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SOLARFOCUS maximus L 150, Installation Manual

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SOLARFOCUS maximus L 150 Installation Manual Download Page 24

5 Installation

5.3 Connecting heat exchanger and bur-

ner

This chapter describes how to make the necessary
connections between the heat exchanger and the bur-
ner.

!

WARNING

- Before connecting the burner

and heat exchanger, check that the sealing
cord

1

in the flue gas pipe flange is in the cor-

rect position.

Abb. 2-18: Sealing cord in the flue gas pipe of the burner

5.3.1 Adjust spacing screws

►

The two lower holes

1

serve to receive the spa-

cing adjustment screws.

Abb. 2-19: Hole for screws

►

Set the two hexagonal screws so that a spacing
of

25 mm

is maintained between the bottom pla-

tes of the burner and the heat exchanger.

►

Push the heat exchanger to the burner (spacing
screws) until the stop.

Abb. 2-20: Distance between the bottom plates

24

Installation manual

maximus L

Summary of Contents for maximus L 150

Page 1: ...Installation manual for qualified personnel Read carefully before operating DR 0160 EN v25 202206 Commercial boiler maximus L ...

Page 2: ... the chimney 29 5 12 1 Flue gas pipe Hole for emission measurement 30 5 13 Mounting ash container 30 5 14 Mounting cladding on the boiler 31 6 Hydraulic connection 32 6 1 Boiler connections 32 7 Electrical connection 33 7 1 Power supply for the heating system 33 7 2 Boiler control cabinet 33 7 3 Terminal assignment 34 7 4 Connections functions 35 7 4 1 Connect overtemperature reset 35 7 4 2 Connec...

Page 3: ...bed in this manual must be carried out by qualified specialist per sonnel Work on electrical components must only be per formed by trained electricians and in accordance with the relevant rules and directives Installation and commissioning System may only be installed and brought into operation by certified qualified personnel SOLARFOCUS service technician or SOLARFOCUS service partner Keep unauth...

Page 4: ...en sioning take material combinations into account Repair leaks immediately Expansion tank 9 prevents air from being drawn in when the system cools down Cor rectly set the pressure check it regularly Existing underfloor heating Take care with old diffusion open plastic pipes 9 Return temperature in the boiler A temperature below the dew point leads to corrosion in the boiler must be prevented by a...

Page 5: ...ployment of unqualified personnel Use of non approved spare parts Technical modification of the product by the sys tem operator 3 2 Standards guidelines regulations The following bodies of regulations must be con sidered and adhered to during planning installation and operation of the heating system Standards for heating systems EN 303 5 Part 5 Heating boilers for solid fuels manually and automati...

Page 6: ...el Chimney The chimney must be resistant to moisture Use fire brick or stainless steel The chimney must conduct away the flue gases reliably at all times Connect the chimney condensate drain to the sewage system Connect the condensate drain line of the chimney to the domestic sewage system to drain con densate rainwater Use DN 25 diameter pipe install siphon Provide each boiler with its own chimne...

Page 7: ...ger horizontal pipe sections L 20xD and at the high point before drop ping down the flue gas pipe an explosion flap must be installed independent of the boiler output From 100 kW boiler output an explosion flap is requi red in the flue gas pipe This avoids damage to the boiler or the flue gas system even when deflagrations occur 3 5 Supply air in the installation room The following applies for Aus...

Page 8: ...pecific system volume for the system must be determined System volume divided by total heat output results in the specific system volume 1166 litres 25 kW 46 64 l kW specific system volume Table Total permitted hardness of the fill up water Total heat output Specific system volume VDI 2035 20 l kW 20 50 l kW 50 l kW 50 kW 16 8 dH 11 2 dH 0 11 dH 50 200 kW 11 2 dH 8 4 dH 0 11 dH 20 600 kW 8 4 dH 0 ...

Page 9: ... expansion tank prevents air from being drawn in when the system cools down issue oxy gen input heating system s fill up water 8 Dimension the expansion tank with a capacity of 12 of the total hydraulic system volume Secure the expansion tank against shut off To do this either use the shut off options on the way to the expansion tank as cap valves or unscrew the hand lever handwheel and attach it ...

Page 10: ...wers the risk of defects and malfunctions over the long term Helps ensure quality heating water even in the case of existing systems for example 4 Product information 4 1 Product description maxi mus L is a boiler for firing wood pellets and wood chips The boiler has an automatic fuel ignition system automatic fuel supply and automatic heat exchan ger cleaning The ash produced is collected in an a...

Page 11: ...ervice menu System para meters button General settings button The Service menu can only be accessed by qualified personnel code input required Thermal overload protection The thermal overload protection prevents an uncontrolled increase in temperature and pres sure of the boiler Functioning At a boiler water temperature 95 C the valve opens and directs cold water through the two series connected s...

Page 12: ...tside the boiler room in a safe place that is easy to access Install EMERGENCY OFF switch 37 Temperature monitor in the fuel storage room TM Required according to guideline TRVB 118 H for wood chips depending on system design hea ting 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 ...

Page 13: ...m directly above the deli very line in front of the wall or ceiling passage in such a way that the greatest possible success can be achieved in extinguishing The empty piping must be connected directly to a pres surized water supply and provided with a shut off valve arranged in the boiler room Mark this valve with a sign Extinguisher Fuel Storage Room The execution of the extinguishing system mus...

Page 14: ... 63793 Further information is provided in the docu mentation of the ash extraction system DR 9969 Abb 2 7 240 litre standard bin Abb 2 8 600 litre tipping container 4 5 Dimensioning the boiler The boiler must be dimensioned in terms of output in the right proportion to the underlying heat distribution system For a correct design see the calculations according to standard EN 12828 14 Installation m...

Page 15: ...3 Technical requirements Installation manual maximus L 15 4 6 Dimensions The following figures show the maxi mus L with mounted intermediate pellet store Top view Abb 2 9 ...

Page 16: ...Front Abb 2 10 Side view Abb 2 11 3 Technical requirements 16 Installation manual maximus L ...

Page 17: ...lls down through the grate The ash pusher 4 push the ashes to the ash auger 5 and the auger transports the ash into the ash container 6 Airflow Primary air is drawn in at the opening 7 forwarded in a space on the left and right side of the boiler At the holes 8 the primary air escapes from under the stainless steel combustion grate and makes it way through the feed grate into the combustion chambe...

Page 18: ...combustion chamber flows through the heat exchanger 2 past the electrostatic dust separator 3 into the flue gas pipe 4 and into the chimney De ashing The ash that accumulates on the feed grate in the burner is transported from the transverse ash auger burner 5 into the ash container 6 The ash that accumulates on the electrostatic dust collector 3 is transported forwards by the ash auger heat excha...

Page 19: ...or operation without fill up water kg 3290 3290 3290 3290 Water side Water content burner and heat exchanger l 565 565 565 565 Operating temperature C 70 90 70 90 70 90 70 90 Maximum permissible temperature C 90 90 90 90 Max permissible operating pressure bar 3 3 3 3 Min return temperature C 60 60 60 60 Boiler flow boiler return connection G 2 ET G 2 ET G 2 ET G 2 ET Drain connection G 1 ET G 1 ET...

Page 20: ...ute test report No 18 IN AT UW OÖ EX 205 1 TÜV Austria Interpolation accor ding to EN 303 5 Interpolation accor ding to EN 303 5 18 IN AT UW OÖ EX 205 2 TÜV Austria CO full load mg m 3 3 3 6 3 6 CO partial load mg m 29 29 29 29 NOX full load mg m 112 112 113 113 NOX partial load mg m 83 83 83 83 Org C full load mg m 2 2 2 2 Org C partial load mg m 2 2 2 5 Dust content full load mg m 1 8 2 10 2 Dus...

Page 21: ...r content Class A2 indi cates a slightly higher ash content and or water content B1 extends the origin and source of class A and includes other materials such as e g short rotation coppice wood from gardens and plantations etc as well as chemically untreated waste wood from industry B2 not approved for maxi mus L includes waste wood from industry also chemically treated wood and che mically untrea...

Page 22: ... to 25 25 to 35 Conifer tree species Bulk volume kg m 160 to 180 180 to 200 200 to 225 Property class BD150 BD150 BD200 Deciduous tree species Bulk volume kg m 225 to 250 250 to 280 280 to 320 Property class BD200 BD250 BD250 3 Technical requirements 22 Installation manual maximus L ...

Page 23: ...urner is taken from the front the front door must first be removed When the load of the heat exchanger is taken from the rear some of the mechanical com ponents must first be removed electric motor gearbox drive chain Option 2 Lifting with a crane WARNING When using a hoist e g chain make sure that the angle does not fall below 45 degrees If it falls below this excessively high forces act on the c...

Page 24: ... the cor rect position Abb 2 18 Sealing cord in the flue gas pipe of the burner 5 3 1 Adjust spacing screws The two lower holes 1 serve to receive the spa cing adjustment screws Abb 2 19 Hole for screws Set the two hexagonal screws so that a spacing of 25 mm is maintained between the bottom pla tes of the burner and the heat exchanger Push the heat exchanger to the burner spacing screws until the ...

Page 25: ...serve this can impair the performance of the burner 5 3 3 Install automatic ash extraction i Hint on assembling the components Mount the parts by hand first and then tighten once they are joined correctly Check the correct position of the ash auger heat exchangers The auger must be locked in the rear drive in the bayonet mount Abb 2 22 Check auger drive Mount auger trough 1 on heat exchanger Abb 2...

Page 26: ...eby creating a radial seal Abb 2 27 Tighten sealing elements Insert ash auger burner 1 into auger trough Abb 2 28 Insert the auger Mount geared motor on auger shaft 1 Use key 2 and two securing rings 3 Abb 2 29 Drive on right side of burner 5 3 4 Connect flue gas recirculation line Join flue gas recirculation line with elbow joint 1 and 0 5 m pipe 2 adapt length of pipe as necessary Abb 2 30 26 In...

Page 27: ...arbox 4 Connect motor Cable X4 7 X4 9 is pre routed in ducts 3 and 2 38 Abb 2 32 Mount feeder grate drive Connect the feed grate motor Connect the pre routed cable as shown in the ter minal area of the motor Abb 2 33 Connect the cable in the motor terminal area 5 5 Install the feeder unit Mount the feeder unit 1 including installed rotary valve on the burner with 4 hexagon screws Set adjustable fo...

Page 28: ...Abb 2 52 34 5 6 Install the hot air fan Mount cover 1 and 2 Install hot air fan 3 in ignition pipe and secure with t bolt hose clamp Connecting to terminals Fan A1 X7 Heating element A1 X4 The cable is pre routed in ducts 3 and 2 38 Abb 2 37 Install the hot air fan 5 7 Install safety valve Install the safety valve 1 or boiler safety group in the boiler supply line at the highest point of the line ...

Page 29: ...t thermal overload protection Safety heat exchanger in the heat exchanger Abb 2 39 Fit the thermal overload protection valve before as seen from the direction of flow the safety heat exchanger i e no water pres sure building up in the heat exchanger Abb 2 40 Function of the thermal overload protection schematic representation 5 10 Install temperature monitor TM Mount the temperature monitor on the...

Page 30: ...y case place the measuring point before any existing draught stabilisers You can find the function for carrying out the emission measurement in the boiler operation manual keyword Chimney sweep function Flue gas pipe horizontal Flue gas pipe vertical 5 13 Mounting ash container Abb 2 41 Check seal Check that seal 1 is positioned correctly Abb 2 42 i Ensure that connection is correctly sealed Relia...

Page 31: ...h container Adjust safety switch of ash container The switch must be adjusted to the height distance of the ash container Loosen 4 screws 1 and adjust height of switch retaining plate 2 Abb 2 45 Adjust safety switch 5 14 Mounting cladding on the boiler Mount two covers on the back Illustration of further boiler covers 44 Installation manual maximus L 31 ...

Page 32: ...ion sleeves on the burner 1 Sensor for thermal overload protection TOP 2 Boiler temperature sensor 3 Sensor for overtemperature reset button STB Install thermal overload protection 29 Return sensor pressure sensor Abb 2 48 1 Return sensor 2 Pressure sensor 3 blank Boiler draining Abb 2 49 Draining on the back of the heat exchanger 1 Boiler draining G 1 OT 32 Installation manual maximus L ...

Page 33: ...ermediate pellet store 41 see delivery systems 48 7 1 Power supply for the heating system Provide a separate power circuit in the Heizraum for the heating system Connection 400 V AC 50 Hz 16 A 3P N PE Connect the boiler with the plug CEE 5 x 16 A Use a heat resistant PVC or silicone cable with 5 pin min 2 5 mm as the supply cable The rotating field must turn anti clockwise Connection in boiler con...

Page 34: ..._A5 46 A2 X4 Electrostatic dust collector Analogue output 0 10V nominal voltage for high voltage module_A5 46 0 30kV A2 X7 Electrostatic dust collector Analogue output 0 10V nominal current for high voltage module_A5 46 0 4mA A2 X8 Electrostatic dust collector Analogue input 0 10V actual voltage for high voltage module_A5 46 0 30kV A2 X9 Electrostatic dust collector Analogue input 0 10V actual cur...

Page 35: ...F switch 37 Ash box safety switch connection A1 X50 can also be used as an option X6 1 X6 8 Overtemperature reset OTR 35 X6 1 X6 8 Boiler power supply 400V 33 X0 Fault 37 A1 X29 Temperature monitor in fuel storage room TM 29 A1 X21 Temperature monitor in fuel storage room TM 29 Warning device visual or acoustic X7 3 X7 4 Feed grate motor 27 X4 7 X4 9 Heat exchanger cleaning motor 46 X4 10 X4 12 7 ...

Page 36: ...or secondary air 46 connect on site Rotary drive for flue gas recirculation 46 Induced draft fan 47 Join MATE N LOK connector 1 for primary air X200 Join MATE N LOK connector 2 for secondary air X201 Abb 2 56 Connect bus cable Connection X20x rotary drive for primary air and secondary air Order of bus slaves 7 4 5 Connection for electronic modules CAN OUT interface X6 See power element_A3 optional...

Page 37: ...xtraction motor Connection X14 on the power element PE PE 1 N N 2 L3 L 3 L2 TC 4 L1 TC 5 Third party manufacturer system Use e g for pellet box transfer unit auger and for the pellet mole these systems have integrated motor thermal protection Bridge the two thermal contact terminals TC on the power element Use 3x1 5 mm2 cable 7 4 8 External boiler request A1 X28 Potential free Relay output for swi...

Page 38: ...must be connected The following sections connecting apply to the direct extraction auger and the intermediate auger s Motor of feeder unit 27 Direct extraction auger RA1 Motor of direct extraction auger Direct extraction auger intermediate auger RA1 Motor of intermediate auger RA2 Motor of direct extraction auger Direct extraction auger intermediate auger 1 intermediate auger 2 RA1 Motor of interm...

Page 39: ...xtraction auger Connection in motor terminal area Abb 2 62 Connect the safety switch in the motor terminal area 7 7 Sensor resistance table Type KTY 81 110 PT100 PT1000 KTY 81 210 Tolerance 3 0 7 1 3 C Ohm Ohm Ohm Ohm 20 684 92 16 922 1367 10 747 96 09 961 1485 0 815 100 1000 1630 10 886 103 9 1039 1772 20 961 107 79 1078 1922 25 1000 109 74 1097 2000 30 1040 111 69 1117 2080 40 1122 115 54 1155 2...

Page 40: ...ernal elec tronics for main transformer F9 T 800mA 5x20 mm Fuse 18V AC Internal elec tronics standby transformer display supply F10 T 10A 5x20 mm Spare fuse F11 F 8A 5x20 mm Spare fuse F12 F 0 5A 5x20 mm 230 VAC fuse Relay outputs X26 X27 and X80 F13 F 0 5A 5x20 mm Spare fuse for F12 7 9 Connecting boiler control to the inter net To enable the Internet connection of the ecomanager touch boiler con...

Page 41: ...t angular compensator BEFORE assembly As an alternative to joining the angular compensator when setting up the container it is possible to assemble the entire angular compensator in advance and screw the intermediate store to the angular compensator placed on top of it using the straight flange If necessary Install intermediate store rotated If necessary due to the set up situation the inter media...

Page 42: ...Mount the drive unit Mount the drive unit 1 on the shaft 2 and attach using the securing ring 3 Abb 2 68 Connect pellet hose Abb 2 69 Notes on installing the pellet hose 47 Connect electrical components Connect components cables are in pre routed in ducts 3 and 2 38 of boiler Use the cable duct that runs vertically along the intermediate pellet store Abb 2 70 Intermediate pellet store 1 Pellet suc...

Page 43: ...boiler to the mains power supply Carry out the commissioning routine in the boiler control Complete the commissioning log send it i Once commissioning is complete the completed commissioning log should be sent to SOLARFOCUS If this does not happen then for guarantee and warranty claims of any kind the date of shipment from the manufacturer to the dealer according to the delivery note and invoice w...

Page 44: ...11 Annex 11 1 Mounting boiler covers overview Abb 2 72 Abb 2 73 11 Annex 44 Installation manual maximus L ...

Page 45: ...1 Abb 2 74 Power element_A2 Power element_A3 or optional power element_A4 Abb 2 75 Abb 2 76 Power element_A3 direct extraction 1 RA1 Power element_A4 direct extraction 2 RA2 Access to the power element 33 Electrical fuses on the power element 40 Connections X on the boiler power unit and power elements 34 ...

Page 46: ...g of components in the event that they need to be repla ced Burner Front Abb 2 77 1 Rotary drive for primary air Burner Back Abb 2 78 1 Rotary drive for secondary air 2 Hot air fan Heat exchanger Top side Abb 2 79 1 Lambda sensor 2 Motor for heat exchanger cleaning 3 Rotary drive for flue gas recirculation Heat exchanger Side Abb 2 80 1 High voltage module_A5 for electrostatic dust col lector 2 Hi...

Page 47: ...ture resistance of the hose 60 C Always push the end of the hose fully onto the pipe connection as far as the stop The hose will slide on to the connection pipe better if you apply a little water to the pipe Tighten hose clamps firmly Detachment of the hose and the intake of false air must be reliably prevented Electrically earthing the pellet hose i A metal braid is integrated into the inside of ...

Page 48: ...or 1 connection A3 X2 2 Pellet delivery auger direct extraction motor 2 connection A1 X14 Mole suction system Abb 2 84 1 Container auger motor 42 direct extraction motor 1 connection A3 X2 2 Connect mole to A1 X14 the parameter in the manufacturer s manual is called Boiler request mole is unlike direct extraction motor 2 Wood chips Direct extraction with leaf spring agitator Abb 2 85 1 Direct extr...

Page 49: ...ction auger motor direct extrac tion motor 1 connection A3 X2 2 Bunker filling auger motor direct extraction motor 2 connection A4 X2 Direct extraction by downpipe Abb 2 87 1 Direct extraction auger motor direct extrac tion motor 1 connection A3 X2 Installation manual maximus L 49 ...

Page 50: ...11 Annex 50 Installation manual maximus L ...

Page 51: ...11 Annex Installation manual maximus L 51 ...

Page 52: ... þ_Heat pumps þ_Fresh water technology Everything from a single source Pellets Log wood Wood chips Heat pump Innovative products that are easy on the environment and your wallet Log wood pellets Solar energy Fresh water makes you independent ...

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