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Topling BTA350 User Manual

Hot water pellet boiler
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BTA User Guide
PRIVATE COMPANY FOR PRODUCTION,
SERVICES AND TRADE
TOPLING d.o.o. PRNJAVOR
BOSNIA AND HERZEGOVINA
www.topling.com
info.topling@gmail.com
USER GUIDE
Hot Water Pellet Boiler
BTA
Topling Prnjavor
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Summary of Contents for Topling BTA350

  • Page 1 BTA User Guide PRIVATE COMPANY FOR PRODUCTION, SERVICES AND TRADE TOPLING d.o.o. PRNJAVOR BOSNIA AND HERZEGOVINA www.topling.com info.topling@gmail.com USER GUIDE Hot Water Pellet Boiler Topling Prnjavor Page 1...

  • Page 2: Table Of Contents

    6.1. Frequency of cleaning and maintenance 7. Warranty 7.1. Period of warranty 7.2. Terms of warranty 7.3. When the guarantee is not recognised 8. Addendum 1 9.1. Boiler Feed Water 9. Addendum 2 10.1. Wiring Diagram Topling Prnjavor Page 2...
  • Page 3 KEEP THIS USER GUIDE FOR LONG-TERM USE AND IN AN ACCESSIBLE PLACE FOR FURTHER REFERENCE. Please feel free to contact us if we can provide you with any further information Topling d.o.o. – Prnjavor Address: Topling d.o.o. Magistralni put bb 78430 Prnjavor Bosnia and Herzegovina Tel./fax...
  • Page 4 In the case of non- compliance with this obligation, the producer does not bear any responsibility for any possible damages which occurred in connection with an untrained operator. Topling Prnjavor Page 4...

  • Page 5: Notes On This User Guide

    We reserve the right to make changes on the boilers that would differ in technical data and drawings herein. Written approval of Topling d.o.o. to copy, store in electronic form, transfer information in electronic format, photography, translation of this manual in whole or in part is required.

  • Page 6: Glossary

    95˚C. Reservoir for storing a pellet that is transported to firebox by screw Pellet Storage conveyor. Serves for detecting certain parameters (temperature, feeder Probe level, etc.) and forwards them to the central unit for further processing. Topling Prnjavor Page 6...

  • Page 7: Proper Use

    As a user, you can enter or alter the operating parameters within the limits prescribed by these instructions. Entering any other value of the operating parameters that are not listed in this leaflet, can lead to errors in the functioning of the system Topling Prnjavor Page 7...

  • Page 8: Present Risks

    RECOMMENDED CHARACTERISTICS OF PELET Topling’ recommends pellet of 6 mm diameter and a 10-30 mm length. Quality and geometric characteristics of pellets are prescribed by the German Standard DIN 51731 or Austrian Standard ONORM 7135 Pay special attention to the quality of pellet, both when ordering and admission.

  • Page 9: Used Warning And Safety Signs

    Flammable. Work in areas marked with this symbol can lead to fire. Attention Danger of freezing. Work in areas marked with this symbol can lead to freezing. Notes on proper disposal. Additional information for the operator. Topling Prnjavor Page 9...

  • Page 10: Duty- Be Informed

    This manual must be constantly ''at hand'' where the boiler is installed. Particular attention should be paid to the standards applicable to the place where the boiler is in Topling Prnjavor Page 10...

  • Page 11: Description And Purpose Of Boiler

    The boiler is well insulated with hard-pressed mineral wool in a quality tin plating. Assembly and commissioning of the furnace are simple, and the connectors are standard. Boiler is tested for water resistance. Allowable working pressure is 2.5 bar. Topling Prnjavor Page 11...
  • Page 12 Bosna i Hercegovina We state with personal responsibility that the product: boiler BTA Mark..........: Type / Model........ : BTA350, BTA450, BTA550, BTA750, BTA1000, BTA1200, BTA1500, BTA2000 Year of production ...... : 2013 On wich this declaration is stuck on, in accordance with the following normative documents : In accordance with EC-Directives : EC-Directive –...
  • Page 13 The system is easy for servicing, maintenance and cleaning. Combustion process is very good, so the contamination of exchange surfaces is minimal, and layers of ashes can be simply removed. Cleaning equipment is delivered together with this system by the producer. Topling Prnjavor Page 13...
  • Page 14 BTA User Guide Figure 1 . Boiler room with two system units and external silo Topling Prnjavor Page 14...
  • Page 15 BTA User Guide Figure 2. Boiler dimensions with pellet burner Topling Prnjavor Page 15...
  • Page 16 Topling Prnjavor Page 16...
  • Page 17 (glycol, for example). When calibrated pressure is reached, the valve opens and, by means of the discharge to atmosphere, prevents the pressure of the system from reaching levels which would be dengerous for the boiler Topling Prnjavor Page 17...
  • Page 18 The temperature relief valve is set to 95 C . When the setting temperature is reached, the cold cooling water inlet to the boiler and the overheated boiler hot water is drained and pass to the Topling Prnjavor Page 18...
  • Page 19 C not to cause condansate. In the event of severe winter weather and low temperature, and when the boiler is not used it is necessary to drain waiter from the system or fill it with antifreeze liquid. Topling Prnjavor Page 19...
  • Page 20 660 720 840 960 1080 1200 1320 1500 1920 2160 2400 2700 3000 3300 3600 4200 4800 5400 6000 6600 7200 8400 dB(A) LM 25 80A-4 0,55 1375 Presure drop (mm H LM 28 80B-4 0,75 1375 LM 33 90S-4 1410 112M-4 1420 98 101 103 110 115 118 118 118 115 113 LM 39 Topling Prnjavor Page 20...
  • Page 21 - t ≤ 250ºC = 1200 Pa at 250ºC = 2300 Pa at 20ºC = 4 kW -N = 2800 o/min -U = 3 x 400 V -f = 50 Hz Ekovent C4-62 No4.5 Flue gas fan characteristics Topling Prnjavor Page 21...
  • Page 22 BTA User Guide Silo Figure 5. According to available space, silos of different dimensions and shapes are added on BTA systems. Topling Prnjavor Page 22...
  • Page 23 BTA User Guide Gear motor GFL, producer Lenze. Gear motor GSS, producer Lenze. Figure 6. Depending on the boiler power ratings, geometric characteristics of boiler room and the customer's requirements, different types of gear motors are used accordingly. Topling Prnjavor Page 23...
  • Page 24 BTA User Guide helical shaft mounted gear motors ( tip 112 N ) (screw feeder and inter screws.) Output shaft Carrier Motor Figure 7. Dimensions of helical shaft mounted gear motors Topling Prnjavor Page 24...
  • Page 25 - the shock absorber. Figure 8 – Shock absorber Table 5. Dimensions of shock absorber dimensions Torque compressive screw type force (Nm) OM-90N 12,5 2700 M12x80 OM-100N 3300 M14x100 OM-112N 5000 M20x120 OM-132N 1800 8100 M20x120 Topling Prnjavor Page 25...
  • Page 26 BTA User Guide Figure 9. Bearings SKF 722509 DA (screw feeder, rotary feeder) Table 6. Dimensions and marks of bearings Topling Prnjavor Page 26...
  • Page 27 BTA User Guide The system includes rotary feeder which gradually separates two screw feeders and prevents the return of fire into the main silo. Figure 10 Rotary feeder Topling Prnjavor Page 27...
  • Page 28 The system must not be put into operation without protective chain cover. The chain cover must not be removed during the operation of the system. Figure 11. Power transmision by sprockets and roller chains Table 7. Sprocets Topling Prnjavor Page 28...
  • Page 29 Figure 12 Multi cyclone – chimney connection Before installation of the chimney, it is necessary to make the basis of the chimney with anchor bolt M36. Anchor bolts are delivered by the producer, as well as the sketch of the basis, Topling Prnjavor Page 29...
  • Page 30 The chimney is installed via anchor plate and is tightened with nuts. Necessary Tightening torque is 236 kpm. The chimney is first covered with mineral wool, and then with sheet metal. This installation is done on the site. Topling Prnjavor Page 30...

  • Page 31: Boiler Room And The Storage Of Fuel

    Bright surface of windows should be at least one-twelfth of the main boiler. Apparatus for opening and closing the window must be within reach and easy to handle. The walls, ceiling and floor of boiler room must be made of inflammable material. Topling Prnjavor Page 31...
  • Page 32 If the boiler does not have outer walls, the ventilation needs to be regukated by channel distribution. The air outake mounth must not have a grid. Minimum recommended distance from the wall for the assembly and maintenance should taken from manufacturer's recommendations. Topling Prnjavor Page 32...
  • Page 33 3000 3000 3000 3000 3000 3000 3000 Boiler room min. min. min. min. min. min. min. min. height(mm) 3500 3500 3500 3500 3500 3500 3500 3500 Door height(mm) 3000 3000 3000 3000 3000 3000 3000 3000 Topling Prnjavor Page 33...

  • Page 34: The Storage Of Fuel

    Chambers and tank that are in free area and are built of non-combustible materials, for example of steel, must be at least 5 cm away from the building, which exterior walls do not meet the requirements for fire resistant walls or can be made of Topling Prnjavor Page 34...
  • Page 35 (nails, wire, various metal pieces, and large pieces of wood which due to the dimensions can not pass through the screw conveyor, can cause damage to the dosing system. In case of system failure caused above-mentioned cases, manufacturer shall responsible. Topling Prnjavor Page 35...
  • Page 36 Pellet in group of size HP5 is made of pressed wood chips of intact wood including bark, with no additional bonding materials. The energy that is contained in 2 kgs of pellet corresponds roughly to the energy contained in 1 liter of heating oil (10 kWh). Topling Prnjavor Page 36...
  • Page 37 10% max. 8% max. 1.5% max. 1.5% max. 0.5% max. 0.5% Ash content Abrasion of pellet max.2.3% max.2.3% Sulphur content max. 0.04% max. 0.04% Nitrogen content max. 0.3% max. 0.3% Chlorine content max. 0.02% max. 0.02% Topling Prnjavor Page 37...
  • Page 38 When setting up a parallel group of multiple systems, one or both of the cables as a common (safety distribution or saftey backflow route) may be extended. To prevent the lowering Topling Prnjavor Page 38...
  • Page 39 Vent and overflow pipe must not be taken out. Overflow pipe can also be used as a vent pipe, if a curved branch is expanded in the level of expansion vessel. Topling Prnjavor Page 39...
  • Page 40 1. Boiler BTA 2. Pellet burner 3. Dosing screw 4. Vented expansion vessel 5. Water softener 6. Collector 7. Boiler controller water supply Figure 16. Connecting hot water boiler BTA to heating system with an open expansion vessel Topling Prnjavor Page 40...
  • Page 41 3. Dozin screw 4. Expansion module EM 2A 5/10K 5. Water softener 6. Collector 7. Boiler controller 8. Safety valve Water supply Figure 17. Connecting hot water boiler BTA to heating system with an expansion module Topling Prnjavor Page 41...
  • Page 42 BTA User Guide Figure 18. Connecting two hot water boilers BTA to heating system with an expansion module ad two heating circuits. Furnace is preferably placed as close as possible to the chimney. Topling Prnjavor Page 42...
  • Page 43 Insufficient airflow, ie. when geometric features of chimney as indicated in Figure 5 herein have not been met, there is a real risk of transmission of the flame from the firebox into the pellet feeder tube, and then in the pellets reservoire which can cause a fire. Topling Prnjavor Page 43...
  • Page 44 C not to cause condensate. In the event of severe winter weather and low temperature, and when the boiler is not used it is necessary to drain waiter from the system or fill it with antifreeze liquid. Topling Prnjavor Page 44...
  • Page 45 To enter a password press the button , enter the correct password and confirm the input by pressing the button . The password is a four-digit numeric string. Topling Prnjavor Page 45...
  • Page 46 1. TEMPERATURE 2. PELLET FEEDING 3. AIR SUPPLY 4. SUBPRESSURE 5. TIME 6. SCREW CONVEYOR 7. SOLAR CELL 8. MANUALLY 9. ALARMS 10. EXIT TEMPERATURE There are two options under item TEMPERATURE: 1. SET TEMEPRATURE, DISPLAY TEMPERATURES. Topling Prnjavor Page 46...
  • Page 47 On the first display of the submenu TEMPERATURE SETTINGS the maximum temperature of the boiler during operation is set. When the boiler temperature reaches this value, fuel delivery stops and subpressure in the boiler is maintained at a lower value. Topling Prnjavor Page 47...
  • Page 48 If the burner temperature exceeds the defined maximum temperature of the burner or falls below the defined minimum temperature of the burner, the boiler stops working and goes into a state of alarm. Topling Prnjavor Page 48...
  • Page 49 (3/3)). Operation time of the screw conveyor is ss.hh, while the pause is in mm:ss. Upon completion of puller, rotary encoder and screw conveyor are left to work for some time. This time is referred to as THE DELAY IN SWITCHING OFF SCREW CONVEYOR and it is in mm:ss. Topling Prnjavor Page 49...
  • Page 50 On the displays AIR SUPPLY (1/2) and AIR SUPPLY (2/2) the speed of the fan, which injects air into the burner at various temperature intervals of the burner is adjusted. Values are given in percentages, and the fan speed is automatically regulated with frequency converter. Topling Prnjavor Page 50...
  • Page 51 (in percent) and the current rate of primary air fan (in percent). At the next display the values of the subpressures in phase of the boiler operation and its rest are set. Here you can define the minimum and maximum fan speed of flue gases (in percent). Topling Prnjavor Page 51...
  • Page 52 In submenu OPERATION TIME (VRIJEME RADA), time intervals of boiler operation and rest are set. It is possible to set time interval program separately for every day, four intervals for operation and four intervals for ret. Topling Prnjavor Page 52...
  • Page 53 There is a probe on the screw feeder pipe which measures the temperature of feeder pipe, and the information is forwarded to the controller. Current temperature of screw feeder is shown in the first line of the text on the following display. If the temperature of screw Topling Prnjavor Page 53...
  • Page 54 This value is specified in mm.ss format if the photocell is in dark during this time, the boiler stops normal operation and begins the process of'' firing'' Parameters important for the process of firing display PHOTOCELL (FOTOĆELIJA)(2/3). One attempt of firing: wait that certain amount of pellet defined with Topling Prnjavor Page 54...
  • Page 55 “1” in front of their name, and are turned off by setting “0”. . Pressing button you exit manual mode of the boiler and the boiler returns in the state it was before switching to manual mode. Topling Prnjavor Page 55...
  • Page 56 EXIT Here is possible to pass on stand by and lock the controller. It is possible to enter stand by display by pressing the button for two seconds. Topling Prnjavor Page 56...
  • Page 57 (for flue gas probe) and possibly scaling (for water probe), if necessary Annually Detailed annual cleaning at Clean all the components that are heating listed in the upper part of this table season Topling Prnjavor Page 57...
  • Page 58 Figure 24. Cleaning of tubes Important: Cleaning shall be performed only when the system is not in operation. After termination of the operation, wait for 15 minutes and then start cleaning. Topling Prnjavor Page 58...
  • Page 59 (i.e. open doors, removed flue pipe or curve). Never leave the boiler door open excepr when necessary. NOTE At the end of the heating season, the boiler must be cleaned thoroughly as it increases the life of the boiler exploitation. Topling Prnjavor Page 59...
  • Page 60 Lubrication of carrier All carriers come from the factory ready to drive, filled with standard lubricant for the desired mounting position, where the sound power level LWA and effective vibration velocity is in accordance with applicable standards. Topling Prnjavor Page 60...
  • Page 61 If the pass goes hard, turn the bed and pull the sleeve from other side. Do not pull a sleeve through by force since this case will not work. Housing Assembly Topling Prnjavor Page 61...
  • Page 62 In case of damage to certain parts of bearing assembly during overhaul or exploitation, do not install damaged parts but install new ones. Topling Prnjavor Page 62...
  • Page 63 BTA User Guide Seal on the bottom of the shaft housing Inspection of mouth position on overlapping surpfaces Tightening the housing cover Tightening housing to the flange Topling Prnjavor Page 63...
  • Page 64 B a housing through which the shaft entirely passes through. If there is a label A instead of B, it would apply to the case in which the shaft ends. Table 12 Housing-technical data Topling Prnjavor Page 64...
  • Page 65 BTA User Guide Housing type DB Housing type DA Figure 28. Type of housing Topling Prnjavor Page 65...

  • Page 66: Warranty

    You have a one-year warranty on the boiler. 7.2. Conditions of the warranty The boiler must be put into operation by the Topling company or our authorized service provider The boiler must be used in accordance with the recommendations stated in this...

  • Page 67: Addendum

    500 ° C the strength decreases by 75%. It is clear that such metal can not bear the working pressure of the boiler. Deposition of scale in the boiler affects the reduction of the efficiency. Table shows that the fuel consumption increases if the scale thickness increases. Topling Prnjavor Page 67...
  • Page 68 Above-mentioned also shortens the life of the boiler. In Addendum, complete instructions for water softener JOP 1 manufacture red by Klenik - Gradiska. Topling Prnjavor Page 68...

  • Page 69: Addendum

    BTA User Guide 9. Addendum 2 9.1. Wiring diagram Wiring diagram of the control cabinet is shown in several figures in this Section. Topling Prnjavor Page 69...
  • Page 70 BTA User Guide Topling Prnjavor Page 70...
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  • Page 80 BTA User Guide Topling Prnjavor Page 80...
  • Page 81 BTA User Guide Warranty tkp 35 kw product : bta______ producer: »topling« d.o.o. prnjavor »topling« d.o.o. prnjavor holder of the warranty: »topling« d.o.o. prnjavor authorized service : serial number: ___/__ date of production 20__ date of the commissioning : information about the buyer and the owner of the product:...

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