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SOLARFOCUS Therminator II, Installation Manual

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SOLARFOCUS Therminator II Installation Manual Download Page 11

Product information 

Installation manual 

thermi

nator

 II touch

 

11 

 

Wood chip boiler 

 

1  Lambda sensor 

2  Boiler control operating unit 

3  Electrical power element 

4  ID fan 

5  Filling chamber door 

6  Filling chamber 

7  Heat  exchanger  with  interior  turbula-

tors 

8  Stainless  steel  hopper  with  stainless 

steel combustion grate 

9  Combustion chamber door 

10  Combustion chamber 

11  Ignition device 

12  Flue ash container 

13  Feeder unit 

14  Direct extraction auger 

15  Rotary valve 

 

3.5  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. 
 
 

 

3 

1 

10 

4 

6 

15 

2 

8 

9 

5 

7 

12 

13 

14 

Summary of Contents for Therminator II

Page 1: ...re operating Biomass boiler therminator touch Installation manual for qualified personnel DR 6083 EN v29 202002 Log wood boiler Dual fuel boiler Wood chip boiler Dual fuel boiler with intermediate pellet store 110L Log wood pellets ...

Page 2: ... overload protection 29 6 6 Return booster module RFB 29 7 Electrical connection 30 7 1 Power supply for the heating system 30 7 2 External boiler request X28 30 7 3 Fault X29 30 7 4 Parameter Function X51 30 7 5 Parameter reserve relay X6 31 7 6 Emergency OFF switch X21 31 7 7 Safety chain X21 31 7 8 Cable management 31 7 9 Electrical fusing 31 7 10 Internet connection 31 7 11 Connecting pellet c...

Page 3: ... 49 6251 13665 14 Switzerland 41 41 9840889 2 For your safety Note the weight of the individual parts during transport Only tested lifting equipment crane conveyor belt ropes belts etc is permitted for use The therminator may only be installed by qualified personnel It is vital that you note and adhere to the proce dures described in this installation manual In order to prevent later problems and ...

Page 4: ...h hPa 1550 4 9 2310 8 8 3090 15 7 4199 26 3 5140 35 6 Flow rate differential pressure at ΔT 20 K kg h hPa 770 1 8 1160 2 1 1540 4 0 2097 6 9 2570 9 4 Fuel Fuel Log wood beech Filling chamber opening WxH cm 34x24 34x24 39x24 54x24 54x24 Filling chamber capacity for log wood l 145 145 186 290 290 Maximum log wood length cm 56 56 56 66 66 Flue gas side Flue gas pipe diameter cm 13 13 15 20 20 Height ...

Page 5: ...acc to ONORM M 7133 log wood Filling chamber opening WxH cm 34x24 39x24 54x24 54x24 Filling chamber capacity for log wood l 145 186 290 290 Maximum log wood length cm 56 56 66 66 Flue gas side Flue gas pipe diameter cm 13 15 20 20 Height to centre of flue gas pipe 1 cm 78 88 90 90 Minimum draught requirement 3 Pa 5 5 5 5 Maximum flue gas temperature 4 full load C 140 140 140 140 Maximum flue gas t...

Page 6: ... thread 1 2 Internal thread 1 2 Internal thread 1 2 Flow rate differential pressure at ΔT 10 K kg h hPa 1710 5 8 2474 11 5 3430 18 6 5140 35 6 5140 35 6 Flow rate differential pressure at ΔT 20 K kg h hPa 860 1 5 1237 3 0 1710 4 9 2570 9 4 2570 9 4 Fuel Fuel Wood pellets acc to EN14961 2 ENplus A1 Log wood Filling chamber opening WxH cm 34x24 34x24 39x24 54x24 54x24 Filling chamber capacity for lo...

Page 7: ... a room sealed draught stabiliser 4 The maximum flue gas temperature can be adjusted electronically 5 Flue gas values in mg m are based on 13 O2 of the volume flow 3 2 Scope of delivery Designation Wood chip boiler Qty Dual fuel boiler Qty Log wood boiler Qty 1 Boiler therminator II touch preassembled including electronic control 1 1 1 2 Stainless steel combustion grate for wood chips 1 3 Stainles...

Page 8: ...B and T see technical data table 3 3 2 Dual fuel boiler Auger extraction for direct extraction Graphical overview of available dual fuel boiler storage and conveyor systems 36 Boiler cm A therminator II 22 45 therminator II 30 45 therminator II 40 47 therminator II 49 54 therminator II 60 54 Installation angle from 0 to 180 Covered length For dimensions B and T see technical data table 20 30 B 11 ...

Page 9: ...ts 3 3 3 Wood chip boiler direct extraction Boiler cm A therminator II 30 47 therminator II 40 47 therminator II 49 59 therminator II 60 52 Covered length Installation angle α from 0 to 180 For dimensions B and T see technical data table 3 3 4 Shaker motor for stainless steel combustion grate Series with wood chip boiler optionally with dual fuel boiler Item Autom switching of log wood to pellets ...

Page 10: ...chamber door 10 Combustion chamber 11 Ignition device Dual fuel boiler 1 Lambda sensor 2 Boiler control operating unit 3 Electrical power element 4 ID fan 5 Filling chamber door 6 Filling chamber 7 Heat exchanger with interior turbulators 8 Stainless steel hopper with stainless steel combustion grate 9 Combustion chamber door 10 Combustion chamber 11 Ignition device 12 Intermediate pellet store 11...

Page 11: ...ainless steel hopper with stainless steel combustion grate 9 Combustion chamber door 10 Combustion chamber 11 Ignition device 12 Flue ash container 13 Feeder unit 14 Direct extraction auger 15 Rotary valve 3 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 accordi...

Page 12: ...brick parts etc during transport setup is not recom mended 4 1 1 Remove boiler covers 4 1_002 Open cladding door 1 Lift front cover 2 upwards no tools re quired Release the 4 self tapping screws and remove the rear cover 3 4 1 2 Disassemble the cladding door 4 2_008 Remove cover 3 and disconnect the cables on the underside of the display For each hinge loosen 2 x screws 1 and remove cladding door ...

Page 13: ...he boiler remove the perforated parts 1 from the boiler clad ding 4 4_012 Transport hook art no 98534 not included For lifting the boiler by means of a hoist Remove perforated area 1 from cover 2 Mount hook 3 on the console 5 with the 2 x M20x35 hex bolts 4 therminator II 49 60 Hooking tab 1 on the metal skids bottom of the boiler For securing the boiler in complicated insertion situations e g sli...

Page 14: ...ormation about the boiler room Structural specifications The boiler may only be installed in a dry frost free room the permissible room temperature is 5 to 30 C The boiler may only be used on a non combustible surface with sufficient load bearing capacity Observe spacing to flammable materials regional regulations Note the installation dimensions to ensure sufficient space is provided e g for serv...

Page 15: ...be at least 15 cm to allow cooling The chimney must be commissioned and appropriate for the boiler output The chimney draught must be at least 0 05 and at most 0 10 mbar 5 10 Pa A draught stabiliser must be installed to ensure an even chimney draught The draught stabiliser should be installed as close as possible to the boiler We also recommend the installation of a pressure relief flap in the flu...

Page 16: ...es Intermediate pellet store with suction system 110 litres art no 6218 22 optional Intermediate pellet store 250 litres manual filling art no 6214 or suction system art no 6217 20 optional 5 2 Installation sequence DANGER There is a risk of fatal electric shocks when working on electrical components of the product Work may only be performed by qualified electricians Applicable standards and regul...

Page 17: ...aneous use of Item Intermediate pellet store 110 litre to be mounted on the left and Item Automatic switchover from log wood to pellets shaker motor it is recommended to mount the hot air fan on the left If when mounting the intermediate pellet store 110 litre the hot air fan is mount ed on the left side of the boiler then do not mount the fan cover housing 5 1_001 001BL iAL Separate the perforate...

Page 18: ...em Automatic switchover log wood to pellets DR 0026 For the thermi II Wood chip boiler the following applies For the installation of the shaker motor see the man ual DR 0025 enclosed with the wood chip direct extraction 5 6 Pellet feeder The following steps are valid for the pellet feeder unit art no 68220 used with the conveyor system auger extraction for direct extraction and intermediate pellet...

Page 19: ...4_020 Connect electrical components Lay the cables in duct 1 and lay duct 2 be hind the boiler cladding to the boiler power el ement Connect burn back slide 3 to adapter cable X25 plug 3 plug 14 Connect feed auger motor 4 to X23 Place feeder temperature sensor in pipe 5 clamp with screw and connect to X33 5 5_001AF Attention The cables must not touch the flange plate 1 and the feeder head 2 High t...

Page 20: ...h white ceram ic fibre mat 1 and stainless steel flange plate 2 Fasten with 2x hex bolts M8x70 SW13 3 5 8 Intermediate pellet store 250 litres Scope of delivery Intermediate pellet store 250 L manual filling art no 6214 Quantity Designation 1 Intermediate pellet store Ø700xH1300 mm 1 Split pole geared motor for container auger 1 Connection cable for container auger length 2 5 m Cable ties sticker ...

Page 21: ...nnect the two connecting pipes with hose and hose clamps Connect the horizontally positioned con tainer auger 2 on the boiler power element to X22 5 10_013 For 250 litre intermediate store with suction system additionally Connect the container filling level sensor 1 on the power element to X49 Connect the suction turbine 2 on the power element to X3 Pellet hose Connect the suction hose pellet conv...

Page 22: ...ver housing 5 9 1 Application range with suction system As an intermediate store for the pellet suction system on the biomass boiler therminator II and therminator II touch Pre assembled with high performance suction turbine suction pipe hose clamps and filling level sensor Supplied ready to connect to the boiler electrical power element Can only be installed on the left side of the boiler Art no ...

Page 23: ...DIN 3017 SW10 7 1 Connection hose Ø 70 mm 8 1 Hose clamp for Ø 70 mm SW 7 17 Self tapping screw M4x10 TX20 5 9 4 Dimensions housing 5 9 5 Installation dimensions Allow a gap of at least 10 cm between the interme diate pellet store and the side wall If the unit is set up with the minimum clearance from the wall the container must be accessible from the front and back 6 5 3 4 1 2 8 7 1131 365 834 89...

Page 24: ...g wire cutters Cut out the insulation behind the side cladding 5 4_002 Removing the flange plate Release 4 hex nuts M10 SW17 1 and remove the flange plate 2 5 5_004 Install the feeder unit If the vessel has an existing shaker motor Item Automatic switchover unit from logs to pellets BEFORE installing the feeder unit permanent ly remove the cover housing of the shaker motor Ideally however the shak...

Page 25: ...he power element Remove the front cover red from the boiler Route the following cables across the back of the boil er and into the cable duct to the power element Suction turbine Container auger motor Filling level sensor on the container Connect all routed cables to the boiler power element 1 Plate slide back burning protection X25 2 Feed auger temperature sensor X33 3 Feed auger motor X23 8 4 Su...

Page 26: ...ow as specified Failure to observe this will lead to malfunction Make the following selection Fig 5 10_01 114 02 5 10 Ash pan 5 11_001 Mount 2 x handles 1 with cylinder head screw 2 and nut 3 on the ash pan 4 Use ash pan only during boiler cleaning never place permanently in the combustion chamber 5 11 Fuel chute 5 12_001AJ Adjust the inclination of the fuel chute mounted in the filling chamber wi...

Page 27: ...ank also prolongs the service life of the boiler and reduces emissions For pellet boilers a buffer tank volume of 30 litres per kW heating output is recommended 6 2 Fill up water requirements General recommendations for installation Fit an upstream filter 25 µm to prevent particles getting into the heating water Position shut off valves for each section in buffer tank etc in order to minimise heat...

Page 28: ...after fill ing then check again after 8 12 weeks If there is no increase in value then add 10 g m trisodium phosphate Na3PO4 or 5 g m sodium hydroxide NaOH Allow 2 4 weeks of operation before further correc tions Electrical conductivity Recommendation Low salt driving filling with de mineralised water see VDI 2035 sheet 2 Low salt Salty Electrical conductivity at 25 C 100 µS cm 100 1500 µS cm Comp...

Page 29: ...ain funnel A backflow inhibitor and as a pressure limit ing device a safety valve or an expansion tank with a minimum capacity of 4 litres must be installed at the inlet connection On the left side of the boiler Perforation in the clad ding for easy access when replacing the thermal overload protection heat exchanger 6 6 Return booster module RFB Function of the return flow boosting The return tem...

Page 30: ...ns connection cable e g in case of replacement cable SIHF J 3x1 5 mm 7 2 External boiler request X28 Potential free relay output for switching an external boiler for example an external boiler is controlled by the SOLARFOCUS boiler control ATTENTION The connection is potential free and has a maximum load of 5A 7 3 Fault X29 Potential free relay output for example to switch a warning device optical...

Page 31: ...supplied with power when pellet suction is required 7 6 Emergency OFF switch X21 An emergency OFF switch must be fitted outside the boiler room Observe regional building regulations Connect the cable to the power element X21 7 7 Safety chain X21 Connect all safety related devices EMERGENCY OFF switch if necessary pressure sensor etc in series 7 8 Cable management For all therminator II boiler type...

Page 32: ...cal overview of the storage and conveying systems for the dual fuel boiler 36 7 12 Touch display The touch display is wired at the factory The infor mation here serves for possible replacement of the boiler control Wire Display connection Connection to the power ele ment black SUPPLY 1 24 V DC X54 light argy SUPPLY 2 GND X54 brown IF4 Pin 4 RS485 A X53 A blue IF4 Pin 6 RS485 B X53 B 7 13 Sensor re...

Page 33: ...e reset OTR X21 Safety chain 230 V AC optional e g for emergency off switch X23 System type Pellets Feed motor System type owood chip downpipe or wood chip intermediate auger Feed motor X24 Heat exchanger cleaning motor X25 Burn back slider with pellet feeder X26 Primary air solenoid X28 External boiler request optional X29 Fault optional X30 External boiler sensor X31 Boiler temperature sensor X3...

Page 34: ...er according to the delivery note and invoice will be used Output setting During commissioning set the nominal output 1 of the boiler the system type 2 and the boiler oper ating modes bought 3 Fig 8 1 The output is controlled ID fan control based on parameters set at the factory No further setting work is required for this 9 Annex 9 1 Flue gas pipe Hole for emission measurement Make the hole for t...

Page 35: ... and the intake of false air must be reliably prevented Note on electrical earthing Cut the required length of hard PVC spiral from the hose with a cutter Adjust the cable stripping pliers to the thickness of the metal strand 1 and strip them as with electri cal cables the strand lies loosely in the hard PVC spiral i e it can be easily separated from it Bend the strand onto the inside of the hose ...

Page 36: ... conveying systems for therminator II dual fuel boiler Auger extraction for direct extraction Suction system with suction heads Suction system with suction auger Manual filling of the intermediate store Pellet box with auger extraction Pellet box with suction system ...

Page 37: ...es 4 Sloping floor 5 Single axis rotary valve 6 Motor of the feed auger M2 7 Feeder unit 8 Flue ash container Direct extraction plus ascending auger 9 2_041 1 Motor of the intermediate auger M1 2 Intermediate auger 3 Motor of the direct extraction auger M2 4 Direct extraction auger 5 Agitator with spring leaves 6 Single axis rotary valve 7 Motor of the feed auger X23 8 Feeder unit 1 6 4 3 5 7 2 8 ...

Page 38: ... Downpipe direct extraction system 9 3_029 1 Motor of the direct extraction auger M2 2 Direct extraction auger 3 Agitator with spring leaves 4 Downpipe 5Single axis rotary valve motor M1 6 Motor of the feed auger X23 7 Flue ash container 1 6 3 7 5 4 2 ...

Page 39: ...Annex Installation manual therminator II touch 39 9 6 Commissioning log ...

Page 40: ...Annex 40 Installation manual therminator II touch ...

Page 41: ...Annex Installation manual therminator II touch 41 9 7 Customer service order form ...

Page 42: ...Annex 42 Installation manual therminator II touch ...

Page 43: ...Annex Installation manual therminator II touch 43 ...

Page 44: ...e products that take the strain off the envi ronment and your wallet Everything from a single source Biomass heating Solar systems Heat pumps Fresh water equipment Tested leading edge technology EN ISO 9001 certified Austria Germany ...

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