Bosch boiler with pellet burner Pelet Brenn 2000

Boiler with pellet burner

Bosch boiler with pellet burner Pelet Brenn 2000 Bosch Termotechnika s.r.o.

PRAHA

Krnov 28.5.2015 v.2.0

KRNOV

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KrnP/QMM-STI | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce, kopírování, distribuce, jakožto i prihlášení autorských a jiných ochranných práv.

MĚSTO ALBRECHTICE


Steel boiler with pellet burner  

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Pelet Brenn 2000 25 kW Output 6 till 27 kW For installation with boiler from Bosch production: • Dakon DOR F • Buderus Logano S111-2 • Junkers Supraclass S • Bosch Solid 2000 B

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Burner Pelet Brenn 2000 25 kW with solid fuel boiler 

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High efficiency • set of boiler and pellet burner Comfortable heat solution • tank 195 l (140 kg) • heating about 2-4 days w/o filling • house about 100m2, standard insulation Simple setting, easy operation and cleaning Room thermostat connection Suitable for boilers output 20 and 27 kW The most convenient way of heating with solid fuel • Pellets – wood, A1 by EN 303-5, DIN plus, EN ISO 17 225-2

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Set for pellet heating • Steel boiler from KrnP • Pellet burner with control unit • Conversion set 8 738 104 123 for boilers 20,24 • Conversion set 8 738 104 121 for boilers 25Max/27, 32, 32D • Fuel tank • Fuel auger • Door for burner installation • Bricks of combustion space

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   

Steel boiler from Bosch production • Dakon DOR F • Buderus Logano S111-2 • Junkers Supraclass S • Bosch Solid 2000 B High efficient vertical flue gas ways Easy cleaning from the top Good equipment included Boiler body from steel sheets • EN10025-1 235JRG2 • thickness 4 - 5 mm

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 

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Pellet burner • Pelet Brenn 2000 25 kW, output 6 – 27 kW Easy and quick installation on boiler doors Electronic controller • Automatic regulation of operation • STB • Time program Heat output setting • by object size • by heat energy Efficient combustion for all prescribed types of pellets

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Burner Pelet Brenn 2000 25 kW with solid fuel boiler

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Fuel tank • Volume 195 liters / 140 kg of pellets • Easy and quick assembly from delivered parts • Boiler operation for one filling 3 – 4 days • house about 100 m2 • standard insulation • Fuel feeding by auger from the tank bottom • Complete emptying of the fuel from the tank

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Pellet auger • Auger principle of fuel feeding • Automatic operation of feeding by output power • Settable quantity of pellets by burner output • Delivery max. 8,4 kg/hour, to set burner output power • Adjusting the length of the connecting pipe so that the pellets freely distributed from the feeder to the burner • Simple assembly

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Burner controller ST-717 • Separate control box, mounted to fuel tank • Control of the fan, feeder, CH and DHW pump • Safety thermostat STB • Additional modules Output control • Flow water sensor or room thermostat Error message on CU display Setting • output power • maximal temperature of flow water • operation mode • fan speed • pellet volume • week time program

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Bricks in combustion space • regulate the flow of flue gas in combustion space • High temperature concrete • easy installation • wear parts • Two sizes for boilers • 20, 24 • 25Max/27, 32, 32D

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Burner description

1. Burner body 2. Air channel 3. Internal wall 4. PCB 5. Internal feeder motor 6. Photocell 7. Fan 8. Burner tube 9. Burner holder 10.Grate 11.Internal auger 12.Burner wall 13.Heater 14.Pin 15.Cover 16.Bushing 17. Feeder temp. sensor

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Technical data of boiler with pellet burner Parameter

Unit

Boiler size

-

-

20

24

25Max/27

Nom. output with burner

kW

kW

20

24

27

Min. output with burner

kW

kW

6

6

6

Efficiency at nom. output

%

%

85

85

84

Efficiency at min. output

%

%

81

81

83

Kg/h

Kg/h

4,9

5,5

6,4

-

-

4

4

4

Fuel consumption Boiler class

DOR F/S111-2 with Pelet Brenn 2000 25 kW

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Technical data Parameter

Unit

Value

Output power

kW

13,4 – 34,1

Fuel consumption

kg/h

2,9 – 7,2

Voltage

V/Hz

230/50

-

IP X0D

Input power

W

100

Input power of igniter

W

300

Burner weight

kg

11

Fuel tank volume

ltr/kg

195/140

Pellet dimension (diam./length)

mm

6/30

Requested chimney draught

Pa

20

El. shield protection

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Device dimmension Boiler size 20 24 25Max/27 32 32D

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A [mm] 990 990 990 990 1060

B [mm] 730 730 830 830 830


Burner installation 

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Unscrew the two screws on the bottom hinge and remove the ash door Remove the cotter pin of grate lever, disconnect lever and grate, remove grate lever Remove rotary grate and front grate

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Bricks for boiler size 20, 24 kW (8 738 104 123)

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Bricks for boiler size 25Max/27, 32, 32D kW (8 738 104 121)

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Insert ceramics bricks into the boiler

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Burner installation   

Install and screw the door for the burner to the boiler Install the burner into door The tube for pellet input install to the burner depend on fuel storage tank position (better on right side from the boiler)

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Close the tertian air inlets by covers

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Fuel tank assembly 

Assemble and set up the fuel tank next to the boiler (right / left)

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Fuel tank assembly 

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Auger tube insert into the tank through a seal ring at the lowest point of fuel tank Fill the tank by pellets

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Burner assembly 

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Fix the CU to front wall of the fuel tank Unscrew the cap under the flow water outlet of the boiler and install well ½" for temperature sensors Insert into the basin and fix • temperature sensor • STB sensor

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Burner assembly 

To the burner terminal engage • cable from CU – 2, 3, 5 – pole connectors • Cable bushing fix to burner body

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Connection of control unit

El. supply Main switch

Burner

PE / N Internal feeder Fan Heater Signal common. Feeder sensor Fan sensor Flame sensor

Buffer sensor bottom Buffer sensor top DHW sensor CH sensor

STB

2x RS

CH pump

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DHW pump

Main feeder


Control unit ST-717 

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Control of boiler operation  Fuel feedeing  Combustion air Control  CH pump  DHW pump  buffer Additional modules  Mixing circuit module (up to 2)  GSM module  Internet module  Roo thermostat  Data communication RS  On/Off

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Control unit ST-717 Description  

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Big graphic display with all necessary data Control by rotating switch  By rotation select item or set value of parameter  By pressing confirm selection or set Taste  - Stand-by  Exit – leaving actual menu /item w/o change Actual version of SW  1.2.0 ZPID STUB X99 ST-717NK

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Control unit ST-717 – function Basic display

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DHW operation mode, level of the fuel in storage tank Operation mode of the boiler Time, date, roomstat status Temperature of CH system  actual  requested Fan operation or Temperature of DHW  actual  requested Feeder run Fan output CH Pump Heater DHW pump

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Control unit ST-717 – operation modes Firing  Activated by user  Filling of the feeder and burner by fuel  Ignition by hot air  Active until flame is detected Operation  Primary operation of the boiler  Boiler works on nominal power to achieve requested boiler temperature  Then switch to minimal power, the temperature should decrease  If temperature decrease by hysterese, boiler switch to maximal power again  If requested temperature is exceeded, boiler is switch to Damping mode

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Control unit ST-717 – operation modes Dumping  Activation  By user for boiler switch off  At exceed of boiler temperature by 5°C  External feeder stops , internal feeder works  Fan is running to fuel burn out / flame fade  Pump in operation  Cleaning procedure by fan  Pump are switch off at activation temperature  In case of exceeding of boiler temperature start new ignition of the burner ater end of cleaning proces

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Control unit ST-717 – Main menu               

Screen Firing up Fuel tank full Requested boiler temperature Requested DHW temperature Manual operation Internal feeder – feeders are off, only fan Parameters for maximal power Parameters for minimal power Week based control of boiler temperature Pump mode Installer settings Service settings Factory settings Software version

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Control unit ST-717 - Screen   

Basic information about status of the boiler Valve statust (additional module is needed) Other screens are without sense for boiler and CU configuration

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Control unit ST-717 – Firing up    

Tray full

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Start by user Filling up of the feeder and burner by the fuel Ignition of the fuel by hot air Finish of this mode in detection of the flame by photo cell, switch to Operation mode

After filling up of the fuel tank is performed this choice On basic screen is shown level of the fuel in tank. This level is calculated from feeder operation. At first the fuel tank has to be calibrated

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Control unit ST-717 – Temperatures of CH and DHW 

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Temperature of flow water  Requested temperature  Setting is possible from basic screen Temperature of DHW  Requested temperature od DHW

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Control unit ST-717 – Manual mode 

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Feeder  On/Off Internal feeder  On/Off Fan  On/Off Blow force  Set of fan power 1 – 100% CH pump  On/Off DHW pump  On/Off Heater  On/Off Valve 1, Valve 2 – if mixing module is used  Open / Close / Stop / Pump

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Control unit ST-717 – Max. / min. power 

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Maximum power – setting of burner parameters for nominal power Minimum power – setting of burner parameters for minimal power (30%)  Feed time  Time of fuel feeding in seconds  Feed interval  Time when feeder is stop in seconds  Feeding period – summa of feed time and feed interval  Blow force  Fan output in % of maximum power  Fan starts always on 100% power due to clear from the dust

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Control unit ST-717 – Weekly control 

Week-base regulation – regulation of CH and DHW temperatures or/and damping mode every day/hour  Daily cycle operation  Boiler is damped in requested time  Boiler week-based operation  DHW week-based operation  Temperatures are changed in requested time  Mode 1 – day /hour control of temperature  Mode 1 setting  Setting of damping time  Setting of temperature change  The time is necessary to set

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Control unit ST-717 – Pump modes 

Pump modes  House heating  DHW pump is off  Water heat priority  The DHW tank is charged if internal temperature is below requested  Parallel pump  In case of request to heat up of DHW tank is CH pump in operation as well  Summer mode  CH pump is off  Buffer – storage tank for CH water  Buffer is charged by CH pump  Pump start if Bottom temperature is below set  Funkce horního čidla ??

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Control unit ST-717 – Installers menu 

Fitters menu – setting of boilers parameters for system  Boiler – correction parameters of burner  Ignition parameters – for firing of the burner  Ignition function - ??  Minimum operation - behavior at req. temperature  Tray full / Empty tray – calibration of fuel tank  Temperature settings  Valve1, 2 – setting of valve parameters  Room regulator – type and function of roomstat  GSM module – setting of GSM control  Internet module – setting of internet control  Clock / Date – setting of time  Encoder sensitivity – sensitivity of rotation switch  Langue version – set of communication language  Display contrast – setting of best display readability  Factory settings – reset of all parameters to factory values

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Control unit ST-717 - Boiler 

Boiler – modification of feeders and fan operation  Fan coefficient  Adjust of the fan speed for best combustion  Feeder coefficient min.  Feeder coefficient max.  Optimal setting of fuel feeding based on caloric value of the fuel  For minimal and maximal output

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Control unit ST-717 – Ignition parameters 

Ignition procedure  Step 1 – Blow-by  fan is running for a specified period of time.  Step 2 – Initial fuel feeding  feed for filling up of the burner  Step 3 – Heater  Ignition of the fuel by hot air from the heater  Photocell indicate flame in combustion space  Step 4 – Delay  Stabilization of the flame

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Control unit ST-717 – Ignition parameters 

Ignition parameters  Internal feeder delay  Internal feeder is deactivated after the main feeder  Fire sensor threshold  Level of flame signal to detect flame – end of step 3  Heater delay  Max time for ignition – detection of the flame  Fan speed  Fan output for ignition – step 3  Fan speed delay  Fan output for stabilization – step 4  Firing up delay  Duration of step 4  Duty time  Feeder operation during step 4  Pause time  Feeder pause during step 4

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Control unit ST-717 – Minimum operation 

Minimum operation  Behavior of the boiler when boiler temperature reached requested value  On  Boiler is switched to Damp mode  Off  Boiler is switched to minimal output mode

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Control unit ST-717 – Fuel tank calibration Calibration of fuel tank  Tray full – calibration of fuel tank  Before calibration is the tank filled and then carry out this option.  Empty tray  After consumption of the fuel from the tank this option is made  CU now has information about the fuel consumption and can be calculated content of the fuel in the tank based on the operation of the feeder  After new filling of the tank is made option Main menu -> Tray full  The indication of the fuel amount in the tank appears on the main display or on the controller

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Control unit ST-717 – Temperature control 

Temperature settings  Boiler hysteresis  If temperature of boiler fall under requested by hysteresis value, boiler switch to maximal operation  DHW hysteresis  If DHW temperature fall under requested by hysteresis value, the DHW pump charge DHW tank  Pump switch on temperature  Minimal temperature of flow water when start both pumps

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Control unit ST-717 – Valve 1, 2 

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Registration  Input of module number for relevant valve Valve status  On/Off of the valve Valve setpoint temp  Setting of requested temperature on the valve Opening time  Maximum time for full valve opening Single stroke  Max. value of valve opening change in case of the change requirement Minimal opening  Minimal valve opening Valve type  Floor heating mixing circuit  Radiators mixing circuit

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Equitherm regulation  On/Off  Parameters setting for equitherm regulation  work. point 1 – heating water temperature at outside temperature -20°C  work. point 2 – heating water temperature at outside temperature 0°C  work. point 3 – heating water temperature at outside temperature +20°C

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Return inlet protection  Protects boiler from to cold return water from heating system  On/Off  Minimal temperature of return water  Maximal temperature of return water Additional sensors  Sensors of return water and outside temperature are used from  Own unit  From second, main unit

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Pump activation  Condition of the switch on of valve pump  Always – sustain operation  Never – pump is stop  Above threshold – at min. temperature  CH pump activation temp. – set of temp. Factory settings  Set of valve parameters to factory value Valve removal  Valve cancellation

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Control unit ST-717 – Room regulator 

Room regulator  On/Off  Standard regulator – On/Off  TECH regulator – Data regulator RS  Room regulator device  Off – the room regulator is off  CH boiler – when the room temperature is reached, the boiler temperature is reduced  CH pump – when the room temperature is reached, the CH pump off

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Control unit ST-717 – Other settings 

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GSM module  On/Off of module for mobile control by SMS Internet module  Setting of communication parameters Clock  Setting of actual time Set date  Setting of actual date Langue version  Setting of communication language Display contrast  Best readability of the display Factory settings  Return to producer parameters values

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Control unit ST-717 – Service menu 

Service menu  Setting of factory parameters for basic behavior of the boiler  Relevant for safety of the boiler  Access code

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Control unit ST-717 – Service menu  

Select PID Work  Operation control  Cleaning period  Feeding time min  Feeding time max  Feeding interval min  Feeding interval max  Min. fan work  Max fan work  Fan speed min  Fan speed max  Power coef. Max  Power coef. Min

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Ignition parameters  Underpour time  Internal feeder delay  Fire sensor threshold  Heater delay  Fan speed  Fan speed delay  Duty time  Pause time Damping parameters  Damping delay  Blow force  Damping protection  Min damping

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Control unit ST-717 – Service menu 

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Temperature settings  Max exhaust temperature  Priority temperature  CH pump emergency  Anti-freeze temperature  Boiler alarm temperature Fire sensor Fan Hall sensor Fan  Code  Fan min  Fan max  Fan speed min  Fan speed max  Growth impulses

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Lambda  First lambda update time  Update time  Oxygen stroke  Fan stroke  Sum  Min change  Max change  Lambda 100%  Lambda 1% Min boiler temperature Flow Display contrast Factory settings

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Control unit ST-717

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Control unit ST-717

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Burner operation setting 

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For proper operation of the boiler with pellet burner • recommended flue gas temperature 170 – 220°C • under pressure in the combustion chamber 12 Pa Required quality according to EN ISO 17 225-2 • A1 – diameter 6mm, length 30 mm (DIN plus) • Caloric value 15 – 18 MJ/kg (4,2 – 5 kWh/kg) Filling the feeder by pellets • Manual mode -> Feeder till auger is filled in by pellets Check delivery of pellets in hour by feeder manual mode • Calculate Feeder time and Feeder interval for requested minimal and maximal output power • Set fan power to best quality of combustion / emissions • Content of CO2 should be app. 15%, O2 app. 5%, CO max. 300 ppm Set rest of parameters by central heating configuration

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Burner operation – Start procedure

Flow water temperature [°C]

80°C

Step 3

Step 2 Step 1

Full output

Step 1

Step 2

Step 3

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Full output

Step 1

Burner output [step]

Step 4


Burner operation – Minimum operation Off Achieving hysteresis, burner switch to max power

Temp. don‘t decrease, burner switch to damp procedure

Flame fade

Feeder stop

Thermotechnology KrnP/QMM-STI | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce, kopírování, distribuce, jakožto i prihlášení autorských a jiných ochranných práv.

50%

30%

Fan output [%]

Start sequence

100%

Max output Min output

59

Start procedure

85°C 80°C 70°C

Damp sequence


Achieving water temperature, burner switch to min power


Burner operation – Minimum operation On Flame fade

Start procedure

Max output

Boiler off

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100%

50%

30%

Fan output [%]

Start sequence

Feeder stop

Damp sequence

80°C 70°C

Damp sequence


Achieving water temperature, burner switch to damp mode


Burner operation – Damp procedure


80°C

Step 3

Step 2 Step 1

Full output

Step 1

Step 2

Step 3

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Full output

Step 1

Burner output [step]

Step 4


Quality of pellets 

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Quality of pellets is important pro reliable burner operation Requested quality by EN ISO 17 225-2 • A1 – diameter 6mm, length 30 mm • (C1 by EN 303-5), DIN plus • heat content 15 – 18 MJ/kg It is not allowed to use of vegetable pellets, grains, pellets with high bark content, etc.

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Quality of pellets Production 

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When processing wood there is also unusable waste This waste can be processed into pellets, without any chemical additives They are variously mixed finely ground sawdust and wood chips It is precisely defined moisture of the components The mixture is pressed through a circular form There is no need for chemical additives Lignin acts as a binder, is contained in the wood Such chipsticks of pellets are made

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Quality of pellets

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Quality of pellets – the mark of quality Good

Certification by DIN CERTCO program

Certification Pelletsverbände (PVD, PVA)

Certification by ÖNorm 7135

Certification by DIN 51731 not certified pellets

Bad

Attention, unknown volume of ash, corrosion risk!

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Quality of pellets – the mark of quality Good

How can you recognize a good pellet? • Ash content < 0,5-1% (DIN Plus < 0,3%) • Lignin content is defined • Max. moisture 10-20% v • Diameter: 3-6 mm, length: 2-3 cm • Made from quality wood • Shiny, smooth surface • No longitudinal or transverse cracks • Low dust content at delivery • The same size of pellets • Clean water at the test

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Burner setting Delivery of pellets / Output power  Control unit  Max output  Min output • Fuel feeding • Feeding pause • Fan speed 

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Fuel delivery setting  Amount

of the fuel in kg per hour  By manually operation of both feeders

Boiler output = feeder time / feeding period * fuel amount * caloric value * boiler efficiency Sample of calculation Feeder time = 15 sec Feeder pause = 5 sec Feeding period = 15 + 5 = 20 sec Amount of the fuel = 8,4 kg/hour Caloric value = 18 MJ/kg = 5,0 kWh/kg Fuel efficiency = 85% Boiler output = 15/20 * 8,4 * 5,0 * 0,85 = 26,8 kW Fan power by combustion quality – CO2 > 15%, O2 < 5% Thermotechnology

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Before starting the burner 

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Check the mounting of the burner to the boiler door, sealing of doors and other parts Connecting of the boiler to the chimney, combustion air inlet, filling the system with water Connecting of the fuel feeder, connecting of hose without bends, feeling of fuel tank Location and fixing temperature sensors in the basin Set the parameters according to the desired operating mode

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Maintenance 

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Regular cleaning of the burner • Clean the grate from the ash or slag (lower quality pellets) • Check the resistance of lighter (155 Ohm) • Photocell control function (t20), position in burner body (lock) • Clean dust from the pellets tank Burner adjustment using a combustion analyzer • max. burner power for min. 10 minutes • Setting O2 to 5% (up to 10%) • at high O2 decrease fan power • CO in range of 150 - 1000 ppm • output power by fuel amount • for lower levels correct fan parameters and amount of fuel

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Alarm messages of CU Message

Cause

Solution

CH sensor fault DHW sensor falut Boiler temo. too high Mosfet temp. too high

Boiler sensor faulty DHW sensor faulty Too high boiler temperature Fan capacitor faulty or wrong fan connection to the burner No fuel

Change the boiler sensor Change the DHW sensor Cool down and reset the boiler Check the fan

Firing up alarm

Hall sensor STB C1 or C2 sensor fault No 50Hz No valve communication

Photo cell faulty Heather faulty Hall sensor faulty Fan faulty Too high boiler temperature STB faulty Sensors C1 or C2 (additional pumps) faulty CU problem Wrong connection Error by valve registration

Refuel the fuel tank Check the feeder motors (int/ext) Check and replace photo cell Check and replace heather Replace fan Replace fan Cool down and reset the boiler Replace STB Replace sensors Replace CU Check the connection Register the valve again

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Problem solving Code

Failure

Cause

Solution

A02

Parasitic flame signal

Short cut of photoconductor

Photoconductor change

Another light source

Removal this light source

STB open

Boiler overheating

Remove the cause of overheating, heating system, temperature setting

Bad STB

STB change

Ignition parameters are wrong

Check the parameters t03, t04

clogged flue ways , chimney

Check the chimney draught remove of dirty

Bad safety feeder thermostat

Safety thermostat change

A03

A04

Safety feeder thermostat open

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Problem solving Code

Failure

Cause

Solution

F02

Parasitic flame signal

Flame signal is detected after end of operation request

Post-ventilation finishing

F05

Air sensor failure

Blocked air sensor tube

Check the tube

Bad fan

Change

Dirty fan wheel

Clean, change

F06

Air sensor disconnected

Cable interrupt

Cable check, sensor change

F10

Flow ware sensor failure

Sensor damaged

Change sensor

Short cut or interrupted sensor

Sensor and cable check, change

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Comments 

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For proper operation of the boiler with pellet burner must be inside of the boiler (combustion space, internal flue ways) vacuum. Therefore minimal chimney draught is 20 Pa Before equipment installing must be checked chimney. Setting of required chimney draft can be adjusted by draught regulator If chimney draft is insufficient (chimney can be blocked), safety feeder thermostat can be activated Starting boilers with pellet burner can be done by servicemen which were trained by manufacturer only , after all checks and inspection (flue gas ways) according to local regulations Operation is possible only in accordance with safety requirements, flue gas ways and other legal requirements The installation company that sells / installs equipment is required to ensure all the checks and inspections, educate customers on safe operation of the equipment and give him all the documents (manuals, protocols, review)

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Thank you for attention Marek Lapiš KrnP/QMM-STI [email protected] +420 554 694 120 +420 603 155 469

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TT/SCZ-ASA14 | 16.9.2013 | © Robert Bosch GmbH 2012. Všechna práva vyhrazena, také pro prípad dalšího používání, reprodukce, kopírování, distribuce, jakožto i prihlášení autorských a jiných ochranných práv.

Bosch boiler with pellet burner Pelet Brenn 2000

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