Download M20i • M40i • M80i

MANUAL FOR INSTALLATION
M20i  M40i  M80i
Version 1.5 – May 2011
This manual should be read carefully before the installation commences!
How to assemble the plant .............................................................................page 2
Connection to the heating system ..................................................................page 4
Connection of the sprinkler.............................................................................page 4
Connection of the safety heat exchanger .......................................................page 5
(Only for boilers provided with safety heat exchanger)
Connection to the chimney .............................................................................page 6
Connection of the external auger ...................................................................page 6
(Only for plants provided with automatic fill in)
Connection to the electrical net ......................................................................page 7
Diagram 1 – How to fit the water cooled burner tube, boiler side ...................page 8
Diagram 1.1 – How to fit the water cooled burner tube, boiler rear ................page 9
Diagram 2 – Connection to the heating system............................................page 10
Diagram 3 – Connection to the chimney ......................................................page 11
Diagram 4 – Connection of the external auger .............................................page 12
(Only for plants provided with automatic fill in)
Diagram 5 – Electrical diagram 400V – 3 phase 500&700 l fuel store..........page 13
Diagram 5.1 – Electrical diagram 230V – 1 phase 500&700 l fuel store.......page 14
Diagram 5.2 – Electrical diagram 400V – 3 phase 1400 l fuel store .............page 15
Diagram 5.3 – Electrical diagram 230V – 1 phase 1400 l fuel store .............page 16
Diagram 6 – Electrical diagram, start-stop signal for external auger ...........page 17
(Only for plants provided with automatic fill in)
Starting up the boiler – See users manual section 2
Nørrevangen 7  DK-9631 Gedsted  Phone +45 98645222  Fax. +45 98645244
Mail: [email protected]  Web: www.twinheat.dk
2
The installation of this plant must be made in accordance with the local rules and
regulations on the place of installation
Before the plant is placed on its final place it should be inspected carefully for
transport damages. Possible damages should be reported to the forwarder.
How to assemble the plant
You should not fit any parts of the permanent buildings installations onto this
plant, as this inconveniences later service and repair work.
The plant is delivered on 2 Euro pallets and consists of a boiler, a fuel store and a
burner tube, which must be assembled before installation.
Fuel store can either be type 500/700 litre or type 800/1400 litre.
800/1400 litre fuel store must be sealed in the joint between lower and upper part.
Unscrew the 4 bolts in the joint and the clamp holding the pressure equalising pipe,
and then lift the upper parts app. 20mm up. Seal the joint with the included sealing
compound. Lift the upper part down again and mount all 48 bolts
1. The water cooled burner tube is fixed on the fuel store by means of bolts included.
The gasket for the flange is under the fuel store lid.
2. The fuel store with the now fitted burner tube is pushed into the pre made hole
with flange in the boiler.
3. Before you fixate the fuel store and burner tube to the boiler (with 2 bolts) you
must adjust the height of the fuel store by means of the 4 adjustment screws on
the legs, so that it is placed horizontal and in a 90 º angle to the boiler. It is
absolutely important, that the water cooled burner tube is horizontal as you
otherwise might experience air pockets in the system.
(By 800 and 1400 litre fuel store, mount wheels under fuel store and adjust
height.)
4. The water cooling of the burner tube can now be fitted as shown on diagram 1.
or diagram 1.1, depending on plant layout. All parts including fittings and
circulation pump are in the accessories box included. (Please note, that the
circulation pump is for circulation between boiler and burner tube only)
5. The combustion fan is fitted on the square stud on the side of the burner tube, no
gasket needed.
6. The hose for pressure equalising in the fuel store is fitted on opposite square stud
on burner tube
7. The draft regulator, needed by manual heating, is fixed on the top of the boiler in
the same side as the door hinges for the combustion room door. The chain is
connected to the lower air inlet on the boiler.
8. The plug for power to the boiler is pushed in and secured by a screw. The cable is
placed in the tray underneath the plug. Cable W7 is for the circulation pump.
9. Only by 500/700 fuel store: If you want to use a fuel which is likely to build
bridges* in the fuel store you must fit the included chain and the stirrer wings
(according to demand). See enclosure 1 in Users manual (* wood chips,
sawdust, wood shavings and the like)
INSTALLATION
3
The sketches indicate the recommended minimum distances in the boiler room.
The boiler room must be equipped with a ½ to ¾ inch high pressure water tap and a
ventilation opening, either as a window or as a ventilation grill
E
A
E
A
D
40
B
D
F
40
B
C
F
Flue outlet spigot
Flue outlet spigot
80
C
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on side of boiler with 500 or 700 litre fuel store
All dimensions in centimetres
Dimensions
Clerance
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on rear of boiler with 500 or 700 litre fuel store.
All dimensions in centimetres
Recommended
size of boiler room
Dimensions
Clerance
Recommended
size of boiler room
A
B
C
D
E
F
A
B
C
D
E
F
265
116
120
7
312
220
M20i
285
77
120
12
445
169
M40i
290
164
160
10
337
290
M40i
350
77
160
12
550
169
M80i
350
171
160
10
397
320
M80i
380
96
160
10
580
186
M20i
E
A
E
A
5
D
40
B
B
D
C
40
F
F
Flue outlet spigot
Flue outlet spigot
80
C
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on side of boiler with 800 or 1400 litre fuel store
All dimensions in centimetres
Dimensions
Clerance
Recommended minimum distances in boiler room (seen from above)
Stoker inlet on rear of boiler with 800 or 1400 litre fuel store.
All dimensions in centimetres
Recommended
size of boiler room
Dimensions
A
B
C
D
E
F
272
140
120
7
319
254
M20i
M40i
297
164
160
10
347
311
M40i
M80i
357
171
160
10
407
311
M80i
M20i
INSTALLATION
Clerance
Recommended
size of boiler room
A
B
C
D
E
F
304
121
120
7
453
208
371
121
160
10
561
211
407
133
160
10
591
223
4
Connection to the heating system
See diagram 2
The boiler must be connected as shown in diagram 2 or as demanded by local
statutes. Further information is in the user manual, section. 7
The minimum amount of water passing through the boiler must be (see table)
Plant type
M 20i
M 40i
M 80i
Nom. effect
[kW]
29
48
80
Min. Amount of
water [m³/h]
2,5
4,1
6,9
Water returning to the boiler must always be min. 60°C
If the above is not adhered to you will risk increased tear of the steel in the
boiler, resulting in a shorter life expectation for the plant.
According to Danish laws and regulations this boiler must be connected to a
system with “open” expansion tank. Please check you local regulations
General
The expansion tank must be able to contain at least 4 % of the total amount of
water in the heating system. Should the plant be installed with an accumulation
tank, then the expansion tank must be able to contain at least 8 % of the total
amount of water in the heating system.
The boiler must be in non blockage connection to the expansion tank (You must
not be able to block the pipe between)
Should the open expansion tank be placed in a not frost safe place, the tank
itself must be protected against frost. The circulation to the tank must be
controlled by a thermostatic valve or similar in order to secure, that the boiler
water is getting minimum access to oxygen.
Connection of the sprinkler
The sprinkler system on the fuel store must be under constant water pressure
from a ½ inch tap with a safety faucet and be connected to the dirt collector
under the pressure tank.
Please make sure, that pipes / hoses are free of dirt or metal shavings.
You must test the system, when it has come under pressure.
The easiest way to test the sprinkler system is to unscrew the hose from the
thermostatic valve to the auger channel. Then press the red cap under the valve
to activate it
After testing the sprinkler system it is important to check that the valve is closing
properly! (Dirt ore the like, in the valve seat, can prevent this)
By an extended auger channel (750 mm) we deliver the sprinkler system
separately. The sprinkler including pressure tank must be fitted on the wall next
to the auger channel.
INSTALLATION
5
Connection of the safety heat exchanger (Quenching coil)
(Only for boilers provided with safety heat exchanger)
The boiler has a build-in safety
heat exchanger which cools the
boiler in case of pump failure or
the like. The system will be
activated
if
the
water
temperature in the boiler
exceeds 95°C.
Drain from quenching coil
Supply cold water for
quenching coil
Thermal safety valve - 95°C
Temperature sensor
for thermal safety valve
The thermal safety valve must
be connected to constant water
pressure from a G¾”/22mm
pipe. The water pressure must
be minimum 2 bar and the
temperature maximum 15°C
There must be no shutoff valves
on the pipe supplying the valve.
Flush
the
pipes
before
connecting to the thermal safety
valve. Dirt or metal shavings
can cause the valve to
malfunction.
The return drain from the safety heat exchanger G¾” must be connected to a
drain.
The pipe used to connect to the drain must have a sufficient size to avoid the
emergence of backpressure.
After installation the system must be tested to ensure free passage trough the
safety heat exchanger. The thermal safety valve can be manually activated by
pressing the red cap.
INSTALLATION
6
Connection to the chimney
See diagram 3
Further information is in the user manual, section. 7
In order to get a good heating economy and to avoid smoke problems you must
connect the boiler to a suitable chimney. The boiler should be placed as close
to the chimney as possible.
Should the chimney be too unsuitable or under difficult draft conditions you
might have to install a flue fan.
It is in general recommended to install a draft stabilizer (See diagram 3)
A chimney with unstable draft can case unstable running conditions of the plant.
It is important that the flue pipe is insulated with a 30mm fire resistant
mat, to avoid that the flue gasses are condensing in it.
.
Recommended chimney dimensions.
Plant
type
M20i
M40i
M80i
Max. effect,
input
34 kW.
55 kW.
92 kW.
Flue outlet on
boiler
Ø 155 mm
Ø 187 mm
Ø 215 mm
Free opening in
chimney
Ø 160-180 mm
Ø 180-200 mm
Ø 200-250 mm
Height of
chimney
5-6 metre
5-8 metre
6-8 metre
Connection of the external auger
(Only for plants provided with automatic fill in)
See diagram no 4
The connection must be made with a flexible hose. The auger must not support
on the stoker unit and vibrations from the auger must not be transmitted to the
stoker unit.
In case the plant is connected to a silo placed at the loft above you should also
use a flexible hose, which must be emptied after each filling. The hole through
the ceiling must be made fire-proof.
INSTALLATION
7
Connection to the electrical net
See diagram no 5 / 5.1
The boiler can be built for either 400V 3 phase or 230V single phase
connection.
Check boiler data plate for electrical connection.
In Denmark the installation must be made by an authorised electrician. Here too
we ask you to check your local regulations
Electrical supply for the stoker plant:
There should be a specific switch for this plant only
Electrical supply for the internal circulation pump:
The internal circulation pump (placed under the burner tube) is to be connected
to cable no. W7
The pump must not be started before filled with water, as this might damage it.
Setting of the internal circulation pump:
The pump must be set to run in a fixed step. It must not run in Auto mode!
Boiler
M20i
M40i
M80i
Pump step
I
I
II
Extended auger channel
If you request an extended auger channel, we supply the control as a separate
unit to be fitted on the wall above the auger channel, in the boiler room.
Check cable length before you decide where to place the control
Connection of start – stop signal for external auger:
(Only for plants provided with automatic fill in)
See diagram no 6
The motor protection relay (contact) for the external auger must be supplied
with a start – stop signal from the controlling unit of the plant, which is placed in
a plastic box at the side of the fuel valve, on top of the fuel store.
INSTALLATION
8
Diagram 1 - How to fit the water cooled burner tube by
plants with stoker placed at the side of the boiler
Draft regulator
Supply boiler
Hose for pressure
equalising pipe
Fan (no gasket)
Connection for sprinkler
Fuel store
Boiler
Burnertube
Included fittings
2 pcs. ¾" hose
1 pcs. ¾" safety valve
2 pcs. ¾" shutoff valve
1 pcs. ½" shutoff valve
1 pcs. cirkulation pump
5 pcs. ¾" hexagon nipple
1 pcs. ¾" ¾" ½" tee
1 pcs. 1" ¾" hexagon nipple
1 pcs. ¾" tee
2 pcs. ¾" elbow
2 pcs. ¾" union joint for pump
Elbows and valves are to
be placed horizontal, to
avoid airpockets in the
hoses!
By M40 is included a 3/4" connection sleeve
DIAGRAM 1
9
Diagram 1.1 - How to fit the water cooled burner tube by
plants with stoker placed at the rear end of the boiler
Fan (no gasket)
Draft regulator
Connection for sprinkler
Supply boiler
Hose for pressure
equalising pipe
Fuel store
Boiler
Burnertube
Included fittings
2 pcs. ¾" hose
1 pcs. ¾" safety valve
1 pcs. cirkulation pump
2 pcs. ¾" union joint, for pump
2 pcs. ¾" shutoff valve
1 pcs. ½" shutoff valve
5 pcs. ¾" hexagon nipple
1 pcs. ¾" tee
1 pcs. ¾" x ¾" x ½" tee
1 pcs. ¾" plug
Elbows and valves are to
be placed horizontal, to
avoid airpockets in the
hoses!
M20: ¾" x 1" hexagon nipple
M40: ¾" x 1½" hexagon nipple
M80: ¾" x 2" connection nipple + ¾" hexagon nipple
DIAGRAM 2
10
Diagram 2 – Connection to the heating system
Open expansion vessel
EÅ
shutoff valve
V1-V2
shutoff valves on supply and return, in the boiler
room. More can be installed if needed.
V3
Boiler shunt valve secure that the return water to the
boiler always is over 60°C.
V4
To protect open expansion vessel against frost
Can be thermostatic return valve
Airing
V5
Airing, possible automatic, placed where needed.
Thermometer
T1-T4
Thermometer for supply, water return before and
after shunt valve and for flue temperature
Temperature sensor
TF1
Temperature sensor to regulate shunt valve.
Manometer
M1
Manometer for boiler pressure.
Pump
P1
Circulation pump for heating system
3 way thermostat
controlled mixing valve
(shunt valve)
Manuel regulation valve
(return valve)
DIAGRAM 2
11
Diagram 3 – Connect to the chimney
* Prefabricated module chimneys should not be placed on top of the flue
outlet, as this allows rainwater or possible condense water to run directly
down into the heat exchanger of the boiler, where it will cause corrosion !
Brick-build or block-build chimney
Brick-build or block-build chimney
Insulation
Elbow with clean out hole
Draft stabilizer mounted
in chimney
Draft stabilizer mounted
on flue pipe
Clean out
Clean out
*Module chimney with steel or ceramic liners
*Module chimney with steel or ceramic liners
Insulated tee module with
draft stabilizer
Insulated tee module with
clean out
Insulation
Insulated tee module with
clean out
Elbow with clean out hole
Wall support
Draft stabilizer mounted
on flue pipe
Wall support
DIAGRAM 3
12
Diagram 4 – Connection of the external auger
(only for plants provided with automatic fill in)
Fuel from silo placed at
the loft above
Flexible hose
Fuel Valve
Automatic fire damper
closes incase of fire in the
boiler room
Fuel from external silo
Flexible hose
Fuel valve
The auger must not support on the stoker
unit and vibrations from the auger must
not be transmitted to the stoker unit.
DIAGRAM 4
U
V
W
DIAGRAM 5
1
2
3
Silo-auger
Brown
Capacitive
sensor
White
Blue
Contaktor Safety
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Relay Silo auger
Relay Belimo motor
24VAC
O2 +Signal
Black
OVSignal
Grey
White
White
0VAC
12VAC
12VDC
Lid Safety-Switch
N
U3
12VDC
N
Hot boiler thermostat
NTC
JP3
22
23
24
25
26
27
28
29
30
31
32
41
42
43
44
45
46
Boiler temp sensor
F1 4AT
33
34
35
36
12VDC
12VDC
Capacitive
sensor
0VDC
12VAC
12VDC
Contakt
Belimo
0VAC
24VAC
0VAC
T2
T1
L2
L1
L3
T3
lysrød
24VAC
rød
0V
white
F3
315mAT
A2
12VAC
orange
F2
4AT
A1
37
38
39
40
AC-1
12VAC
AC-GND
0VAC
N2
U2
Condensator
U1
V1
W1
N
N
W5
V1
U1
W1
W
V
U
N
Diagram 5 – Electrical diagram 400V – 3 phase 500&700
fuel store
13
DIAGRAM 5.1
09.01.2012 MM
1 x 230VAC + N + PE
TWIN HEAT
El-diagram
TH2006 M20-80 Inwerter
X5
1
2
3
JE776
4
5
6
7
8
9
10
11
12
13
X6
Alarm
0VDC
12 VDC
14
15
16
17
18
24VAC
19
20
21
X11
Power Supplay
1 x 230V AC
+ N + PE
M
Cirkulations
pump
Burner
O2 +Signal
O Volt Signal
8 5 6
Lambda
Sonde
Black
7
PE
Grey
White
White
0V AC
12V AC
8 5 6
N
L1
W2
7
N
W
N
22
23
24
1
1
2
2
W3
N
25
26
27
28
29
30
31
32
X3
V
W4
3
3
4
4
N
F4
315mAT
Blower
L3
0VAC
12VAC
41
42
43
44
45
46
1 2 36
Inverter
N2
U2
11 14
Steering box
Stokermotor
12VAC
orange
X9
W5
A2
Brown
Black
White
Yellow/
Green
Blue
Black
Blue
Grey
Stoker
Motor
Brown
A1
230VAC
X8
N
X1
A1
13
F2
4AT
N
12VAC
A2
14
W1
X2
0VDC
37
38
39
40
0VAC
L2
L1
T3
V1
X10
Watertemp
NTC
X4
U
High Tempartur
JP3
F1
4AT
33
34
35
36
12VDC
12VAC
T2
T1
Pink
24VAC
Red
0V
white
F3
315mAT
U1
V1
U1
W1
Trafo
U
V
White
W
Black
X7
N
Blue
Brown
Yellow/
Green
Diagram 5.1 – Electrical diagram 230V – 1 phase 500&700
fuel store
14
U
V
W
N
U3
DIAGRAM 5.2
1
2
3
Contaktor Safty
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
O2 +Signal
Sort
Grå
Hvid
Hvid
O Volt Signal
0V AC
12V AC
22
23
24
12VDC
25
Lid Safety Switch
26
12VDC
27
Hot Bolier sensor
28
29
30
31
32
N
NTC
41
42
43
44
45
46
Bolier tempsensor
JP3
F1
4AT
33
34
35
36
12VDC
0VDC
37
38
39
40
12VAC
0VAC
0VAC
T2
T1
L2
L1
L3
T3
lysrød
24VAC
rød
0V
white
F3
315mAT
A2
12VAC
orange
F2
4AT
A1
12VAC
ACGND
AC-1
N2
U2
Condensator
U1
V1
W1
N
N
W5
V1
U1
W1
W
V
U
N
Diagram 5.2 – Electrical diagram 400V – 3 phase 1400 fuel
store
15
09.01.2012 MM
1 x 230VAC + N + PE
TWIN HEAT
El-diagram
TH2006 M20-80 Inwerter 1400L
Alarm
1
2
3
0VDC
4
5
6
7
8
9
10
11
12
13
12 VDC
Rotor
Motor
O2 +Signal
14
15
16
17
18
24VAC
19
20
21
Power Supplay
1 x 230V AC
+ N + PE
M
Cirkulations
pump
Burner
Lambda
Sonde
8 5 6
7
1
1
2
2
W3
N
3
3
W4
4
4
N
F4
315mAT
X2
Blower
0VDC
X3
High Tempartur
8 5 6
0V AC
Black
7
O Volt Signal
PE
N
L1
33
34
35
36
12VDC
22
23
24
12V AC
Grey
White
White
X1
12VAC
11 14
Steering box
Stoker/
Rotormotor
1 2 36
Inverter
X9
A2
Blue
Brown
Brown
White
Black
Blue
Yellow/
Green
Black
Grey
W1
Stoker
Motor
V1
U1
A1
230VAC
X8
X7
Yellow/
Green
Trafo
W
Black
X4
0VAC
X5
N
W2
N
W
V
Watertemp
NTC
JP3
V
White
41
42
43
44
45
46
F1
4AT
U
X10
12VAC
X6
X11
L2
25
26
27
28
29
30
31
32
U
A1
13
37
38
39
40
L3
12VAC
12VAC
orange
F2
4AT
L1
N2
U2
Pink
24VAC
Red
0V
white
F3
315mAT
0VAC
A2
14
T3
T2
T1
W5
N
N
W1
V1
DIAGRAM 5.3
U1
N
Blue
Brown
JE776
16
Diagram 5.3 – Electrical diagram 230V – 1 phase 1400 fuel
store
17
Diagram 6 – Electrical diagram, Start – stop signal for
external auger
(Only for plants provided with automatic fill in)
DIAGRAM 6