Wood logs boiler with a gasification effect IGNIS 20-40 KW

INSTRUCTIONS MANUAL for usage and maintenance

Prhovacka bb 22310 Simanovci, SrbijaTel/Fax. +381 22 480404 +381 63 259422office@termomont.rs www.termomont.rs

May 7, 2014

Contents

1 Boiler design and properties 21.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Technical properties according to EN 303-5 . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 On product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 How It Works 3

3 Recommendations for boiler shipment and storage 43.1 Delivery form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.2 What’s in the box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Boiler installation 54.1 Boiler placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5 Connecting the boiler with a central heating system 75.1 Closed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.2 Closed system combining floor and radiator heating . . . . . . . . . . . . . . . . . . . . . . 85.3 Open system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

6 Boiler In Use 116.1 Circulation Pump Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.2 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Safety features 117.1 Thermal safety in case of overheat (closed systems) . . . . . . . . . . . . . . . . . . . . . . 11

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1 Boiler design and properties

1. Upper door for placing wood-logs 2. Secondary air inlet (manual regulation) 3. Lower door for cleaning4. Primary air regulation 5. Thermostatic draught regulator 6. Chain for air regulation 7. Connectors forsafety heat exchangers 8. Connection for excess water outlet 9. Sensor placement 10. Flue box 11. Flue 12.Secondary flue (flap) 13. Secondary flue flap handle 14. Opening for cleaning the flue box 15. Fill/Drain tap16. Return 17. Base 18. Flow

1.1 DimensionsType IGNIS Weight (kg) A

(mm)B(mm)

C(mm)

D(mm)

E(mm)

F(col)

G(mm)

H(mm)

I(mm)

L(mm)

IGNIS 20 320 726 648 468 480 160 5/4 490 1220 900 845IGNIS 30 340 736 858 578 590 160 5/4 660 1220 900 1045IGNIS 40 350 736 1135 578 590 160 5/4 860 1220 900 1245

1.2 Technical properties according to EN 303-5

Nominal power IGNIS (KW) 20 30 40Power range (KW) 15-20 20-30 30-40Necessary draught (mbar) 25 26 28Water content (l) 45 60 70Flue gases temperature (at nominal power) (◦C) 200 200 200Heating chamber volume (dm3) 50 80 100Mass flow at nominal power (kg/s) 0,016 0,021 0,045IP Protection 30 30 30Temperature regulation range (◦C) 60-90 60-90 60-90Min. temperature of the return line (◦C) 60 60 60Efficiency (at nominal power) 80% 81% 80%Boiler class 2 2 2

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1.3 On product

• Boiler primarily uses dry wood as fuel with caloric value > 15 MJ/kg, max. moisture content 15%;

• Boiler is produced following the guidelines of the European norm EN 303/5;

• According to norm demands, inner walls of the boiler are 5 mm thick;

• Combustion takes place inside the heating chamber which specially designed to facilitate load of alarge portion of wood-logs;

• Single combustion load can hold up to 6 hours;

• Boiler comes with removable ash-tray, cleaning kit and thermometer;

• Cast-iron bottom grid for long-term boiler exploitation;

• The upper zone of the heating chamber is round shape (so-called ’catalyst’) - made of fireproofceramics with tubulators for optimum efficiency;

• Water test is done at 6 bar pressure.

2 How It Works

IGNIS primarily uses wood-logs as fuel - by its construction it could be thus called a ’boiler with wood-gasification effect’. Following image depicts the combustion principle of this boiler.

1. Combustion chamber 2. ’Catalyst’ with tubulators 3. Heat exchanger of the safety valve line 4. Tubu-lators (heat exchangers inside the upper zone) 5. Secondary flue opening 6. Flue box (a part of the heatingchamber around the flue) 7. Boiler water 7.1 Boiler water around the flue chamber 8. Secondary air inlet 9.Primary air inlet 10. Return 11. Flow

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As IGNIS is similar to wood gasification boilers, main properties of a wood gasification boiler will beoutlined first. A wood gasification boiler, thanks to its special geometry, and the use of a fan, brings thewood logs in the state of ’gasification’ - the process where light weighted hydrocarbons are released outof the wood. The flame has a specific blue colour and the efficiency of such solid fuel boiler is 10-15%greater than with the traditional solid fuel boilers with no regulation. Another interesting feature of woodgasification boilers is that the wood logs are placed in the upper chamber and the flame is thus inverse -going upside down contrary to conventional boilers with vertical flame.

Wood gasification requires a constant and stationary boiler operation. It is thus necessary to havean additional heat tank to accept the excess heat made by boiler. It is also necessary to perfectly adjusttemperatures between the heat tank, flow and return line of the boiler to prevent condensation. All inone, wood gasification allows maximum comfort with wood-logs as a fuel, but with certain investment tobe made into additional equipment.

The IGNIS boiler fills the room between the less costly conventional boilers (demanding manual refuelmore often) and maximum comfort yet more expensive wood gasification boilers (with an additional heattank). Because of its construction, IGNIS achieves the wood gasification effect (in an amount much lessthan ’real’ wood gasification boilers) but only using the natural draught of the boiler, without a fan andwithout a necessary heat tank. What is still necessary is the protection against condensation (mixedvalve, by pass of the boiler). IGNIS combusts with a vertical flame, not inverse.

As it does not posses the automatic regulation via fan, optimum combustion is achieved by setting theprimary and secondary air. Primary air is controlled by the draught regulator (to be ordered separately)and the secondary air is to be set manually.

In which way the wood gasification effect is achieved? Wood gasification process takes place in theupper zone of the boiler - within the so-called ’catalyst’ zone. This is a special cylindric part of theheating chamber. On its upper side there are special heat exchangers (tubulators). Below the catalystand in presence of secondary air, at very high temperatures, solid particles are accelerated to certain leveluntil they combust completely. Short-chain hydrocarbons are released. Flue gases are passing throughturbulators - in contact with increased surface of the tubulators, flue gases are additionally cooled down -exit flue gas temperature is thus lower compared with conventional boilers. The efficiency is higher. Theconcentration of dust, particles and COX/NOX is lower.

IGNIS has a secondary flap inside the chamber. The role of this is to shorten the passage of fluegases and increase the draught in the boiler when necessary (during ignition for instance). When thecombustion is stabilized this secondary flap should be closed. IGNIS also has a so-called ’flue-box’ - watercontent of the boiler is maximized occupying this additional part of the flue chamber.

3 Recommendations for boiler shipment and storage

3.1 Delivery form

The boiler comes wrapped with plastic sheet, transported on wood pallet.The boiler must always stand in its vertical position. The rotation of the boiler during the shipment orinstallation represents a serious risk and can lead to damaging the boiler. It is forbidden to stack boilersvertically one onto other.The boiler can be stored only in closed rooms with no atmospheric influence. The humidity in the storingroom also must not exceed the critical value of 80%, so as not to create any condensate. The temperatureof the storing room must be in the range of +/- 40 ˚C.

3.2 What’s in the box

The following parts are supplied together with the boiler:

• Cleaning kit

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• Cleaning brush

• Warranty paper

4 Boiler installation

4.1 Boiler placement

The boiler room should have air-conditioning. The boiler should be mounted in the boiler room permitingaccess to all its parts as shown below:

4.2 Chimney

Boiler connection to the chimney is shown in the figure:

Proper dimensioning of the chimney is a very important premise for optimum boiler performance.The purpose of the chimney is to take out the products of combustion but also to secure necessary airdraught in the boiler. The graph shows how to chose the necessary height for the chimney as a func-tion of chimney opening. Proper chimney insulation is very important and should be at least 50 mm thick.

Depending on the necessary draught of the boiler, the cross section and the height of the chimney aredetermined. Please advise technical material given by chimney producer. Minimum chimney height forwood boilers is 6 m. Round chimney made of stainless steel modules is recommended in order to keepthe condensation influence low.

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5 Connecting the boiler with a central heating system

5.1 Closed system

The following schemes show how to connect the boiler to the central heating installation with or withouta heat accumulator tank:

System parts: 1. Boiler 2. Heat accumulator 3. Heat exchanger 4. Non-return valve 5. Mixing valve6. Pump of the radiator heating 7. Automatic regulation for the radiator heating 8. Expansion vessel 9.Exchanger pump 10.Valve 11.Thermo-manometer 12. Expansion vessel 13. Four-arm mixing valve 14.

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It is not necessary to install the heat accumulator. However, it is recommended.For 1 KW power ofthe boiler, a capacity of the heat accumulator of 25-50 l is recommended. One must also bear in mindthat the power of the boiler must be enough in order to both warm up the water in the accumulator,as well as to provide direct feed to the installation in very cold periods – the chosen power of the boilershould be 1.5 higher than the power of an oil-gas boiler for the given squaring.

It is recommended that the closed central heating system is supplied with an expansion tank, thecapacity of which must amount to at least one tenth of the total capacity of the system (including thewater volume in the boiler). The system must also have an automatic aeration valve with the help ofwhich air will be eliminated from the system. The use of a safety valve is obligatory (with a 2-3 barthreshold, depending on the power of the boiler) and it must be mounted near the boiler.

It is also necessary that the system has a thermometer and manometer in order to read the temperatureand pressure in the system. In case of using conventional solid fuel, the temperature of the return lineshould not fall below 60˚C, so as to avoid leaking, i.e. condensation in the boiler, which can further leadto corrosion. The temperature of the starting line should not fall below 70˚C. It is recommended to usea four-arm mixing valve on the return line of the boiler or a regulation group such as LADDOMAT 21.It is also recommended to mount a filth catcher on the return line.

Qualified installer should be entrusted with the mounting of the heating and the initial operation.This must be a person who will take over the responsibility and guarantee the correct operation of theboiler and of the complete central heating system. In the case of an incorrectly planned system withmanifesting deficiencies caused by the respective person’s incorrect installation of the system, which canagain lead to an incorrect operation of the boiler, the complete liability for the material damage andpotential new costs arising in relation to it is borne exclusively by the person who was entrusted withthe mounting of the central heating system, and not by the boiler manufacturer, sales representative orseller.

5.2 Closed system combining floor and radiator heating

The following scheme depicts a heating system connected over a hybrid solar boiler within an accumalationtank:

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System parts: 1. Boiler 2. Heat accumulator 3. Heat exchanger 4. Non-return valve 5. Distributor 6.Mixing valve 7. Pump of the radiator heating 8. Pump of the floor heating 9. Regulator of the automaticregulation for the radiator heating 10. Regulator of the automatic regulation for the floor heating 11. Receiver12. Expansion tank 13. Exchanger pump 14.Valve 15.Thermo-manometer 16. Filth catcher 17. Four-armmixing valve 18. Safety valve

5.3 Open system

The following scheme shows how to connect the boiler to the open central heating system:

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System parts 1. Boiler IGNIS 2. Valve 3. Thermo-manometar 4. Boiler circle pump 5. Three-way mixingvalve or LADDOMAT 21 6. Heat accumulator tank 7. Three-way mixing valve 8. Automatic three-way mixingvalve 9. Circulation pump for radiator heating 10. Open expansion vessel 11. Automatic regulation MRTRPlus (First) 12. Heating circle 13. Sanitary water circulation pump 14. Sanitary water accumulation tankSOLAR I

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6 Boiler In Use

6.1 Circulation Pump Thermostat

Boiler should be equipped with a thermostat for the system circulation pump. The thermostat thresh-old can be set on certain value and only when the temperature is higher than that, the circulation pumpwill be turned on.

This thermostat is primarily used in order to prevent the low temperature of the return line whichcan lead to condensation as a consequence. The default value for temperature threshold is set at 60 ◦C.

6.2 Maintenance and cleaning

Using wood pellets as a primary fuel means very low level of ashes (less than 1%). The cleaning of theboiler can thus be performed once per week and does not take more than 5 minutes. Burner ash-trayshould be however cleaned every day or two - operation which takes less than a minute.

Using pellets means also low temperature of the flue gases due to the high efficiency of combustion.This means the boiler would last much longer compared to combustion with traditional solid fuels suchas wood or coal.

7 Safety features

7.1 Thermal safety in case of overheat (closed systems)

For additional hydraulic protection in the closed systems it is necessary to install to safety thermal valveshown on image (to be bought separately, not an integral part of the boiler).

If for some reason the temperature of the water inside the boiler should exceed 95◦C this valve wouldrelease the water from the water supply system to cool down the water temperature inside the boiler.

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Connection scheme for the thermal safety valve: 1. Cold water entering from the water supply system 2.Cold water entry into boiler 3. Hot water going outside the boiler 4. hot water ending in the sewage watersystem 5. Thermo-valve sensor

To connect the safety valve:

• Connect the sensor of the valve (outter thread 1/2") at depicted place on the boiler, position 5(inner thread 1/2")

• Connect the cold water entry (on valve’s input is marked with C) than connect the exit line (valvemarked with:→) with the corresponding exit line on the boiler (position 21)

• Connect position 21 (on the boiler) with the input line on the valve (valve is marked with: ←)

• Connect the valve (marked with S) to the sewage system.

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