SAS Agro Eco Operation And Maintenance Documentation
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SAS Agro Eco Operation And Maintenance Documentation

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SAS
AGRO
ECO
BOILER
Operation and Maintenance
DOCUMENTATION
for SAS AGRO-ECO boiler for a water-based
central heating system, biomass-fired
(pellets, oats, dry fruit stones, etc.)

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  • Page 1 AGRO BOILER Operation and Maintenance DOCUMENTATION for SAS AGRO-ECO boiler for a water-based central heating system, biomass-fired (pellets, oats, dry fruit stones, etc.)

  • Page 2: Table Of Contents

    Equipment for a SAS AGRO-ECO boiler Table 2 Spare parts catalogue – ceramic panels Table 3 Technical and operational parameters for a SAS AGRO-ECO 17-48 kW boiler Table 4 Technical and operational parameters for a SAS AGRO-ECO 58-150 kW boiler Table 5...

  • Page 4: Declaration Of Conformity

    The declaration for the above-mentioned product shall become invalid when any design changes are introduced to it without manufacturer's consent. Should the title to the device be transferred on another person, this declaration should accompany the boiler. Manufacturer company seal Owner: Mieczysław SAS...

  • Page 6: Preface

    These boilers may also work with domestic hot water systems through a heat exchanger of any producer that meets current standards. The boiler cannot be used as a continuous flow water heater. The SAS AGRO-ECO boiler is also not intended to be used as an air heater.

  • Page 7: Boiler Design And Operation

    3. BOILER DESIGN AND OPERATION The SAS AGRO-ECO heating boiler is a low temperature central heating boiler adapted to high performance, fully automated firing of biomass in form of wood granulate (pellets of parameters specified according to EN 14961-2) and oats.

  • Page 8: Figure 1 Flue Gas Temperature Sensor Installed In A Flue

    Figure 1 Flue gas temperature sensor installed in a flue NOTE: For correct operation of a controller controlling the burning process – work of the automated fuel feeding system – periodic cleaning of dust and soot deposits from the sensor surface is recommended. Due to an overpressure in the whole inner space of the boiler, it is provided with fire doors and inspection hatches with circumferential sealing (ceramic rope, gaskets) and screwed connection, ensuring for its tight closing.

  • Page 9: Figure 2 Location Of A Temperature Sensor With A Capillary Tube– Thermal Protection Sensor

    The user is responsible for possible installation of ad- justment feet, according to guidelines provided in this instruction (Fig. 8). A characteristic feature of SAS AGRO-ECO boilers is an automated high-per- formance self-cleaning furnace burning precisely the amount of fuel necessary to obtain the temperature set on a controller by the user.

  • Page 10: Figure 3 Moving Grate Positioning Sensor (Hall Effect Sensor )

    3 to 5 mm, these components should be aligned axially. The fuel feeder design developed at ZMK SAS, using a set of two screws, is protected by an application No. W.120870 issued by the Polish Patent Of- fice.

  • Page 11: Figure 4 Connection Terminal Strip Supplying Control Equipment

    A microprocessor controller automatically controls operation of the fuel feeder, the blower fan, the fuel igniting heater and the furnace cleaning mechanism. During the final phase of biomass burning, a residual negligible non-flammable part of fuel – ash – is transferred to the ash box chamber equipped with a remov- able ash drawer that should be emptied periodically (ash resulting from biomass burning can be used as valuable ecological fertiliser for soil enrichment).

  • Page 12: Figure 5 Module Controlling Burner Operation

    (e.g., verification of the furnace operation), to prevent emergency situations. Generally, the SAS AGRO-ECO boiler is operated automatically (in a con- tinuous mode) using a unit consisting of the gearmotor-driven fuel feeder, the self-cleaning blower furnace, and the digital temperature controller.
  • Page 13 (such as petrol, kerosene, or solvents) for boiler firing, as this may result in a fire or explosion. To ensure safe operation, the SAS AGRO-ECO boiler is equipped with a secu- rity system consisting of several steps. The protective devices include protection...

  • Page 14: Sas Agro-Eco Boiler Equipment

    4. SAS AGRO-ECO BOILER EQUIPMENT SAS AGRO-ECO, the automatic boiler with a control system and a self-clean- ing furnace is delivered in an assembled state, equipped with a controller, a fan, a fuel feeder with a gearmotor, a fuel lighter, ceramic panels, a fuel tank, an automat-...
  • Page 15 Table 1 SAS AGRO-ECO boiler equipment Boiler standard equipment Boiler operating and maintenance documentation pieces (operating manual + warranty card) Operating manual + warranty card for a temperature regulator (controller) pieces Warranty card for a blower fan pieces Temperature regulator (controller operating a mixing valve*,...

  • Page 23: Technical And Operational Parameters

    5. TECHNICAL AND OPERATIONAL PARAMETERS Basic output parameters together with technical and operational parameters for SAS AGRO-ECO boilers are listed in Tab. 3, Tab. 4, and Fig. 6 and Fig 7. 6. FUEL A trouble-free operation of a SAS AGRO-ECO boiler with an automated burner and a fuel feeder depends on use of appropriate fuel or adapting a boiler operation mode to available fuel.
  • Page 24 Table 3 TECHNICAL AND OPERATIONAL PARAMETERS SAS AGRO-ECO 17-48 kW BOILER for operation at a moderate load (50% of boiler nominal output) for basic fuel. when recommendations concerning maintaining of a specified range of heating water temperatures are not followed, the boiler must be obligatorily connected to the heating system equipped with a three- or four-way valve protecting against so-called "low-temperature corrosion"...
  • Page 25 Table 4 TECHNICAL AND OPERATIONAL PARAMETERS SAS AGRO-ECO 58-150 kW BOILER for operation at a moderate load (50% of boiler nominal output) for basic fuel. when recommendations concerning maintaining of a specified range of heating water temperatures are not followed, the boiler must be obligatorily connected to the heating system equipped with a three- or four-way valve protecting against so-called "low-temperature corrosion"...
  • Page 26 *** The emergency grate is not a standard boiler equipment. **) when adjustment feet are used (excluding boilers of output exceeding 36 kW), the dimension increases from min. 29 mm to max. 56 mm. ***) SAS AGRO-ECO 17-48kW is equipped with a controller installed in the mounting box...
  • Page 27 CONSTRUCTION DIAGRAM OF A SAS AGRO-ECO Figure 7. BOILER (concerns boilers of up to 58-150 kW)
  • Page 28 NOTE! Use of fuels other than recommended by the manufacturer may damage the feeder resulting in a loss of a warranty for a given feeder. It is forbidden to burn plastic materials; this may result in damage to the furnace. Contamination of the heat exchanger surface leads to reduced boiler efficiency and deterioration in the burning process.

  • Page 29: Table 5 Basic Parameters Of Pellets For Sas Agro-Eco Boilers

    Table 5 Basic parameters of pellets for SAS AGRO-ECO boilers: Parameter Unit Scope Diameter 6–8 Length 5–35 ≥ 600 Bulk density kg/m³ Calorific value MJ/kg 16.5–19 ≤ 2.5 Abrasion resistance ≤ 0.5 Ash content ≤ 0.03 Sulphur content ≤ 0.3 Nitrogen content ≤...

  • Page 30: Boiler Installation Guidelines

    7. BOILER INSTALLATION GUIDELINES The boiler must be installed by qualified personnel holding relevant licenc- es (a professional, appropriately trained and holding required licences to perform maintenance and repair works). An installer is obliged to become thoroughly ac- quainted with the product and its function, and an operating mode of its protective systems.

  • Page 31: Noise And Noise Reduction Methods

    NOTE: Use of mechanical ventilation is unacceptable. The boiler room should be provided with natural and artificial lighting. FOR SAFETY REASONS IT IS RECOMMENDED TO EQUIP THE BOILER ROOM WITH A CARBON OXIDE (CO) AND A SMOKE SENSORS. 7.2. NOISE AND NOISE REDUCTION METHODS The manufacturer made all efforts possible to maintain a noise emitted by the heating device at a safe acceptable level of <65dB(A).

  • Page 32: Figure 8 Installation Of Adjustment Feet In A Sas Agro-Eco Boiler

    (item 3) and block the whole set by screwing on the upper blocking nut (item 2). The wrench No. 19 is not provided with the boiler. The SAS AGRO-ECO boiler with the adjustment feet installed is shown in Fig. 8 B).

  • Page 33: Boiler Stack Connection

    7.4. BOILER STACK CONNECTION The design of a flue pipe and its connection to the boiler should conform to the requirements of current national regulations in a country of destination (e.g., Minis- ter of Infrastructure Regulation concerning technical conditions that should be met by buildings and their setting, of 12 April 2002, Journal of Laws No.

  • Page 34: Boiler Connection To A Heating System

    The SAS AGRO-ECO 17-100 kW boiler can be connected to an open vent- ed or a sealed system, according to the requirements of current specific reg- ulations of a country of destination and manufacturer guidelines specified below.

  • Page 35: Open Vented System

    SAS AGRO-ECO boilers can work with gravitational or forced water flow. When a circulatory pump is installed in an open vented system, a differential pressure...
  • Page 36 temperature above 95 °C), the thermostat valve installed on the boiler opens, and supplied water from the water system cools the boiler, leaves the system through an overflow pipe (RP) of an open expansion vessel (item 10) flowing to a cooling well (item 11), and then to a sewage system.

  • Page 37: Sealed System

    7.5.2. SEALED SYSTEM It is possible to connect the SAS AGRO-ECO boiler of 17–100 kW out- put, equipped with a factory installed air supply system and a controller, to a sealed system, provided a pressure relief valve, a diaphragm expansion vessel, equipment for control and measurements (manometer, thermometer, etc.), and devices for removing excess heat, e.g., thermal protection valve...
  • Page 38 Figure 9. General diagram for connection of the SAS AGRO-ECO boil- er to an open vented central heating and domestic hot water system with a forced water circulation and a four-way valve. 1 –SAS AGRO-ECO boiler; 8 – central heating system circu- 2 –...
  • Page 39 Figure 10. General diagram for connection of the SAS AGRO-ECO boil- er to a central heating and domestic hot water system. The boiler in an open vented system working with the system through a plate exchang- er, protected against overheating with a Regulus thermostatic valve type BVTS.
  • Page 40 Figure 11. General diagram for connection of the SAS AGRO-ECO boiler to a central heating and domestic hot water system. The boiler in the sealed system, secured against overheating with a SYR thermostatic valve, type 5067...
  • Page 41 5067 THERMAL PROTECTION rys.1 unspecified dimensions, as mm Applications: Thermal protection device 5067 for the system is used to protect solid fuel boilers operated in heating systems equipped with thermostatic valves, in accordance with the Polish Standard PN-EN303-5. Recommended in particular for boilers not equipped with a cooling exchanger. Fig.

  • Page 42: Boiler Connection To A Power Supply System

    An example of the SAS AGRO-ECO boiler installation in a sealed central heating and domestic hot water system is shown in Fig. 11. The standard boiler equipment (not applicable to boilers above 100 kW) in- cludes a connector for a temperature sensor with a capillary tube (item 3); the temperature sensor=150, is installed in the hottest part, at the top of the boiler.

  • Page 43: Guidelines For Use And Operation

    An attention should be paid to route cables supplying energized equip- ment away from the boiler components that become hot during operation (flue, doors). It is recommended to connect the heating device on a separate power circuit with a protective device in the main switchboard. An emergency power supply for the heating system (controller, fan, gearmotor, circulatory pumps, mixing valves with an actuator) should be provided in the event of power outage, from additional equipment: UPS with a sine wave output or a...
  • Page 44 Water for filling of the system should meet the following require- ments: • pH: 8.0–9.0 – in a copper system or systems of combined materials steel/copper; 8.0–9.5 – in a system of steel and cast iron; 8.0–8.5 – in a system with aluminium radiators. •...

  • Page 45: Boiler Firing And Operation

    8.2.1. BOILER FIRING AND OPERATION IN AN AUTOMATED MODE AUTOMATIC FIRING. The burner in the SAS AGRO-ECO boiler is lit automatically with an integrated electrical lighter. Therefore, the boiler start-up (furnace firing) is just limited to acti- vation of the "FIRING" function in the controller menu.
  • Page 46 Flue gases emitted from an obstructed stack are hazardous. The stack and the connector should be kept clean; they should be cleaned according to the manufacturer instruction. Boiler flue gas ducts should be kept clean. Use only recommended types of fuel. In the boiler firing mode the regulator automatically controls the fuel feeder operation –...
  • Page 47 Activities related to controller operation should be performed according to procedures included in the controller operating manual. Depending on the weather conditions, burning intensity and the boiler heat output should be adjusted accordingly, regulating a temperature of water leaving the boiler (or, when the three- or four-way valve is installed, by changing settings of the control shutter).

  • Page 48: Boiler Firing And Operation In An "Emergency Burning" (Steel Grate)

    8.2.2. BOILER FIRING AND OPERATION IN AN "EMERGENCY BURNING" (STEEL GRATE) Before the firing procedure is started, open the feed door; the clean out hatch door and the ash-box door must be completely closed. An emergency steel grate must be installed in the furnace chamber, in brackets designated for its installation –...

  • Page 49: End Of Burning

    NOTE: From the moment of boiler firing to its putting off the boiler operation is monitored with a flue gas sensor installed in the flue. It is recommended to clean the sensor surface regularly, to ensure a correct temperature read-out in the flue gas duct and correct control over the burning process.

  • Page 50: Conditions For Safe Operation

    9 CONDITIONS FOR SAFE OPERATION To maintain safe operational conditions for the boiler, the following rules must be observed: • the boiler can only be operated by adults, according to guidelines provided in the documentation supplied together with the device; •...

  • Page 51: Operation And Maintenance Of A Feeder And A Burner

    10. SERVICE AND MAINTENANCE OF A FEEDER AND A BURNER The biomass burner is designed in a way not requiring complicated operation and expensive maintenance. However, its correct operation (influencing boiler performance and burning economy) requires certain rules to be observed during the feeder operation and regular perfor- mance of certain activities.

  • Page 52: Statuses Of Incorrect Boiler Work

    11. STATUSES OF INCORRECT BOILER WORK CAUSE/ PROBLEM REMEDIES APPEARANCE clean the flue gas ducts through the contamination of flue gas ducts clean out hatch door check the condition of the supply no air supply to the boiler room ventilation in the boiler room, improve its patency.
  • Page 53 Sudden increase valves in the system closed open the valves in the temperature and the pressure in provide thermal insulation on the expansion vessel is frozen the boiler expansion vessel at each boiler start-up and after each boiler "sweating, retting", downtime "warm the boiler up", i.e., Water leaking from this is a natural phenomenon...

  • Page 54: Protective Devices

    12. PROTECTIVE DEVICES To ensure possibly failure-free and safe operation, the boiler controller is equipped with numerous protective devices. The software installed con- trols operation of semi-assemblies and performs monitoring and safety operations to prevent hazardous conditions (e.g., power outage and its restoration).
  • Page 55 TEMPERATURE PROTECTION The controller is provided with additional software (digital) tempera- ture protection against dangerous increase in the temperature. When the alarm temperature (set within the 80 °C–85 °C range) is exceeded, the blower fan and the fuel feeder are disconnected. At the same time, active pumps start to work to distribute heat in the system.
  • Page 56 The controller is additionally secured against flashback to the fuel tank (hopper). The boiler is equipped with a feeder pipe sensor measuring temperature near the fuel tank. When the temperature increases sig- nificantly (when the set temperature is exceeded), the internal controller software automatically activates procedures protecting the boiler against overheating or fire in the fuel feeder.

  • Page 57: Delivery Terms And Conditions

    THERMAL PROTECTION VALVE PROTECTING AGAINST OVER- HEATING (optional) In its standard version, the SAS AGRO-ECO boiler is equipped with a connector for installation of the temperature sensor with a capillary tube (does not apply to boilers of output exceeding 100 kW); the thermostat valve (optional), e.g., Regulus type BVTS is a thermal protection device for...

  • Page 58: Boiler Disposal

    Components protecting the boiler for the transport: plastic film, bags, plastic materials, should be transferred to a relevant waste collection entity. The SAS AGRO-ECO boiler is equipped with dig- ital equipment subject to selective collection of electrical and electronic equipment (a sign of a crossed-out basket on a nominal plate).

  • Page 59: Warranty Terms And Conditions

    15. WARRANTY TERMS AND CONDITIONS 1. The manufacturer grants to the Buyer a warranty for the SAS AGRO- ECO boiler under terms and conditions specified in this warranty. It is confirmed with the company seal. 2. The manufacturer guarantees efficient work of the boiler when it is installed and operated according to all conditions and guidelines specified in the operation and maintenance documentation.
  • Page 60 8. Only original spare parts offered by the Metal Products and Boiler Production Plant "SAS" should be used. The manufacturer shall not be held responsible for defective work of the SAS AGRO-ECO boiler when incorrect spare parts are used. 9. The sealing rope in the clean out, furnace or ash-box doors is not covered by the warranty.
  • Page 61 Owczary, ul. Przemysłowa 3, 28-100 Busko-Zdrój Tel. 41 378 46 19, fax 41 370 83 10 e-mail:biuro@sas.busko.pl maintenance service: Phone 41 378 15 00, 41 378 50 80, serwis@sas.busko. technical assistance for SAS boilers: phone 505 950 252 TECH controllers: Phone 33 875 19 20 RECALART controllers: Phone 77 46 25 877;...

  • Page 62: Service Repairs

    SERVICE REPAIRS...

  • Page 63: Warranty Card

    WARRANTY CARD According to the specified terms and conditions, a 60 (24*) months warranty is granted for the low temperature heating boiler, type SAS AGRO-ECO, operated according to operation and maintenance documentation Boiler No. – ............. Heat output – .............
  • Page 64 MODERN AND ENVIRONMENTALLY FRIENDLY CENTRAL HEATING BOILERS water-based, steel, low temperature, with a certificate of energy and emission tests Manufactured in several variants: UNIVERSAL BOILERS for burning of coal, fine coal and fuel wood (with/without a blower) BOILERS WITH AN ECO FEEDER adapted to fine coal and pea coal burning.

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