�� 14
Transporting�� 15-17
Installation�� 18-21
Start-Up�� 22
Maintenance�� 23-25
Troubleshooting�� 26
Misc. Information�� 27
General Information
Identification and purpose of the document
This instruction guide drafted by D'Alessandro Termomeccanica, original manufacturer, is an integral part of
the boiler. North American licensed production and distribution handled through ABioNova US. Any reproduction, even partial, is prohibited. The aim of this manual is to provide all the necessary information for the correct use guaranteeing maximum safety for people, animals and objects.
The company ABioNova US is indicated as Manufacturer in North America, in compliance with ASME Section
IV.
The Legal Name of the Original Manufacturer is:
D'Alessandro Termomeccanica - C.da Cerreto 55
66016 Miglianico (CH) - Italia
North American Licensed Prodution and Distribution by:
ABioNova US LLC
1550 Utica Ave S #740
Saint Louis Park, MN 55416
National Board of Boiler Inspectors - Pressure Vessel Identification Plate
The plate installed on the boiler displays the legal name of the manufacturer along with the following details:
-Year of manufacture
-Serial number
-Maximum working pressure
-Maximum working temperature
-Water content
-Empty weight
-Power consumption
-Mains voltage
CE marking
The plate with the legal name of the manufacturer, the machine identification data, the CE marking and the
declaration of conformity enclosed certify that the machine complies with the applicable European Directives.
2
WoodMaster Commercial Owners Manual
April 2012
Reference Standards
Reference standards
This manual has been written in compliance with the following Directives, Laws and
Standards:
1. ASME Section IV
2. Directive 85/374/EEC on responsibility for defective products
3. Directive 92 /59/EEC on General Safety of products
4. Directive 2006/42/EC on Machinery safety
5. Directive 2006/95/EC on electrical material safety
6. Directive 2004/108/EC on electromagnetic compatibility
7. Technical standard UNI EN 12100-1/2 on machinery safety (Principals)
8. Technical standard UNI EN 1050 on machinery safety (Principles for risk evaluation)
9. Technical standard IEC EN 60204-1 on machine safety (electrical equipment)
10. European standard UNI EN 303-5 solid fuel boilers with manual and automatic feeding and nominal heat
output up to 1,024,327 BTU (300 kW) – Terminology, requirements, tests and marking.
11. UL 508A NFPA
Warranty and Liability
The warranty refers to both the mechanical and electrical parts of the boiler, in compliance with Northwest
Manufacturing, Inc. Warranty description which protects the user against construction defects for a period of
one year.
The warranty is valid only for the original customer and only when he/she becomes exclusive owner of the
machine. Any controversy between Northwest Manufacturing, Inc. and the purchaser are settled by
arbitration; in case of non-agreement upon the arbitration board, the place of jurisdiction shall be Minnesota.
The aforementioned points are contained in the NWM-BM-10.1, which are an integral part of the purchase
agreement. Refer to the general conditions of sale also for cases not mentioned in this document.
Warranty or manufacturer liability cannot be called upon in case of damages to people and/or objects due to:
-Incorrect installation of the machine
-Improper use of the boiler
-Modifications to the boiler
April 2012
3
Safety
• All installation and operations must follow STATE and LOCAL CODES for wiring, plumbing, and firing of this
unit. These CODES may differ from this manual. Installation must be performed by a qualified installer.
• Anyone who is not familiar with and/or has not been trained to operate the WoodMaster Commercial
Series may not operate the system. Only responsible adults should operate your boiler. If the boiler is not
fired properly damage could result and the warranty may be voided.
• Never allow children to play near or tamper with the boiler, fuels, tanks or any other part of the system.
• Always keep the area around, and in front of fuel door clean and free from combustible materials.
• Keep animals away from the boiler.
• The operation may not be continued or restarted in the event of visible damages (for example, water
leaks, thermal distortion, traces of smoke or fire, mechanical damages, etc.). Any damages must be
repaired. In the event of any doubts, please contact your authorized WoodMaster Dealer.
• Only touch the handles during the operation. Temperatures at other points (for example, chimney, ash
door, buffer tank, lines…) can be very high.
• The WoodMaster Commercial Series must be operated exclusively according to the guidelines for
planning, assembly, regulations, statutes and product related instructions. The manufacturer is not liable
for damages and their results, if they occurred due to improper assembly, operation, application and also
inadequate maintenance and cleaning.
• Do not connect this unit to a chimney flue serving another appliance. Follow all state/local codes.
• Read and follow these directions carefully. Retain this manual for as long as you own your boiler.
• The use of silicone with the WoodMaster Commercial Series can cause damage to the Lambda (02) sensor
and is not to be used for any purpose with this product
Intended Use Of The Boiler
The boiler produces low pressure hot water and is suitable for combustion with mechanized feeding. Any other
use is improper.
Improper Use Of The Boiler
The use of large sized wood or other similar products in a closed expansion tank system is also considered
improper use.
Installing the boiler outdoors exposed to weather agents represents a case of improper use.
4
April 2012
Safety
Risks Connected To The Use Of The Machine
Safety of this boiler have been considered during the design stage, however, hazardous situations may arise if:
• The boiler is used improperly.
• The boiler is installed by non-qualified personnel.
• Instructions regarding safety contained in this manual are not complied with.
Residual risks
The boiler has been designed and built in compliance with all the current applicable Safety Standards. Although every possible risk has been considered, it is possible that besides the risks deriving from improper use,
the following risks may occur:
BURNING HAZARD
When starting the firebox, accessing the inspection doors or cleaning while the firebox is not completely off.
ELECTROCUTION HAZARD
The boiler is connected to and controlled by an electrical panel equipped with all the protection
devices against overloads and short circuits. To protect against the indirect contacts, we recommend
powering the panel with a line protected by differential switch with intervention threshold not higher
than 30 mA.
HAND INJURY HAZARD
During cleaning or maintenance operations on the fuel feeding screw.
FINGER INJURY HAZARD
During control and maintenance operations on chain transmission components located in correspondence of the gear motor.
SUSPENDED LOAD HAZARD
During boiler transport and handling operations
ASPHYXIATION HAZARD
in case of inadequate fume evacuation (draught). We recommend periodically cleaning the boiler
flue, tube nest and firebox thoroughly.
PROTECTIVE GLOVES ARE MANDATORY
Protective gloves must be used during all maintenance and cleaning operations.
PROTECTIVE HELMET IS MANDATORY
During every boiler transport or handling operation
PROTECTIVE MASK IS MANDATORY
During maintenance and cleaning operation on the flues.
April 2012
5
Technical Features
Boiler Operation Illustration
Biomass boiler with three flue passes for the production of hot water for residential and commercial central
heating. The operation of the “BM” boiler is described in figure A, while figure B describes the operation of the
“BMC” boiler.
N1
Outlet Water
Tube Nest
N4
Chimney
Hopper
Upper
Door
Central
Pipe
Fuel
Sight
Glass
Rotary
Air Fans Valve
Combustion
Chamber
Down
Door
Water Inlet
N2
Secondary
Air Fan
Primary
Air Fan
fig. A
Upper
Auger
Burner Auger
Burner Box
Motor & Gearbox
N1
Outlet Water
Tube Nest
N4
Chimney
Upper
Door
Hopper
Central
Pipe
Sight
Glass
Down
Door
Fuel
Combustion
Chamber
Primary
Air Fan
6
Upper
Auger
Water Inlet
N2
Secondary
Air Fan
fig. B
Air Fans Rotary
Valve
Agitator
Burner Box
Burner Auger
Motor & Gearbox
April 2012
Technical Features
Boiler operation description
For BM type boilers (Page 8, Figure A), the fuel descends by gravity from the intermediate hopper into the upper feeding auger, where it is pushed into the rotary valve (optional) or directly into the stoker auger.
For BMC type boilers (Page 8, Figure B), the fuel is extracted from the intermediate hopper by means of motorized agitator that convey it to the upper feeding auger.
The rotary valve has a double function. On one hand, it doses the fuel towards the stoker auger while, on the
other it breaks fuel continuity between the two feeding screws, thereby preventing fume back flow and flames
that could reach the intermediate hopper.
The rotation speed of the lower feeding screw determines the correct brazier feeding and is therefore an essential element for the correct operation of the boiler.
The fuel contained in the firebox is burnt through the primary and secondary air input.
The heat that develops in the combustion chamber is conveyed in the interspace full of water through the steel
walls of the boiler.
The hot fumes pass from the combustion chamber through the central tube and, by means of the hollow space
in the upper door, cross the tube nest and are finally expelled in the fume pipe fitting, making those three flue
passes that are the distinctive mark of this type of boiler.
Optimal combustion control is obtained adjusting the primary and secondary air and the amount of fuel. Combustion quality can be verified either visually or by means of smoke analyzers.
April 2012
7
Technical Features
List of components and spare parts
The main BM and BMC boiler components are shown in the figures below. The list of parts will be subsequently mentioned for identifying spare parts and as a reference for descriptions in the following sections.
BM Model
Number Description
1
WoodMaster Commercial Series burner
base
2
Firebox
3
Secondary air nozzles
4
Combustion chamber
5
Boiler and base anchoring joint
6
Lower door
7
Inspection window
8
Upper door
9
Tube nest
10
Hot water delivery flanged socket
11
Boiler lifting eyebolt
12
Boiler ID plate
13
Pressure vessel
14
Safety limit switch
15
Primary air solenoid valve
16
Primary air adjustment knob
17
Hot water return flanged socket
18
Rear inspection door
19
Fume pipe fitting cover
20
Fume pipe fitting
21
Fuel hopper
22
Emergency cooling connectors
23
Transmission system protection guard
24
Stoker auger gear box
25
Stoker auger motor
26
Upper auger
27
Stoker auger
28
Rotary valve housing
29
Drainage manifold
30
Secondary air solenoid valve
31
Secondary air adjustment knob
8
April 2012
Technical Features
BMC Model
April 2012
Number
Description
1
WoodMaster Commercial Series burner base
2
Firebox
3
Secondary air nozzles
4
Combustion chamber
5
6
Lower door
7
Inspection window
8
Upper door
9
Tube nest
10
Hot water delivery flanged socket
11
Boiler lifting eyebolt
12
Boiler ID plate
13
Pressure vessel
14
Safety limit switch
15
Automatic loading connection
16
Fuel hopper
17
Safety limit switch on hopper door
18
Fume pipe fitting
19
Fume pipe fitting cover
20
Rear inspection door
21
Boiler hot water return flanged socket
22
Minimum fuel level sensor
23
Thermal socket
24
Stoker auger gear box
25
Stoker auger motor
26
Primary air fan
27
Primary air adjustment knob
28
29
Heat dissipater connectors
30
Electromechanical control panel
31
Hopper inspection door
32
Level sensor connectors
33
Transmission system protection guard
34
Agitator
35
Fuel capacity adjustment knob
36
Upper auger
37
Stoker auger
38
Rotary valve housing
39
Water drainage manifold
40
Secondary air fan
41
Secondary air adjustment knob
9
10
(kW)
(MBTU)
(MBTU)
(PSI)
(PSI)
(°F)
(V)
(kW)
(Lb/Hr)
(PSI)
(Gallons)
(°F)
(Pa)
(Pa)
(Inch)
CFM
(Cubic Ft)
(Inch)
(Lb)
Firebox Power Supply
Nominal Power
Maximum Working Pressure
Hydraulic Test Pressure
Maximum Working Temperature
Main Voltage - 3-Phase
Installed Motor Power (Options Excluded)
Normal Fuel Consumption
Water Side Pressure Drop
Boiler Water Content
Average Fume Temperature (Clean Boiler)
Minimum Flue Draft Depression
Maximum Flue Draft Depression
Flue Diameter
Fume Capacity (355°F)
Combustion Chamber Volume
Combustion Chamber Opening Dim - L x H
Boiler Unladen Weight (Tolerance +/- 5%)
2734
16.5
12.4
3175
28.8 x 18.1
321
11.4
-45
153
215
-42
119
3.34
98
.72M
.51M
69
.83M
.65M
.46M
1.8
271
212
154
1.4
244
191
139
3638
20.6
400
-47
195
121
1.8
.92M
BM230
BM180
BM130
5291
28.3
521
-50
268
158
3.1
1.21M
1.09M
353
318
BM300
6063
33.5 x 26.4
35.2
697
13.4
-52
330
4.21
211
3.1
1.6M
1.44M
470
423
BM400
212°
65.2
30
2.61M
2.35M
765
689
BM650
507
344
4.8
6834
42.2
871
-54
-20
11905
55.8
1130
-56
355° (#20%)
392
264
3.1
110/230/480
2.0M
1.8M
588
529
BM500
13118
39.4 x 27.9
68.4
1392
17.3
-58
615
4.79
427
4.8
3.21M
2.88M
941
847
BM800
14330
80.9
1651
-60
722
503
5.2
3.82M
3.43M
1118
1006
BM950
21275
135.9
2260
-62
1135
688
6.3
5.22M
4.69M
1530
1377
BM1300
in Prospect 8 of the standard EN303-5 for test fuel "C".
Note: The "Normal Fuel Consumption" line indicates the required amount of fuel to feed the boiler Fuel LCP (Lower Caloric Power) equal to 17.6 MJ (4.9 kWh/kg) as
(kW)
Nominal Power
BOILER MODELS
24030
51.2 x 63.2
159.6
2866
21.3
-64
1312
5.8
872
6.3
6.62M
5.95M
1940
1746
BM1650
BM (Pellet) Series - Technical Features
The following tables show the technical data for the BM and BMC boiler series.
Technical features
27117
183.3
3478
-66
1492
1059
6.3
8.04M
7.23M
2355
2120
BM2000
Technical Features
April 2012
April 2012
(PSI)
(°F)
(V)
(kW)
(Lb/Hr)
(PSI)
(Gallons)
(°F)
(Pa)
(Pa)
(Inch)
CFM
(Cubic Ft)
(Inch)
(Lb)
Hydraulic Test Pressure
Maximum Working Temperature
Main Voltage - 3-Phase
Installed Motor Power (Options Excluded)
Normal Fuel Consumption
Water Side Pressure Drop
Boiler Water Content
Average Fume Temperature (Clean Boiler)
Minimum Flue Draft Depression
Maximum Flue Draft Depression
Flue Diameter
Fume Capacity (355°F)
Combustion Chamber Volume
Combustion Chamber Opening Dim - L x H
Boiler Unladen Weight (Tolerance +/- 5%)
3086
16.5
12.4
3527
28.8 x 18.1
321
11.4
-45
153
215
-42
119
98
69
3.34
2.2
1.8
3968
20.6
400
-47
195
121
2.2
.92M
.83M
.65M
.46M
.72M
271
212
154
.51M
244
191
139
5512
28.3
521
-50
268
158
3.5
1.21M
1.09M
353
318
6283
33.5 x 26.4
35.2
697
13.4
-52
330
4.21
211
3.5
1.6M
1.44M
470
423
212°
65.2
30
2.61M
2.35M
765
689
507
344
5.2
7055
42.2
871
-54
-20
11905
55.8
1130
-56
355° (#20%)
392
264
3.5
110/230/480
2.0M
1.8M
588
529
13118
39.4 x 27.9
68.4
1392
17.3
-58
615
4.79
427
5.2
3.21M
2.88M
941
847
14330
80.9
1651
-60
722
503
5.6
3.82M
3.43M
1118
1006
21495
135.9
2260
-62
1135
688
6.7
5.22M
4.69M
1530
1377
in Prospect 8 of the standard EN303-5 for test fuel "C".
24250
51.2 x 63.2
159.6
2866
21.3
-64
1312
5.8
872
6.7
6.62M
5.95M
1940
1746
27337
183.3
3478
-66
1492
1059
6.7
8.04M
7.23M
2355
2120
BMC130 BMC180 BMC230 BMC300 BMC400 BMC500 BMC650 BMC800 BMC950 BMC1300 BMC1650 BMC2000
Note: The "Normal Fuel Consumption" line indicates the required amount of fuel to feed the boiler Fuel LCP (Lower Caloric Power) equal to 17.6 MJ (4.9 kWh/kg) as
(PSI)
Maximum Working Pressure
(BTU)
Nominal Power
(BTU)
(kW)
(kW)
Nominal Power
BOILER MODELS
BMC (Chip) Series - Technical Features
Technical Features
11
Technical Features
General Dimensions: BMC Series
The distance “G” corresponds to the minimum space required for the removal of the screw in case of maintenance/replacement. Should this space not be obtained inside the thermal station, we recommend making a
hole on the wall in correspondence with the burner feeding screw and then covering it with a grid
or a removable door.
Figure C
Models
A
Inch
B
Inch
C
Inch
D
Inch
E
Inch
F
Inch
G
Inch
H1
Inch
H2
Inch
H3
Inch
H4
Inch
L
Inch
X1
Inch
X2
Inch
Y
Inch
BMC130
BMC180
BMC230
BMC300
BMC400
BMC500
BMC650
BMC800
BMC950
BMC1300
BMC1650
BMC2000
126.8
61.8
62.1
39.4
51.9
15.7
90.6
70.1
62.2
15.4
17.3
40.6
16.2
42.5
5.9
131.9
73.6
73.8
39.4
51.9
15.7
90.6
70.1
62.2
15.4
17.3
40.6
16.2
66.1
5.9
131.9
85.4
80.7
39.4
51.9
15.7
90.6
70.1
62.2
15.4
17.3
40.6
16.2
54.3
5.9
165.4
86.2
98.1
51.2
66.9
17.7
129.9
88.2
68.1
19.3
22.1
55.1
17.9
64.2
9.1
165.4
100
84.3
51.2
66.9
17.7
129.9
88.2
68.1
19.3
22.1
55.1
17.9
77.9
9.1
165.4 113.8
70.5
51.2
66.9
17.7
129.9
88.2
68.1
19.3
22.1
55.1
17.9
91.7
9.1
208.7 115.4
79.3
62.9
78.7
19.7
167.3 101.2
74.8
21.7
25.2
64.2
24.1
88.4
13.4
208.7 113.1
97.1
62.9
78.7
19.7
167.3 101.2
74.8
21.7
25.2
64.2
24.1
106.1
13.4
208.7 150.8 114.8
62.9
78.7
19.7
167.3 101.2
74.8
21.7
25.2
64.2
24.1
123.8
13.4
261.4 162.2
88.2
80.7
98.4
22.1
212.6 124.9
85.1
24.6
28.5
80.7
26.4
127.9
17.1
261.4 181.9 107.9
80.7
98.4
22.1
212.6 124.9
85.1
24.6
28.5
80.7
26.4
147.6
17.1
261.4 201.6 127.6
80.7
98.4
22.1
212.6 124.9
85.1
24.6
28.5
80.7
26.4
167.3
17.1
12
April 2012
Technical Features
General Dimensions: BM Series
The distance “G” corresponds to the minimum space required for the removal of the screw in case of maintenance/replacement. Should this space not be obtained inside the thermal station, we recommend making a
hole on the wall in correspondence with the burner feeding screw and then covering it with a grid
or a removable door.
Figure D
Models
A
Inch
B
Inch
C
Inch
D
Inch
E
Inch
F
Inch
G
Inch
H1
Inch
H2
Inch
H3
Inch
H4
Inch
L
Inch
X1
Inch
X2
Inch
Y
Inch
BMC130
BMC180
BMC230
BMC300
BMC400
BMC500
BMC650
BMC800
BMC950
BMC1300
BMC1650
BMC2000
118.1
61.6
62.9
39.4
51.9
13.4
90.6
68.5
62.2
17.3
17.3
40.6
16.2
42.5
5.9
123.2
73.4
56.7
39.4
51.9
13.4
90.6
68.5
62.2
17.3
17.3
40.6
16.2
66.1
5.9
123.2
85.4
44.9
39.4
51.9
13.4
90.6
68.5
62.2
17.3
17.3
40.6
16.2
54.3
5.9
166.1
86.2
98.1
51.2
66.9
17.7
129.9
88.2
78.2
19.3
22.1
55.1
17.9
64.2
9.1
166.1
100
84.3
51.2
66.9
17.7
129.9
88.2
78.2
19.3
22.1
55.1
17.9
77.9
9.1
166.1 113.8
70.5
51.2
66.9
17.7
129.9
88.2
78.2
19.3
22.1
55.1
17.9
91.7
9.1
208.7 115.4
79.3
62.9
78.7
19.7
167.3 101.2
82.7
21.7
25.2
64.2
24.1
88.4
13.4
208.7 113.1
97.1
62.9
78.7
19.7
167.3 101.2
82.7
21.7
25.2
64.2
24.1
106.1
13.4
208.7 150.8 114.8
62.9
78.7
19.7
167.3 101.2
82.7
21.7
25.2
64.2
24.1
123.8
13.4
261.4 162.2
88.2
80.7
98.4
22.1
212.6 124.9
89.4
24.6
28.5
80.7
26.4
127.9
17.1
261.4 181.9 107.9
80.7
98.4
22.1
212.6 124.9
89.4
24.6
28.5
80.7
26.4
147.6
17.1
261.4 201.6 127.6
80.7
98.4
22.1
212.6 124.9
89.4
24.6
28.5
80.7
26.4
167.3
17.1
April 2012
13
Fuels
Fuels used with the BM model
Only premium wood pellets certified by the Pellet Fuels Institute may be used and must follow these
guidelines:
• Bulk density per cubic foot must be a minimum of 40 pounds
• The diameter is between 1/4 inch to 5/16 inch
• Maximum length is 1.5 inches
• Fines (dust) of not more than 0.5% by weight
• Sodium content shall be less than 300 parts per million
• Ash content of 1% or less
• Moisture content of 10% or less
Fuels used with the BMC model
Organic crushed and flaked solid fuel can be used, such as:
• Wooden Pellets (same requirements as the BM model above)
• Wood chips With Flakes Of The Following Maximum Dimensions: Width 0.787”, Length1.181” , Thickness
0.394” (Width 2 cm, Length 3 cm, Thickness 1 cm)
Other Fuels
For other fuels not mentioned above, please contact our technical office.
Dereating Diagram
The nominal power of WoodMaster Commercial Series boilers is guaranteed with a biomass relative humidity
under 30%. For biomasses with higher humidity, refer to the power dereating table below.
1.0
K (Conversion factor)
1.0
.9
.85
.8
.71
.7
.6
.57
.5
.43
.4
0
10
20
30
40
Moisture Percentage of Fuel
50
All fuels must conform to certain quality standards to ensure trouble free operation of the furnace. Use of
unapproved fuels may result in faulty operation and a voided warranty. Never use the following: trash, plastics, gasoline, rubber, or naphtha. Please contact Northwest Manufacturing for any questions on fuel use.
14
April 2012
Transporting
General information
The boiler is supplied fully assembled and ready for installation up to models BM950 and BMC950. Models
BM1300-2000 and BMC1300-2000 are supplied with separate burner and boiler body for transport purposes.
BM130-180 and BMC130-180 are supplied with wooden pallet for handling by means of a forklift.
Transport and Handling
Transport and handling operations must be carried out by qualified personnel with adequate lifting means. The
boiler is equipped with eyebolts (fig.G) for hooking with cables, ropes or chains adequately chosen for lifting
the boiler. We recommend using certified lifting means and consulting the load tables indicated by the manufacturer. To lift the boiler, refer to the unladen weight indicated on the identification plate. Examples
referring to lifting operations for the various models are provided in the following pages.
CAUTION!
TRANSPORT AND HANDLING MUST BE CARRIED OUT BY
QUALIFIED PERSONNEL WITH ADEQUATE LIFTING MEANS
AND PERSONAL PROTECTION EQUIPMENT
Forklift
4 Feet
Figure G
Example for Lifting and Handling
BM-BMC 130-180 Boilers on Pallet
Figure H
April 2012
15
Transporting
Figure I
Example for lifting and handling bm-bmc 130-180 boilers by means of lifting equipment.
Figure J
16
April 2012
Transporting
Figure K
Figure L
Example for lifting and handling bm-bmc 1300-2000 boilers on burner basement by means of lifting equipment.
April 2012
17
Installation
Note: The use of silicone with the WoodMaster Commercial Series can cause damage to the
Lambda (02) sensor and is not to be used for any purposes with this product
Hydronic connections
The following table refers to figures C and D on the previous pages and summarizes the dimensions of all the
boiler hydraulic connections according to the model.
Pos.
Description
Type
BM-BMC
130-230
BM-BMC
300-500
BM-BMC
650-950
BM-BMC
1300-2000
N1
N2
N3
Delivery
ANSI
DN 65-2.5”
DN 80-3”
DN 100-4”
DN 125-5”
Return
ANSI
Dn 65-2.5”
DN 80-3”
DN 100-4”
DN 125-5”
Emptying
Heat Dissipater
Inlet/Outlet
manifold
DN 25-1”
DN 25-1”
DN 40-1.5”
DN 40-1.5”
socket
DN 15-0.5”
Dn 15-0.5”
DN 25-1”
DN 32-1.25”
N4
To improve water output, optimizing its return circulation to the system, we recommend connecting both N2
flanged fittings to the return circuit in models ranging between 650 and 2000 kW, as shown in fig E.
Figure E
18
April 2012
Installation
To install the temperature safety relief valve (bulb) in the 1/2” burner trap (as shown in fig. F), the door located
on the trap must be removed or you will have to unscrew and remove the upper panel.
T
Temperature Safety Relief Valve
Inlet Water
minimal pressure 1.5 bar
1
2
Probe Connection 1/2”
N4
Figure F
CAUTION!
TRANSPORT AND HANDLING MUST BE CARRIED OUT BY
QUALIFIED PERSONNEL WITH ADEQUATE LIFTING MEANS
AND PERSONAL PROTECTION EQUIPMENT
CAUTION!
CONNECT THE TEMPERATURE SAFETY RELIEF VALVE BEFORE
COMMISSIONING THE BOILER THE TEMPERATURE SAFETY
RELIEF VALVE IS NOT SUPPLIED BY WOODMASTER.
April 2012
19
Installation
General installation requirements
The electrical and hydronic installation of the boiler and any other assistance or maintenance operation must
be carried out by a certified and approved Northwest Manufacturing, Inc. Dealer or installer.
Installer requirements. (by state)
The creation of central heating or hot water production plants based on boilers as those described in this
manual, is regulated by different regulations in the various states therefore, the installer must refer to the local
regulations in force.
Flue and draught
The flue is one of the most important elements for a correct boiler operation. In general, a good draught is
obtained when the flue is thermally insulated, designed with a double wall and insulated to prevent the fumes
from cooling, thus maintaining the pressure difference that allows the fumes to go up the flue to the external
outlet. We recommend using stainless steel for the parts in contact with the fumes in order to prevent acid
condensation due to the features of the used fuel. The surrounding structures may affect the correct operation
of the flue: e.g., the distance and height of nearby buildings.
An excessive draught will reduce the boiler efficiency: part of the combustion gas is sucked in the flue together
with the fuel particles before being fully burnt, thus increasing fuel consumption.
A poor draught, on the other hand, reduces the boiler efficiency causing fume and carbon monoxide back flow.
If boiler is not equipped with a draft fan the flue section must have the same diameter as the fume pipe fitting (Page 10 Pos. 20 - Page 11 Pos. 18). Narrower sections are not allowed. Moreover, its weight must not lay
on the fume pipe fitting in order to prevent collapses in the structure of the boiler. Figure P on the next page
shows how to install it correctly. The flue must be sized according to the boiler section and the firebox power
supply by qualified personnel. For boilers connected in parallel, each boiler must have its own flue.
Due to the various installation places, during normal operation, the flue section and height must guarantee a
minimum draught of –20 Pa measured by applying a 1/4” hose connection to the manifold located on the side
of lower door inspection window as in figure N and by inserting a rubber pipe connected to a deprimometer
(Tables on pages 12 & 13) indicate maximum draught values.
Should you not be able to obtain a sufficient draught, we recommend installing an electric fan for forced
draught on top of the flue as in figure M.
A chimney cover on top of the stack is recommended to keep out moisture and debris. Fig O \
Note: The use of silicone with the WoodMaster Commercial Series can cause damage to the
Lambda (02) sensor and is not to be used for any purposes with this product
20
April 2012
Installation
Final Testing
The final testing can only take place once installation is completed i.e., once the boiler is positioned and levelled, connected to the hydraulic circuit, electric panel and supplied with suitable fuel. The end customer is
responsible for all the connections mentioned.
Figure M
Figure N
Guyings
Figure O
Smoke Measurement
Nozzle
Figure P
Inspection Door
Condendate Discharges
Anchoring Bolt
April 2012
21
Start-Up
Checks prior to start-up
Before starting the boiler, always make sure that:
• The water system is regularly filled with the right amount of liquid in the OPEN or CLOSED expansion tank.
• The stoker auger and fan motors rotate in the correct direction.
• The hopper is filled with suitable fuel (see chapter 4)
Start-up
Start-up must be performed by a certified Northwest Manufacturing, Inc. Dealer or installer.
Normal operation
Once the start-up and adjustments are completed the boiler will operate automatically.
22
April 2012
Maintenance
General information
The firebox and the flues must be periodically cleaned from combustion solid residues (ashes).
Keeping the flues free from ashes ensures an effective draught and the best boiler efficiency.
CLEANING THE FIREBOX
OPERATION
FREQUENCY
NOTES
REFERENCE
Remove Ashes From The Sides Of The firebox and combustion chamber
4-5 Days
Ash Extractors Reduces Manual Work by Appx. 50%
Page 24, Figure V
CLEANING THE TUBE NEST
OPERATION Check and remove ashes from the tube nest by opening the upper door. Should turbulators
(optional) be inserted, they must be removed from each tube before cleaning.
FREQUENCY 5-10 Days
A compressed air cleaning system allows postponing manual cleaning operations. A visual
NOTES
check must be carried out approximately every 90 days of operation.
REFERENCE Page 24, Figure X
FUME PIPE FITTING
OPERATION
FREQUENCY
NOTES
REFERENCE
Check and remove ashes from the bottom in correspondence with extraction doors.
20-30 Days
Regularly check the flue and the seals.
Page 24, Figure W
AIR PIPES
OPERATION Check and remove ashes from the air pipes by removing the lower base covers. Remove any
encrustation from the holes of the firebox cast-iron components.
FREQUENCY Once a Year
Page 24, Figures V & Y
NOTES
REFERENCE We recommend using an industrial vacuum cleaner.
AIR PIPES
OPERATION Check and remove from the empty hopper any dust and encrustation due to humidity and
to the type of fuel.
FREQUENCY 30-60 Days
Make sure that the fuel does not contain foreign bodies that could damage the feeding
NOTES
screws.
REFERENCE Page 8, Position 21 and Page 9, Position 16
April 2012
23
Maintenance
CAUTION!
BEFORE CARRYING OUT CLEANING OPERATIONS DISCONNECT THE
BOILER POWER SUPPLY BY MEANS OF THE MAIN SWITCH AND MAKE
SURE THAT ANY RESIDUAL FUEL IN THE FIREBOX IS OFF AND COLD.
After every cleaning and maintenance operation, we recommend cleaning and checking the cover seals, in
order to prevent the emission of hazardous dust or fumes.
Figure V
Figure W
Figure X
Figure Y
24
April 2012
Maintenance
Seasonal Maintenance
The boiler must undergo regular seasonal maintenance to guarantee proper operation and burn efficiency.
CAUTION!
MAINTENANCE MUST BE CARRIED OUT BY QUALIFIED PERSONNEL.
CAUTION!
BEFORE CARRYING OUT MAINTENANCE OPERATIONS DISCONNECT THE
BOILER POWER SUPPLY BY MEANS OF THE MAIN SWITCH AND MAKE
SURE THAT ANY RESIDUAL FUEL IN THE FIREBOX IS OFF AND COLD.
OPERATION
COMPONENT TO
BE CHECKED
OPERATION
PRIMARY AND
SECONDARY AIR
FANS
Check that the fans turn and
do not cause vibrations. ReBeginning of Season
move excessive dust and dirt
if needed.
ELECTRICAL
SYSTEM
Check the status of the relay
Beginning of Seacontacts and of the control
son or Following a
panel switches. Test the difPeriod of Extended
ferential switch and check
Downtime
the ground connection.
REDUCERS
Check the oil level of the
Beginning of Season reducers by means of the
indicator light. Fill if low.
CHECK
LUBRICATION
VENTILATION
AIR PIPE BLADES
April 2012
FREQUENCY
Apply oil by spray or brush
Beginning of Seato lubricate the transversal
son or Following a
rotation pin of the primary
Period of Extended
and secondary air pipe interDowntime
nal blade.
REFERENCE
Page 8, Position
15-30
Page 9, Position
36-40
-
Page 8, Position 24
Page 9, Position
24-25
-
25
Troubleshooting
CAUTION!
BEFORE CARRYING OUT CLEANING OPERATIONS DISCONNECT THE
MAIN POWER AND WAIT FOR THE BOILER TO COOL.
PROBLEM
Insufficient fuel flow
rate.
POSSIBLE CAUSE
1) Make Sure there is adequate fuel in the hopper.
2) Make sure that there are no foreign objects in
the hopper that could obstruct the fuel flow. Check
to make sure the fuel has not bridged.
3) Check the operation of the auger motor and
check the transmission chain pinon.
4) Remove the carter to make sure the safety nut
which fastens the pinon to the secondary shaft is
not broken
The fuel feeding screw
speed cannot be
adjusted by means of
the manual adjuster.
There is not enough air
for combustion.
Smoke returns inside
the fuel hopper.
Incorrect Combustion
26
SOLUTION
Fill the hopper with fuel.
Mix the fuel inside the hopper.
Make sure that the motor is
powered. If not call for technical assistance.
Should the nut be broken,
call for technical assistance.
5) Remove the carter to make sure the transmisCall for technical assistance.
sion chain does not skip the pinion teeth for lack of
tautness.
1) The mechanical adjuster is broken.
Call for technical assistance.
1) Check the operation of the fans. Make sure
Remove any foreign objects
there are no foreign objects hindering the fans and and make sure that the electhat the motor is powered properly.
tric connector is connected.
Should the problem persist,
2) Make sure the adjustment knob can be loosRemove any buildup on the
ened and tightened and that it is not blocked with knob treading and lubricate.
foreign material.
Should the problem persist,
3) Make sure that the burner holes are not clogged Clean the furnace as previby fuel residue.
ously described.
4) Check for the presence of dust on the fan
Remove any dust using comblades.
pressed air.
Make sure that the flue draught is within the deCall for technical assistance.
sired range.
Check the balance between the fuel flow rate and Should the problem persist,
low air ratio.
April 2012
Misc. Information
Noise
The boiler acoustic pressure levels are not significant. Measurements carried out in typical environment (thermal station of over 6 sqm) have shown continuous sound pressure levels Leq,d and peak values below 76 dB(A)
Decommissioning & Scrapping
The boiler is fully made of ferrous materials and does not contain any hazardous material.
April 2012
27
www.woodmaster.com / 800-932-3629 / Manual PN: 7994-400
Northwest Manufacturing, Inc / 600 Polk Ave SW / Red Lake Falls, MN 56750

woodmaster commercial series

Transcription

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