Wood logs boiler with a gasi�cation e�ect IGNIS 20-40 KW

INSTRUCTIONS MANUAL for usage and maintenance

Prhovacka bb 22310 Simanovci, SrbijaTel/Fax. +381 22 480404 +381 63 259422o�ce@termomont.rs www.termomont.rs

May 17, 2011

Contents

1 Boiler design and properties 2

1.1 Dimenzije . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 Technical properties according to EN 303-5 . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 On product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2 How It Works 3

3 Recommendations for boiler shipment and storage 4

3.1 Delivery form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43.2 What's in the box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4 Boiler installation 5

4.1 Boiler placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54.2 Chimney . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

5 Connecting the boiler with a central heating system 7

5.1 Closed system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75.2 Closed system combined heating with solar panels . . . . . . . . . . . . . . . . . . . . . . 85.3 Closed system combined heating with solar panels . . . . . . . . . . . . . . . . . . . . . . 95.4 Open system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

6 Boiler In Use 11

6.1 Circulation Pump Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116.2 Maintenance and cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

7 Safety features 11

7.1 Thermal safety in case of overheat (closed systems) . . . . . . . . . . . . . . . . . . . . . . 11

A Deklaracija o Konformnosti 13

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1 Boiler design and properties

1. Upper door for placing wood-logs 2. Secondary air inlet (manual regulation) 3. Lower door for cleaning4. Primary air regulation 5. Thermostatic draught regulator 6. Chain for air regulation 7. Connectors forsafety heat exchangers 8. Connection for excess water outlet 9. Sensor placement 10. Flue box 11. Flue 12.Secondary �ue (�ap) 13. Secondary �ue �ap handle 14. Opening for cleaning the �ue box 15. Fill/Drain tap16. Return 17. Base 18. Flow

1.1 Dimenzije

Type IGNIS Weight (kg) A(mm)

B(mm)

C(mm)

D(mm)

E(mm)

F(col)

G(mm)

H(mm)

I(mm)

L(mm)

IGNIS 20 320 726 648 468 480 200 2 490 1220 900 845IGNIS 30 340 736 858 578 590 200 2 660 1220 900 1045IGNIS 40 350 736 1135 578 590 200 2 860 1220 900 1245

1.2 Technical properties according to EN 303-5

Nominal power IGNIS (KW) 20 30 40Power range (KW) 15-20 20-30 30-40Necessary draught (mbar) 25 25 28Water content (l) 45 60 70Flue gases temperature (at nominal power) (◦C) 200 200 200Heating chamber volume (dm3) 50 80 100Mass �ow at nominal power (kg/s) 0,016 0,021 0,045Electrical network (V/Hz) 230/50 230/50 230/50IP Protection 30 30 30Temperature regulation range (◦C) 60-90 60-90 60-90Min. temperature of the return line (◦C) 60 60 60E�ciency 76% 76% 75%Boiler class 2 2 2

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1.3 On product

• Boiler primarily uses dry wood as fuel with caloric value > 15 MJ/kg, max. moisture content 15%;

• Boiler is produced following the guidelines of the European norm EN 303/5;

• According to norm demands inner walls of the boiler are 5 mm thick;

• Combustion takes place inside the heating chamber specially designed to put large amount of wood-logs

• Single combustion load can hold up to 6 hours

• Boiler comes with removable ash-tray, cleaning kit and thermometer;

• The upper zone of the boiler has a special round shape made of �reproof ceramics with turbulatorsfor optimum e�ciency;

• Water test is done at 6 bar pressure.

2 How It Works

IGNIS uses wood-logs - by its construction it could be called a 'boiler with wood gasi�cation e�ect'.Following image depicts the combustion principle of this boiler.

1. Combustion chamber 2. 'Catalyst' with tubulators 3. Heat exchanger of the safety valve line 4. Tubu-lators (heat exchangers inside the upper zone) 5. Secondary �ue opening 6. Flue box (a part of the heatingchamber around the �ue) 7. Boiler water 7.1 Boiler water around the �ue chamber 8. Secondary air inlet 9.Primary air inlet 10. Return 11. Flow

As IGNIS is similar to wood gasi�cation boilers, the main properties of the wood gasi�cation boilerswill be outlined �rst. A wood gasi�cation boiler, thanks to its special geometry, and thanks to use of the

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fan, brings the woodlogs in the state of 'gasi�cation' - the process where light weighted hydrocarbons. The�ame has a specyphic blue colour and the e�ciency of such solid fuel boiler is 10-15% greater than that ofthe conventional ones. Another interesting property of wood gasi�cation boilers is that the woodlogs areplaced in the upper chamber and the �ame is inverse - going upside down contrary to conventional boilers.

Wood gasi�cation combustion requires a constant and stationary boiler operation. It is thus necessaryto have an additional heat tank to accept the excess heat made by boiler. It is also necessary to perfectlyadjust temperatures between the heat tank, �ow and return line of the boiler to prevent condensation. Allin one, wood gasi�cation allows maximum comfort with wood-logs as a fuel, but with certain investmentto be made into additional equipment.

The IGNIS boiler �lls the room between the less pricey conventional boilers, which demand re�llof wood more often and maximum comfort yet more pricey wood gasi�cation boilers (with heat tank).Because of its technical construction IGNIS allows the wood gasi�cation e�ect (in amoutn much lessthan 'real' wood gasi�cation boilers) but only using the natural draught of the boiler, without a fan andwithout a necessary heat tank. What is still necessary is the protection against condensation (mixedvalve, by pass of the boiler). IGNIS does not have an inverse �ame.

As it does not posses the automatic regulation via fan, optimum combustion is achieved by setting theprimary and secondary air. Primary air is controlled by the draught regulator (to be ordered separately)and the secondary air is to be set manually.

In which way the wood gasi�cation e�ect is achieved? Wood gasi�cation process takes place in theupper zone of the boiler - within the so-called '�reproof catalyst'. This is a special cylindric part of theheating chamber. On its upper side there are special heat exchangers (tubulators). Below the catalystwith presence of secondary air, at very high temperatures, solid particles are accelerated to certain leveluntil they combust completely. Short-chain hydrocarbons are released. Flue gases are passing throughturbulators - in contact with increased surface of the tubulators �ue gases are additionally cooled down -exit �ue gas temperature is thus lower compared with conventional boilers. The e�ciency is higher. Theconcentration of dust, particles and COX/NOX is lower.

IGNIS has a secondary �ap inside the chamber. The role of this is to shorten the passage of �uegases and increase the draught in the boiler when necessary (during ignition for instance). when th e�reis stable this secondary �ap should be closed. IGNIS also has a so-called '�ue-box'. Water content of theboiler is maximized occupying a part of the �ue chamber.

3 Recommendations for boiler shipment and storage

3.1 Delivery form

The boiler comes in three parts, boiler chamber, pellet storage and the boiler housing packed separately.Chamber is wrapped with plastic sheet, and upper door containing �reproof glass should have a smallstyrofoam protection sheet. The whole set is transported on wood pallet.The boiler must always stand in its vertical position. The rotation of the boiler during the shipment orinstallation represents a serious risk and can lead to damaging the boiler. It is forbidden to stack boilersvertically one onto other.The boiler can be stored only in closed rooms with no atmospheric in�uence. The humidity in the storingroom also must not exceed the critical value of 80%, so as not to create any condensate. The temperatureof the storing room must be in the range of +/- 40 �C.

3.2 What's in the box

The following parts are supplied together with the boiler:

• Cleaning kit

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• Cleaning brush

• Warranty paper

4 Boiler installation

4.1 Boiler placement

The boiler room should have air-conditioning. The boiler should be mounted in the boiler room permitingaccess to all its parts as shown below:

4.2 Chimney

Boiler connection to the chimney is shown in the �gure:

Proper dimensioning of the chimney is a very important premise for optimum boiler performance.The purpose of the chimney is to take out the products of combustion but also to secure necessary airdraught in the boiler. The graph shows how to chose the necessary height for the chimney as a func-tion of chimney opening. Proper chimney insulation is very important and should be at least 50 mm thick.

Depending on the necessary draught of the boiler, the cross section and the height of the chimney aredetermined. Please advise technical material given by chimney producer. Minimum chimney height forwood boilers is 6 m. Round chimney made of stainless steel modules is recommended in order to keepthe condensation in�uence low.

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5 Connecting the boiler with a central heating system

5.1 Closed system

The following schemes show how to connect the boiler to the central heating installation with or withouta heat accumulator tank:

System parts: 1. Boiler 2. Heat accumulator 3. Heat exchanger 4. Non-return valve 5. Mixing valve6. Pump of the radiator heating 7. Automatic regulation for the radiator heating 8. Expansion vessel 9.Exchanger pump 10.Valve 11.Thermo-manometer 12. Expansion vessel 13. Four-arm mixing valve 14.

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It is not necessary to install the heat accumulator. However, it is recommended.For 1 KW power ofthe boiler, a capacity of the heat accumulator of 25-50 l is recommended. One must also bear in mindthat the power of the boiler must be enough in order to both warm up the water in the accumulator,as well as to provide direct feed to the installation in very cold periods � the chosen power of the boilershould be 1.5 higher than the power of an oil-gas boiler for the given squaring.

It is recommended that the closed central heating system is supplied with an expansion tank, thecapacity of which must amount to at least one tenth of the total capacity of the system (including thewater volume in the boiler). The system must also have an automatic aeration valve with the help ofwhich air will be eliminated from the system. The use of a safety valve is obligatory (with a 2-3 barthreshold, depending on the power of the boiler) and it must be mounted near the boiler.

It is also necessary that the system has a thermometer and manometer in order to read the temperatureand pressure in the system. In case of using conventional solid fuel, the temperature of the return lineshould not fall below 60�C, so as to avoid leaking, i.e. condensation in the boiler, which can further leadto corrosion. The temperature of the starting line should not fall below 70�C. It is recommended to usea four-arm mixing valve on the return line of the boiler or a regulation group such as LADDOMAT 21.It is also recommended to mount a �lth catcher on the return line.

Quali�ed installer should be entrusted with the mounting of the heating and the initial operation.This must be a person who will take over the responsibility and guarantee the correct operation of theboiler and of the complete central heating system. In the case of an incorrectly planned system withmanifesting de�ciencies caused by the respective person's incorrect installation of the system, which canagain lead to an incorrect operation of the boiler, the complete liability for the material damage andpotential new costs arising in relation to it is borne exclusively by the person who was entrusted withthe mounting of the central heating system, and not by the boiler manufacturer, sales representative orseller.

5.2 Closed system combined heating with solar panels

The following scheme depicts a heating system connected over a hybrid solar boiler within an accumalationtank:

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System parts: 1. Boiler 2. Heat accumulator 3. Heat exchanger 4. Non-return valve 5. Distributor 6.Mixing valve 7. Pump of the radiator heating 8. Pump of the �oor heating 9. Regulator of the automaticregulation for the radiator heating 10. Regulator of the automatic regulation for the �oor heating 11. Receiver12. Expansion tank 13. Exchanger pump 14.Valve 15.Thermo-manometer 16. Filth catcher 17. Four-armmixing valve 18. Safety valve

5.3 Closed system combined heating with solar panels

Termomont in its o�er of solar boilers also has a 'hybrid' version of a heat accumulation tank andstainless steel solar boiler in one: ATS combined tank. When boiler heats up the 'technical' water insidethe boiler - as do the solar panels through the spirale. The drinking water is inside the inner vessel which

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is heaten indirectly by the technical water.

5.4 Open system

The following scheme shows how to connect the boiler to the open central heating system:

System parts 1. Boiler IGNIS 2. Valve 3. Thermo-manometar 4. Boiler circle pump 5. Three-way mixingvalve or LADDOMAT 21 6. Heat accumulator tank 7. Three-way mixing valve 8. Automatic three-way mixingvalve 9. Circulation pump for radiator heating 10. Open expansion vessel 11. Automatic regulation MRTRPlus (First) 12. Heating circle 13. Sanitary water circulation pump 14. Sanitary water accumulation tankSOLAR I

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6 Boiler In Use

6.1 Circulation Pump Thermostat

Boiler should be equipped with a thermostat for the system circulation pump. The thermostat thresh-old can be set on certain value and only when the temperature is higher than that, the circulation pumpwill be turned on.

This thermostat is primarily used when �ring with solid fuel, in order to prevent the low temperatureof the return line which can lead to condensation as a consequence. As the heating up process with woodpellets is usually much faster compared to conventional wood, the e�ect of condensation should not takeplace at all when burning pellets. The default value for temperature threshold is set at 60 ◦C.

6.2 Maintenance and cleaning

Using wood pellets as a primary fuel means very low level of ashes (less than 1%). The cleaning of theboiler can thus be performed once per week and does not take more than 5 minutes. Burner ash-trayshould be however cleaned every day or two - operation which takes less than a minute.

Using pellets means also low temperature of the �ue gases due to the high e�ciency of combustion.This means the boiler would last much longer compared to combustion with traditional solid fuels suchas wood or coal.

7 Safety features

7.1 Thermal safety in case of overheat (closed systems)

Burner has two main safety features: The internal feeeding auger prevents �re passing from the boiler tothe burner body. The other feature is that if the temperature of the �ue gases does not drop below 250◦C the burner will be forced to work with minimum power (which means minimum quantity of pelletsadded every time).

For additional hydraulic protection in the closed systems it is necessary to install to safety thermalvalve shown on image (to be bought separately, not an integral part of the boiler).

If for some reason the temperature of the water inside the boiler should exceed 95◦C this valve wouldrelease the water from the water supply system to cool down the water temperature inside the boiler.

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Connection scheme for the thermal safety valve: 1. Cold water entering from the water supply system 2.Cold water entry into boiler 3. Hot water going outside the boiler 4. hot water ending in the sewage watersystem 5. Thermo-valve sensor

To connect the safety valve:

• Connect the sensor of the valve (outter thread 1/2") at depicted place on the boiler, position 5(inner thread 1/2")

• Connect the cold water entry (on valve's input is marked with C) than connect the exit line (valvemarked with:→) with the corresponding exit line on the boiler (position 21)

• Connect position 21 (on the boiler) with the input line on the valve (valve is marked with: ←)

• Connect the valve (marked with S) to the sewage system.

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A Deklaracija o Konformnosti

We, Termomont d.o.o. with legal seat on the address Prhova£ka street bb, 22310 �imanovci, Republicof Serbia, under sole responsibility declare that:

Kotlovi na £vrsto gorivo tipa IGNIS 20, IGNIS 30, IGNIS 40

produced 2010. and 2011. as by its construction, design and performances are in accordance with thefollowing norms and directives prescripted by the European Union:

• 97/23 EEC �Pressure device directive�

• EN 303/5 �Norm for solid fuel boilers"

�imanovci, May 17, 2011

Signature of the responsible person

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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