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Translation of the original German version Version 1.6 en, 06.09.2021 Moving grate combustion system UTSR without boiler Series, Type: UTSR without boiler Serial number: See nameplate System name: Year of manufacture: 2021 Schmid AG energy solutions Hörnlistrasse 12 8360 Eschlikon Switzerland www.schmid-energy.ch...
This is clearly stated in the order confir- mation of Schmid AG energy solutions and in the system overview. Any other use, or the use of any other fuels is considered contrary to the intended use. The manufacturer is not liable for any damage resulting from such use.
1 Safety instructions 1.1.2 Combustion grate The values specified on the nameplate must be adhered to. Failure to adhere to these specifications voids the warranty on system parts, mechanics and guaranteed emissions. This applies to the following values in particular: •...
1 Safety instructions Residual risks The machine is built to the state of the art and in conformity with recognized safety stan- dards. The following residual risks exist and should be kept in mind when operating the machinery. Residual risks associated with specific phases of the service life of the system are detailed in the corresponding chapters of these instructions.
1 Safety instructions DANGER! Risk of explosion (deflagration)! Risk of flame exposure when opening the combustion chamber door! In the event of faulty pre-ventilation or incomplete combustion, an explosive atmo- sphere can occur in the combustion chamber due to the formation of carbon monoxide (CO).
1 Safety instructions WARNING! Risk of injury due to rotating parts. Before entering the combustion chamber, switch off the grate de-ashing screw on the maintenance switch and secure with the personal padlock to prevent reactivation. Warning signs Sign below the main switch of the elec- RISK OF FATAL ELECTRIC SHOCK trical circuit cabinet 5 compulsory safety rules for working...
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1 Safety instructions DANGER OF EXPLOSION/ DEFLAGRATION! Do not open the furnace door during start-up and ignition! HOT SURFACES! Always wear full protection gear (gloves, goggles, long-sleeved cotton garments). Sign next to combustion chamber door FIRE HAZARD/ • Do not open during start-lighting RADIANT HEAT! procedure Only open the furnace door briefly...
1 Safety instructions Emergency shut down The movement of the wood combustion system can be stopped at any time by activating the emergency stop button. Opening the combustion chamber door stops the movement of the system. Exception: the flue gas fan continues to run. Removal of the ash container stops the movement of all of the ash removal components.
1 Safety instructions 1.7.1 Combustion air supply to the heating room Depending on the desired capacity, a certain air flow rate is necessary for wood combus- tion (combustion air). The size of the openings is determined during planning in accordance with the valid local directives (e.g.
1 Safety instructions Safety and monitoring systems The detailed description of the error messages is given in Register "C User manual, Control unit", section "11 Events". 1.8.1 Overview 7, 8 Fig. 1 Safety and monitoring systems Item Description Function Limit switch, grate door Only allows the grate door to be opened when the “Open combustion chamber door”...
An annual functional check must be carried out on the thermal extinguishing water valve. This inspection work may only be carried out by service personnel of Schmid AG energy solutions. Moving grate combustion system UTSR without boiler D-14 1.6 en...
The customer can provide emergency stop buttons on the access doors and escape routes to the heating room that can be integrated into the control cabinet front. Actu- ating the emergency stop button stops the system controlled by Schmid AG energy solu- tions.
1 Safety instructions Operator workstations Access to the system must be possible on all sides for the following tasks: • General operation • Fire monitoring • Flue gas duct cleaning and flue gas recovery • Cleaning of the combustion chamber •...
2 Description UTSR Description UTSR Introduction This automatic moving grate combustion system is designed for economical and low- emission combustion of forest woodchips and pellets. The energy released by combus- tion is used thermally. Depending on the heat requirements, the combustion system adjusts its capacity within a range of 30 to 100 percent.
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2 Description UTSR Fig. 3 Cross-section of the moving grate combustion system Moving grate combustion system UTSR without boiler D-18 1.6 en...
2 Description UTSR Description of functions To ensure optimal combustion, the fuel, which is dosed with the stoker screw or pusher, undergoes four phases. • Drying • Gasification (pyrolysis) • Combustion (oxidation) • Charcoal burnout In order to control this process, the system has two different air supply zones. •...
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2 Description UTSR The following measurements control the combustion process: • Primary air quantity • Secondary air quantity • Combustion temperature • Excess air measurement (O sensor) • Underpressure in the combustion chamber • Temperature of the refractory lining (UTSR 700 and larger) •...
2 Description UTSR Design of the moving grate combustion system The automatic wood combustion system consists of the following system components: 13/14 37, 38, 39 Fig. 5 Design of the moving grate combustion system Moving grate combustion system UTSR without boiler 1.6 en D-21...
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2 Description UTSR Item Designation Function Fuel transport, inlet Inlet for fuel, e.g. via stoker screw Combustion grate Consists of a vault, refractory lining, and a moving grate Grate de-ashing Possible location: right or left side Supply air fans 1 to 3 fans to provide the air supply for combustion Supply air ducts Distribution of the primary and secondary...
2 Description UTSR 2.3.1 Automatic ignition (optional) Automatic ignition is performed with an industri- al hot air blower installed on the side of the com- bustion system. The fuel is ignited automatically directly in the combustion chamber. The auto- matic ignition consists of: •...
2 Description UTSR 2.3.3 Flue gas recovery (option) The flue gas recovery unit is a system that recirculates part of the flue gas to the primary air zone (up to 900kW) or the primary and secondary air zone (from 1200kW). This reduces the combustion chamber temperature.
2 Description UTSR Inlet design variants For combustion of wood chips, shavings etc., in accordance with the order confirmation and system overview. Water-cooled grate inlet for the ESC hydraulic push- er and HFE horizontal conveyor unit Grate inlet for the HFE horizontal conveyor unit Grate inlet to the stoker screw Fig.
3 Transport Transport All of the products offered by Schmid AG energy solutions are transported by our own specialists and delivered to the correct location. The components of the system are protected against corrosion for transport and storage. The components of the combustion system are delivered separately as follows: •...
Alternatively, the system components can also be unloaded using a forklift. In this case make sure to tell the Schmid AG energy solutions project lead. In this case the compo- nents are supported with pallets or squared timber during truck loading.
4 Installation, commissioning Commissioning All Schmid AG energy solutions products are normally taken into operation by our trained staff. An essential part of the commissioning process includes the instruction of the future equipment operators. The equipment operators must be present during commissioning. The personnel should be familiar with the instruction manual prior to commissioning.
4 Installation, commissioning 4.2.1 Requirements for circulating water up to 110° In order to prevent damage, particularly due to scaling in the hot water boilers circu- lating water in new and refills must fulfil the following conditions: Characteristic Value Notes Total water hardness Max 0.2°...
4) Once dry, the refractory should be heated at a rate of 50°C/h until it reaches the maximum temperature. We recommend letting specialists from Schmid AG energy solutions or from another specialised service provider heat up the moving grate combustion system for the first time.
5 Operation Operation General instructions The moving grate combustion system can be ignited and controlled via a central control unit (optional). If the automatic ignition system does not work or is not installed, the system must be ignited manually. The moving grate combustion system may only be operated in a safe, functional and good condition.
5 Operation 5.1.1 System operation To guarantee minimum system wear, continuous operation is necessary. With contin- uous operation, the thermal loads from repeated cooling and heating are prevented, which has a positive effect on the service life of the entire system. With regard to the set number of activation/deactivation operations per day and the minimum combustion time, in Switzerland the regulations of the canton must be taken into account.
5 Operation Switching the combustion system on DANGER! Explosion hazard due to deflagration! An overfilled combustion chamber can create an explosive atmosphere, which can cause serious injury when lit. Empty the combustion chamber before firing. Never use fire accelerants (petroleum or similar) when lighting the fire. The detailed description of how to switch on the combustion system is given in Register "C User manual, Control unit", section "4.2 Automatic mode".
5 Operation 5.2.1 Correct manual lighting Materials: Firewood and wax-soaked wood shavings or wood chips. Never use fire accelerants (e.g. petroleum or similar) for lighting - risk of burns. In addition to these highly flammable ma- terials, add middle sized and large pieces of firewood, observing the rule of thumb: "From fine to coarse, from soft to hard"...
5.4.2 Machine control unit The entire system can only be operated via the control unit. It is set up by Schmid AG energy solutions personnel during the commissioning process (see «4 Installation, commissioning»). Changes to the settings may only be made by Schmid AG energy solutions service personnel.
5 Operation Recommissioning after a longer interruption No special measures are necessary if recommissioning after a period of downtime of up to one year. After longer periods of downtime, proceed according to «4.2 Commissioning». During commissioning the moving grate combustion system should be checked for flawless operation without fuel.
Maintenance contract In order to prevent faults and defects to the system, and to ensure optimal combustion, we recommend maintenance of the system by Schmid AG energy solutions either annu- ally or every 4000 hours of operation. Schmid AG energy solutions offers maintenance contracts with different performance levels.
6 Maintenance Cleaning WARNING! Risk of injury when entering the combustion chamber. Always secure the combustion chamber door. Before entering the combustion chamber always secure the combustion chamber door with the personal padlock. WARNING! Risk of injury due to rotating parts. Before entering the combustion chamber, switch off the grate de-ashing screw on the maintenance switch and secure with the personal padlock to prevent reactivation.
6 Maintenance WARNING! Surfaces and interior are very hot and can cause burns. Before cleaning allow the combustion system to cool. Always wear personal protective equipment. Secure the system against accidental activation. WARNING! Dust and fly ash can negatively influence breathing and cause irreversible damage to lungs and respiratory tracts.
6 Maintenance 6.3.2 Clean fan Procedure: 1. Open cleaning opening. 2. Clean the fan hub with a brush (preliminary cleaning using the square brush, final cleaning with a round brush). 3. Close the cleaning opening. Moving grate combustion system UTSR without boiler D-44 1.6 en...
6 Maintenance 6.3.3 Clean vault/intermediate ceiling Procedure: 1. Remove panel cover. 2. Open the door. 3. Put on heat resistant gloves and remove the door inserts. 4. Push the ash rearward into the combustion chamber. Moving grate combustion system UTSR without boiler 1.6 en D-45...
3. Clean the grate bars mechanically and check for damage. 4. Refit the grate bars in the same sequence. Do not confuse the sequence of the rows when refitting. The grate bars and rows may only be changed by Schmid AG energy solutions service personnel. 6.3.5 Clean lower grate Procedure: ...
6 Maintenance Maintenance overview The maintenance and inspection data are based on continuous operation. If the require- ment is not fulfilled within the corresponding period, the period can be extended. However, a complete overhaul must be performed every two to three years. Fig.
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6 Maintenance Maintenance tasks Visually inspect the combustion chamber (31) and fire appearance. Check the flue gas temperature 6.5.1 Listen for unusual noise in the motor or other unusual noises Check the fill level of the ash container. Operating manual, de- ashing sys- Check fuel level in the silo BA silo...
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Check the wear of the grate bars (18) and re- place any damaged bars. Only have carried out Check the back fire thermostat by Schmid Check the rotary valve or back fire protection AG energy slide solutions Check the differential pressure gauge...
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6 Maintenance Maintenance tasks The safety valves of the compressed air tank 2.3.2, 4.2.3 (e.g. the compressor and automatic boiler tube cleaning) must be checked regularly by venting (EKAS directive no. 6516). Furthermore the spe- cific national standards must be complied with. The safety valves of the compressed air tank Every 8 years 2.3.2, 4.2.3...
Please coordinate the inspection date with our customer service department as early as possible. In the event of deviation from the values determined during commissioning, the system must be cleaned or Schmid AG energy solutions customer service must be contacted. 6.5.2 Clean the O...
6 Maintenance 6.5.4 Maintenance work on components with drive units All drives are equipped with a maintenance switch and can be individually disconnected from the mains for maintenance purposes. Exception: The flue gas fan and the combustion air fan can only be deactivated with the main switch of the system.
6 Maintenance 6.5.6 Oil hydraulics WARNING! High pressures, incorrect assembly or brittle hydraulic lines can result in injury caused by high pressure streams of fluid! Check the hydraulic lines regularly in accordance with the maintenance schedule. If defective hydraulic lines or leaks are discovered, they must be repaired immediately. The hydraulic lines must be checked and replaced every six years by a hydraulics engi- neer.
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6 Maintenance Oil level check/oil change Check the oil level monthly in the inspection window of the hydraulic power unit. The oil level should be kept at the "max." mark when all cylinders are retracted. Change oil according to manufacturer's spec- ifications in the supplier documentation.
6 Maintenance 6.5.7 Lubrication All the parts of the system are lubricated prior to delivery. Periodic lubrication is indis- pensable for fault-free operation of the system and prevents expensive repairs (refer to the maintenance table). Fig. 17 Lubrication points Moving grate combustion system UTSR without boiler 1.6 en D-55...
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6 Maintenance Item Maintenance tasks Lubricant Lubricate flanged bearings, roller Multi-purpose grease, lithium saponified, chains, and bearing points on screw e.g. High-performance lubricating grease conveyors Motorex FETT 3000 art. no. 6000.4374 Grease bearings on flue gas fans, Special high-temperature grease, (up to 7.5 generally 11 kW capacity and above kW, usually permanently lubricated), e.g.
Disassembly and disposal Disassembly Schmid AG energy solutions strongly recommends that disassembly be carried out by our specialists. Schmid AG energy solutions assumes no liability for injury, damage to machinery or buildings resulting from improper disassembly performed by third parties. WARNING! Improper disassembly can cause damage to persons and to the building! Before disassembly, it is essential to disconnect the power supply.
Under certain circumstances, the installation and use of such products may have a negative impact on and thus affect the safety of the system's design fea- tures. In principle, only original components or those that are approved by Schmid AG energy solutions may be installed in the system. Note: The following spare parts lists correspond to standard systems (valid in March 2014).
8 Spare parts UTSR moving grate combustion system 16,17 18,19 28,29 1,2,3 4,5,6 41,42,43 9,10 Fig. 18 Spare parts for the UTSR moving grate combustion system Moving grate combustion system UTSR without boiler 1.6 en D-59...
8 Spare parts 8.3.1 UTSR 150 Quan- Item Description Article no. Notes tity Grate bar short cam 3 mm, 330/65 2000.2135 Vault firebrick 380 x 100 x 75 4000.6791 Bronze for grate carriage, 60 x 60 x 4000.4289 Grate carriage 400 mm LB50 Bronze ø82/ø35 x 36 mm, cylinder...
8 Spare parts 8.3.2 UTSR 180-240 Quanti- Item Description Article no. Notes Grate bar short cam 3 mm, 330/65 mm 2000.2135 M60t vault firebrick pressed, 480 x 100 x 132 4000.6792 Bronze for grate carriage, 60 x 60 x 400 mm LB50 4000.4289 Grate carriage Bronze ø82/ø35 x 36 mm, cylinder guide for cyl-...
8 Spare parts 8.3.3 UTSR 300-360 Quanti- Item Description Article no. Notes Grate bar short cam 3 mm, 330/65 mm 2000.2135 M60t vault firebrick pressed, 580 x 100 x 165 4000.6793 Refractory arch stone A45t pressed, 4000.6794 580x185x100 Bronze for grate carriage, 60 x 60 x 400 mm LB50 4000.4289 Grate carriage Bronze ø82/ø35 x 36 mm, cylinder guide for cyl-...
8 Spare parts 8.3.4 UTSR 450-550 Quanti- Item Description Article no. Notes Grate bar long cam 5.5 mm, 450/ 2000.4426 64.5 mm heat resistant Grate bar long cam 5.5 mm, 450/ 2000.4435 62.5 mm heat resistant Grate bar long cam milled 4001.1766 450/ 59mm, heat-resistant Vault firebrick A63C pressed 2-part 4001.2827 UTSK/UTSR 450-1200...
8 Spare parts 8.3.5 UTSR 700-900 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 mm 2000.4426 Heat resistant Grate bar wide, 450/123 mm heat resis- 2000.2142 tant Grate bar long cam 3.5 mm, 450/64.5 mm 2000.2136 Grate bar short cam 3 mm, 330/65 mm...
8 Spare parts 8.3.6 UTSR 995 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 2000.4426 Heat resistant Grate bar long cam 3.5 mm, 450/64.5 2000.2136 Bronze for grate carriage, 4000.4040 Grate carriage zone 1 60x60x650mm LB50 Bronze for grate carriage,...
8 Spare parts 8.3.7 UTSR 1200 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 2000.4426 Heat resistant Grate bar long cam 3.5 mm, 450/64.5 2000.2136 Bronze for grate carriage, 4000.4040 Grate carriage zone 1 60x60x650mm LB50 Bronze for grate carriage,...
8 Spare parts 8.3.8 UTSR 1600 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 2000.4426 Heat resistant Grate bar long cam 3.5 mm, 450/64.5 2000.2136 Bronze for grate carriage, 4000.3996 Grate carriage zone 1 60x60x600mm LB50 Bronze for grate carriage,...
8 Spare parts 8.3.9 UTSR 2000 Quan- Item Description Article no. Notes tity Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 2000.4426 Heat resistant Grate bar wide, 450/123 mm heat re- 2000.2142 sistant Grate bar long cam 3.5 mm, 450/64.5 2000.2136 Bronze for grate carriage,...
8 Spare parts 8.3.10 UTSR 2400 Quan- Item Description Article no. Notes tity Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/ 2000.4426 Heat resistant 64.5 mm Grate bar wide, 450/123 mm heat 2000.2142 resistant Grate bar long cam 3.5 mm, 450/ 2000.2136...
8 Spare parts 8.3.11 UTSR 3200 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 2000.4426 Heat resistant Grate bar wide, 450/123 mm heat re- 2000.2142 sistant Grate bar long cam 3.5 mm, 450/64.5 2000.2136 Looser-bronze for slide bearings, 4000.4726 Grate carriage...
8 Spare parts Quanti- Item Description Article no. Notes 2x2.9 Gasket KERA, 30x30mm (600°) type 6000.1344 Side door seal 2x2.1 Gasket KERA, 30x30mm (600°) type 6000.1344 Side door seal 8.3.12 UTSR 4200 Quanti- Item Description Article no. Notes Grate bar wide, 450/125 mm 2000.2139 Heat resistant Grate bar long cam 5.5 mm, 450/64.5 mm 2000.4426 Heat resistant Grate bar wide, 450/123 mm heat re-...
8 Spare parts Quanti- Item Description Article no. Notes 2.12 m Gasket KERA, 22x22mm (1050°) type 6000.1371 Seal grate door 2.12 m Gasket KERA, 22x22mm (1050°) type 6000.1371 Seal burnout door 4 x 2.9 Gasket KERA, 30x30mm (600°) type 6000.1344 Side door seal 8.3.13 UTSR 5000 Quanti-...
8 Spare parts Quanti- Item Description Article no. Notes 2.1 m Gasket Kera, 25x25mm (1200 °) 6000.1370 Seal burnout door type IC 41 4 x 3.16 Gasket KERA, 30x30mm (600°) 6000.1344 Side door seal type SC 42 2 x 2.56 Gasket KERA, 30x30mm (600°) 6000.1344 Side door seal type SC...
8 Spare parts Back fire protection BRA Fig. 20 Back fire protection BRA UTSR 150-550 (with single stoker) Quanti- Item Description Article no. Notes Extinguishing water valve, AVTA 2000.0956 Complete, probe, cor- 20 3/4 inch 50-90°C rugated tube and valve...
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8 Spare parts Moving grate combustion system UTSR without boiler D-76 1.6 en...