Gasifying boilers VIGAS Ecological Boilers VIGAS MANUAL FOR INSTALLATION, ASSEMBLY AND USE VIGAS and VIGAS Lambda Control with AK 3000 Certificate of warranty VIMAR 2010 1 Gasifying boilers VIGAS Content Page Declaration of conformity...................................................................................................... 3 1. Technical description...................................................................................................... 4 2. Technical data................................................................................................................ 5 3. Description of AK 3000 control...................................................................................... 7 4. VIGAS boiler in basic configuration............................................................................... 9 5. VIGAS boiler in configuration with gases thermometer.................................................. 11 6. VIGAS boiler in configuration with gases thermometer and discharge fan.................... 12 7. VIGAS in configuration with gases thermometer.......................................... 13 Lambda Control 8. VIGAS in configuration with gases thermometer and discharge fan............ 15 Lambda Control 9. Time setting.................................................................................................................... 17 10. Hardware and software information............................................................................... 18 11. Error messages.............................................................................................................. 18 12. Service settings PIN 0000 protected.............................................................................. 18 13. Operating instructions..................................................................................................... 21 14. Boiler maintainance and repairs.................................................................................... 24 15. Accesories assembly..................................................................................................... 26 16. Listo fo guarantee and afterguarantee services............................................................. 28 17. Problems solving............................................................................................................ 28 18. Assembly instruction...................................................................................................... 29 19. Electric scheme of connection VIGAS boilers................................................................ 31 Letter of guarantee......................................................................................................... 32 Confirmation of VIGAS boilers commissioning.............................................................. 33 2 Gasifying boilers VIGAS DECLARATION OF CONFORMITY Issued according to Section 12, par. 3, letter a) Act No. 264/1999 Coll. and 97 / 23 EC We, VIMAR Vigaš Pavel M. Čulena 25 974 11 Banská Bystrica SLOVAKIA IČ DPH: SK 1020548001 hereby declare that the undermentioned products comply with technical regulations and the products are safe if determined conditions are followed and we took all possible measures to assure the compliance of products with technical documentations as well as with relevant instructions requirements of government. Product: Thermal boiler VIGAS and VIGAS with AK 3000 control Lambda Control Type: VIGAS 16, VIGAS 16 Lambda Control VIGAS 25, VIGAS 25 Lambda Control VIGAS 40, VIGAS 40 Lambda Control VIGAS 60, VIGAS 60 Lambda Control VIGAS 80, VIGAS 80 Lambda Control VIGAS 100, VIGAS 100 Lambda Control VIGAS 29 UD Producer: VIMAR Vigaš Pavel M. Čulena 25, 974 11 Banská Bystrica, SLOVENSKO The above-mentioned products comply with the following standards: STN 07 7401, STN 73 4210, STN EN 303-5, STN EN 61000-3- 2:2000+A1:2001+A2:2001, STN EN 61000-3-3:2000. Supplementary data: Certificates, Test report Issued in: Banská Bystrica Name: VIGAŠ Pavel Date of issue: Title: Owner Signature: 3 Gasifying boilers VIGAS 1. TECHNICAL DESCRIPTION Thermal boilers VIGAS are designed for combustion of dry wood material, starting from sawdust up to logs in the length according to the dimensions of gasification chamber, maximum 20 cm. Sawdust, chippings, splinters and cuttings must be burn together with logs. Thermal boiler, VIGAS UD 29 is designed for burning brown coal. It is also possible to use dry wooden material as a substitute fuel. Boilers are welded from 4- 6 mm steel sheets. Inner boiler sheets that have contact with boiler waste gases are 6 mm thick, others are made of 4 mm sheet. Heat exchanger is welded from steel pipes, 57x 5 mm. Exterior boiler shell is made of 0.8 mm sheet. Thermal insulation of the boiler is made of insulation material, NOBASIL, 20 and 50 mm thick. Boiler waste gases go away through steel neck to chimney. Inner boiler space consists of gasification chamber, where fuel is dried and gasified. Then created gas goes through fireproof /concrete/ nozzle into combustion chamber, where it burns with the help of secondary air. Boiler waste gasses are intensively cooled in exchanger. Wood that is not burnt must be removed from combustion chamber. The boiler has a lighting up damper that is controled by operating rod at the front part of boiler. In order the boiler complies with the requirements for non-demanding operation, it is equipped with AK 3000 control unit that is situated in the upper part of boiler. The used system of control allows very effective combustion of various kinds of fuel. AK 3000 control with grpahical display, in basic configuration allows: (cid:131) to control temperature of heated water in range 60 ÷ 85 °C (cid:131) smooth and automatic control of forced draft fan according to required output and (cid:131) to connect discharge fan (cid:131) to connect circulation pump (cid:131) to connect gases thermometer (cid:131) to connect and to control boiler by space temperature regulator (cid:131) to connect extended regulation (EXPANDER) via AK BUS (cid:131) to connect module with Ethernet interface and SD-card for data saving and concsequtive evaluation via PC (cid:131) grpahical scheme indication of hydraulic connection as requested (cid:131) real time set In configuration VIGAS also allows : Lambda Control (cid:131) Utilizes informations from lambda sensor of oxygen overflow in gases, to control the chimney flap of primary and secundary air. (cid:131) Gases thermometer as a standard Boilers are equiped with thermal fuse that ensures disconnection of forced draft fan if boiler is overheated above 100 0C and safety exchanger against overheating according to the standard, STN EN 303/5. Its recommended, by producer, to buy a release valve Honeywell TS 130 ¾” for safety exchanger against over heating. 4 Gasifying boilers VIGAS 2. Technical data Tab.1 THERMAL BOILERS VIGAS 16 25 40 60 80 100 UD 29 Nominal boiler output kW 16 25 40 60 80 100 29 Boiler class according to EN 303-5 3 Max. operating pressure bar 3 Fuel Wood, max. moisture 20% ;heating min. 15 MJ/kg Brown coal Output capacity kW 12 - 18 5 - 31 8 - 41 15 - 72 25 - 92 25-100 8-35(8-29)* Fuel consumption with kg/hod 4,5 7,6 11,2 19 25 30,4 7,8 (8,0)* nominal output Substituite fuel Wood waste, splinters, saw dust, saw dust briquettes (for UD 29 also wood of max. moisture 20%) Chimney daught mBar 0,20 – 0,25 0,20 – 0,35 0,30 – 0,40 0,20 – 0,25 Weight kg 400 430 460 760 930 950 430 Height with regulation A mm 1135 1135 1385 1420 1120 Height of exhaust branch B mm 975 1045 1310 1400 1045 Height of inlet branch C mm 115 125 215 110 Height of feed-water valve D mm 55 60 70 135 55 Height of chimney neck E mm 890 1110 1170 890 Width including rod F mm 645 785 645 Width including shell G mm 590 760 590 Depth H mm 840 1070 1260 1650 1070 Exhaust brand I mm 240 520 240 Diameter od draught neck J mm 160 200 160 Dimmension from edge of 188 305 880 1210 230 K mm boiler Spacing of feed pipes L mm 405 70 350 Diameter of inlet brand G/mm 2“ Diameter of exhaust brand G/mm 2“ Diameter of feed-water valve G ½“ ¾“ ½“ Volume of water l 75 93 180 205 215 75 Gases temperature 0C 240 With nominal output 0C 150 With minimal output Dimensions of gasification 560 750 1150 1090 490/440 chamber mm 370 Depth Height mm 490 750 730 500 Width mm 440 575 440 Dimensions of gasification 575 – 318 435 - 255 chamber mm 435 -255 (width-height) Max. weight of fuel kg 20 30 40 80 150 30 Capacity of gasification 120 185 315 483 457 105 dm3 80 chamber Noisness dB 45 45,5 47,7 51,4 54,2 45,5 Max. electric input W 70 140 70 Voltage/Frequency V/Hz 230ACV / 50 Hz Pressure loss of water : Δt 10 0C mBar 9,70 9,75 10,48 12,77 11,83 11,53 9,97 Δt 20 0C mBar 1,00 1,05 2,55 3,19 2,96 2,84 1,15 Time of burning with nominal hod 4,5 4,20 4,30 4,20 4,20 4,0 5,60 (4,10) output Cooling exchanger of heat - temperature of inlet water 0C 4 – 15 - pressure of inlet water bar min 1 – max 4 Safety Release valve Honeywell TS 130 ¾” for safety exchanger against over heating, Opening temperature 95°C STB fuse, blow temperature 100oC (tolerance: -6oC –- 0 oC) Weight flow of gases kg/s 0,034 – 0,047 * specification for wood fu 5el Gasifying boilers VIGAS 2.1 DIMENSION CHART AND THE POSITION OF PROTECTIVE SUPPORT PLATE ON EASILY IGNITABLE FLOOR Pic.1 Pic.2 (cid:110) Inlet water neck for valve (Danfoss) (cid:111) Hole for submersible case (Danfoss) (cid:112) Exhaust brand of cooling water (cid:113) Exhaust water neck (cid:114) Inlet water neck (cid:115) Filling neck 2.2 BOILER SCHEMATICS Scheme VIGAS 16 Scheme VIGAS 25 Scheme VIGAS 40 Pic.3 Scheme VIGAS 29 UD Scheme VIGAS 60,80 Scheme VIGAS 100 KEY 11. Door closing device 22. Lambda sensor 1. AK 3000 control 12. Fireclay bricks 23. Gases thermometer 2. Upper door 13. Bottom door 24. Exchanger pipes 3. Chimney flap operating rod 14. Chimney neck 25. Heat proof /concrete/ filling 4. Fuel bunker 15. Exchanger ca p 26. Secondary air 5. Primary air conduction 16. Lighting up damper 27. Combustion chamber 6. Flap for Lambda control servo 17. Upper back cover 28. Direction of gases 7. Fan 18. Outlet water neck 29. Neck of reversible water 8. Fan cover 19. Thermal fuse 30. Fillng neck 9. Heatproof nozzle 20. Thermometer 31. Cleaning flap for 29UD 10. Secondary air screen 21. Upper front cover 32. Cleaning hole for 29UD 6 Gasifying boilers VIGAS 3. DESCRIPTION OF AK 3000 CONTROL 3.1 Safety Instructions (cid:131) Check protection (cover) metal sheet before plug-in the power wire (cid:131) Avoid any contact of power wire with hot parts of the boiler (f.e. chimney) (cid:131) Make sure, no water is allowed under the upper isolation (risk of short circuit) (cid:131) Do not stress the power wire (cid:131) Always disconnect the power wire when a new electrical components are connecting (f.e. indoor thermostat, discharge fan or circulation pump) (cid:131) Do not remove protection (cover) metal sheet during the boiler operation, especially from fan (cid:131) Compare working voltage displayed on the label with your distribution network (cid:131) Always observe safety regulations 3.2 Connecting to the distributing network AK 3000 control is integral part of VIGAS boilers. Control is connected when power wire is plugged in to the distributing network 220/230V. Display is active when power wire is plugged-in (Pic.4). Servo-flat used in VIGAS is set to Lambda Control base position (Pic.5). Pic.4 Pic.5 3.3 Working conditions Operation temperature range of AK 3000 control is +5°C to +45 °C. Control may not be used in humid enviroment or direct sunlight. 3.4 Maintainance of AK 3000 control Keep in clean and dust-free enviroment. Antistatic, or wet wipper is adivsed to wipe-off dust and impurities from metal cover and control panel. 3.5 Control panel Part of the electronic control is panel, equipped with buttons, pictograms and display. Futher informations will be available in the next part of this manual. Pic.6 1. Graphical display 128 x 64 pixels 2. Button ◄ with functions 3. Button ▲ with functions 4. Button ► with functions 5. Button (ENTER) with functions 6. LED control 7. Button with functions 7 Gasifying boilers VIGAS Functionality of each button are composite and their functionality deppends accompanying description on display and from manufacture settings. 1. Real time indication. Pic.7 2. Indication of current boiler values. Modification ▲ or . 3. Indication od discharge fan, lambda sensor, gases thermometer 4. Indication of nominal boiler output when switched off. 5. Graphically indicated hydraulic scheme of connection. 6. Indication of boiler status. 3.6 Symbols Boiler Storage tank External boiler Boiler „ON“ ON DUOMIX Heating circuit DUOMIX with Indoor Boiler „OFF“ OFF servomotor thermostat 3-way Heating Pump thermostatic ON valve Burning Discharge fan LADOMAT 73 0C Afterflaming Lambda λ Fan 52 0C End of burning Thermometer T Fan change END output Indoor Error indication termostat x Open flap servo 50% value decay Minimal value Maximal value Adding fuel of gases min of gases max Temperature Parameter Time setting settings settings Error Konfiguration Program messages informations Service message 8 Gasifying boilers VIGAS 4. VIGAS BOILER IN BASIC CONFIGURATION (without discharge fan, gases thermometer and lambda sensor) 4.1 VIGAS BOILER OPERATING 4.1 .1 Boiler activation If boiler is in unactive status with symbol „OFF“, as displayed on the picture, by pressing the central button ENTER the boiler start the operation. 4.1.2 Boiler activated – heating mode Boiler is set to heating mode, if temperature of outgoing water is lower, then set shotdown temperature of the boiler. Shotdown temeperature is in settings. Usually is set to 500C. Pump is pulse working in dependence on temperature of the boiler water! The pump is working, when symbol flash. 4.1.3 Boiler activated – burning mode The burning mode is active after the shotdown temeprature is higher + time deviation. In this mode pump is working pulse (bolier protection against low-temperature corrosion), 50C before set temperature constantly. The pump is working, when symbol flash. Boiler is responsive to indoor thermostat, when indoor thermostat is switched off boiler slowly decreasing its output. 4.1.4 Adding fuel, Disconnection the boiler (manually) Using graphical control. To call the graphical control, press central button ENTER. Graphical control offers option to switch off, adding fuel or cancel the graphical control. Choose one option OFF Switch-off Add fuel ⌧ Cancel the control (cid:98)(cid:99) Change the indicated value By pressing „ “ fan will be switched off. By using the rod open the chimney flap, consequently open the upper door. You can add fuel, if necessary. Close the upper door and chimney flap. By pressing „ “ adding fuel will be stopped. Fan will be switched- on automatically. 9 Gasifying boilers VIGAS 4.1.5 Disconnection the boiler (Automatically) When temperature drops under the shotdown temperature (see Parameter settings of Vigas boiler in basic configuration) boiler is switch-off automatically. „END“ will be indicated on the display. By pressing „ENTER“ boiler will start operating again. 4.2 TEMPERATURE SETTINGS OF OUTLET WATER To call temperature setting hold „ENTER“ button at any boiler status. Symbol of the temperature setting will be indicated on the display. Press „ENTER“ again. Symbol of the nominal output will be indicated on the display with value, together with temperature of outlet water in °C. By pressing the „ENTER“ button, the value start to flash. „ENTER“ Temperature is flashing, by using „ENTER“ buttons ▲ choose requested value. Button ► will exit the temperature settings. 4.3 PARAMETERS SETTING OF VIGAS BOILER To call parameters setting hold „ENTER“ button at any boiler status and by pressing ▲ button. Press „ENTER“ again Symbol of the parameters setting will be indicated on the display. By pressing the „ENTER“ button twice, the values you can set will be indicated on the display. „ENTER“ „ENTER“ By ▲ buttons set the parameter you want to edit and by pressing „ENTER“ button, the value starts to flash. ▲ buttons set requested value. end Choose shotdown temperature of the boiler Increase or decrease the value, maximal output will be „ “ changed. Is adviced to decrease the value in transition period (boiler tar level will drop). (cid:194) Brightness Roll Press „yes“ will acitivate the value rolling (Pic.6/2) Help 0s Set the time when graphical control will be indicated 10