SOLARFOCUS Maximus 150 Bedienungsanleitung

Operation manual for qualified personnel

Read carefully before operating.

DR-0160-EN / v4b-201903

Commercial boiler maximus

1 About this manual

1 About this manual 2

2 Safety information 3

3 Standards, guidelines, regulations 3

4 Product information 4

4.1 Fuel 4

4.2 Safety devices 5

4.3 Dimensions 7

4.4 Functional components, combustion prin-

ciple 9

4.5 Technical specifications 11

5 Prior to assembly 13

5.1 Transport 13

5.2 Boiler room 13

5.3 Chimney, flue gas pipe 14

6 Installation 16

6.1 Mount heat exchanger on the burner 16

6.1.1 Adjust spacing screws 16

6.1.2 Screw on flue gas pipe flange 17

6.1.3 Install automatic ash extraction 17

6.1.4 Connect flue gas recirculation line 18

6.1.5 Connect burner and heat exchanger hydraulically 19

6.2 Install the hot air fan 19

6.3 Mount feeder grate drive 19

6.4 Install the feeder unit 20

6.5 Install safety valve 20

6.6 Install return booster 20

6.7 Install thermal overload protection 21

6.8 Install temperature monitor (TM) 21

6.9 Fill the heating system 22

6.10 Bleed the heating system 22

6.11 Establish the chimney connection 22

6.11.1 Flue gas pipe: Hole for emission measurement 22

6.12 Mount ash container 22

6.13 Mount cladding on the boiler 23

7 Hydraulic connection 23

7.1 General information 23

7.2 Boiler connections 24

7.3 Make-up water requirements 25

8 Electrical connection 26

8.1 Boiler control cabinet 26

8.2 Connection assignment 26

8.3 Voltage supply for the heating system 27

8.4 Connect components to the control cabinet

(on site) 28

8.4.1 Connect overtemperature reset 28

8.4.2 Connect the boiler temperature sensor 28

8.4.3 Connect combustion chamber temperature sensor 28

8.4.4 Connect ash extraction burner 28

8.4.5 Connect rotary actuators 29

8.5 Connect additional components (on site) 30

8.6 Cable ducts on the boiler 31

8.7 Sensor resistance table 31

8.8 Connecting the control to the internet 32

9 Installing the intermediate pellet store 32

10 Initial start-up 33

11 Annex 34

11.1 Boiler covers - overview 34

11.2 Boiler power element, circuit boards 35

11.3 Electrical components: Overview 36

11.4 Connect pellet hose 37

11.5 Delivery systems (pellets, wood chips) 38

1 About this manual

Dear heating installer

To ensure reliable and efficient operation of the heating

system, the following points are extremely important:

–Correct installation

–Training of customers in commissioning

–Comply with the specifications and instructions in

this manual

–Regular maintenance by the system operator

–Regular maintenance by qualified personnel

Language

The language of the original manual is German. All

other language versions of this manual are trans-

lations of the original.

Storage

Keep the manual for the entire service life of the pro-

duct and ready to hand. The manual must be pas-

sed on to the new owner when the product is

dismantled/reused. If the manual is lost or

destroyed, request a new copy from the manu-

facturer.

Tips and Warnings

The tips used in this manual are highlighted with

symbols and signal words. The signal word indi-

cates the level and nature of the danger and how to

avert it.

iIndicates information for correct handling of the

product.

2 Operation manual maximus

Content

2 Safety information

!CAUTION - Failure to comply with this instruc-

tion could result in damage to property.

DANGER - Failure to comply with this instruc-

tion poses a danger to people.

Explanation of symbols

þPrecondition for an action

► Instruction

ÄResult of an action

>Reference to page, figure, Chapter,...

Manufacturer

SOLARFOCUS GmbH

Werkstrasse 1, A-4451 St.Ulrich

Company register no. 281755x

Tel.: +43 7252 50 002-0, Fax: +43 7252 50 002-10

office@solarfocus.com

www.solarfocus.com

Technical questions about our products

–Service-Hotline

0043 7252 50002-4920

service@solarfocus.at

2 Safety information

Qualification of personnel

–The work procedures described in this manual

must be carried out by qualified specialist per-

sonnel.

–Work on electrical components must be performed

by trained electricians and in accordance with the

relevant laws and directives.

Installation and commissioning

–System may only be serviced and put into ope-

ration by certified qualified personnel

(SOLARFOCUS service technician or

SOLARFOCUS service partner.

Keep unauthorized persons and children away

–Danger of burns due to hot lines and hot com-

ponents, risk of injury from mechanically moving

parts. Keep unauthorised persons away, do not

leave children unattended, and control access to

the boiler room and fuel storage room.

Safety devices

–Never disengage the safety equipment > 5 of the

heating system. In case of failure, arrange for

immediate repair.

Maintenance and repair

–Perform maintenance activities at the specified

intervals. No or incorrect maintenance leads to inef-

ficient operation, higher failure risk of the boiler and

increased potential for hazards.

–Have repairs done by qualified personnel only

Improper repairs can lead to risks for the user and

impaired operation

–Store hot ashes only in metal containers. Never

put hot or warm ash in the dustbin. There is a great

danger of fire.

–For repairs use only original spare parts or parts

approved by the manufacturer (e.g. standard

parts).

Damage to the system

–If the electrical insulation on cables, plugs, swit-

ches becomes damaged, switch off the voltage

supply and have the insulation repaired.

–In the case of visible damage (e.g. thermal defor-

mation, mechanical damage) the operation of the

system must not be continued. The system may

only be operated if it is in perfect technical con-

dition.

3 Standards, guidelines, regu-

lations

The following bodies of regulations must be con-

sidered and adhered to during planning, installation and

operation of the heating system:

–Respective state building codes

–Firing ordinance of the respective country

–Commercial and fire department rules and regu-

lations

–VDI 2035 - Preventing scale formation in hot water

heating and hot water warming systems

–DIN EN 12828 Heating systems in buildings - plan-

ning for water-based heating systems

–EN13384 - Flue gas systems - thermal and flow-

based calculation methods

Operation manual maximus 3

4 Product information

Austria

–TRVB H 118 -Technical guidelines for preventive

fire protection

–ÖNORMH 5170 - Heating systems - requirements

for construction and safety technology as well as

for fire and environmental protection

–ÖNORMH 5195-1 - Heat transfer media for buil-

ding services systems, Part 1: Preventing damage

from corrosion and scale formation in closed hot

water heating systems

–Art. 15a Agreement - Protective measures for

small solid-fuel boilers

–Art. 15a Agreement on energy savings

Germany

–EnEG - Law on energy savings, with the relevant

issued decrees

–EnEV - Ordinance on energy-saving thermal insu-

lation and energy-saving plant technology in buil-

dings

–DIN18160 - Flue gas systems - planning and exe-

cution

–1. BImSchV (Federal Immission Control Ordinance

- Ordinance on Small and Medium Solid-fuel

Boilers

Switzerland

–VKF/AEAI - Fire Protection Guidelines (25-03 and

105-03)

4 Product information

Fig. 2-1

4.1 Fuel

Pellets

Use wood pellets only in accordance with these spe-

cifications:

–Pellets according to the ISO 17225-2 standard,

class A1.

–Pellets that meet the additional ENplus cer-

tification.

–Pellets that meet the additional DINplus cer-

tification.

Wood chips

Use wood chips only in accordance with these spe-

cifications:

–Wood chips according to the EN ISO 17225-

4:2014 standard

–Classes A1, A1, A2, B1

–Sizes P16S and P31S

–Moisture content maximum 40%(M40)

4 Operation manual maximus

2 Safety information

4.2 Safety devices

Heat dissipation

–This function of the boiler control is a safety device

that prevents overheating of the boiler.

–Functioning: If the boiler temperature exceeds the

set Heat dissipation maximum boiler temperature

(in the service menu - General Settings), all pumps

relating to the energy consumer units (e.g. heating

circuit, DHW tank, buffer tank, etc.) will be swit-

ched on and the heating circuit mixer opened. In

this way, energy is drained from the boiler and it

may be possible to prevent other safety devices

tripping.

–If the boiler temperature falls below the set Heat

dissipation maximum boiler temperature minus

1°C again, the pumps and mixers will be operated

in standard mode again.

Thermal overload protection

–The thermal overload protection prevents an uncon-

trolled increase in temperature and pressure of the

boiler.

–Functioning: At a boiler water temperature > 95°C,

the valve opens and directs cold water through the

two series-connected safety heat exchangers.

This lowers the temperature of the boiler and avo-

ids the need for further safety precautions or equip-

ment damage.

►Install thermal overload protection > 21

Overtemperature reset (OTR)

The safety temperature limiter (STL) is a safety device

that prevents overheating of the boiler.

Functioning: The STL stops the heating process at a

boiler temperature ~95°C (exclusively electrical func-

tion; fuel and air supply are interrupted).

After tripping, the STL must be manually released

again by unscrewing the black sealing cap 1and pres-

sing the button as soon as the boiler temperature falls

below 60°C.

If the safety overtemperature reset trips, this is indi-

cated in the boiler control display.

Fig. 2-2:Unscrew the closure cap

►Install overtemperature reset > 28

Safety valve (to protect against excess pres-

sure in the system)

–The safety valve 1is a safety device for protecting

against overpressure in the water circuit of the hea-

ting system.

–Functioning: The valve opens when the system

pressure exceeds 3 bar. Water/steam are dischar-

ged into an open drain via a discharge line, which

avoids consequential damage to the heating sys-

tem. The valve is closed during normal operation.

–For normative specification see EN 12828.

Fig. 2-3: Safety valve integrated into boiler safety group

►Install safety valve > 20

Operation manual maximus 5

2 Safety information

EMERGENCY OFF switch

–The EMERGENCY OFF switch is a manually ope-

rated safety device. The burner and the fuel supply

to the boiler are stopped. Circulation pumps remain

in operation to dissipate heat and cool the boiler.

–The switch must be installed outside the heating

room in a safe place that is easy to access.

►Install EMERGENCY OFF switch > 30

Temperature monitor in the fuel storage

room (TM)

–Required according to guideline TRVB 118 H for

wood chips, depending on system design, heating

capacity and fuel storage quantity.

–Functioning: On the channel of the fuel delivery

auger, a temperature sensor of a protected design

must be installed in the area of the wall penetration

(inside the storage room). When a temperature of

about 70°C is exceeded, the warning device is

(optically or acoustically)triggered.

–Art. No.: 6565 and 6567

►Install temperature monitor > 21

Automatically triggered extinguishing

device (ATED)

Fig. 2-4

1 Pocket sleeve for temperature sensor

2 Connection for water discharge

–Functioning: If at the temperature sensor 1the

temperature exceeds 50°C (direct extraction) or 95

°C (downpipe extraction), the valve 2opens and

floods the feeder channel with water.

–This extinguishing device serves to automatically

suppress burn-back within the feeder. Due to the

proper nature and location of the fire detection

element, burn-back must be reliably detected and

the extinguishing device must be triggered instanta-

neously and automatically (this must be ensured

even in the event of a power failure).

–The extinguishing device must be connected either

directly to a pressurised water supply or to a water

reservoir (Note: Domestic waterworks may also be

affected in case of power failure).

–The water supply must be equal to three times the

volume of the feeder equipment, but at least 20

litres. The container must be equipped with a fill

level monitor, including connection to the warning

device (temperature monitor > 6). The extinguis-

hing water inlet opening in the feeder is to be

arranged and executed so that blockage by

delivery operation is not possible and this can

easily be checked at any time. The routing of the

extinguishing system must be made as a non-

combustible version.

–Art. No.: 63260 and 6553

–Specification yes/no see TRVB 118 H

Manually triggered extinguishing device

(MTED)

–This extinguishing device is used to combat a fire

source in the fuel storage room, or fuel storage in

the area of the extraction/delivery line. The trig-

gering must be done manually.

6 Operation manual maximus

2 Safety information

–This device consists of an empty pipe with a mini-

mum nominal size of DN 20 and is to be installed in

the fuel storage as specified by the manufacturer

of the firing system directly above the delivery line

in front of the wall or ceiling passage in such a way

that the greatest possible success can be achie-

ved in extinguishing. The empty piping must be

connected directly to a pressurized water supply

and provided with a shut-off valve arranged in the

boiler room. Mark this valve with a sign "Extin-

guisher - Fuel Storage Room".

–The execution of the extinguishing system must be

done so that damage during fuel feed or from the

extraction device is not possible. In addition, make

sure that the fuel supply to the delivery line is not

affected.

–Specification yes/no see TRVB 118 H.

Rotary valve

The rotary valve installed in the standard equipment ful-

fils all normative requirements for the approved fuels

regarding fire protection, burn-back safety, backflow of

gases:

Fig. 2-5:Rotary valve

–Complies with requirements regarding burn-back

protection devices (BPD) according to TRVB 118

–Prevents backflow of flammable products of com-

bustion into the fuel supply or into the intermediate

store (according to EN 303-5).

–Prevents spreading of fire into the fuel supply or

into the intermediate store (according to EN 303-5).

Safety switch on the channel cover

Opening the channel cover interrupts the power supply

to the motor of the extraction auger.

Heating system encompassing several fire

compartments

If the boiler room and fuel storage room are located in

different fire compartments, optional equipment must

be installed in addition to the factory safety equipment,

e.g.

–a temperature monitor (TM) > 6

–a manually triggered extinguishing device (MED) >

4.3 Dimensions

Side view

Operation manual maximus 7

2 Safety information

Top view

Front

8 Operation manual maximus

2 Safety information

Operation manual maximus 9

4.4 Functional components, combustion principle

Burner

Fig. 2-6

Functional components

1 Rotary valve 5 Ash extraction burner 9 Secondary air opening

2 Feeder unit 6 Ash container 10 Combustion chamber temperature sensor

3 Push grate 7 Primary air opening 11 Flue gas recirculation line

4 Ash scraper 8 Primary air outlet

Fuel path

–The fuel falls through the rotary valve 1into the channel of the feeder unit 2. The auger delivers the fuel to the

feed grate 3.

–During combustion, the fuel is transported on the feed grate, and the resulting ash falls down through the grate.

–The ash pusher 4push the ashes to the ash auger 5, and auger takes over the transport into the ash box 6.

Airflow

–Primary air is sucked in at the opening 7, forwarded in a space on the left and right side of the boiler; at the holes

8the primary air exits under the combustion grate.

–Secondary air is sucked in at the opening 9, and passes through holes in the fire brick (left, right, back) above the

combustion grate in the combustion chamber.

–Recirculation opening 10: If the sensor measures 11 too high a combustion chamber temperature, then air from

the flue gas pipe 12 is introduced here and added to the primary air. This leads to the cooling of the combustion

chamber and thus to lower stress on the components.

Heat exchanger

Fig. 2-7

Functional components

13 Ash container 15 Ash extraction heat exchanger

14 Electrostatic separator 16 Heat exchanger

Ash path

–The ashes falling on the feed grate are transported from the transverse ash auger into the ash container 13.

–The ashes falling on electrostatic separator 14 are transported forward by the auger 15 into the ash container.

Airflow

–The flue gas from the combustion chamber flows past the heat exchanger 16, on the electrostatic separator into

the flue gas pipe and into the chimney.

2 Safety information

10 Operation manual maximus

Andere Handbücher für maximus 150

Dieses Handbuch passt für folgende Modelle

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