Max-Ox MX-900B Operator's Manual

Commercial wood chip-fired hydronic boiler

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Max-Ox™ MX-900B

Commercial Wood Chip-Fired

Hydronic Boiler

Operators Manual

Max-Ox™ MX-900B Operators Manual, Rev. 0

Page 1 of 54

Table of Contents

Summary of Contents for Max-Ox MX-900B

Page 1 Max-Ox™ MX-900B Commercial Wood Chip-Fired Hydronic Boiler Operators Manual Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 1 of 54...
Page 2 Hydronic Boiler Operators Manual Please include the Manual Issue shown below when communicating with Technical Support regarding this publication. Publication History Issue Date Description of Changes Rev. 0 2/09/09 Original Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 2 of 54...
Page 3: Table Of Contents
Ash Removal Wood Chips as Fuel Safety Information Installation Operation – Start-up Operation – Shut-down Touch Screen Controls Ash Cleaning Routine Lubrication Boiler Water Treatment Program Fuel Feed Jam Clearing Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 3 of 54...
Page 4: Overview Of This Publication
To help ensure safe installation of the Max-Ox™ MX-900B, please refer to the following NFPA publications: • NFPA 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances, 2006 Edition.
Page 5: Codes And Insurance Notice
MX-900B Operators Manual Codes and Insurance Notice The Max-Ox™ MX-900B Commercial Wood-chip Fired Hydronic Boiler is a mechanical draft, direct-vented, NON-PRESSURIZED VESSEL, solid fuel burning appliance. It must be installed in accordance with this Manual, NFPA 211, Federal, State, and Local codes, and your Insurance Underwriter’s requirements.
Page 6: Technical Support
Max-Ox™ MX-900B Commercial Wood-chip Fired Hydronic Boiler. Please record the model number and serial number of your Max-Ox™ MX-900B in the space provided, and have this information available when contacting your factory-authorized Sales Representative: Model number: ________________...
Page 7: Warranty Registration
Max-Ox™ Warranty Registration Form All Max-Ox™ products must be registered to activate the warranty, and we encourage you to send this registration form back to us within 10 days of installation. Please mail or fax the completed Max-Ox™ Warranty Registration...
Page 8: Limited Warranty
Hydronic Boiler, and its component part(s), to be free from defects in materials and workmanship, under normal use and service, for the Applicable Warranty Periods. At its option, Max-Ox will repair or replace defective Max-Ox™ Wood-chip fired Hydronic Boiler, or defective component part(s), in accordance with the terms of the Limited Warranty, if it fails in normal use and service during the Applicable Warranty Periods..
Page 9 For example, in the first year Max-Ox will pay 100% of the cost of any failed item; in the second year Max-Ox will pay 100% less 33.3% of the whetted hydronic heat exchanger components and cast refractory components (3 year pro-rated);...
Page 10 Unit per applicable codes, or good plumbing, electrical, or HVAC trade practices. 8. Damages, malfunctions, or failures resulting from failure to install, operate, or maintain the Unit in accordance with the Max-Ox™ MX- 900B Operators Manual. 9. Damages, malfunctions, or failures resulting from over-firing the Unit on combustible materials other than Approved Fuels.
Page 11 Page 4 of 5 Labor, Shipping, and Processing Costs (continued) Max-Ox, LLC will pay for delivery of an “in-warranty” replacement Unit or component part(s) to a location at or near the original point of delivery. The Owner is responsible for any additional local delivery, equipment rigging, and reinstallation charges.
Page 12 Page 5 of 5 How to Obtain Warranty Claim Assistance (continued) Max-Ox, LLC reserves the right to inspect, or require the return of, a failed Unit for defective part(s). If requested items are not returned, or are returned without all of the component parts intact, Max-Ox, LLC reserves the right to invoice the Owner for the replacement Unit or part(s).
Page 13: Special Symbols
CAUTION: Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury, or serves as a reminder to follow appropriate safety practices. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 13 of 54...
Page 14 Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 14 of 54...
Page 15: Specifications
MX-900B Operators Manual Specifications Your new Max-Ox™ MX-900B is classified as a fully modulated (automatic), induced draft, under-grate stoker fed wood chip-fired hydronic heating (hot water) boiler. a. Nominal Output, BTU/hr: 900,000 b. Design Supply Temperature: 180°F c. Approved Fuels: o wood chips <...
Page 16 Fuel Auger Tube Fire Extinguisher Water connection: _ female NPT, 1/2 inch minimum supply pipe diameter @ 40 psi minimum water pressure y. Dry (shipping & rigging) weight: 7,800 lbs Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 16 of 54...
Page 17: How It Works
MX- 900B Control System: The automatic control system of the MX-900B system is a modern version of proven combustion control strategy. The MX-900B Control System hardware consists of an industrial-duty programmable logic...
Page 18: Fuel In-Feed Conveyor (By Customer)
Fuel In-Feed System Conveyor ( by Customer): You will need to provide wood chip fuel in-feed conveyor system in order to supply fuel to your MX-900B unit. Your fuel in-feed system should be tailored to your specific site layout requirements.
Page 19: Under-Fire Stoker Grate
A second slide gate serves to manually adjust and set the Secondary combustion air flow rate into the Secondary Combustion Chamber lower combustion air inlets. A third slide gate Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 19 of 54...
Page 20: Secondary Combustion Chamber
On cool days you will see this water vapor form a vapor cloud plume as the exhaust rises up into the atmosphere. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 20 of 54...
Page 21: Exhaust Fan
20% ash by weight. When compared to coal ash, wood ash is much more soft, fine, and fragile, and as such becomes airborne more easily. Your MX-900B ash removal system has been designed to address wood ash removal as follows: Rotating Ash Ring, Ash Plow, Ash Auger &...
Page 22 Particulate Cyclone: Coupled to the boiler is a high efficiency particulate cyclone dust collector designed to remove fly ash from the Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 22 of 54...
Page 23: Wood Chips As Fuel
The container is removed and emptied during routine maintenance. Wood Chips as a Fuel: Your MX-900B Combustion System has been designed for, and is approved for, the efficient combustion of dry wood chips, green (fresh- cut) wood chips, hogged (shredded) dry wood, hogged (shredded) green (fresh-cut) wood, and shredded wood construction demolition waste (tramp metal removed), for all species of wood.
Page 24: Safety Information
National Fire Protection Association 211, Standard for Chimneys, Fireplaces, Vents, and Solid Fuel-Burning Appliances, for installation of MX-900B, as well as for installation of fuel storage containers, bins, silos, and fuel transfer conveyor equipment, and for installation of, or connection to chimney connectors and/or chimney systems.
Page 25 “attention”, “be alert”, and “your safety is involved”. Maintenance Safety Electrocution Hazard. Disconnect and lock-out / tag-out the electrical power supply to the Max-Ox™ 900B, prior to performing any service or maintenance. Do Not Operate the MX- 900B without all safety guards in place, and all doors closed and latched..
Page 26 Do not place waste other than ashes in same container. Surfaces may be Hot! Please wear full coverage protective clothing , shoes, leather gloves, and safety glasses when performing routine maintenance on your MX-900B. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 26 of 54...
Page 27: Installation
Your Insurance Underwriter may also have specific guidelines with respect to installation and inspection requirements for your solid fuel burning appliance. The Max-Ox™ MX-900B must be installed per the requirements of National Fire Protection Association (NFPA) 211: Standard for Chimneys, Fireplaces, Vents, and Solid Fuel Burning Appliances, 2006 Edition.
Page 28 The MX-900B must be shimmed level and plumb during installation. All aspects of installation shall conform to good plumbing, electrical, or HVAC trade practices. Proper pump(s) and piping sizing is the responsibility of your qualified installer. The Max-Ox™ MX-900B is an open system NON-PRESSURIZED hydronic Boiler.
Page 29 14. Press the Feed Auger icon to go to Feed Auger screen 15. Press the “Auto” icon to enable automatic feed auger control 16. Press the “Start” icon to start the feed auger motor. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 29 of 54...
Page 30 25. Press the Feed Auger “SP” (set-point) icon 26. On the Keypad screen, enter a value of 50 (percent) 27. Press the Feed Auger Speed Control “Manual” icon Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 30 of 54...
Page 31 35. Manually adjust the secondary air gate to approximately _ open of full gate travel. Note: this is an initial setting for the Secondary air gate, and will be final adjusted after the combustion chamber warms up. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 31 of 54...
Page 32 On Overview screen, confirm: • Rotary Selector Switch icon screen indicates “On” (green) • ID Fan icon indicates “On” (green) • Circulator pump indicates “On” (green) Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 32 of 54...
Page 33 Metering Bin. Note: When shutting down the MX-900B, the boiler and load circulating pumps must be operated until the fuel in the combustion chamber is consumed. As long as there is burning fuel in the combustion chamber, the water in the boiler will continue to absorb heat.
Page 34: Touch Screen Controls
• Located above the ID Fan icon • Displays flue gas temperature, °F O2 % • Located to right of ID fan icon. • Displays (%) oxygen concentration in flue gas Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 34 of 54...
Page 35 • Displays Boiler Pump motor status: run (green), stop (red) Load Btu/hr • Displays the instantaneous power output of the boiler vessel, BTU/hr Boiler Vessel • Press Boiler Vessel icon to open Supply Temp. Controller screen. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 35 of 54...
Page 36 Disable • Press Disable icon to shut off the Fuel InFeed system and commence automatic shutdown of the Combustion System. Overview • Press Overview icon to open the Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 36 of 54...
Page 37 • Displays the current ID Fan speed set-point as a percentage of the available speed range bounded by the minimum and maximum motor frequency set-points Motor Control Start • Press Start icon to manually start ID Fan Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 37 of 54...
Page 38 • Press Minimum icon to change the ID Fan minimum speed set-point Maximum Speed • Press Maximum icon to change ID Fan maximum speed set-point Overview • Press Overview icon to open the Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 38 of 54...
Page 39 • Displays boiler supply (outlet) water temperature, °F • Press Supply Temperaature scale icon to open the Supply Temperature Controller screen. Return Temperature • Displays the boiler return (inlet) water temperature, °F Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 39 of 54...
Page 40 • Press manual icon to disengage automatic O2 % control O2 Idle Mode • Press O2 Idle Mode icon to display O2 Idle Mode screen Overview • Press Overview icon to return to Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 40 of 54...
Page 41 • Press Idle Differential mode icon to change the Idle Mode Differential Return • Press Return icon to return to Stack O2 screen Overview • Press Overview icon to return to Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 41 of 54...
Page 42 • Displays the actual boiler supply (outlet) water temperature, °F Control Value • Displays the instantaneous Combustion System power output as a percentage of full power. Overview • Press Overview icon to open the Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 42 of 54...
Page 43 • Displays the set-point time delay between Metering Bin refill cycles, minutes • Press PRE icon change Metering Bin Fill Time Delay set-point. Bin Fill Time Delay Current Status • Displays time remaining until Metering Bin refill cycle begins Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 43 of 54...
Page 44 Motor Control Stop • Press Stop icon to stop the Feed Auger motor Motor Control Forward • Press Forward icon to select continuous forward rotation of the Feed Auger motor. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 44 of 54...
Page 45 • Press Minimum icon to change Feed Auger minimum speed set-point Maximum Speed • Press Maximum icon to change Feed Auger maximum speed set-point Overview • Press Overview icon to open the Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 45 of 54...
Page 46 • Press Manual icon to disengage automatic speed control of Ash Auger motor Motor Control Start • Press Start icon to start the Ash Auger motor Motor Control Stop • Press Stop icon to stop the Ash Auger motor Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 46 of 54...
Page 47 • Press Minimum icon to change Ash Auger minimum speed set-point Maximum Speed • Press Maximum icon to change Ash Auger maximum speed set-point Overview • Press Overview icon to open the Overview screen Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 47 of 54...
Page 48 • Metering Bin Air Gate Open: Initiates if gate position is opposite its required position • Emergency Stop: Initiates upon manual actuation of E-Stop button • Boiler Pump Flow: Initiates upon loss of Flow Switch signal Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 48 of 54...
Page 49 Keypad Entry Screen Keypad Entry Screen • Used as a touch keypad for operator entry of control system set- points. Keypad functions are analogous to those found on a Personal Computer keyboard. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 49 of 54...
Page 50: Ash Cleaning
(3) days. Note: Ash bin fill rates vary with fuel type ash content. The MX-900B Unit should be cleaned of ash deposits every 2 to 3 weeks of operation. In general, the ash cleaning frequency is dependent on the type of fuel being burned, and the rate of fuel consumption. The...
Page 51 To clean the ash from your MX-900B, proceed as follows: 1. Shut down the Unit as per the Shut-down procedure in this manual. 2. Ash cleaning may commence after all fire has extinguished in the stoker, however glowing embers may still be present. Please adhere to the Caution and Warning statements above.
Page 52: Routine Lubrication
Dispose of the contents properly. Re-install and latch the Ash Bin. 15. Vacuum any fugitive ash dust from around the MX-900B. Routine Lubrication ID Fan Bearings: Every 3 months of operation, add high quality high temperature grease to both ID Fan shaft pillow block bearings using a grease gun.
Page 53: Boiler Water Treatment Program
3. If the “Rotation Fault” alarm does not recur, proceed with normal operation of the MX-900B. 4. If the “Rotation Fault” recurs, the MX-900B must be shut down, and the Feed Auger train cleaned as follows: 5. Perform a normal shut-down of the MX-900B.
Page 54 Metering Bin will pack tight into the back of the Metering Bin and result in bending of the helical auger flight adjacent to the gear reducer. Max-Ox™ MX-900B Operators Manual, Rev. 0 Page 54 of 54...