bosch boiler with pellet burner pelet brenn 2000 -...

Boiler with pellet burner

KRNOV

Thermotechnology

PRAHA

KrnP/QMM-STI | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce,

kopírování, distribuce, jakožto i prihlášení autorských a jiných ochranných práv.

Bosch boiler with pellet burner Pelet Brenn 2000

Bosch Termotechnika s.r.o. Krnov 28.5.2015 v.2.0

MĚSTO ALBRECHTICE

1




ThermotechnologyThermotechnology

Steel boiler with pellet burner

Pelet Brenn 2000 25 kW

Output 6 till 27 kW

For installation with boiler from

Bosch production:

• Dakon DOR F

• Buderus Logano S111-2

• Junkers Supraclass S

• Bosch Solid 2000 B

2




Burner Pelet Brenn 2000 25 kW with solid fuel boiler

High efficiency

• set of boiler and pellet burner

Comfortable heat solution

• tank 195 l (140 kg)

• heating about 2-4 days w/o filling

• house about 100m2, standard insulation

Simple setting, easy operation and cleaning

Room thermostat connection

Suitable for boilers output 20 and 27 kW

The most convenient way of heating with

solid fuel

• Pellets – wood, A1 by EN 303-5, DIN plus,

EN ISO 17 225-2

3






Set for pellet heating

• Steel boiler from KrnP

• Pellet burner with control unit

• Conversion set 8 738 104 123 for boilers 20,24

• Conversion set 8 738 104 121 for boilers 25Max/27, 32, 32D

• Fuel tank

• Fuel auger

• Door for burner installation

• Bricks of combustion space

4






Steel boiler from Bosch production

• Dakon DOR F

• Buderus Logano S111-2

• Junkers Supraclass S

• Bosch Solid 2000 B

High efficient vertical flue gas ways

Easy cleaning from the top

Good equipment included

Boiler body from steel sheets

• EN10025-1 235JRG2

• thickness 4 - 5 mm

5






Pellet burner

• Pelet Brenn 2000 25 kW, output 6 – 27 kW

Easy and quick installation on boiler doors

Electronic controller

• Automatic regulation of operation

• STB

• Time program

Heat output setting

• by object size

• by heat energy

Efficient combustion for all prescribed types of pellets

6






Fuel tank

• Volume 195 liters / 140 kg of pellets

• Easy and quick assembly from delivered parts

• Boiler operation for one filling 3 – 4 days

• house about 100 m2

• standard insulation

• Fuel feeding by auger from the tank bottom

• Complete emptying of the fuel from the tank

7






Pellet auger

• Auger principle of fuel feeding

• Automatic operation of feeding by output power

• Settable quantity of pellets by burner output

• Delivery max. 8,4 kg/hour, to set burner

output power

• Adjusting the length of the connecting pipe

so that the pellets freely distributed from

the feeder to the burner

• Simple assembly

8





Burner Pelet Brenn 2000 25 kW with solid fuel boiler Burner controller ST-717

• Separate control box, mounted to fuel tank

• Control of the fan, feeder, CH and DHW pump

• Safety thermostat STB

• Additional modules

Output control

• Flow water sensor or room thermostat

Error message on CU display

Setting

• output power

• maximal temperature of flow water

• operation mode

• fan speed

• pellet volume

• week time program

9






Bricks in combustion space

• regulate the flow of flue gas in combustion space

• High temperature concrete

• easy installation

• wear parts

• Two sizes for boilers

• 20, 24

• 25Max/27, 32, 32D

10





Burner description

11


1. Burner body

2. Air channel

3. Internal wall

4. PCB

5. Internal feeder motor

6. Photocell

7. Fan

8. Burner tube

9. Burner holder

10.Grate

11.Internal auger

12.Burner wall

13.Heater

14.Pin

15.Cover

16.Bushing

17. Feeder temp. sensor




Technical data of boiler with pellet burner

Parameter Unit DOR F/S111-2 with Pelet Brenn 2000 25 kW

Boiler size - - 20 24 25Max/27

Nom. output with burner kW kW 20 24 27

Min. output with burner kW kW 6 6 6

Efficiency at nom. output % % 85 85 84

Efficiency at min. output % % 81 81 83

Fuel consumption Kg/h Kg/h 4,9 5,5 6,4

Boiler class - - 4 4 4

12





Technical data

Parameter Unit Value

Output power kW 13,4 – 34,1

Fuel consumption kg/h 2,9 – 7,2

Voltage V/Hz 230/50

El. shield protection - IP X0D

Input power W 100

Input power of igniter W 300

Burner weight kg 11

Fuel tank volume ltr/kg 195/140

Pellet dimension (diam./length) mm 6/30

Requested chimney draught Pa 20

13





Device dimmensionBoiler size A [mm] B [mm]

20 990 730

24 990 730

25Max/27 990 830

32 990 830

32D 1060 830

14





Burner installation

Unscrew the two screws on the bottom hinge and remove the ash

door

Remove the cotter pin of grate lever, disconnect lever and grate,

remove grate lever

Remove rotary grate and front grate

15





Burner installation

Bricks for boiler size 20, 24 kW (8 738 104 123)

16





Burner installation

Bricks for boiler size 25Max/27, 32, 32D kW (8 738 104 121)

17






Burner installation

Insert ceramics bricks into the boiler

18

19 KrnP/QMM-STI | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce,



Burner installation

Install and screw the door for the burner to the boiler

Install the burner into door

The tube for pellet input install to the burner depend on fuel storage

tank position (better on right side from the boiler)





20


Burner installation

Close the tertian air inlets by covers




Fuel tank assembly

Assemble and set up the fuel tank next to the boiler (right / left)

21





Fuel tank assembly

Auger tube insert into the tank through a seal ring at the lowest point

of fuel tank

Fill the tank by pellets





Burner assembly

Fix the CU to front wall of the fuel tank

Unscrew the cap under the flow water outlet of the boiler and install

well ½" for temperature sensors

Insert into the basin and fix

• temperature sensor

• STB sensor

23





Burner assembly

To the burner terminal engage

• cable from CU – 2, 3, 5 – pole connectors

• Cable bushing fix to burner body

24




Thermotechnology


Thermotechnology

Connection of control unitEl. supply

Main

switch

STB

DHW pump

Heater

2x RS

Buffer sensor topFeeder sensor

DHW sensorCH sensor

Buffer sensor bottom

Main feeder

Internal feederFan

CH pump

Burner

Signal common.

Fan sensorFlame sensor

PE / N





Control unit ST-717

Control of boiler operation

Fuel feedeing

Combustion air

Control

CH pump

DHW pump

buffer

Additional modules

Mixing circuit module (up to 2)

GSM module

Internet module

Roo thermostat

Data communication RS

On/Off





Control unit ST-717

Description

27

Big graphic display with all necessary data

Control by rotating switch

By rotation select item or set value of

parameter

By pressing confirm selection or set

Taste

- Stand-by

Exit – leaving actual menu /item w/o

change

Actual version of SW

1.2.0 ZPID STUB X99 ST-717NK





Control unit ST-717 – function

Basic display

28

DHW operation mode, level of the

fuel in storage tank

Operation mode of the boiler

Time, date, roomstat status

Temperature of CH system

actual

requested

Fan operation or Temperature of

DHW

actual

requested

Feeder run

Fan output

CH Pump

Heater

DHW pump





Control unit ST-717 – operation modes

29

Firing

Activated by user

Filling of the feeder and burner by fuel

Ignition by hot air

Active until flame is detected

Operation

Primary operation of the boiler

Boiler works on nominal power to achieve

requested boiler temperature

Then switch to minimal power, the temperature

should decrease

If temperature decrease by hysterese, boiler switch

to maximal power again

If requested temperature is exceeded, boiler is

switch to Damping mode





30

Control unit ST-717 – operation modes

Dumping

Activation

By user for boiler switch off

At exceed of boiler temperature by 5°C

External feeder stops , internal feeder works

Fan is running to fuel burn out / flame fade

Pump in operation

Cleaning procedure by fan

Pump are switch off at activation temperature

In case of exceeding of boiler temperature start

new ignition of the burner ater end of cleaning

proces





Control unit ST-717 – Main menu

31

Screen

Firing up

Fuel tank full

Requested boiler temperature

Requested DHW temperature

Manual operation

Internal feeder – feeders are off, only fan

Parameters for maximal power

Parameters for minimal power

Week based control of boiler temperature

Pump mode

Installer settings

Service settings

Factory settings

Software version





Control unit ST-717 - Screen

32

Basic information about status of the boiler

Valve statust (additional module is needed)

Other screens are without sense for boiler and

CU configuration





Control unit ST-717 – Firing up

33

Start by user

Filling up of the feeder and burner by the fuel

Ignition of the fuel by hot air

Finish of this mode in detection of the flame by

photo cell, switch to Operation mode

Tray full After filling up of the fuel tank is performed this

choice

On basic screen is shown level of the fuel in tank.

This level is calculated from feeder operation.

At first the fuel tank has to be calibrated





Control unit ST-717 – Temperatures of CH and DHW

34

Temperature of flow water

Requested temperature

Setting is possible from basic screen

Temperature of DHW

Requested temperature od DHW





Control unit ST-717 – Manual mode

35

Feeder

On/Off

Internal feeder

On/Off

Fan

On/Off

Blow force

Set of fan power 1 – 100%

CH pump

On/Off

DHW pump

On/Off

Heater

On/Off

Valve 1, Valve 2 – if mixing module is used

Open / Close / Stop / Pump





Control unit ST-717 – Max. / min. power

36

Maximum power – setting of burner

parameters for nominal power

Minimum power – setting of burner

parameters for minimal power (30%)

Feed time

Time of fuel feeding in seconds

Feed interval

Time when feeder is stop in seconds

Feeding period – summa of feed time

and feed interval

Blow force

Fan output in % of maximum power

Fan starts always on 100% power

due to clear from the dust





Control unit ST-717 – Weekly control

37

Week-base regulation – regulation of CH and DHW

temperatures or/and damping mode every day/hour

Daily cycle operation

Boiler is damped in requested time

Boiler week-based operation

DHW week-based operation

Temperatures are changed in requested time

Mode 1 – day /hour control of temperature

Mode 1 setting

Setting of damping time

Setting of temperature change

The time is necessary to set





Control unit ST-717 – Pump modes

38

Pump modes

House heating

DHW pump is off

Water heat priority

The DHW tank is charged if internal

temperature is below requested

Parallel pump

In case of request to heat up of DHW tank is

CH pump in operation as well

Summer mode

CH pump is off

Buffer – storage tank for CH water

Buffer is charged by CH pump

Pump start if Bottom temperature is below set

Funkce horního čidla ??





Control unit ST-717 – Installers menu

39

Fitters menu – setting of boilers parameters for system

Boiler – correction parameters of burner

Ignition parameters – for firing of the burner

Ignition function - ??

Minimum operation - behavior at req. temperature

Tray full / Empty tray – calibration of fuel tank

Temperature settings

Valve1, 2 – setting of valve parameters

Room regulator – type and function of roomstat

GSM module – setting of GSM control

Internet module – setting of internet control

Clock / Date – setting of time

Encoder sensitivity – sensitivity of rotation switch

Langue version – set of communication language

Display contrast – setting of best display readability

Factory settings – reset of all parameters to factory

values





Control unit ST-717 - Boiler

40

Boiler – modification of feeders and fan operation

Fan coefficient

Adjust of the fan speed for best combustion

Feeder coefficient min.

Feeder coefficient max.

Optimal setting of fuel feeding based on caloric

value of the fuel

For minimal and maximal output





Control unit ST-717 – Ignition parameters

Ignition procedure

Step 1 – Blow-by

fan is running for a specified period of time.

Step 2 – Initial fuel feeding

feed for filling up of the burner

Step 3 – Heater

Ignition of the fuel by hot air from the heater

Photocell indicate flame in combustion space

Step 4 – Delay

Stabilization of the flame

41





Control unit ST-717 – Ignition parameters

42

Ignition parameters

Internal feeder delay

Internal feeder is deactivated after the main feeder

Fire sensor threshold

Level of flame signal to detect flame – end of step 3

Heater delay

Max time for ignition – detection of the flame

Fan speed

Fan output for ignition – step 3

Fan speed delay

Fan output for stabilization – step 4

Firing up delay

Duration of step 4

Duty time

Feeder operation during step 4

Pause time

Feeder pause during step 4





Control unit ST-717 – Minimum operation

43

Minimum operation

Behavior of the boiler when boiler temperature reached

requested value

On

Boiler is switched to Damp mode

Off

Boiler is switched to minimal output mode





Control unit ST-717 – Fuel tank calibration

44

Calibration of fuel tank

Tray full – calibration of fuel tank

Before calibration is the tank filled and then

carry out this option.

Empty tray

After consumption of the fuel from the tank this

option is made

CU now has information about the fuel

consumption and can be calculated content of the

fuel in the tank based on the operation of the

feeder

After new filling of the tank is made option Main

menu -> Tray full

The indication of the fuel amount in the tank

appears on the main display or on the controller





Control unit ST-717 – Temperature control

45


Boiler hysteresis

If temperature of boiler fall under requested by

hysteresis value, boiler switch to maximal

operation

DHW hysteresis

If DHW temperature fall under requested by

hysteresis value, the DHW pump charge DHW

tank

Pump switch on temperature

Minimal temperature of flow water when start

both pumps





Control unit ST-717 – Valve 1, 2

46

Registration

Input of module number for relevant valve

Valve status

On/Off of the valve

Valve setpoint temp

Setting of requested temperature on the valve

Opening time

Maximum time for full valve opening

Single stroke

Max. value of valve opening change in case of

the change requirement

Minimal opening

Minimal valve opening

Valve type

Floor heating mixing circuit

Radiators mixing circuit






47

Equitherm regulation

On/Off

Parameters setting for equitherm regulation

work. point 1 – heating water temperature at

outside temperature -20°C


outside temperature 0°C


outside temperature +20°C






48

Return inlet protection

Protects boiler from to cold return water from

heating system

On/Off

Minimal temperature of return water

Maximal temperature of return water

Additional sensors

Sensors of return water and outside

temperature are used from

Own unit

From second, main unit






49

Pump activation

Condition of the switch on of valve pump

Always – sustain operation

Never – pump is stop

Above threshold – at min. temperature

CH pump activation temp. – set of temp.

Factory settings

Set of valve parameters to factory value

Valve removal

Valve cancellation





Control unit ST-717 – Room regulator

50

Room regulator

On/Off

Standard regulator – On/Off

TECH regulator – Data regulator RS

Room regulator device

Off – the room regulator is off

CH boiler – when the room temperature is

reached, the boiler temperature is reduced

CH pump – when the room temperature is

reached, the CH pump off





Control unit ST-717 – Other settings

51

GSM module

On/Off of module for mobile control by SMS

Internet module

Setting of communication parameters

Clock

Setting of actual time

Set date

Setting of actual date

Langue version

Setting of communication language

Display contrast

Best readability of the display

Factory settings

Return to producer parameters values





Control unit ST-717 – Service menu

52

Service menu

Setting of factory parameters for basic

behavior of the boiler

Relevant for safety of the boiler

Access code






53

Select PID

Work

Operation control

Cleaning period

Feeding time min

Feeding time max

Feeding interval min

Feeding interval max

Min. fan work

Max fan work

Fan speed min

Fan speed max

Power coef. Max

Power coef. Min

Ignition parameters

Underpour time

Internal feeder delay

Fire sensor threshold

Heater delay

Fan speed

Fan speed delay

Duty time

Pause time

Damping parameters

Damping delay

Blow force

Damping protection

Min damping







Max exhaust temperature

Priority temperature

CH pump emergency

Anti-freeze temperature

Boiler alarm temperature

Fire sensor

Fan Hall sensor

Fan

Code

Fan min

Fan max

Fan speed min

Fan speed max

Growth impulses

Lambda

First lambda update time

Update time

Oxygen stroke

Fan stroke

Sum

Min change

Max change

Lambda 100%

Lambda 1%

Min boiler temperature

Flow

Display contrast

Factory settings

54





Control unit ST-717

55





Control unit ST-717

56




Burner operation setting

For proper operation of the boiler with pellet burner

• recommended flue gas temperature 170 – 220°C

• under pressure in the combustion chamber 12 Pa

Required quality according to EN ISO 17 225-2

• A1 – diameter 6mm, length 30 mm (DIN plus)

• Caloric value 15 – 18 MJ/kg (4,2 – 5 kWh/kg)

Filling the feeder by pellets

• Manual mode -> Feeder till auger is filled in by pellets

Check delivery of pellets in hour by feeder manual mode

• Calculate Feeder time and Feeder interval for requested minimal and

maximal output power

• Set fan power to best quality of combustion / emissions

• Content of CO2 should be app. 15%, O2 app. 5%, CO max. 300 ppm

Set rest of parameters by central heating configuration

57





Burner operation – Start procedure

80°C

Step 1

Step 2

Step 3

Step 4

Step 1 Step 2 Step 3 Step 1

58

Boiler with pellet burnerF

low

wa

ter

tem

pe

ratu

re [°C

]

Bu

rne

r o

utp

ut [s

tep

]

Full output Full output




Burner operation – Minimum operation Off

Flo

w w

ate

r te

mp

era

ture

[°C

]

Fa

n o

utp

ut[%

]

80°C

70°C


59

85°C

30%

50%

100%

Da

mp

se

qu

en

ce

Sta

rts

eq

uen

ce

Achieving water

temperature,

burner switch to

min power

Max output Min output

Achieving

hysteresis,

burner switch

to max power

Temp. don‘t

decrease, burner

switch to damp

procedureStart

procedureFlame fade

Feeder

stop




Burner operation – Minimum operation On

Flo

w w

ate

r te

mp

era

ture

[°C

]

Fa

n o

utp

ut[%

]

80°C

70°C


30%

50%

100%

Da

mp

se

qu

en

ce

Sta

rts

eq

uen

ce

Achieving water

temperature,

burner switch to

damp mode

Max output Boiler off

Start

procedureFlame fade

Feeder

stop

60

Da

mp

se

qu

en

ce




Burner operation – Damp procedure

80°C

Step 1

Step 2

Step 3

Step 4

Step 1 Step 2 Step 3 Step 1

Boiler with pellet burnerF

low

wa

ter

tem

pe

ratu

re [°C

]

Bu

rne

r o

utp

ut [s

tep

]

Full output Full output

61




Quality of pellets

Quality of pellets is important pro reliable

burner operation

Requested quality by EN ISO 17 225-2

• A1 – diameter 6mm, length 30 mm

• (C1 by EN 303-5), DIN plus

• heat content 15 – 18 MJ/kg

It is not allowed to use of vegetable

pellets, grains, pellets with high bark

content, etc.

62





Quality of pellets

Production

When processing wood there is also unusable

waste

This waste can be processed into pellets,

without any chemical additives

They are variously mixed finely ground

sawdust and wood chips

It is precisely defined moisture of the

components

The mixture is pressed through a circular form

There is no need for chemical additives

Lignin acts as a binder, is contained in the

wood

Such chipsticks of pellets are made

63





Quality of pellets

64





Quality of pellets – the mark of quality

Bad

Good

Certification by DIN 51731

Certification by ÖNorm 7135

Certification by DIN CERTCO program

Certification Pelletsverbände (PVD, PVA)

not certified pellets

Attention, unknown volume of ash, corrosion risk!

65





Quality of pellets – the mark of quality

Bad

Good How can you recognize a good pellet?

• Ash content < 0,5-1% (DIN Plus < 0,3%)

• Lignin content is defined

• Max. moisture 10-20% v

• Diameter: 3-6 mm, length: 2-3 cm

• Made from quality wood

• Shiny, smooth surface

• No longitudinal or transverse cracks

• Low dust content at delivery

• The same size of pellets

• Clean water at the test

66





Burner setting

Delivery of pellets / Output

power

Control unit

Max output

Min output

• Fuel feeding

• Feeding pause

• Fan speed

67






Fuel delivery setting

Amount of the fuel in kg per hour

By manually operation of both feeders

Boiler output = feeder time / feeding period * fuel amount * caloric value *

boiler efficiency

Sample of calculation

Feeder time = 15 sec

Feeder pause = 5 sec

Feeding period = 15 + 5 = 20 sec

Amount of the fuel = 8,4 kg/hour

Caloric value = 18 MJ/kg = 5,0 kWh/kg

Fuel efficiency = 85%

Boiler output = 15/20 * 8,4 * 5,0 * 0,85 = 26,8 kW

Fan power by combustion quality – CO2 > 15%, O2 < 5%




Before starting the burner

Check the mounting of the burner to

the boiler door, sealing of doors and

other parts

Connecting of the boiler to the

chimney, combustion air inlet, filling

the system with water

Connecting of the fuel feeder,

connecting of hose without bends,

feeling of fuel tank

Location and fixing temperature

sensors in the basin

Set the parameters according to the

desired operating mode

69





Maintenance

Regular cleaning of the burner

• Clean the grate from the ash or slag (lower

quality pellets)

• Check the resistance of lighter (155 Ohm)

• Photocell control function (t20), position in burner

body (lock)

• Clean dust from the pellets tank

Burner adjustment using a combustion analyzer

• max. burner power for min. 10 minutes

• Setting O2 to 5% (up to 10%)

• at high O2 decrease fan power

• CO in range of 150 - 1000 ppm

• output power by fuel amount

• for lower levels correct fan parameters and

amount of fuel

70





Alarm messages of CU

Message Cause Solution

CH sensor fault Boiler sensor faulty Change the boiler sensor

DHW sensor falut DHW sensor faulty Change the DHW sensor

Boiler temo. too high Too high boiler temperature Cool down and reset the boiler

Mosfet temp. too high Fan capacitor faulty or wrong fan

connection to the burner

Check the fan

Firing up alarm No fuel Refuel the fuel tank

Check the feeder motors (int/ext)

Photo cell faulty Check and replace photo cell

Heather faulty Check and replace heather

Hall sensor Hall sensor faulty Replace fan

Fan faulty Replace fan

STB Too high boiler temperature Cool down and reset the boiler

STB faulty Replace STB

C1 or C2 sensor fault Sensors C1 or C2 (additional

pumps) faulty

Replace sensors

No 50Hz CU problem Replace CU

No valve

communication

Wrong connection Check the connection

Error by valve registration Register the valve again

71





Problem solving

Code Failure Cause Solution

A02 Parasitic flame

signal

Short cut of photoconductor Photoconductor change

Another light source Removal this light source

A03 STB open Boiler overheating Remove the cause of

overheating, heating system,

temperature setting

Bad STB STB change

A04 Safety feeder

thermostat open

Ignition parameters are

wrong

Check the parameters t03, t04

clogged flue ways , chimney Check the chimney draught

remove of dirty

Bad safety feeder

thermostat

Safety thermostat change

72





Problem solving

Code Failure Cause Solution

F02 Parasitic flame

signal

Flame signal is detected

after end of operation

request

Post-ventilation finishing

F05 Air sensor failure Blocked air sensor tube Check the tube

Bad fan Change

Dirty fan wheel Clean, change

F06 Air sensor

disconnected

Cable interrupt Cable check, sensor change

F10 Flow ware sensor

failure

Sensor damaged Change sensor

Short cut or interrupted

sensor

Sensor and cable check, change

73





Comments

For proper operation of the boiler with pellet burner must be inside of the boiler

(combustion space, internal flue ways) vacuum. Therefore minimal chimney

draught is 20 Pa

Before equipment installing must be checked chimney. Setting of required

chimney draft can be adjusted by draught regulator

If chimney draft is insufficient (chimney can be blocked), safety feeder

thermostat can be activated

Starting boilers with pellet burner can be done by servicemen which were

trained by manufacturer only , after all checks and inspection (flue gas ways)

according to local regulations

Operation is possible only in accordance with safety requirements, flue gas

ways and other legal requirements

The installation company that sells / installs equipment is required to ensure all

the checks and inspections, educate customers on safe operation of the

equipment and give him all the documents (manuals, protocols, review)

74


TT/SCZ-ASA14 | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce,



Thank you for attention

Marek Lapiš

KrnP/QMM-STI

[email protected]

+420 554 694 120

+420 603 155 469

75


bosch boiler with pellet burner pelet brenn 2000 -...

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