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Bonus Plus Instructions Tarm Biomass 1-800-782-9927 Version 11/14 Page 14

3.0 Boiler Installation & Start-up

This section is directed at the installer.

3.1 Planning

3.1.1 Sizing the Boiler

It is critical to size the boiler properly. A proper, up to date heat load calculation is advised. An accu-
rate history of building fuel usage over several years can help to calculate the proper size boiler.

Boiler sizing is the responsibility of the installer.

Tarm Biomass bears no responsibility for boiler

sizing, but can provide sizing input.

3.1.2 Choosing an Installer

Choosing a competent, licensed installer is critical to the successful installation of the boiler.

The

installer is responsible for all planning, installation, start-up, troubleshooting, owner training, and an-
nual maintenance for the boiler. Some aspects of the system piping, start-up, and operation may differ
from normal practice in fossil fuel boiler installation. To be successful, the installer must study this
manual, understand the installation tasks, and contact Tarm Biomass for help when necessary.

3.1.3 Locating the Boiler and Boiler Clearances

The boiler must be installed with the

minimum installation clearances

to combustible materials out-

lined on the next page. Clearances may only be reduced by means approved by the regulatory authori-
ties.



The boiler is not suitable for outdoor installation. It must be located in a conditioned space.



The boiler must be placed on a level, non-combustible floor, such as a concrete slab on earth.
If you have the boiler 8” above the floor it makes it easier to load and clean the boiler.



If the boiler is placed near inhabited rooms, so that flue gas can easily penetrate into these
rooms, a carbon monoxide alarm must be installed that can give a warning regarding possible
escapes of carbon monoxide into the inhabited rooms.

Boiler Installation & Start-up > Planning

CAUTION

Safety faults or deficiencies with the boiler or installation must be rectified as quickly
as possible. Either by the owner/system operator or the installer.

☼

All cover plates, enclosure, and guards must be maintained in place at all times, except
during maintenance and servicing.

☼

CAUTION

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Содержание Bonus Plus 30

Страница 1: ...iomass 1 800 782 9927 Version 11 14 Bonus Plus Model 30 Installation and Operations Manual Wood fired central heating boiler Report 236 S 09 2 UL 2523 2009 R2013 Solid Fuel Fired Hydronic Heating Appliances Water Heaters and Boilers ...

Страница 2: ......

Страница 3: ...onsibilities 12 3 0 Boiler Installation and Start up 13 3 1 Planning 13 3 1 1 Sizing the Boiler 13 3 1 2 Choosing an Installer 13 3 1 3 Locating the Boiler and Clearances 13 3 1 4 Plumbing and Mechanical 15 3 1 5 Electrical 16 3 2 Preparing the Chimney 16 3 2 1 Outside Combustion Air 18 3 3 Setting the Boiler 18 3 3 1 Receiving the Boiler 18 3 3 2 Temporary Storage 19 3 3 3 Moving the Boiler 19 3 ...

Страница 4: ...g the Primary Air Channels 36 4 10 5 Smoke Pipe Inspection and Cleaning 38 4 10 6 Chimney Fires 38 4 10 7 Checking the Barometric Damper 39 4 10 8 Cleaning the Jacket 39 4 10 9 Check for Creosote Build up 39 4 10 10 Seasonal Shutdown Procedure 39 4 10 11 Checking the Pressure Relief Valve 39 4 10 12 Checking System Pressure 39 4 10 13 Heat Storage System Maintenance 39 4 11 Power Outages 39 5 0 Tr...

Страница 5: ...ic all plumbing fittings are British Straight Thread In this manual the convention used for dimensions is that values are presented in English units fol lowed by metric units in parenthesis for example 6 152 mm Note A conversion table between Centigrade and Fahrenheit is provided in Appendix A In this manual temperatures are presented first as degrees Centigrade then as degrees Fahrenheit in paren...

Страница 6: ...ng to the recommendations of the manufacturer Failure to follow these instructions could result in property damage bodily injury or death All boilers must be installed in accordance with national state and local plumbing heating and electrical codes and the regulations of the serving electric water and gas utilities Contact local building or fire offi cials before installation about restrictions a...

Страница 7: ...equirements for Safe Operation Boiler Overview 8 1 2 4 5 6 7 1 Control Panel 2 Loading Door 3 Fire Chamber 4 Primary Air Adjustment 5 Secondary Air Adjustment 6 Ash Door 7 Sight Glass 8 Gasification Tunnel 9 Secondary Air Injection 10 Heat Exchanger Tubes and Flue Gas Turbulators 11 Cleanout 12 Primary Air Injection 13 Flue Collar 14 Induced Draft Fan 15 Cleanout Cover 3 9 10 12 11 14 15 13 Fig 2 ...

Страница 8: ...primary air control 4 and the secondary air control 5 Secondary combustion takes place behind the ash door 6 and ashes are also removed through this door Combustion can be monitored through the sight glass 7 Chimney connector is attached to the flue collar 13 The clean out cover 15 is detachable and allows access for cleaning the heat exchanger pipes 2 1 2 Boiler Control Panel Product Description ...

Страница 9: ...ir valves Primary air then is drawn into the firebox where it is dispersed behind the firebox aprons into the primary combustion chamber just above the top of the ceramic refractory combustion stones Secondary air is drawn downward and then back into the center combustion stone where it enters the combustion throat Here secondary air is turbulently mixed at high velocity with hot combustion gasses...

Страница 10: ...or at least 10 of the boiler s maximum rated output assuming an ambient temperature of 65 ºF in the area heated by the loop and a mean water temperature of 180 ºF 82 ºC See Section 3 4 2 2 2 4 Accessories The boiler is shipped with loose and installing parts See Section 3 3 2 for a complete listing of these parts Cleaning tools are provided with the boiler A barometric damper draft stabilizer is a...

Страница 11: ... system capable of absorbing the complete output of the boiler during periods when the building is not calling for heat 2 1 6 Models and Applications The Bonus Plus model 30 is available with an output of 102 000Btu hr 30 kW Specification data for the Bonus Plus is provided in Section 6 3 The boiler can be utilized as a single heat source or in parallel with another boiler Residential and non resi...

Страница 12: ...od of generating creosote in the boiler burning wet wood uses a substantial amount of the wood energy to evaporate the water present in the wood reducing the available energy for heat Fig 2 2 The wood will dry out most quickly if it is cut into the appropriate length and split into pieces 4 6 100 120mm thick The best length is 20 0 5 m for the Bonus Plus 30 The wood is best stored in the open air ...

Страница 13: ...ot water systems with permissi ble outflow temperatures of up to 203 ºF 95 ºC 2 5 Owner Responsibilities Successful operation of this boiler will require daily involvement by the owner system operator Biomass boilers operate differently from fossil fuel boilers requiring more oversight and a diligent cleaning regimen The owner system operator is responsible for correct operation of the boiler per ...

Страница 14: ...derstand the installation tasks and contact Tarm Biomass for help when necessary 3 1 3 Locating the Boiler and Boiler Clearances The boiler must be installed with the minimum installation clearances to combustible materials out lined on the next page Clearances may only be reduced by means approved by the regulatory authori ties The boiler is not suitable for outdoor installation It must be locate...

Страница 15: ...for Blower Maintenance Inches 21 B Minimum Clearance to Combustibles Inches 12 C Minimum Distance for Cleaning and Maintenance Tasks Inches 21 D Minimum Clearance to Combustibles Inches 36 E Minimum Clearance to Combustibles Inches 24 F Minimum Distance for Combustibles to Pipe Inches 18 G Maximum Distance for Flue Pipe Feet 0 4 H Ideal Location for Draft Regulator Barometric Damper Boiler Install...

Страница 16: ...ditional cost A circulator Size and brand to be determined by the installer not provided should be installed as C3 per drawings suggested by Tarm Biomass An aquastat Honeywell L4008B provided must be installed to protect the boiler from over temperature conditions by energizing a chosen heating zone An aquastat Honeywell L6006A provided must be installed to protect the boiler from over temperature...

Страница 17: ...eet 0 9 m above the roof and 2 feet 0 6 m above any structure within 10 feet 3 0 m measured horizontally For the Bonus Plus 30 best draft will be provided by a chimney which has an 6 152mm ID round flue is 20 30 feet 6 0 9 0m in height and which is located inside the heated structure The chimney must be capable of maintaining a breech draft of 0 05 1 25mm WC during normal boiler opera tion Your Bo...

Страница 18: ...arly strong natural draft can cause the Bonus Plus boiler to continue burning heating when the draft fan is off This is an unlikely scenario as the blower on a Bonus Plus used with a thermal storage system should rarely be off while a fire is present If however an irregular or excessively high draft presents problems the solution is the use of a barometric draft regulator or the use of a proper ch...

Страница 19: ...xcessive condensation on windows in the winter 6 A non balancing ventilation system is installed in the house 7 Where fans are used in the fuel storage area they should be installed so as not to create nega tive pressures in the room where the boiler is located If these or other indications suggest that infiltration air is inadequate additional combustion air should be provided from the outdoors B...

Страница 20: ...wedges located within the boiler They will burn away within a few hours of initial firing 3 4 Connections to the Boiler The following connections must be made to the boiler in order for it to function The boiler flue gas exhaust collar must be connected to the chimney system The heating system piping must be connected to the boiler supply and return connections Electrical power must be provided at...

Страница 21: ...1 is recommended and if possible the loop should be located and pitched to maximize natural thermal convection of the water The loop must be positioned above the boiler The design of the loop must be such that it can be made inoperative only in a deliber ate manual action If large enough an existing heating radiation zone may be used for the over heat loop The loop must be equipped with zone valve...

Страница 22: ...ells which are not used in the chosen form of installation 3 4 6 Expansion Tank The size of the expansion tank is determined by the total water content of the heating system 3 4 7 Pump Size The size of the circulation pump is determined by the size of the system and the pipe dimensions 3 4 8 Installing the Circulator Aquastat The Honeywell L6006A aquastat provided is installed to activate the boil...

Страница 23: ...ill be activated pulling heat away from the boiler Boiler Installation Start up Connections to the Boiler Remove left knock out on side panel The side panel can now be re installed The Honeywell L6006A aquastat can now be attached to sensor well Note Image does not show side panel installed Find the spare sensor well 8 located on the top of the boiler located on the right side of boiler Remove the...

Страница 24: ...y 20 and split to the proper size 6 What is the condition of the firebox ceramics In most instances low stack temperatures are an indication that the wood is not dry If boiler operations have been producing consistent temperatures and the flue temperature has been creeping upward this is an indication that it is time to clean the heat exchange tubes by brushing 3 4 11 Electrical Connections The co...

Страница 25: ...e which is screwed onto the boiler drain and connected to a water supply faucet Fill the hose prior to filling the boiler otherwise air in the hose will be pushed into the boiler system Remove the hose after filling up High quality air elimination equipment is recommended in the heating system installation NOTE The heating system main supply and return piping will need to be at least 1 25 32 mm fo...

Страница 26: ...C Boiler temperature gauge D Overheat Thermostat 100 C 212 F manual reset after boiler drops below 75 C 165 F E Boiler circulator pump switch not used in North America F Fan switch H Operating Thermostat 0 90 C 0 195 F The recommended set point tem perature is 82 85 C 180 185 F I Lo Limit Thermostat The Lo Limit Thermostat switches off the fan when the wood has burned out It is set to 90 C Minor a...

Страница 27: ...emperature setting H should only be adjusted by a qualified user only The standard operating temperature of the boiler should be at least 80 C The recom mended default setting is 85 C and can be monitored by the boiler thermometer C The boiler must be used with a thermostatic boiler protection device such at the Lk Armatur LK810 Loading Unit with the ability to supply a minimum return water temper...

Страница 28: ...rmostat D This thermostat cuts the electricity supply to the combustion fan if the boiler temperature exceeds 100 C 212 F If this happens it is advised that you 1 Wait for the boiler to cool down to 75 C 167 F or lower 2 Unscrew the cap D push the little button under the cap which resets the safety thermo stat screw the cap back on 3 Restart the boiler and use normally If this happens again please...

Страница 29: ...floor of the firebox Crumple several sheets of newspaper and lay it on top of the kindling Light the newspaper 2 Immediately turn on the fan by pressing the reset switch G Leave the loading door open slightly Air will be pulled through the boiler and the wood will ignite quickly Remain at the boiler during this lighting stage 3 The fire is well established once a small bed of embers has formed Wit...

Страница 30: ...e by placing fresh wood in on top of red coals Kindling may not be necessary It is good prac tice to clean out the U shaped tunnel stone accessed through the ash door before each firing If black cinders are present leave them between the U stone and door they will be burned 4 6 Shutting Down the Boiler Switch off the boiler by turning off the fan switch on the control panel The circulating pump wi...

Страница 31: ...reosote makes an extremely hot fire The chimney and chimney connector should be inspected at least twice monthly during the heating season to determine if a creosote build up has occurred If creosote has accumulated it should be removed to reduce the risk of a chimney fire 4 9 Adjusting Combustion The Bonus Plus features adjustable and secondary air controls for optimal burning The controls are lo...

Страница 32: ...le floor or on the ground well away from all combustible materials pending final disposal If the ashes are disposed of by burial in soil or otherwise locally dispersed they should be retained in the closed container until all cinders have thoroughly cooled Other waste should not be placed in this container 4 10 Cleaning and Maintenance 4 10 1 Removing Ash Regular maintenance cleaning of the boiler...

Страница 33: ...l from behind the tunnel stone Removing ash from behind the tunnel must be done regularly Ash depth should not be allowed to exceed 2 Ash removal from the upper firebox and checking of the primary air outlets Ash removal from the upper firebox should be done when the ash bed reaches 2 Ashes may also be removed sooner Be sure not to let ashes accumulate in the corners of the firebox The quantity of...

Страница 34: ...t exchange tubes NOTE Clean heat exchanger tubes and smoke box mean better heat transfer from the flue gas to the water and thus better operating economy NOTE Cleaning the heat exchange tubes The vertical tubes at the back of the boiler are the primary means of capturing heat from the burning process Being the last passage in the boiler that the hot exhaust gasses pass through they will accumulate...

Страница 35: ...an the fan blades fan housing and the flue gas sensor well pipe See pictures on following page For inspection and cleaning remove the induced draft fan on the back of the boiler Check for build up and damage 2 3 times per year Clean the draft fan wheel inside and out using a stiff brush Re move ash deposits from the induced draft fan housing using a putty knife and vacuum loosened mate rial from t...

Страница 36: ... 800 782 9927 Version 11 14 Page 36 Loosen Nuts 8mm x 4 Clean the fan blades fan housing Clean the flue gas sensor well pipe located in the fan housing 3 4 Fig 4 14 Fig 4 15 Boiler Operation Maintenance and Service Cleaning and Maintenance ...

Страница 37: ...with a screwdriver or a chisel 3 Clean the sealing groove 4 Press new sealing into the groove When half the sealing has been inserted adjust the end and press in the rest 5 Secure the sealing by gently tapping with a hammer 6 Replace the door 7 Close the door and check its seal 4 10 4 Cleaning the Primary and Secondary Air Channels The primary air channels on both sides of the boiler can occasiona...

Страница 38: ...the boiler is used how much wood is burned the type and quality of the wood burned and how well the boiler is maintained Wear is perfectly normal and these pieces items must be replaced only when they are not fulfilling their functions Minor cracks and crumbling will not normally require replacing the refractory insert or tunnel stone as long as they are still functioning properly This kind of wea...

Страница 39: ...e Pipe Inspection and Cleaning The chimney and the chimney connector must be inspected and cleaned annually Annually disassem ble the stove pipe and clean ash accumulation and inspect for corrosion If any pipe is substantially corroded this section must be replaced Cleaning the connecting pipe between the boiler and the chimney is very important for horizontal smoke pipes 4 10 6 Chimney Fires Chim...

Страница 40: ...y released The pressure relief valve should be seated properly and not drip system water The pressure relief valve should be inspected and maintained according to the manufactures recommendations 4 10 12 Checking System Pressure The system expansion tank in a closed system allows for the thermal expansion of the fluid in the heating system See the expansion tank s operating instructions for mainte...

Страница 41: ... 90 C 194 ºF to switch over the min thermostat If normal operating temperature is not reached the fan will not switch off but continue to run even though the wood has burned out and the min thermostat temperature has fallen below 90 C 194 ºF Ensure that the boiler is brought to normal operating temperature about 85 90 C 185 194 ºF each time it is used Boiler temperature doesn t increase or increas...

Страница 42: ...he boiler shuts down If the fuel is too wet combus tion temperatures will be very low and boiler output reduced Too much ash in upper firebox Combustion can be stifled by an accumu lation of too much ash in the upper fire box Too much ash can restrict combus tion air flow which will result in reduced heat output to the point where stack tem perature drops too low and the boiler shuts down Nothing ...

Страница 43: ...nection inches 1 4 Side Connection Both Sides inches 5 Side Connection Both Sides inches 1 6 Pressure Gauge Sensor Well inches 7 Boiler Temperature Sensor Well inches 8 Overheat Aquastat Sensor Well inches 9 Flue Gas Temperature Sensor Well inches 10 Drain Fill Connection inches 11 Flue Pipe External Diameter inches 5 B1 Measurement inches 21 B2 Measurement inches 45 B3 Measurement inches 43 B4 Me...

Страница 44: ...learance for Blower Maintenance inches 21 B Minimum Clearance to Combustibles inches 12 C Minimum Distance for Cleaning and Maintenance Tasks inches 21 D Minimum Clearance to Combustibles inches 36 E Minimum Clearance to Combustibles inches 24 F Minimum Distance for Combustibles to Pipe inches 18 G Maximum Distance for Flue Pipe feet 0 4 H Ideal Location for Draft Regulator Barometric Damper Fig 6...

Страница 45: ...amber Volume gals cubic ft 23 7 3 2 Recommended Wood Length inches 18 20 Wood Diameter Max Softwood inches 4 Wood Diameter Max Hardwood inches 6 OPERATING DATA Operating Temperature Water Fº 180 190 Nominal Output Btu Hr 102 000 Flue Gas Temperature at Nominal Output Fº 363 Required Draft inch WC 025 to 05 Safety Listings UL 2523 2009 ELECTRICAL DATA Boiler Power Requirement 120V 60Hz 15A Electric...

Страница 46: ...Bonus Plus Instructions Tarm Biomass 1 800 782 9927 Version 11 14 Page 46 6 4 Electrical Diagrams 6 4 1 Wiring Diagram A Boiler Circuit Ladder Diagram Data and Drawings Electrical Diagrams ...

Страница 47: ...ge 47 6 4 2 Circulator and Overheat Aquastat Wiring Connections Data and Drawings Electrical Diagrams L6006A Aquastat Junction Box Incoming Power Circulator Power Suggested Wiring Layout Mount Over Round Knockouts Overheat Aquastat Connections C 3 Circulator Connections ...

Страница 48: ...ed unit on the date of purchase to the original purchaser toward of the cost of repair of the warranted item or if Tarm Biomass and the original purchaser agree use the resultant sum as a partial allowance toward Tarm Biomass s replacement of the warranted item The original purchaser shall be responsible for all shipping and installation charges in connection with any replacement or repair Warrant...

Страница 49: ...his limited warranty the prevailing party shall be entitled to recover all reasonable expenses it incurs in the action including its reasonable attorneys fees from the nonprevailing party TARM USA S LIMITED WARRANTY EXPRESSLY EXCLUDES COVERAGE FOR THE FOLLOWING 1 Ordinary wear and tear and repairs or replacements necessitated by normal use 2 Repairs or replacements arising from corrosion including...

Страница 50: ... _________________ Boiler System Installed and Adjusted ________________________________ Date Warranty Certificate Filled and Sent _________________________________ Date Measured and Adjusted Values Date Date Date Date Fuel Type Fuel Moisture Content Secondary Air Setting Primary Air Setting Pump Speed C 3 Other Data Adjustments Setting Done By Signature Installation Report for Boiler System Insta...

Страница 51: ... 293 230 446 52 125 6 86 186 8 150 302 235 455 54 129 2 88 190 4 155 311 240 464 56 132 8 90 194 160 320 245 473 58 136 4 92 197 6 165 329 250 482 60 140 94 201 2 170 338 255 491 62 143 6 96 204 8 175 347 260 500 64 147 2 98 208 4 180 356 265 509 66 150 8 100 212 185 365 270 518 68 154 4 105 221 190 274 275 527 70 158 110 230 195 383 280 537 72 161 6 115 239 200 392 285 545 74 165 2 120 248 205 40...

Страница 52: ... Contact Information Manufacturer Importer Local Dealer Appendix B Contact Information HS Tarm A S Smedevej 2 Tarm Denmark PHONE 45 9737 1511 E MAIL info hstarm dk www hstarm dk Tarm Biomass 4 Britton Lane Lyme NH 03768 PHONE 800 782 9927 E MAIL info woodboilers com www woodboilers com ...

Страница 53: ...age 53 Appendix C Quick Start Guide Appendix C Quick Start Guide How much fuel See next page Adjust air supply See next page Cover the bottom with kindling Add crumpled newspaper Add some more kindling Leave upper door cracked Wait for kindling to catch fire completely ...

Страница 54: ...burned Otherwise the boiler will get full of soot All of the energy created by the boiler should be able to go to the storage tank and or heating system Use the curves to the right as a guide for the correct amount of logs Read the three temperatures on the tank add them together and find the recommended amount of fuel to fill the boiler The heating system is not included in these equations Hard w...

Страница 55: ...Bonus Plus Instructions Tarm Biomass 1 800 782 9927 Version 11 14 Page 55 ...

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