Wood logs boiler with a gasication eect IGNIS 20-40 KW

INSTRUCTIONS MANUAL for usage and maintenance

Prhovacka bb 22310 Simanovci, Srbija
Tel/Fax. +381 22 480404 +381 63 259422
oce@termomont.rs www.termomont.rs
May 7, 2014
Contents
1 Boiler design and properties 2
1.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Technical properties according to EN 303-5 . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 On product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2 How It Works 3
3 Recommendations for boiler shipment and storage 4
3.1 Delivery form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3.2 Whats in the box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4 Boiler installation 5
4.1 Boiler placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
5 Connecting the boiler with a central heating system 7
5.1 Closed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5.2 Closed system combining oor and radiator heating . . . . . . . . . . . . . . . . . . . . . . 8
5.3 Open system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 Boiler In Use 11
6.1 Circulation Pump Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.2 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7 Safety features 11
7.1 Thermal safety in case of overheat (closed systems) . . . . . . . . . . . . . . . . . . . . . . 11
1
1 Boiler design and properties
1. Upper door for placing wood-logs 2. Secondary air inlet (manual regulation) 3. Lower door for cleaning
4. Primary air regulation 5. Thermostatic draught regulator 6. Chain for air regulation 7. Connectors for
safety heat exchangers 8. Connection for excess water outlet 9. Sensor placement 10. Flue box 11. Flue 12.
Secondary ue (ap) 13. Secondary ue ap handle 14. Opening for cleaning the ue box 15. Fill/Drain tap
16. Return 17. Base 18. Flow
1.1 Dimensions
Type 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 900 845
IGNIS 30 340 736 858 578 590 160 5/4 660 1220 900 1045
IGNIS 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 40
Power range (KW) 15-20 20-30 30-40
Necessary draught (mbar) 25 26 28
Water content (l) 45 60 70
Flue gases temperature (at nominal power) (

C) 200 200 200

Heating chamber volume (dm3) 50 80 100
Mass ow at nominal power (kg/s) 0,016 0,021 0,045
IP Protection 30 30 30
Temperature regulation range (

C) 60-90 60-90 60-90

Min. temperature of the return line (

C) 60 60 60
Eciency (at nominal power) 80% 81% 80%
Boiler class 2 2 2
2
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 a
large 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 reproof
ceramics with tubulators for optimum eciency;
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-
gasication eect. 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 ue opening 6. Flue box (a part of the heating
chamber around the ue) 7. Boiler water 7.1 Boiler water around the ue chamber 8. Secondary air inlet 9.
Primary air inlet 10. Return 11. Flow
3
As IGNIS is similar to wood gasication boilers, main properties of a wood gasication boiler will be
outlined rst. A wood gasication boiler, thanks to its special geometry, and the use of a fan, brings the
wood logs in the state of gasication - the process where light weighted hydrocarbons are released out
of the wood. The ame has a specic blue colour and the eciency of such solid fuel boiler is 10-15%
greater than with the traditional solid fuel boilers with no regulation. Another interesting feature of wood
gasication boilers is that the wood logs are placed in the upper chamber and the ame is thus inverse -
going upside down contrary to conventional boilers with vertical ame.
Wood gasication requires a constant and stationary boiler operation. It is thus necessary to have
an additional heat tank to accept the excess heat made by boiler. It is also necessary to perfectly adjust
temperatures between the heat tank, ow and return line of the boiler to prevent condensation. All in
one, wood gasication allows maximum comfort with wood-logs as a fuel, but with certain investment to
be made into additional equipment.
The IGNIS boiler lls the room between the less costly conventional boilers (demanding manual refuel
more often) and maximum comfort yet more expensive wood gasication boilers (with an additional heat
tank). Because of its construction, IGNIS achieves the wood gasication eect (in an amount much less
than real wood gasication boilers) but only using the natural draught of the boiler, without a fan and
without a necessary heat tank. What is still necessary is the protection against condensation (mixed
valve, by pass of the boiler). IGNIS combusts with a vertical ame, not inverse.
As it does not posses the automatic regulation via fan, optimum combustion is achieved by setting the
primary 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 gasication eect is achieved? Wood gasication process takes place in the
upper zone of the boiler - within the so-called catalyst zone. This is a special cylindric part of the
heating chamber. On its upper side there are special heat exchangers (tubulators). Below the catalyst
and in presence of secondary air, at very high temperatures, solid particles are accelerated to certain level
until they combust completely. Short-chain hydrocarbons are released. Flue gases are passing through
turbulators - in contact with increased surface of the tubulators, ue gases are additionally cooled down -
exit ue gas temperature is thus lower compared with conventional boilers. The eciency is higher. The
concentration of dust, particles and COX/NOX is lower.
IGNIS has a secondary ap inside the chamber. The role of this is to shorten the passage of ue
gases and increase the draught in the boiler when necessary (during ignition for instance). When the
combustion is stabilized this secondary ap should be closed. IGNIS also has a so-called ue-box - water
content of the boiler is maximized occupying this additional part of the ue 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 or
installation represents a serious risk and can lead to damaging the boiler. It is forbidden to stack boilers
vertically one onto other.
The boiler can be stored only in closed rooms with no atmospheric inuence. The humidity in the storing
room also must not exceed the critical value of 80%, so as not to create any condensate. The temperature
of the storing room must be in the range of +/- 40 C.
3.2 Whats in the box
The following parts are supplied together with the boiler:
Cleaning kit
4
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 permiting
access to all its parts as shown below:
4.2 Chimney
Boiler connection to the chimney is shown in the gure:
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 air
draught 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 are
determined. Please advise technical material given by chimney producer. Minimum chimney height for
wood boilers is 6 m. Round chimney made of stainless steel modules is recommended in order to keep
the condensation inuence low.
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6
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 without
a heat accumulator tank:
System parts: 1. Boiler 2. Heat accumulator 3. Heat exchanger 4. Non-return valve 5. Mixing valve
6. 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.
7
It is not necessary to install the heat accumulator. However, it is recommended.For 1 KW power of
the boiler, a capacity of the heat accumulator of 25-50 l is recommended. One must also bear in mind
that 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 boiler
should 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, the
capacity of which must amount to at least one tenth of the total capacity of the system (including the
water volume in the boiler). The system must also have an automatic aeration valve with the help of
which air will be eliminated from the system. The use of a safety valve is obligatory (with a 2-3 bar
threshold, 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 temperature
and pressure in the system. In case of using conventional solid fuel, the temperature of the return line
should not fall below 60C, so as to avoid leaking, i.e. condensation in the boiler, which can further lead
to corrosion. The temperature of the starting line should not fall below 70C. It is recommended to use
a 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 lth catcher on the return line.
Qualied 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 the
boiler and of the complete central heating system. In the case of an incorrectly planned system with
manifesting deciencies caused by the respective persons incorrect installation of the system, which can
again lead to an incorrect operation of the boiler, the complete liability for the material damage and
potential new costs arising in relation to it is borne exclusively by the person who was entrusted with
the mounting of the central heating system, and not by the boiler manufacturer, sales representative or
seller.
5.2 Closed system combining oor and radiator heating
The following scheme depicts a heating system connected over a hybrid solar boiler within an accumalation
tank:
8
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 oor heating 9. Regulator of the automatic
regulation for the radiator heating 10. Regulator of the automatic regulation for the oor heating 11. Receiver
12. Expansion tank 13. Exchanger pump 14.Valve 15.Thermo-manometer 16. Filth catcher 17. Four-arm
mixing valve 18. Safety valve
5.3 Open system
The following scheme shows how to connect the boiler to the open central heating system:
9
System parts 1. Boiler IGNIS 2. Valve 3. Thermo-manometar 4. Boiler circle pump 5. Three-way mixing
valve or LADDOMAT 21 6. Heat accumulator tank 7. Three-way mixing valve 8. Automatic three-way mixing
valve 9. Circulation pump for radiator heating 10. Open expansion vessel 11. Automatic regulation MRTR
Plus (First) 12. Heating circle 13. Sanitary water circulation pump 14. Sanitary water accumulation tank
SOLAR 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 pump
will be turned on.
This thermostat is primarily used in order to prevent the low temperature of the return line which
can 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 the
boiler can thus be performed once per week and does not take more than 5 minutes. Burner ash-tray
should be however cleaned every day or two - operation which takes less than a minute.
Using pellets means also low temperature of the ue gases due to the high eciency of combustion.
This means the boiler would last much longer compared to combustion with traditional solid fuels such
as 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 valve
shown 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 would

release the water from the water supply system to cool down the water temperature inside the boiler.
11
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 water
system 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 valves input is marked with C) than connect the exit line (valve
marked 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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