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6 Installation

6 Installation

6.1 Mount heat exchanger on the burner

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 correct posi-
tion.

Fig. 2-11: Sealing cord in the flue gas pipe of the burner

6.1.1 Adjust spacing screws

►

The two lower holes

1

serve to receive the spa-

cing adjustment screws.

Fig. 2-12: 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.

Fig. 2-13: Distance between the bottom plates

16

Operation manual

maximus

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Содержание maximus 150

Страница 1: ...Operation manual for qualified personnel Read carefully before operating DR 0160 EN v4b 201903 Commercial boiler maximus ...

Страница 2: ...t 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...

Страница 3: ...ent 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 operat...

Страница 4: ...ing 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 Pellet...

Страница 5: ...e 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 manuall...

Страница 6: ... 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 conne...

Страница 7: ...ry 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 H Prevents backflow of flammable products of com bustion into the fuel supply or into the intermediate st...

Страница 8: ...2 Safety information Top view Front 8 Operation manual maximus ...

Страница 9: ...ate and the resulting ash falls down through the grate The ash pusher 4 push 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 8 the primary air exits under the combustion grate Secondary air is sucked in at the opening 9 and passes through h...

Страница 10: ...re 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 ...

Страница 11: ...0 70 90 70 90 Maximum permissible tem perature C 90 90 90 90 Max permissible operating pres sure bar 3 3 3 3 Min return flow temperature C 60 60 60 60 Connection Boiler inflow Boiler return flow G 2 OT G 2 OT G 2 OT G 2 OT Drain connection 1 1 1 1 Connection for thermal overload protection G 1 2 OT G 1 2 OT G 1 2 OT G 1 2 OT Electrical systems Electrical connection 400 V AC 50 Hz 16 A 3P N PE 400 ...

Страница 12: ...st 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 2 Dust content full load mg m 6 5 8 8 7 10 2 Dust ...

Страница 13: ...g 2 9 Metal eyelets for crane transport 5 2 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 sufficiently stable and non combustible surface Observe spacing to flammable materials regional regulations Note the installation dimensions to ensure suf ficient space is provided ...

Страница 14: ...1 90 kW 276 927 130 kW 347 252 372 1339 200 kW 533 336 540 2060 400 kW 1067 576 1020 4120 5 3 Chimney flue gas pipe Chimney cross section and chimney height The necessary cross section depends on the nominal output of the heating system and the effective chim ney height at least 6 5 m We recommend that you have the calculations performed by an expert Chimney execution The chimney must be resistant...

Страница 15: ...ulated fly ash there must be an easily acces sible cleaning opening Recommendation Coordinate the number and pla cement of the cleaning openings with the chimney sweep Opening for emissions measurement in the flue gas pipe Make an opening hole in the flue gas pipe to perform the prescribed emission measurement 22 Minimum draught requirement for boiler 5 Pa A draught stabiliser must be fitted if th...

Страница 16: ...nge is in the correct posi tion Fig 2 11 Sealing cord in the flue gas pipe of the burner 6 1 1 Adjust spacing screws The two lower holes 1 serve to receive the spa cing adjustment screws Fig 2 12 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 u...

Страница 17: ...the correct position of the ash auger heat exchangers The auger must be locked in the rear drive in the bayonet mount Fig 2 15 Check auger drive Mount Auger channel 1 on the heat exchanger Fig 2 16 Mount the auger channel Slide metal rings 1 and 2 and gasket 3 onto the auger channel Fig 2 17 Slide on sealing elements Screw flange plate onto the screw channel Fig 2 18 Mount flange plate Operation m...

Страница 18: ...ating a radial seal Fig 2 20 Tighten sealing elements Slide the ash extraction auger 1 into the auger channel Fig 2 21 Insert the auger Dismantle cover 1 Fix auger shaft 2 into the receptacle 4 with hexa gonal screw 3 and hex nut Fig 2 22 Connect the auger shaft 6 1 4 Connect flue gas recirculation line On the back connect the flue gas recirculation line from the burner 1 to the ID fan 2 Fig 2 23 ...

Страница 19: ... 2 25 Install the hot air fan 6 3 Mount feeder grate drive Mount drive unit 1 plate housing motor gearbox to the burner with 4 pcs hexagonal screws Mount connecting rod 2 with washer and circlip on the bolt 3 If necessary to turn the crank remove motor gearbox 4 Connect motor to X4 7 X4 9 the cable is pre rou ted in ducts 3 and 2 31 Fig 2 26 Mount feeder grate drive Connect the feed grate motor Co...

Страница 20: ...ng tube Connect to A1 X33 cable is pre routed in ducts 3 and 2 31 Fig 2 29 Install the feeder sensor Connect the feeder motor Connect the pre routed cable as shown in the ter minal area of the motor Fig 2 30 Connect the cable in the motor terminal area 6 5 Install safety valve Install the safety valve in the boiler supply line at the highest point of the line as close as possible to the boiler Obs...

Страница 21: ...y heat exchangers installed one in the burner one in the heat exchanger The two safety heat exchangers are connected in series Only the connection to the burner has to be made on site Connect the thermal drain safety device as shown i e inflow line 1 backflow line 2 Fig 2 31 Connect thermal overload protection Fit the thermal overload protection in the direction of flow as seen before the safety h...

Страница 22: ... pipe Hole for emission mea surement Make the hole for the emission measurement according to the following images recom mendation according to standard If these specifications cannot be implemented then make the measuring point after a calming section i e after the longest straight section of the pipe The tube orientation horizontal vertical oblique plays no role in this case In any case place the...

Страница 23: ...ion Hydraulic switch A hydraulic switch separates the flows in boiler and heating circuits If the heating system is operated without a buffer tank a hydraulic switch must be instal led between flow and return Buffer tank Use dimensioning The use of a buffer cylinder is to be recommended in any case as the boiler can then always operate in the optimum load range This prevents frequent and unne cess...

Страница 24: ... use of residual heat When the temperature in the buffer cylinder has fallen to lower than that in the burner the pumps start up again the return mixer opens and the residual heat from the boiler is transferred to the buffer i The use of a return booster module is a pre requisite for SOLARFOCUS warranty and gua rantee claims 7 2 Boiler connections Boiler flow boiler return Fig 2 36 1 Boiler flow G...

Страница 25: ...ample The fill and make up water should meet the following guideline values according to VDI 2035 Part 1 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 1 dH 50 200 kW 11 2 dH 8 4 dH 0 1 dH 20 600 kW 8 4 dH 0 1 dH 0 1 dH 600 kW 0 1 dH 0 1 dH 0 1 dH In the event of exceeding the above values the filling water is to be treated e g ion exchanger re...

Страница 26: ...tional components see intermediate pellet store 32 see delivery systems 38 8 1 Boiler control cabinet Fig 2 40 Position of the control cabinet Components circuit boards in the control cabi net Fig 2 41 Detailed illustrations of the power element A1 and the circuit boards A2 and A3 A4 35 Position high voltage module_A5 36 8 2 Connection assignment Designation Connection Ash extraction burner Motor ...

Страница 27: ... 10 X4 12 Hot air fan Fan 19 A1 X7 Hot air fan Heating element 19 A1 X4 Induced draft fan 37 X4 1 X4 3 Intermediate pellet store Container auger 33 A3 X2 Intermediate pellet store Container flap sen sor 33 A2 X12 Intermediate pellet store Filling level sensor 33 A1 X49 Intermediate pellet store Suction turbine 33 X4 13 X4 15 Lambda sensor 36 A1 X45 Overtemperature reset OTR 28 A1 X20 A1 X21 Power ...

Страница 28: ...or Ash extraction burner 8 4 1 Connect overtemperature reset Connect overtemperature reset OTR 1 to A1 X20 Protective conductor yellow green to A1 X21 Fig 2 43 1 Overtemperature reset OTR 2 Sensor for overtemperature reset 8 4 2 Connect the boiler temperature sensor Connect boiler temperature sensor 1 to A1 X31 Fig 2 44 8 4 3 Connect combustion chamber tem perature sensor Connect combustion chambe...

Страница 29: ...otary drive for secondary air 36 connect on site Rotary drive for flue gas recirculation 36 Rotary drive for flue gas booster Induced draft fan 37 Connect the two bus cables 1 to terminal X200 front of burner primary air Connect the two bus cables 2 to terminal X201 back of burner secondary air Fig 2 47 Connection of the bus cable Terminal X200 rotary drive for primary air Terminal X201 rotary dri...

Страница 30: ...ty chain of the boiler connection X6 1 X6 8 Connect other components integrated in the safety chain in series loop through Pellet delivery system A1 X14 Suction system delivery auger Use 5x1 5 mm cable 5 pin connector direct extraction motor Terminal X14 on the power element PE PE N N L L TK TK OEM system Use e g for pellet box transfer unit auger and for the pellet mole these systems have a motor...

Страница 31: ... top Fig 2 49 Heat exchanger longitudinal side Fig 2 50 Burner rear 8 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 2245 50 1209 119 4 1194 2417 60 1299 123 24 1...

Страница 32: ...unction Screen IP VNC Remote access to the control Sending e mails i Additional information on these functions can be found in the operation manual Display Connections Fig 2 51 Connections on the underside of the display Access to the read of the display Lift cover upwards Fig 2 52 9 Installing the intermediate pel let store Connect angle compensation Fig 2 53 Fix retaining plates to the floor Fix...

Страница 33: ...boiler may only be performed by certified personnel SOLARFOCUS service technician or SOLARFOCUS specialist service partner condition for guarantee warranty þ The boiler is hydraulically connected þ The heating system is filled with water and has been vented þ The boiler is electrically connected Connect the boiler to the mains power supply Carry out the commissioning routine in the boiler control ...

Страница 34: ...11 Annex 11 1 Boiler covers overview Fig 2 58 Fig 2 59 11 Annex 34 Operation manual maximus ...

Страница 35: ...s 35 11 2 Boiler power element circuit boards Boiler power element_A1 Fig 2 60 Circuit board_A2 Circuit board_A3 or optional circuit board_A4 Fig 2 61 Fig 2 62 Circuit board_A3 Direct Extraction 1 Circuit board_A4 Direct Extraction 4 ...

Страница 36: ...ts in the event that they need to be replaced Burner Front Fig 2 63 1 Rotary drive for primary air Burner Back Fig 2 64 1 Rotary drive for secondary air 2 Hot air fan Heat exchanger Top side Fig 2 65 1 Lambda sensor 2 Motor for heat exchanger cleaning 3 Rotary drive for flue gas recirculation Heat exchanger Side Fig 2 66 1 Rotary drive for flue gas booster 2 High voltage module_A5 for the electros...

Страница 37: ...not kink the hose observe bending radius of 30 cm The hose is not UV resistant routing outdoors is not permissible Temperature 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 fa...

Страница 38: ...or 1 connection A3 X2 2 Pellet delivery auger direct extraction motor 2 connection A1 X14 Mole suction system Fig 2 70 1 Container auger motor 33 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 Fig 2 71 1 Direct extr...

Страница 39: ...traction 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 Fig 2 73 1 Direct extraction auger motor direct extrac tion motor 1 connection A3 X2 Operation manual maximus 39 ...

Страница 40: ...Austria Biomass heating Solar systems Heat pumps Fresh water equipment Innovative products to spare the environment and your wallet Tested state of the art technology EN ISO 9001 certified Austria makes you independent ...

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