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TECNIKA 28-35

USE AND INSTALLATION MANUAL

Chapter

4

page 28

Installing

Technical dept. - All rights reserved - Reproduction prohibited

Fig. 4.6.6 General hydraulic circuit recommended for connecting the "Tecnika" hot water boiler to
the heating system provided with three-way valve and heat accumulator

Solar control
unit

Solar
panel

Safety
valve

Pressure
switch

Water flow
meter

Tank in Tank
cylinder

Thermostatic
mixer

Safety
valve

High temperature
direct circuit

Solar
pump
station

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30
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Summary of Contents for TECNIKA 28

Page 1: ...USE AND INSTALLATION MANUAL EN COD 8901113900 ...

Page 2: ...pipe 19 5 3 1 Roof outlet along a traditional flue pipe 20 4 4 System connection 21 4 5 Filling the system 21 4 6 Basic requirements for installing Tecnika hot water gasification boiler to allow simple maintenance and servicing 22 5 OPERATION 29 5 1 Tecnika hot water wood gasification boiler interface control panel 29 6 START UP PROCEDURES 31 6 1 Basic requirements 31 6 2 Electrical connections 32...

Page 3: ...aw Incorrect installation or improper maintenance could cause personal injuries harm to animals or property damage for which the manufacturer will not be held liable Before carrying out any cleaning or maintenance operations disconnect the appliance from the mains power supply using the system switch and or the relevant cut off components and close all cocks If the appliance has a fault and or is ...

Page 4: ...orrect use of the appliance may result in hazards and also endanger the user or others or even damage the appliance or other objects The appliance is intended for the operation of hot water heating systems Appliance use in accordance with the envisaged purposes includes scrupulous observance of the instructions provided in this manual RED reserves the right to make any changes to the design and fa...

Page 5: ...hat 1 The boiler is installed in accordance with the applicable standards in force and the instructions provided in the product use maintenance and installation manual by legally qualified personnel Italian Ministerial Decree no 37 of 22nd January 2008 2 The customer holds the documentation certifying its suitability in all parts a INSTALLATION REPORT filled in by the installer b TEST REPORT and G...

Page 6: ...nal injury or harm to animals ensuing from failure to observe all the instructions provided herein and the applicable regulations regarding installation use and maintenance of the appliance The parts replaced will be guaranteed for the remaining guarantee cover period starting from the original date of purchase of the product 2 3 Additional clauses If faulty or malfunctioning parts are detected du...

Page 7: ... Implementation of Directive 97 23 EC P E D on the subject of pressure equipment SCOPE OF APPLICATION liquid fuel naphtha gas oil fuel oil and solid fuel operated appliances ITALIAN LAW no 46 of 5th March 1990 and related applicative regulations Italian Ministerial Decree no 447 of 6th December 1991 and subsequent amendments System safety standards SCOPE OF APPLICATION without limits to heat poten...

Page 8: ... the following components modules heat exchanger consisting of a welded steel plate structure The upper part of the boiler accommodates the fuel hopper which is manually filled with wood logs The fuel chamber is the ideal environment for the fuel pyrolysis process and volatile gases are conveyed towards the lower section of the boiler where they are oxidised in the combustion chamber The combustio...

Page 9: ... with mineral wool to minimise thermal dispersion doors of the fuel hopper and the combustion chamber are made of cast iron to ensure high thermal resistance and sealing of the boiler external casing of the boiler is made with sheet steel 3 3 Technical data Thermal and technical data of TECNIKA hot water wood gasification boilers PARAMETERS UNIT OF MEASURE VALUES MODEL 28 35 HEAT OUTPUT AT COMBUST...

Page 10: ... LOG LENGTH mm 330 500 DIMENSIONS L WIDTH mm 780 P DEPTH 975 1123 A HEIGHT 1282 OPERATING PRESSURE OF CIRCULATING WATER bar 2 HYDRAULIC PRESSURE LOSS AT NOMINAL HEAT OUTPUT Pa 20 21 TYPE OF EXPANSION VESSEL FOR THE HEATING SYSTEM Open or closed PRESSURE TESTED IN THE FACTORY bar 4 RECOMMENDED TEMPERATURE FOR THE WATER CIRCULATING IN THE BOILER C 80 85 RECOMMENDED TEMPERATURE FOR RETURN WATER IN TH...

Page 11: ...oiler technical specifications o the crosswise section diameter of the wood logs must be D 200 mm o the raw material humidity content must be less than 20 Wr 20 o wood based fuel such as sawdust wood chips and other small combustible particles may be used in addition to wood logs but their total amount must be less than 20 of the fuel loaded into the boiler chamber Approximate recommended fuel par...

Page 12: ... dimensions Technical dept All rights reserved Reproduction prohibited 3 5 Main components Fig 3 5 1 View of the TECNIKA hot water wood gasification boiler Description of main components of the boiler COMBUSTION CHAMBER DOOR FUEL HOPPER DOOR BOILER CONTROL PANEL AIR FLOW CONTROL THERMAL VALVE ...

Page 13: ...PLANATION the values of the dimensions indicated by letters L A and P are shown in Table page 12 Fig 3 5 3 Side view of the TECNIKA hot water wood gasification boiler Fig 3 5 2 Front view of the TECNIKA hot water wood gasification boiler Fig 3 5 4 Rear view of the TECNIKA hot water wood gasification boiler Fig 3 5 5 Top view of the TECNIKA hot water wood gasification boiler P ...

Page 14: ...n prohibited Combustion gas outlet conveyed to convective ducting of the boiler Ceramic combustion gas ducting element in combustion chamber Combustion chamber Combustion nozzle Fuel hopper Opening for extracting gas from combustion chamber for start up Primary air inlet opening Fig 3 5 6 Section view of the TECNIKA hot water wood gasification boiler ...

Page 15: ... to make any changes to design and construction of the boiler without having to inform end users of such changes Boiler control box Upper lid of boiler convective ducting Combustion gas fan Combustion gas outlet ducting Combustion nozzle Ceramic coated combustion gas ducting element Lower lid of boiler convective ducting Fig 3 5 7 Longitudinal view of the TECNIKA hot water wood gasification boiler...

Page 16: ...ich can lift the pallet on which it is packaged or the boiler itself directly Take special care not to damage electrical or mechanical parts with shocks or water sprays once the protective packaging has been removed After removing the packaging make sure the boiler is complete and undamaged If in doubt contact the retailer The document envelope contains System manual An instruction manual for inst...

Page 17: ...The flue pipe must have a diameter of no less than the boiler union for flue pipes with a square or rectangular cross section the internal cross section must be increased by 10 compared to the boiler union The useful cross section of the flue pipe can be calculated using the following formula S K x P H S ensuing section in cm2 K reduction coefficient 0 045 for wood P boiler output in kcal h H heig...

Page 18: ...e flue pipe we recommend you end the flue pipe with a horizontal section The outlet ducting must be made with suitable materials which can withstand the products of combustion and any condensation of the same the inspection valve can allow any condensation that has formed to be vented The ducts must be built to ensure maximum seal against smoke UNI 10683 We recommend you insulate the duct especial...

Page 19: ...9 for this particular system configuration Always make sure there is an inspection valve to allow periodic and efficient cleaning as well as the venting of any condensation that may have formed The chimney must under all circumstances be wind proof and rain proof Make sure the smoke outlet duct is suitably insulated in the section that crosses the wall It is advisable for the smoke outlet duct if ...

Page 20: ...of combustion and to the corrosive action of any condensation that may form Prevalently vertical arrangement with deviations from the axis of no more than 45 It is compulsory to plan a chamber for the collection of solid material and or any condensation which can be inspected through an airtight door It is compulsory for you to observe the provisions of standards UNI 9615 and 9731 for the sizing o...

Page 21: ...e system flow return pipes These cocks are provided in the optional kits Caution failure to wash the heating system and to add a suitable inhibitor shall invalidate the appliance guarantee 4 5 Filling the system Before making the boiler connections it is good practice to allow water to flow through the piping to eliminate any foreign bodies that could compromise the correct functioning of the appl...

Page 22: ...1 bar this only applies for systems with a closed vessel consult any local regulations or standards that allow it for systems featuring an open vessel the reintegration is automatic through the vessel itself NOTE In systems with a closed vessel where permitted the water pressure in the heating system when the system is cold should not drop below 1 bar if it does open the system filler cock This sh...

Page 23: ...re is needed when fitting and installing the ceramic element Take all the preventive measures needed to avoid damaging the element After having installed the element in the combustion chamber push it back until it touches the vertical rear plate of the heat exchanger Fig 4 6 1 Ceramic combustion gas ducting element positioned in boiler combustion chamber ...

Page 24: ...ANATION the chain length and inlet air fin opening must be adjusted with the boiler running and once the thermal opening parameters have been reached The air fin must be open to allow the flow of air into the boiler in order to start the boiler Fig 4 6 2 Thermostatic valve for controlling the combustion process air flow is installed and the stem is connected to the air fin by means of the chain ...

Page 25: ... screwed into an opening situated in the upper rear part of the heat exchanger see photo The water flow control module of this thermostat valve must be fitted on one of the ends of the emergency coil either the inlet or outlet end The water flow control module of this thermostat valve must be connected to the water from the cock at DHW network pressure The emergency cooling coil must be connected ...

Page 26: ...N MANUAL Chapter 4 page 26 Installing Technical dept All rights reserved Reproduction prohibited Hot water boiler emergency cooling coil inlet outlet Fig 4 6 4 View from back of boiler with indication of ends of the emergency cooling coil ...

Page 27: ... the hot water boiler inlet and outlet to the heating system using suitable fittings etc according to the installation diagram Flow line to heating system Return line from heating system Combustion gas outlet to flue Exhaust opening Combustion air control fin Fig 4 6 5 Rear view of Tecnika hot water boiler with indication of connection points ...

Page 28: ... 6 6 General hydraulic circuit recommended for connecting the Tecnika hot water boiler to the heating system provided with three way valve and heat accumulator Solar control unit Solar panel Safety valve Pressure switch Water flow meter Tank in Tank cylinder Thermostatic mixer Safety valve High temperature direct circuit Solar pump station ...

Page 29: ...ter wood gasification boiler interface control panel The following control devices are arranged on the front part of the boiler interface control panel Figure 5 1 1 Interface control panel provided with Tecnika hot water boiler control and operation devices front view Switch START START i Combustion gas thermostat Thermometer Operation thermostat Alarm 2 Alarm 1 ...

Page 30: ...ll run at nominal heat output ON or switch to stand by mode OFF START warning light This indicates the START STOP state signal to the boiler combustion gas fan Alarm 1 warning light Overheat emergency This indicates an overheating emergency of the boiler caused by activation of the emergency thermostat In case of activation cool the appliance check and repair the cause of the emergency situation F...

Page 31: ...is not allowed The boiler must be regularly inspected by maintenance personnel or other trained personnel The end user must not carry out interventions or repairs etc on the appliance In case of faults or warning messages refer to the troubleshooting table at the end of this manual and contact the service centre if the situation is not described in the table Setting or increasing the heat output t...

Page 32: ...earthing system built in accordance with the provisions of the applicable safety standards Remember that an easily accessed bipolar switch with a minimum contact opening of 3 mm must be installed on the electrical power supply line to the boiler in order to facilitate and speed up any maintenance operations The power supply cable must only be replaced by authorised technical personnel Failure to o...

Page 33: ... 2 Flue gas FTh2 HL1 HL2 C 1 2 Alarm cleaning OPTION SB2 START 7 8 Room thermostat N Overheating HL3 6 3 1 Wiring diagram The wiring diagram of the Tecnika hot water wood gasification boiler is shown in Figure 6 2 1 Preliminary checks The first start up must be performed by professionally qualified personnel RED will not be held liable for any damage to persons animals or property caused by failur...

Page 34: ...arter materials to start a stable combustion process The opening of the burner must never be obstructed by particles to prevent volatile gases from passing through the nozzle and entering into the combustion chamber 6 4 Igniting the fuel and heating the boiler The boiler operating thermostat must be set to a temperature higher than 60o C Turn the combustion gas thermostat set point to minimum Turn...

Page 35: ...he practical experience needed to start the fire After starting the fire turn the combustion gas fan on turn the START switch to the ON position close the fuel hopper door and close the start up fin by pushing the lever backwards This will make the combustion gas change direction and flow through the burner nozzle the combustion chamber and the convective ducting section of the boiler instead of b...

Page 36: ...f the circulating water and actuates the lever which controls the position of the air control fin At low circulating water temperatures the lever opens the air control fin and conversely at high circulating water temperatures the valve closes the air control find and consequently reduces the air flow for the combustion process thus reducing the heat output of the boiler This thermostatic valve ope...

Page 37: ...usted and only then can be considered working in constant manner If the heating system is provided with a recirculation pump the operation of this pump must comply with the requirements above i e must work with circulating water temperature higher than 65o C If the boiler works at lower temperature levels operation will cause a considerable deposit of tar and a decrease of heat transfer in additio...

Page 38: ...process CAUTION apply all the preventive measures to avoid burns and suffocation caused by combustion gases released from the combustion chamber by wearing protective clothing etc The fuel must be loaded so as to be arranged in the chamber and optimise the volume available in the chamber for this purpose Position the wood logs lengthwise It is advisable to mix combustion residues when opening the ...

Page 39: ...al is loaded into the fuel hopper chamber the particles with a higher humidity content and or larger particles must be arranged in the centre of the chamber while partially dried or smaller particles must be arranged by the side of the chamber This allows to avoid accumulation of fuel directly over the burner nozzle and consequently obstructing the nozzle itself which would greatly decrease the he...

Page 40: ...condary air mixed and oxidised in the combustion chamber of the boiler This process allows effective fuel use with low running costs of the heating system The process could be explained as gas combustion because most of the fuel is gasified and burnt in the oxidisation chamber of the boiler The structure of the boiler allows optimal combustion process conditions and high heat efficiency in additio...

Page 41: ...control fin axes have considerable effects on the combustion process operating conditions and on the general performance of the boiler For this reason any change to the boiler air distribution setting must be followed by an adequate time before the expected result is obtained Practical experience shows that using wood logs compliant with the requirements above the primary air control fin should be...

Page 42: ...operation of the appliance It is advisable to adjust the combustion process by means of measurements made with a combustion gas analyser The flame released from the burner opening is sent downwards thus reaching the ceramic combustion gas ducting element positioned in the boiler combustion chamber The flame colour in nominal operating conditions with an optimal combustion process i e when the proc...

Page 43: ...t particles combustion residues are dark specks The combustion process adjustment amount can be determined by monitoring the colour of the combustion gases released from the chimney connected to the boiler Dark combustion gases mean that the secondary air is not sufficient and or that the amount of fuel is not compliant the content of humidity is higher than required 6 9 Boiler operation in stand ...

Page 44: ...eset the emergency thermostat remove the protective cap and press the stem until the thermostat is reset it will click Then screw the cap back After having checked the boiler and determined and eliminated the cause of overheating turn the POWER switch to ON to operate the boiler in normal working mode CAUTION The procedure for checking the boiler and the heating system to determine the cause of ov...

Page 45: ... High set point temperature of the boiler operating thermostat The set point of the boiler operating thermostat needs to be decreased it is advisable to keep it over 65 o C High temperature set point of the remote room thermostat where connected The room thermostat set point needs to be decreased High heat output of boiler Decrease fuel loading frequency and or decrease amount of loaded fuel 3 Eme...

Page 46: ...xchange surfaces 7 Steam condenses on boiler heat exchange surfaces Low temperature of the water inlet flow Adjust the set point temperature which controls the circulation pump of the heating system It is advisable to set the thermostat to a minimum value of 65o C 8 Combustion gases are released into the boiler room after a certain period of operation Insufficient chimney draught Check and clean t...

Page 47: ...tion and maintenance contract Inspection is necessary to determine the current condition of an appliance and to compare it with the nominal condition This is carried out through measurements checks and observations 8 1 Instructions for inspection and maintenance To ensure the long term operation of your appliance and avoid altering the approved standard conditions of the product only RED genuine s...

Page 48: ...t to scatter material into the environment Collected ashes and combustion residues must be kept in a closed container with a lid or in a suitable container and left to cool down to ambient temperature Consider safety requirements at all times The heat exchanger of the boiler must be cleaned at least once a month Practical experience indicates that approximately 30 40 of the ash content of fuel is ...

Page 49: ...ws that in some cases the seal may not adhere to the convective section plates making it difficult to remove the lids Be careful not to damage the seal bead and replace it if needed Figure 8 1 3 Upper opening convective lid for removing ash collected from heat exchange surfaces of the boiler Figure 8 1 4 Lower opening convective lid for removing ash deposits after cleaning the heat exchange surfac...

Page 50: ...t with a special tool in particular a metallic brush rubbed from the top down After having brushed and removed ash the collected ash residues must be removed by opening the lower lid to scrape ashes from the lower section of the boiler convective heat exchanger Figure 8 1 6 Lift the turbolators to extract them from the convective heat exchanger of the boiler Extract the turbolators upwards Practic...

Page 51: ...nt from one another It is important to remember their position for putting them back correctly one turbolator has shorter and curved elements Consequently in practice arranging the elements incorrectly is not possible due to the particular shape of the boiler Ash must be cleaned from the convective ducting of the boiler as shown in the figure below Figure 8 1 8 Remove ash deposits from the heat ex...

Page 52: ...ION you are keenly recommended to remove the combustion gas fan and clean it well before putting it back onto the boiler paying attention to seal and tightness The boiler must be disconnected from the electric power by unplugging the boiler from the socket before removing combustion gas ashes compulsory procedure Open the lower opening of the convective ducting after having brushed and removed the...

Page 53: ...cedure boiler convective ducting ash residue cleaning procedure procedure for loading wood logs in the fuel chamber logs must be arranged in the fuel hopper in the chamber to facilitate volatile combustion gas flow towards the burner nozzle of the boiler The fundamental requirement is the use of wood logs with humidity content compliant to fuel requirements start up procedure ash cleaning procedur...

Page 54: ...Via La Croce 8 33074 Vigonovo di Fontanafredda PN ITALY Telephone 39 0434 599599 PBX Fax 0434 599598 e mail info red mcz it 8901113900 Rev 0 06 2011 ...

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