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Moderator Smok DTR-AZSB-30 Operating Instructions Manual

Automatic biomass burning set 240kw
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Operating Instructions

Smok 30÷ ÷ ÷ ÷ 240kW
Automatic Biomass Burning Set

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Summary of Contents for Moderator Smok DTR-AZSB-30

  • Page 1: Operating Instructions

    Operating Instructions Smok 30÷ ÷ ÷ ÷ 240kW Automatic Biomass Burning Set...

  • Page 2: Table Of Contents

    4.3. Troubleshooting ....................40 4.3.1. Procedure in Case of Worm Shaft Jamming ............42 5. Spare Parts........................43 5.1. Main Spare Parts List .................... 43 5.2. List of Wearable Parts* ..................43 6. Disposal ........................... 43 “MODERATOR” Company Service Representatives............ 45...

  • Page 3: Dear User

    Thank you for your purchase of our equipment. We would like to congratulate you on your good choice. Moderator Spółka z o.o. has been manufacturing boilers utilizing proprietary technological solutions developed in late 70’s in Hajnówka by engineer Kazimierz Kubacki. During last twenty years these boilers have undergone multiple technological changes and upgrades.
  • Page 4 equipment structure and against failing to follow safety instruction described in these instructions. A failure to follow these recommendations may lead to serious threats and expose the operating personnel to health or life hazard. In case of doubt, please contact our sales department or authorized servicing agent.
  • Page 5 Safety and Warning Signs Please pay attention to warning and safety signs, minding their meaning and placement on the equipment. this is to avoid accidents. Pay special attention in the boiler room keeping in mind that different parts of the boiler and systems may be hot. Keep a safe distance.
  • Page 6 The container may contain carbon oxygen and dust. Vent the container before commencing with loading or prior to its opening. This sign placed on pages of these instructions indicates a warning. Please read corresponding section with utmost care so as to avoid many dangerous situations in future.

  • Page 7: Warranty

    I hereby acknowledge the recommendation of the Moderator boiler manufacturer to subject the device to regular technical inspections. In case of unjustified Moderator service team call to perform a warranty repair, I will cover full costs related thereto (man-hours and costs of transport in both directions).

  • Page 8: Fuel

    Declaration of Conformity Moderator Spółka z o.o. 11 Listopada 16a 17-200 Hajnówka tel. (085) 682-75-20 hereby declare, on our own and sole responsibility that the product: Smok Automatic Biomass Burning Set, with serial number starting from 250, to which this declaration...

  • Page 9: Technical Description

    1.4. Technical Description The AZSB consists of a Moderator-type boiler and Smok fuel feeder, manufactured by Moderator Sp. z o.o. in Hajnówka. The present instruction is applicable to all versions of the device, and that is to: : • heat exchangers – 30, 60, 120, 240 kW •...
  • Page 10 4. Upper washout holes cover 10. Ash pan washout 5. Smoke conduit 11. Return pipe 6. Thermometer 12. Safety valve 7. Supply pipe 13. G 1/2 muff for thermostat Fig. 1. Moderator-type boiler (version designed for use in ABB set) – main parts.
  • Page 11 After the burner is disconnected, the boiler may be used for burning solid fuels in traditional system, with manual charging of the combustion chamber. Such burning shall be however treated as a substitute method to be used in special situations (e.g. power supply failures, damages to the feeder, etc.) and one shall aim at restoring the automated operation mode as soon as possible.
  • Page 12 Ceramic head (Fig. 3) is located near the boiler and thus only the flame enters the combustion chamber. The operating principle of this head is the same as of the cast-iron head, with the difference that ashes are removed to a special washout located under the head and may be removed by emptying a special cassette located there.

  • Page 13: Equipment

    Forced ventilation must not be used. 2.2.1. Boiler Installation Boiler installation shall be performed by installer with appropriate qualifications and experience (we advice to seek help from representative centres, whose installers have undergone training in Moderator Sp. z o.o.). A...

  • Page 14: Feeder Positioning

    Moderator boilers are delivered assembled. During boiler installation, it is necessary to ensure its accessibility in such a way, so that boiler room walls do not render fuel charging, grate cleaning and access to the side washout and fan difficult.

  • Page 15: Connecting To The Chimney

    2.3. Connecting to the Chimney Boiler’s smoke conduit shall be seated directly in the chimney, and after installation sealed along the contact line of: smoke conduit sheet metal – chimney brick. Chimney outlet shall be located 1 meter above the roof ridge. Square or rectangular chimneys shall be made of burnt brick;...

  • Page 16: Protection Of The Installation

    2.5. Protection of the installation 2.5.1. An open system Moderator boilers operating in open central heating systems must be connected according to requirements of the PN-91/B-02413 standard, so that excess heat in the form of steam shall be removed through an open connection (RP overflow pipe) to atmosphere.

  • Page 17: Closed Systems

    2.5.2. Closed Systems Moderator boilers operating in closed systems must be equipped with air supply system (designed by Moderator Sp. z o.o. for Moderator boilers - we advise against installation of other air supply systems) safety valve and additionally thermal protection permitting safe discharge of excessive thermal power.
  • Page 18 This means that the system may not operate if water from in-house water intake is used (e.g. if power supply outage prevents hydrophore switching on), or in places where water supply outages are frequent. In such situations, the boiler shall not be installed in a closed system or only its automatic version should be used (which can not burn solid fuels with manual charging).

  • Page 19: Thermal Protection

    2.5.3. Thermal protection dimensions in mm if not otherwise stated Applications: 5067 thermal protection is designed to protect solid fuel boilers in heating installations fitted with thermostatic valves conforming to the PN- EN303-5 Polish Standard. It is particularly recommended for boilers, which are not equipped with cooling exchanger. Figure 1 presents installation principle, at a close distance from the boiler, with special consideration for such guiding and sizing of pipes so that no pressure losses occur.

  • Page 20: Installation Of The Control System And Electric Connections

    2.6. Installation of the control system and electric connections Safety Guidelines 1. Before connecting the device, it is necessary to read boiler and controller operating instructions. 2. Before commencing with installation, repairs or maintenance or when performing any connecting works, it is absolutely necessary to disconnect the power supply and to make sure that there is no live supply on any of terminals or cabling.

  • Page 21: Description Of Control Box

    2.6.1. Description of control box Figure 6 presents the AZSB or APSB control box cabinet. 1. Controler front panel 6. MENU button 2. ecoMAX800 controller panel 7. Select / change / accept button 3. Display 8. EXIT button 4. Emergency stop pushbutton 9.
  • Page 22 5) Place the control box against the wall in the place intended for its installation and mark 4 holes (e.g. using the drill bit) 6) Using Ø8 drill bit, drill at least 80mm-deep holes in the wall . 7) Attach the box to the wall using expansion plugs. 8) Having performed all of the activities listed above, proceed with electric connections of the device.

  • Page 23: Electric Connections

    2.6.3. Electric connections Before commencing with electric connection, it is necessary to install the wiring (not included) in the boiler room, according to applicable regulations. Cables shall be guided inside casing pipes or dedicated cable trays. This work shall be performed by a licensed electric engineer. It is recommended to use cables with cross sections stated in Table 1 for wiring of respective circuits.
  • Page 24 When connecting cables to the controller, remember to use cable ferrules, which will prevent cable frying. On end sections of cables with removed insulation, on the feeder motor side eyelet terminals shall be crimped. Tin-plating of cable ends connected to terminal strips is not permitted.
  • Page 25 Setting the motor thermal protection switch The purpose of the motor thermal protection switch (fig. 12) is to protect the feeder motor against fuel feeding system overloading consequences. The motor thermal protection switch shall be pre-set with the A knob (the arrow on fig. 12) to appropriate current, according to the table 2.
  • Page 26 SAFETY TEMPERATURE BREAKER – STB Fig.14. a) STB temperature limiter, b) STB with cover removed The role of the safety temperature limiter STB (fig. 14a) is to disconnect blower and feeder power supply when the temperature exceeds 95°C on the central heating system supply pipe.
  • Page 27 STB CAPILLARY BOILER TEMP. SENSOR THERMAL INSULATION 10÷15 cm Fixing clip Fig.15. a) STB installation, b) identification of controller terminals Regulations in force require safety time limiter installation. CENTRAL HEATING PUMP The circulating pump shall be connected to terminal strip (8) (fig. 7) terminals identified with the symbol shown on figure 16.
  • Page 28 ASH REMOVAL The cable used to connect the ash removal system motor shall have the cross-section specified in table 1. Ash-removal motor winding shall be connected according to the diagram located inside the connection box. Fig.18. Identification of connecting terminals. Power supply of the ash removal motor shall be connected to terminals shown on figure 18.
  • Page 29 Fig.20. Identification of connecting terminals czujnika temp. kotła. The sensor shall be installed dry. Do not prime with oil or other liquids!!! FUEL FEEDER TEMPERATURE SENSOR The measuring sensor (C) (fig. 22) shall be installed in the (T) sleeve and fixed by tightening the (S) screw.
  • Page 30 HOT WATER TEMPERATURE SENSOR The sensor shall be installed in the hot water contained in a dedicated place. Connect the sensor to terminals 20 and 21 of the controller identified with the symbol as shown on fig. 23. In order to extend the sensor cable, one may use a cable with cross-section stated in table 1, which does not exceed 10 m in length, as this may adversely affect temperature readouts accuracy.
  • Page 31 FUEL LEVEL SENSOR (applicable to versions with a ceramic head) Te limit switch of the head fuel level sensor is accessible after the yellow cover (O) is removed (fig. 27). Cables shall be connected to COM, NO terminals of the (W) limit switch. Normally-open (NO) terminal. When the „tongue”...

  • Page 32: Device Operation

    Table 3. Maximum output loadings. Circuit Identification Maximum current [A] Remarks 1.7 (0.55kW) depending on the Feeder 2.2 (0.75 kW) rated power of the (Feeder motor) 3.1 (1.1 kW) motor used 3.8 (1.5 kW) Blower Central Heating Pump Hot Water Pump Ash Removal (optional) Mixing Valve Actuator KEEP IN MIND THAT THE TOTAL CURRENT OF ALL DEVICES CONNECTED TO THE...

  • Page 33: Working Settings

    3.2. Working Settings Duration of the „feeding time - operation” and „feeding stop - operation” periods must be set according to the actual type of fuel used. The following table presents approximate pres-et times for various devices, depending on the type of fuel used.

  • Page 34: Burning

    Blower air volume control The correct volume of air needed for combustion can be determined by watching the colour of the flame: optimum colour is yellow. A smoking, dying down flame requires more air. Sharp, short flame, some times lightly bluish or transparent indicates too much air.

  • Page 35: Continuous Operation Mode

    may simply put down the flame. It is necessary to pay attention to correctness of the <CONTROL> mode settings as too much fuel may cause the limit switch to trip (protecting against head combustion chamber overloading) and stop the device, which will require it to be re-ignited. Do not use oil, gas, solvents nor any other flammable material constituting an explosion threat for igniting the boiler.

  • Page 36: Emergency Operation Of The Boiler

    The dosing diaphragm is activated in emergency situations only (e.g. when the flame is suppressed with insufficiently preheated chamber, charged with wet fuel) and it requires operating personnel intervention and boiler re-ignition. The fire protection system is consist of a container and a line connecting it with the stub pipe (10) located on the worm shaft guide casing.

  • Page 37: Cleaning, Ashes

    • when using fuel with different granulation, it shall be charged alternatively (large granulation fuel already glowing in the combustion chamber shall be supplemented with finer grained fuel, e.g. from sawmills – as in other way they will spill through the grate) •...
  • Page 38 In case of heavy contamination of the boiler, chemical agents removing boiler deposits may be used, but only such, which are allowed on the marked (i.e. with CE mark and instructions of use). Fig. 23 Boiler cleaning diagram (the figure presents 30 kW exchanger cleaning (120 and 240kW models have different cross-section, yet the cleaning approach remains the same).

  • Page 39: Program-Initiated Shutdown Of Azsb

    Ashes Ashes shall be removed with the device switched off. In case of cast-iron heads it is sufficient to remove ashes once every 2 weeks. In case of ceramic heads, the washout under the head needs to be emptied once every 2 days. Ash handling procedure is described in p.1 “Safety Instructions”...

  • Page 40: Troubleshooting, Safe Operation Conditions

    The glowing fuel must not be extinguished or cooled down with water. Feeder Set the fuel supply switch in “0” (zero) position. Set the blower switch in the blower (<dmuchawa>) position, switch off feeding – press the red button on the emergency switch.

  • Page 41: Anti-Freeze Protection

    4.2. Anti-freeze protection To prevent damages caused by frost, the main pipe and the bottom of the container may be thermally insulated and additional defrosting device may also be installed. Thermal insulation of the main pipe and the tank bottom is sufficient when the fuel is dry enough and stored indoors.
  • Page 42 container - insufficient chimney draught - use an exhaust fan, improve the draught - using sawdust with dusts - change the fuel content of more than 5%, Fuel clogging in the - too high moisture content in - add a portion of dry fuel and container fuel (above 40%), the fuel mix it thoroughly...

  • Page 43: Procedure In Case Of Worm Shaft Jamming

    build-up fuel according to the instructions, - remove deposit Boiler can not reach - contaminated fan - clean fan blades the preset - too much ash in the (cast- -remove ashes from the head temperature iron) head, blocked ventilation through the washout opening openings in the head - too high moisture content of - charge correct fuel...

  • Page 44: Spare Parts

    9. AZSB grate bottom (1 pc.) *NOTE: The aforementioned parts are not subject to warranty replacement. If their replacement is needed, they are available for purchase from Moderator Sp. z o.o. service department. 6. Disposal Assuming correct operation, the boiler shall operate without problems for about 15 years.
  • Page 45 recommended to provide it for disposal to a specialized machine disassembly and disposal company. In case of the feeder, the fault-free operation time of the head (provided it is maintained, operated and serviced properly) shall reach several years (7 to 9). After that time, it may be necessary to replace cast-iron grate inserts.

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