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Installation and
Operating Instructions
for use by engineers and heating contractors
KPT 390 to KPT 1250 Series
Wood-fired Boiler
Max. output: 390 to 1250 kW (1331 to 4266 MBH)
Min. output: 98 to 370 kW (334 to 1263 MBH)
Pyrotec
r
5603 882 - 01 07/2014
H
IMPORTANT
Please ensure that these instructions are
read and understood before commencing
installation and start-up. Failure to comply
with these Installation Instructions will
render all warranties null and void.
Working on the equipment
The installation, adjustment, service and
maintenance of this product must be
performed by a licensed professional heating
contractor, who is qualified and
experienced in the installation, service
and maintenance of hot water heating
boilers. There are no user serviceable
parts on the boiler or control.
Ensure main power supply to equipment,
the heating system and all external
controls has been deactivated.
Take precautions in all instances to avoid
accidental activation of power during
service work.
Improper installation, service or
maintenance can cause product/property
damage, severe personal injury, and/or
loss of life.
Product may not be exactly as shown
IMPORTANT
Read and save these instructions
.
for future reference
Please file in Service Binder
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Table of Contents
Related Manuals for KOB KPT 390 Series
Summary of Contents for KOB KPT 390 Series
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Page 1: Installation And Operating Instructions
Installation and Operating Instructions for use by engineers and heating contractors KPT 390 to KPT 1250 Series Wood-fired Boiler Max. output: 390 to 1250 kW (1331 to 4266 MBH) Min. output: 98 to 370 kW (334 to 1263 MBH) Pyrotec IMPORTANT Please ensure that these instructions are read and understood before commencing... -
Page 2: Introduction
Introduction Pyrotec Installation & Operating Safety, Installation and Warranty Requirements Please ensure that these instructions are read and understood before commencing installation and service. Failure to comply with the instructions listed below and details printed in this manual can cause product/property damage, severe personal injury, and/or loss of life. -
Page 3: About These Instructions
Introduction Pyrotec Installation & Operating About These Instructions Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. See below. Indicates an imminently hazardous situation which, WARNING if not avoided, could result in death, serious injury or substantial product/property damage. -
Page 4: Table Of Contents
Table of Contents Pyrotec Installation & Operating Page Introduction Safety, Installation and Warranty Requirements....2 About These Instructions..........3 General Information Important Regulatory and Installation Requirements ..6 Codes..............6 Mechanical room...........6 Working on the equipment........6 Technical literature..........6 Product Information.............7 Boiler Description............8 Transport and Installation..........9 Lifting..............9 Delivery Condition.............10 Standard delivery condition........10... - Page 5 Table of Contents Pyrotec Installation & Operating Page Mechanical Fire Extinguishing System.........32 (continued) Assembly of the Fire Extinguishing System....33 Negative Pressure Monitoring Assembly......34 Control Panel............35 Electrical Mounting of control panel........35 Electrical connection..........35 General safety instructions........35 Vitocontrol-C Pyrocontrol KPT......36 Electrical Components..........38 Fuel Transport and Extraction Systems......40 Rotary valve............40 In-feed auger............41...
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Page 6: General Information
General Information Pyrotec Installation & Operating Important Regulatory and Installation Requirements Take note of all symbols and notations intended to draw attention to potential hazards or important product information. These include ”WARNING”, ”CAUTION”, and ”IMPORTANT”. Codes The installation of this unit shall be in accordance with ... -
Page 7: Product Information
General Information Pyrotec Installation & Operating Product Information Viessmann solid-fuel boiler may only be installed and Maximum allowable working pressure (water)...30 or 60 psi serviced by trained personnel. Maximum water temperature…..250° F (120° C) (closed loop) Steel wood-fired hot water heating boiler. Maximum boiler temperature………210°... -
Page 8: Boiler Description
General Information Pyrotec Installation & Operating Boiler Description Supplied with: Description The PYROTEC Grate Firing System (patent no: EP 0 905 - Boiler with combustion chamber and pressure vessel/ 442 B1) was developed for automatic combustion of all dry heat exchanger including supply and return to moist wood fuels (remnant wood, pellets and forest wood temperature sensors and over pressure monitor chips to max. -
Page 9: Transport And Installation
General Information Pyrotec Installation & Operating Transport and Installation IMPORTANT Precautions must be taken to avoid accidents and injury during the transportation of the boiler. Only hoist the boiler when it is entirely empty of water, fuel and ash. Lifting The combustion chamber has four lifting lugs that must be screwed in before lifting. -
Page 10: Delivery Condition
General Information Pyrotec Installation & Operating Delivery Condition Standard delivery condition The standard delivery condition of the Pyrotec boiler includes pre-assembled components as well as components that need to be assembled by the contractor in the field. Components that are attached to the boiler at time of delivery: - Heat exchanger door is mounted to the heat exchanger - Combustion chamber door is mounted to the combustion chamber - Flue gas collector is attached to the heat exchanger... -
Page 11: Wood Fuel Requirements
General Information Pyrotec Installation & Operating Wood Fuel Requirements The Pyrotec is only suitable for burning fuels listed in this IMPORTANT section. A prerequisite for approval is of a fuel by Viessmann is the approval for the fuel by the responsible If different fuels are used, Viessmann will not assume any public authorities. -
Page 12: Non-Wood Fuels
General Information Pyrotec Installation & Operating Wood Fuel Requirements (continued) Maximum water content The maximum allowable water content of the fuel for Pyrotec systems is limited to 50%. The water content impacts the maximum boiler output. Non-wood fuels Non-wood fuels even if consisting of biomass, such as needles, foliage, grain, straw, fruit pits, etc, are unsuited as fuel for boiler operation and may not be used. -
Page 13: Content Limits For Non-Combustable Substances
General Information Pyrotec Installation & Operating Wood Fuel Requirements (continued) Content limits for non-combustible substances - No wood fuels may contain any foreign bodies, such as pieces of metal, stones, masonry remnants or plastics. The following limits (per lb/kg of dry fuel) of contained non-combustible substances apply [ash analyzed at a temperature of 1500°... -
Page 14: Carbon Monoxide
Safety Pyrotec Installation & Operating Carbon Monoxide The U.S. Consumer Product Safety Commission strongly Service/inspection of the boiler and the system must be recommends the installation of carbon monoxide detectors performed on a regular basis. Maintenance, service and in buildings in which wood-burning equipment is installed. cleaning are specified in the “Service and Maintenance Carbon monoxide (CO) is a colorless, odorless gas, which Instructions”. -
Page 15: Hazardous Materials
Safety Pyrotec Installation & Operating Hazardous Materials Fiberglass wool and ceramic fiber materials Suppliers of ceramic fiber products recommend the following first aid measures WARNING - Respiratory tract (nose and throat) irritation: If respiratory tract irritation develops, move the Inhaling of fiberglass wool and/or ceramic fiber person to a dust free location. -
Page 16: Power Failure Provision
Safety Pyrotec Installation & Operating Power Failure Provision Power Failure Provision Customers must ensure that there is a supply of water independent of the electrical supply. This design ensures that in case of a power failure, the boiler will be reliably cooled by the thermal safety flush valve. -
Page 17: Mechanical Room
Safety Pyrotec Installation & Operating Mechanical Room The load-bearing capacity of the heating room floor must Ensure the mechanical room complies with the requirements be designed for the weight of the system plus filling with in these instructions and local codes. water and fuel. -
Page 18: Mechanical Room Conditions
Safety Pyrotec Installation & Operating Mechanical Room (continued) IMPORTANT WARNING Components which are not tested with the heating Incorrect ambient conditions can lead to damage to system may damage the heating system or affect its the heating system and put safe operation at risk. functions. -
Page 19: Combustion Air Supply
Safety Pyrotec Installation & Operating Combustion Air Supply Codes Confined spaces Provision for combustion and ventilation air must be made When a furnace or boiler is enclosed in a space that has in accordance with applicable local codes. a volume less than 20% of that to be heated by the In the absence of local codes, use: appliance, the space shall: CSA B365-10, Installation Code for Solid Fuel Burning... -
Page 20: Technical Data
Mechanical Pyrotec Installation & Operating Technical Data Boiler model KPT- 1250 Maximum output MBH (kW) 1331 (390) 1808 (530) 2457 (720) 3242 (950) 4265 (1250) Minimum output MBH (kW) 334 (98) 450 (132) 614 (180) 812 (238) 1065 (312) Efficiency Fuel Moisture content W 50 Size of wood chips... -
Page 21: Boiler Dimensions
Mechanical Pyrotec Installation & Operating Specifications Boiler Dimensions BR Boiler Return BS Boiler Supply Dimensions Boiler Model KPT- 1250 in. (mm) (2378) (2536) (2834) (3035) (3230) 5 / 8 7 / 8 5 / 8 ½ 1 / 8 in. (mm) (2328) (2486) (2784) -
Page 22: Boiler Components
Mechanical Pyrotec Installation & Operating Boiler Dimensions (continued) Legend A Boiler return B Motor for de-ashing assembly with ash container E Secondary air blower (optional) F In-feed auger C Primary air blower 1 D Boiler supply Dimensions Boiler Model KPT- 1250 in. -
Page 23: Flue Gas Cyclone
Mechanical Pyrotec Installation & Operating Flue Gas Cyclone The flue gas cyclone minimizes dust emissions and is Supplied with: designed as a multi cyclone with axial function. The - 1 flue gas cyclone cyclone is fully insulated and has three covers for cleaning. - 1 ash container 63 USG (240L) or 211 USG (800L) The crude gas chamber is cleaned via the side cleaning cover. -
Page 24: Recirculation System
Mechanical Pyrotec Installation & Operating Recirculation System... - Page 25 Mechanical Pyrotec Installation & Operating Recirculation System (continued) Item Boiler Model KPT- 1250 Description Quantity Quantity Quantity Quantity Quantity Pipe adaptor primary air 1 Pipe adaptor primary air 2 Elbow 130 x 0.9/90° with PD Flue damper blade D=5d in. (130 mm) Pipe 130 x 0.6 in.
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Page 26: Safety Devices
Mechanical Pyrotec Installation & Operating Safety Devices Expansion 1. Install the pressure relief valve, discharge pipe, air vent and pressure gauge as illustrated in section piping With closed expansion, the supply pressure to the and installation of safety devices. expansion tank should be equal to the max. amount of the system pressure plus 3 psi (0.2 bar). - Page 27 Mechanical Pyrotec Installation & Operating Safety Devices (continued) The safety equipment for the heating installation must be installed by a heating contractor authorized to do so. Legend A Nipple, c in. x 1b in. P Pressure relief valve, 30 psi or 60 psi B Reducing coupling, c in.
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Page 28: Piping And Installation Of Safety Devices
Mechanical Pyrotec Installation & Operating Piping and Installation of Safety Devices System fill Drain inspection port System fill Safety heat exchanger top view 3-Way mixing valve System return line Blocked 4 heat port exchanger Bypass line loops and 2 TS2430 for Pyrotec 720, 950 Valve adjustment must... - Page 29 Mechanical Pyrotec Installation & Operating Piping and Installation of Safety Devices (continued) Note: To reliably prevent boiler corrosion caused by Customer supplied: condensation of flue gases, the boiler return flow - PDP Pressure relief valve drain pipe temperature must not under any circumstances be - DCW Cold water inlet, min.
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Page 30: Fire Protection
Mechanical Pyrotec Installation & Operating Piping and Installation of Safety Devices (continued) Design Recommendation (continued): Boiler pump Boiler model KPT- Pump Frequency Voltage and phase UPS 50-80/4 F 60 Hz 3 x 208-230 V UPS 50-80/4 F 60 Hz 3 x 208-230 V UPS 80-160 F 60 Hz 3 x 208-230 V... -
Page 31: Back-Burn Safeguard For The Fuel Supply System
Mechanical Pyrotec Installation & Operating Fire Protection (continued) Back-burn safeguard for the fuel supply system Double rotary valve with pressure compensation system The fire extinguishing system for the conveyor auger and If, due to special circumstances, any mechanically the down pipe depends on specific requirements (location, produced negative pressures or extraordinarily high size of the fuel storage site, material, pressure conditions overpressures are expected in the fuel storage unit,... -
Page 32: Fire Extinguishing System
Mechanical Pyrotec Installation & Operating Fire Extinguishing System The fire extinguishing system functions independent from Fire extinguishing system for the conveyor auger the electrical power and is flooding the material which is Note: The fire extinguishing system for the conveyor still remaining in the in-feed auger in case of back-burn. -
Page 33: Assembly Of The Fire Extinguishing System
Mechanical Pyrotec Installation & Operating Assembly of the Fire Extinguishing System deburr drill hole Connection to the extinguishing water container or cold water supply piping (field supplied). Item No. Quantity Description Item No. Quantity Description Floater switch (N25) Connector b in. Washer Danfoss AVTA Hex nut M6... -
Page 34: Negative Pressure Monitoring Assembly
Mechanical Pyrotec Installation & Operating Assembly of the Fire Extinguishing System (continued) The following assembly instructions for the fire Note: The Weld on nipple (18) is pre-installed at the extinguishing system are to be used with the layout metering container. The Weld on nipple (18) needs and description shown on page 31. -
Page 35: Electrical
Electrical Pyrotec Installation & Operating Control Panel Mounting of the control panel General safety instructions A certified electrician shall mount the control panel. - Retighten all wire holding screws inside the control Optimum positioning of the control panel will minimize panel before start-up. -
Page 36: Vitocontrol-C Pyrocontrol Kpt
Electrical Pyrotec Installation & Operating Control Panel (continued) Vitocontrol - C, Pyrocontrol KPT Mains supply 208V, 3 phase, 60 Hz, see field wiring diagram for details. Customer terminal tag Description Line voltage connections 24V connections Dry contact outputs Alarm outputs... - Page 37 Electrical Pyrotec Installation & Operating Control Panel (continued) Device tags and designations may vary from project to project. Please refer to the field wiring diagram for details. The wiring diagram will be supplied after the control panel is built or with the receipt of the control panel. Components Installed in the Control Panel Components Installed in the Control Panel Device tag...
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Page 38: Electrical Components
Electrical Pyrotec Installation & Operating Electrical Components... - Page 39 Electrical Pyrotec Installation & Operating Electrical Components (continued) M High voltage B sensors N Sensors Y Low voltage S Switches High Voltage Number Designation Device tag Description -3M1 Flue gas exhaust blower (not shown) -9M11 Grate drive -13M13 Secondary air blower (not shown) -14M14 De-ashing auger -15M15...
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Page 40: Fuel Transport And Extraction Systems
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems Rotary Valve Number Designation Device tag Description -9 M9 Motor for rotary valve... -
Page 41: In-Feed Auger
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems (continued) In-feed auger Number Designation Device tag Description -4M2 Motor for in-feed auger -68S2 Limit switch for maintenance lid B31.1 -11B31.1 Light barrier metering container (Transmitter) B31.2 -11B31.2 Light barrier metering container (Receiver) M10.1 -8M10.1 Slide valve T30... -
Page 42: Pellet Extraction Auger
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems (continued) Pellet extraction auger Number Designation Device tag Description -12M32 Motor for pellet extraction auger S32.1 -12S32.1 Limit switch for maintenance lid S32.2 -12S32.2 Limit switch for silo door (not shown) Note: For details on designation see field wiring diagram. -
Page 43: Horizontal Extraction System
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems (continued) Horizontal extraction system Number Designation Device tag Description -12M32 Motor for extraction auger -12M33 Motor for agitator -12B32 Light barrier for extraction auger S32.1 -12S32.1 Safety switch for maintenance lid S32.2 -12S32.2 Safety switch for silo door (not shown) -
Page 44: Walking Floor Auger
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems (continued) Walking floor auger Number Designation Device tag Description -4M2 Motor for walking floor auger -68S3 Safety switch for maintenance lid S3.1 -68S3.1 Safety switch for auger cover B3/1 -61B3/1 Light barrier walking floor auger (Transmitter) B3/2 -61B3/2... -
Page 45: Thermal Storage Tank
Electrical Pyrotec Installation & Operating Fuel Transport and Extraction Systems (continued) Silo Lid Number Designation Device tag Description Y6.3 -22Y6.3 Solenoid valve silo lid open Y6.4 -22Y6.4 Solenoid valve silo lid close S6.1 -22S6.1 Key operated switch for silo lid M901 -24M901 Vibration motor 1... -
Page 46: Boiler Wiring
Electrical Pyrotec Installation & Operating Boiler Wiring CAUTION CAUTION The Viessmann supplied field wiring diagram is not a The information about wire type, wire number and wire complete system drawing. It is the installer’s responsibility gauge made in the wiring diagrams is not obligatory. The to assure that the control is suitable for the respective final decision of these settings has to be made by the installation, and all necessary safety equipment is installed. -
Page 47: Commissioning
Operation Pyrotec Installation & Operating Commissioning Initial startup Fuel for the commissioning Only a Viessmann or another trained specialist may put For the commissioning, sufficient dry fuel (max. W 20%) a newly installed system into operation for the first time. should be stored for approx. -
Page 48: Filling The Fuel Storage Unit
Operation Pyrotec Installation & Operating Filling the Fuel Storage Unit Note: The “SILO FILLING” function cannot be activated When storage facilities for wood are required, the wood until the heating system has been shut off for one should be kept at least 5 ft. (1.5 m) from the heating hour. -
Page 49: Excess Conditions
Operation Pyrotec Installation & Operating Excess Conditions Low water/excess water pressure Excess temperature/power failure Possible causes: CAUTION Low water: Leakage in the heating system. Excess water pressure: The expansion tank is not DANGER OF THIS EQUIPMENT SUDDENLY GOING UP functioning. IN FLAMES: In either case, the boiler should be examined by a qualified DO NOT open the doors or lids on the boiler plant! -
Page 50: Pyrocontrol Control System
Soft touch key 4 Overview, wood-fired boiler Touching it opens Screen 7. Soft touch key 7 Screen for Kob boiler Overview, additional boilers Touching it opens Screen 8. Important: Screen 8 is only available with optional multiple-boiler systems. -
Page 51: Touch Screen, Screen 1-8
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Touch screen, Screen 1-8 In Screen 1 you can choose between 7 or 8 different Screens (8 being for an optional additional boiler). The touch screen is 6¼ in. (160 mm) wide, 4¾ in. (120 mm) high and has a resolution of 640 x 480 pixels. -
Page 52: Screen 1, Object Indicator Light
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) The following applies to all screens. The screen title Screen 1, Object indicator light and user status are shown at the top. The screen title Displays operational status of boiler pump and additional indicates which Screen (1-8) is active. -
Page 53: Screen 2, Alarm List
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Screen 2, Alarm list Touching the red Alarm line soft touch key (in Screen Touching an alarm log line allows the respective error 1) opens Screen 2 (Alarm List with alarm logs, red). All message to be displayed in detail or acknowledged. -
Page 54: Screen 3, Managing The User Status
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Screen 3, Managing the user status When the user level desired (0-4) is selected, a password in the form of a 4-digit code will be asked for, which has Touching the soft touch key “Status Level 0”, …1, 2 or 4 to be entered and confirmed with ENTER by touching the (at the top right of the Screen), the user level can be changed white input cell using the pop-up number keypad. -
Page 55: Screen 4, Adjusting Settings And Parameters
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Screen 4, Adjusting settings and process parameters In the Settings menu, adjustable categories can be The new value is immediately valid in the furnace firing chosen and their parameters changed. and/or heat recovery process. If the value selected is outside the setting range, then the maximum or minimum In the centre the parameters to be set are listed with value possible will be automatically accepted. -
Page 56: Screen 7, Overview Wood Powered Boiler
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Screen 7, Overview, wood-powered boiler Touching the KÖB Boiler soft touch key (photo in Screen 1) (For explanation on the text display, see “Operating modes”). opens Screen 7 (sectional view of the boiler). Measurement operation, emergency operation and the Here the most important process parameters, activity modes activity of the de-ashing assembly with ash container as... -
Page 57: Screen 8, Additional Boilers
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Screen 8, Additional boilers When the soft touch key for additional boilers is touched (For explanation on the text displays, see “Operating modes”). (symbol in Screen 1), Screen 8 opens (symbol for oil or Here the additional boiler can be manually switched on gas boiler, enlarged). -
Page 58: Pyrotec Control System Parameters
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Pyrotec control system parameter Parameters boiler Unit Min. Max. Default Detailed definition 1 Boiler temperature, °C 85.0 Set point for supply temperature, system design forward(out) flow temperature 2 Boiler temperature, return(in) °C 70.0 Set point for return temperature... -
Page 59: Guide For The Technician
Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Pyrotec controller parameter reference guide for the technician Regulator temperature Unit Min. Max. Default Detailed definition Hysteresis(lagging behind) °C 10.0 Value is calculated by value in 7 + value in 9, standby (boiler off) ON puts boiler in standby mode, when boiler is On. - Page 60 Auto Controlled by accumulator system with operating mode Manual 5 sensors /Off Accumulator management system Kob/QM Kob or other system model Accumulator monitoring in B28.1 B28.5 Sensor to be monitored in the thermal accumulator sensor, selected sensor B28.5 storage tank for design temperature Accumulator monitoring in °C...
- Page 61 Operation Pyrotec Installation & Operating Pyrocontrol Control System (continued) Pyrotec controller parameter reference guide for the technician (continued) Accumulator management system Unit Min. Max. Default Detailed definition Starts boiler when temperature falls B28.1 B28.1 Sensor used to start boiler when below below selected sensor in acc B28.5 value in 4...
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Page 62: Operating Modes
Operation Pyrotec Installation & Operating Operating Modes The following terms are displayed in the operating mode line depending on the situation. The boiler is switched off. Filling Cold start. The combustion chamber trough is being filled by the underfeed auger. Auger filling Direct or hot start with combustion chamber still warm. -
Page 63: Full Load Operation
Operation Pyrotec Installation & Operating Operating Modes (continued) Full load operation Transition in output As soon as a combustion chamber temperature of To obtain a good structure of the fire and thus low approximately 356° F (180° C) is reached (adjustable emissions of harmful substances, the switchover from value), the system switches, depending on the boiler “SUSTAIN”... -
Page 64: Heating Up Manually
Pyrotec Installation & Operating Heating Up Manually Filling the burner trough Check heat up successful When the system has been switched off properly, there is The combustion chamber temperature should be over 356° no more fuel in the burner trough or in the underfeed auger. F (180°...