GREN EG-HOLZ 25 User manual

Installation and usage instruction manual
BOILERS FOR WOOD GASIFICATION
EG- OLZ 25/50kW
Edition 2 from year 2014
1

INTRODUCTION
Dear Sir/Madam, Dear Customer,
We would like to welcome you among t e appy users of boilers made by GREŃ
Company. T e device is a product of long and t oroug researc . T e use and
installation require special attention and following t e requirements t at follows.
T is instruction manual was constructed in t e most complete way and allows for
proper boiler installation, its maintenance and usage t at give maximum satisfaction.
It is necessary to read and understand t e following instruction manual and in case of
any doubts please contact t e person w o installed t e boiler or directly wit t e
GREŃ Company.
During installation and starting of t e boiler it is absolutely necessary to ensure all
safety measures are kept, double-c eck any steps and points t at require it and
make sure t at t e boiler is not subjected to any damage or destruction of t e boiler
or any part of t e equipment as t ese types of damages or destruction is not covered
by t e warranty.
Expecting t at all future guidelines listed in t is instruction will be meticulously
followed we are proud to include you as our customers.
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5 Main rules that must be absolutely followed:
1) 1 Use only timber not longer t an 50cm wit big diameter and excluding any
ot er biomass.
2) It is forbidden to make any c anges to t e construction or settings of t e
boiler.
3) It is necessary to follow t e instruction regarding maintenance and loading of
t e combustion c amber to t e letter.
4) T e boiler must always ave t e main water feed connected and be
connected wit t e installation t at will receive t e eat (Central Heating or
Hot Sanitary Water system) ot erwise it mig t be cause of over eating w ic
mig t result in material damage or injury.
5) Before t e boiler is started it is necessary to c eck if t e boiler room is
properly ventilated and t at ex aust and intake ducts are free of any
obstruction.
Users’ responsibilities:
-Usage and maintenance of t e boiler are t e user’s obligation and e is fully
responsible.
-Not following t e instruction manual mig t result in interference wit boiler
operation, insufficient efficiency and s ortened life-span.
-T e boiler use s ould be done only by persons p ysically and mentally fit.
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Table of contents
5 Main rules that must be absolutely followed:..........................................................................3
1. BOILER I STALLATIO ....................................................................................................5
1.1 CO DITIO S TO EMBED THE BOILER:...................................................................5
2. CHARACHTERISTICS OF THE BOILER...........................................................................6
2.1 PHYSICAL CHARACHTERISTICS..............................................................................6
2.2 HYDRAULIC SYSTEM CHARACHTERISTICS.........................................................7
2.3 SAFETY A D CHIM EY..............................................................................................7
2.4 ELECTRICAL SYSTEM CHARACHTERISTICS........................................................8
2.5 MOTOR CHARACHTERISTICS.................................................................................10
2.6 WATER CIRCUIT PUMP.............................................................................................10
2.7 STB:................................................................................................................................10
3. STARTI G THE BOILER...................................................................................................10
3.1 CO ECTIO S:...........................................................................................................10
3.2 HYDRAULIC CICRUIT CO ECTIO S SCHEME.................................................11
3.3 STARTI G A D STOPPI G THE BOILER:.............................................................13
3.4 WOOD:..........................................................................................................................14
3.5 GE ERAL VERYFICATIO :......................................................................................14
3.6 REMOVI G OF ASH:..................................................................................................15
3.7 TURBULATORS:..........................................................................................................15
3.8 EXHAUST PIPE:...........................................................................................................15
4. UPKEEP A D MAI TE A CE OF THE BOILER:........................................................16
4.1 UPKEEP A D USE OF THE BOILER:.......................................................................16
4.2 MAI TE A CE OF THE BOILER:...........................................................................17
Example of the name plate of the EG-Holz boiler:..............................................................18
4.3 TROUBLESHOOTI G:................................................................................................19
WARRA TY CARD...............................................................................................................20
OTES......................................................................................................................................22
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1. BOILER INSTALLATION
Responsibilities of the mounter:
T e installation of t e boiler must be done by a qualified mounter according to all
applicable laws.
T e installers’ responsibility is to follow all instructions provided by boiler
manufacturer as well as to t e instruction manual and installation guide of t e boiler
and assisting equipment as well as to t e ydraulic system sc ematics.
The mounter will be held responsible for any discrepancy in the installation.
1.1 CONDITIONS TO EMBED THE BOILER:
a) Boiler characteristics
Class: 4 according to t e European Standard EN 303-5:2012;
ydraulic requirements: test pressure 5 bar (0,5 MPa), max working pressure
of t e system: 2 bar (0,2 MPa).
rotation: :
t e power of t e boiler must exceed or be equal to t e max:
Heat acceptance (amount of eat required to eat up t e rooms)
Transport loss, production of water for sanitary purposes, etc.)
b) The room in which the boiler will be placed:
T e boiler must be placed in a room t at is a separate space wit air temperature of
no less t an 15 dg. Of C.
T e room must comply wit all laws and regulations. Suc room s ould be properly
prepared and equipped in sufficient ventilation. In order to facilitate easier
maintenance of t e boiler and its parts it is necessary to ensure sufficient space
around and above t e boiler.
WARNING: T e warranty of t e w ole system is void in case t e boiler or any part of
t e equipment t at can cause damage or destruction (c lorine, acid, too ig
umidity).In case of any doubts please contact t e producer.
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c) Boiler placement:
It is necessary to ensure 50cm of free space on t e side of t e boiler, 80cm at t e
back and 100cm on t e front to facilitate t e loading of t e boiler wit timber and
conduct maintenance.
2. C ARACTERISTICS OF T E BOILER
2.1 PHYSICAL CHARACTERISTICS
a) Boiler weight:
BOILER TYPE BOILER WEIG T [kg]
EG-HOLZ 25 500
EG-HOLZ 50 690
Transporting the boiler: On t e pallet using a fork lift or specially prepared loader.
BOILER ROOM CEILING EIG T (minimal)[mm] 2350
b) Water capacity:
BOILER TYPE WATER CAPACITY [l]
EG-HOLZ 25 120
EG-HOLZ 50 134
c) Power of the boiler
Range of boiler power for t e timber wit 20% umidity per gross weig t and wit
calorific power rating (P.C.I) w ic is equal or less t an 3,8 kW /kg.
BOILER TYPE POWER [kW] POWER RANGE
EG-HOLZ 25 25-30 0,25-0,30
EG-HOLZ 50 50 0,50
d) Combustion process and filling height:
BOILER
TYPE
Temperatu
re of flue
gas [°C]
Mass flow
of flue gas
[kg/s]
Mi . i let
water
temp.
[°C]
Time of
bur i g
[h]
Max. filli g
height
[mm]
Volume of
fuel
chamber [l]
EG-Holz 25
kW
150 72 820 220
EG-Holz 50
kW
150 72 1050 280
e) Water flow:
6
Power of boiler [kW] 25 50
0,60 1,19
0,30 0,60
Water flow for temperature
difference equal 10°C [l/s]
Water flow for temperature
difference equal 20°C [l/s]

e) Basic dimensions of EG- olz boilers:
Dimension EG- olz 25 kW EG- olz 50 kW
A1388 1679
B1133 1348
C905 1066
D1533 1824
E1831 2120
F705 713
G926 1105
h1 65 111
h2 433 489
h3 1204 1476
h4 1574 1863
7
Figure 1: Basic dimensions of EG-Holz boilers

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Figure 2: EG-Holz cross section

2.2 HYDRAULIC SYSTEM CHARACHTERISTICS
a) ydraulic connections:
T e ydraulic connections must be done by a qualified specialist and include a 3
point 2 c annel t ermostatic valve, w ic opens at 72ᵒC and will be integrated wit
t e water circulation pump so t at t e water return temperature is always more or
equal to 72ᵒC. T is is to prevent t e boiler corrosion.
Pressure-gauge eig t must correspond wit loss of water in t e system.
Too ig levels of pump mig t cause t e 72ᵒC t ermostat valve to open, t is mig t
cause water condensation on t e eat exc anger. T e division of eat takes place
t anks to t e t ree or four way valve (3-way for floor eating circuit, 4-way for wall
eaters).
T e eat exc anger for sanitary water cannot under any circumstances be operated
by any ot er device. It must be connected in a way t at matc es t e ydraulic
sc ematics and must be equipped wit a t ermostatic regulator on t e water outlet
for sanitary purposes.
b) Pressure drop on the heat exchanger
BOILER TYPE For temperature difference between
water outlet and return that equals 10k
Water
consumption m3/h
Load loss mbar
EG- OLZ 25/50 4,3 28
It is necessary to equip t e system wit t ermal valve t at opens at 95ᵒC (type 544
made by T ermador or similar), w ic will ensure t e cooling of t e boiler wit
system water (see sc ematics on page 20).
-It is necessary to ensure enoug space above t e boiler to make it possible to raise
t e cover and access t e controller.
-Hydraulic connection: eat exc anger joints are made as 2” t readed joints.
2.3 SAFETY AND CHIMNEY
Boiler connection must be made to enable easy disconnection to access t e boiler.
T e flue diameter must be bigger near t e boiler outlet. T e c imney must be
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equipped wit cleaning atc . Must comply wit regulation NF EN 12391-1 from June
2004.
-T e c imney eig t is minimum 5m above t e boiler
-If any orizontal part is ig er t an 1m t e c imney eig t must be raised
accordingly
-T e c imney must absolutely rise at least 70cm above t e crest to prevent t e flame
from c oking.
C imney diameter at t e boiler outlet:
Boiler type Flue diameter [mm] Suggested chimney
diameter [mm]
Chimney
draught [mbar]
EG-HOLZ 25 150 180 0,03
EG-HOLZ 50 180 200 0,03
Exhaust temperature:
Boiler type Average temperature of exhaust gasses at the
boiler exit
Minimal power Nominal power
EG-HOLZ 25/50 90 150
2.4 ELECTRICAL SYSTEM CHARACHTERISTICS
a) main power:
T e boiler power supply must be equipped wit a device to protect from t e power
surges and atmosp eric disc arges.
T e system must include a 30mV residual-current device as well as 2Amp, automatic
dual-polarity switc t e power supply and connections must comply wit law
regulations (regulation NF EN 60335-1, NFC 15-100,…) and must be done by an
aut orized person.
b) electrical connections:
T e standard connection conditions are: 230 Volt (single p ase) 50Hz.
It is necessary to c eck t e compatibility of t e main power and t e boiler
requirements.
c) electronic controller:
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To gain access to t e controller it is necessary to raise t e top cover of t e boiler.
T e controller is equipped wit a removable connection t at eases t e disconnection
of all cables.
Electric scheme of boiler installation:
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2.5 MOTOR CHARACHTERISTICS
Electric motor power:
Boiler type Exhaust extraction motor [W]
EG-HOLZ 25/50 83
2.6 WATER CIRCUIT PUMP
T e water circuit pump allows for filling t e boiler wit water as below:
Boiler type Flow [l/h]
EG-HOLZ 25/50 3250
2.7 STB:
a) Manually armed safety switch:
STB is located next to boiler controller. It is factory set to switc off w en t e
temperature reac es 100 o C.
In case of over eating (water temperature equal or exceeding 100 o C) t e STB will
s ut down t e boiler. After t e root cause of over eating as been eliminated t e
switc must be manually armed so t at t e boiler can resume its normal operation.
To arm t e switc it is only necessary to remove t e black protective cover and press
t e w ite button.
3. STARTING TH BOIL R
3.1 CONNECTIONS:
a) ydraulic connection of the boiler:
To avoid t e risk of over eating and steam condensation in case of all t e boilers for
ard biomass, it is important to make t e ydraulic connections according to all rules,
guidelines and regulations. T e circuit must contain proportional regulations if valves
are installed.
If t e circuit includes eater equipped wit t ermostatic valves it is necessary to
include differential valve as well as “by-pass” wit 14/16 diameter and circulation
pump to unify t e water distribution.
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All safety measures must be kept to prevent t e cold water from suddenly entering
t roug t e ot water outlet (temperature lower t an 72 o C).
The boiler can work along with solar heat exchanger.
3.2 HYDRAULIC CICRUIT CONNECTIONS SCHEME
1 – closed tank
2 – water level pressure guage
3 - 3 bar safety valve connected to t e drain
4 – water circulation pump
5 – 2 c annel valve wit 72 o C opening
6 – circuit filling
7 – circuit water release
8 – t ermal safety valve wit opening set at 95 o C
9 – supply of t e grid wit water
Minimal water usage is 1.1m3/ . Maximum pressure 2 bar.
10 – Floor eating wit controller
11 – All eaters equipped wit t ermostatic valves
12 – 14/16 diameter by-pass
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3.3 STARTING AND STOPPING THE BOILER:
1. Starting the boiler:
- Ensure t at circuit is filled wit water and t e pressure is 1bar.
- Ensure t at t e flue and c imney is correctly connected and equipped wit draug t
controller wit diameter larger t an t e c imney and is partially open.
- C eck if t e distance between grill bars are even.
- Start t e boiler.
- Start t e eating circuit (3 way valve and t ermostatic valves on 2,5 or 3 depending
on t e room).
- Ensure t at t e circulation pump is working properly, t at t e ex aust extractor is
turning and t at t e 2 c annel valve is closing properly.
- Place t in pieces of wood parallel to t e grill on t e eig t of 15-20cm.
- Place a burning piece of newspaper on t e timber. As soon as t e fire spreads put
t e small diameter wood on top and later one wit bigger diameter and close t e
doors.
- Start t e controller wit ON position.
- Set t e boiler temperature to 72ᵒC
Ot er information t at can be displayed:
- Boiler temperature
- Hot sanitary water temperature
- Fan operation
2. Shutting down the boiler:
- Wait until all t e loaded wood is complete burnt to stop t e operation of t e boiler.
Press t e start/stop button and t e display s ould read OFF.
3. Shutting down the boiler during summer time:
- Disconnect t e boiler.
- Completely remove all as
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- Slig tly open t e door to allow for ventilation.
3.4 WOOD:
It is necessary to pay attention to quality and size of t e wood t at will be burnt in t e
boiler.
Only seasoned wood s ould be used ( at least 2 years) wit maximum umidity of
20%.
Only use parted wood wit out any plastic, cardboard, textiles and ot er waste t at
mig t cause corrosion of t e boiler.
On top of t at, it is not allowed to use: wood c ippings, sawdust, or briquette.
Wood logs s ould ave 45-50cm in lengt .
If t e wood is very dry it is advised to use logs not cut in lengt or in in t ick pieces
(blocks). Best results are ac ieved wit wood cut crosswise, dry and of big diameter.
If t e wood is in small pieces it s ould be loaded last.
Conifers give great effects when burning in EG- OLZ provided the wood is dry.
3.5 GENERAL VERYFICATION:
- It is necessary to c eck if t e draug t regulator is mounted according to t e
instruction manual
- It is necessary to c eck if t e circuit as been properly filled wit water up to
pressure of 1 bar. If t e system is equipped wit manual 4 way valve it s ould be alf
open.
- It is necessary to c eck if t e central eating pumps are correctly connected to
electric power supply and set to correct speeds in respective water circuits 1,2,3.
- It is necessary to systematically clean t e installation from any dirt and debris and
flus after any intervention in t e ydraulic circuit (c anging eaters, mounting
additional eaters, replacement of t e boiler, pipes modification, valve replacement
etc.).
3.6 REMOVING OF ASH:
a) Removing ash from the hearth
It is necessary to remove t e as from t e eart at least once a week. It s ould be
done w en t e tank is virtually empty. Wit s ovel collect t e as leaving some c ars
15

on a side. T ere c ars s ould be placed on two oles: air inlet and ex aust pipe to
ease t e starting of t e boiler.
b) Removing ash from the airbox:
It is necessary to perform t is operation once a week. As s ould be removed wit
spatula and collected on a s ovel.
c) Removing ash from the combustion chamber
It is necessary to perform t is operation once a week. As s ould be removed wit
spatula and collected on a s ovel. Please be cautious w en doing t is not to it any
fireproof parts as t is mig t damage t em.
3.7 TURBULATORS:
W irlers s ould be activated manually in regular time frames to clean from t e wood
burning products. It is necessary to c eck if t ey work freely. In general 1 cleaning
per tank filling s ould suffice.
3. EXHAUST PIPE:
Once a year:
- Take of t e ex aust pipe.
- Unscrew t e screws from t e ex aust extractor and remove it, wit out
disconnecting it.
- Carefully clean t e turbine observing not to remove t e balancing weig ts.
-Clean wit a vacuum cleaner.
- Mount t e ex aust box and extractor back on making sure t e supports are clean.
Mount t e ex aust pipe back on.
16

17
Figure 3: Boiler cleaning - front
Figure 4: Boiler cleaning - rear

4. UPKEEP AND MAINTENANCE OF T E BOILER:
4.1 UPKEEP AND USE OF THE BOILER:
Servicing t e loading c amber:
-c amber must always be loaded to t e top
- it is not allowed to press or squeeze t e wood
- it is not allowed to scrape inside of t e tank wit a poker.
- first batc of wood s ould be placed carefully and gently, especially if t ere is a
glow beneat
- once a week allow t e tank to be completely empty , remove t e as and
carbonizations wit a small metal s ovel (leave some c ars on t e air inlet and
ex aust pipe)
Regularly check the state of the grill bars
-put a rod to t e air inlet t roug t e air box
-move t e turbulators and t e fan w en t ey are not operating
It is not allowed to put charred glow on the grill bars since it might cause
overheating.
Loading of t e boiler s ould appen w en t e fan is not working for some time
already. To avoid back droug t of t e ex aust it is necessary to press and old for 5
seconds boiler start button and t e ex aust extractor will start working for 1.5 minute
– during t is time start loading immediately. It is not advised to load t e boiler w en
it’s operational. W en t e eart is full of wood opening of t e door mig t result in a
power increase; it mig t also cause backfire.
Any oles s ould be free of any obstruction since it will prevent from t e proper
operation of t e boiler and mig t cause corrosion on t e edges of t e oles.
No doors should be left open or even slightly ajar.
4.2 MAINTENANCE OF THE BOILER:
Removing of t e as from t e combustion c amber (bottom door) must be done
regularly or it will result in over eating of t e fireproof parts (and loss of warranty).
T is procedure must be done gently especially being careful not to it any part made
of fireproof concrete.
It is necessary to c eck t e correct operation of t e air inlet flap and if t e need
would arise to clean it wit a metal brus .
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It is necessary to c eck for correct operation of draug t regulator.
Once every t ree mont s c eck for correct operation of t e water circulation pump
and safety valve wit 72 o C opening.
** In t e season w en t e boiler is not working it is necessary to clean it.
** In t e season w en t e boiler is not working absolutely leave all doors open to
allow for proper boiler ventilation.
** Never leave any wood in t e boiler w en it is not switc ed on.
**Clean t e ex aust extraction turbine and ex aust box 2-3 times a year.
DO NOT TOUC T E BALANCING WEIG T.
**Oil t e inges and door andles.
CAUTION: good condition of seal between doors and the boiler has a great
impact on a proper boiler operation. S ould t ere be any damage or deformation
to t e doors replace t em immediately.
19

Example of the name plate of the EG-Holz boiler:
20
43 200 Pszczyna Ul. Karola Miarki 1b
Type EG-Holz
Year of production:
Nominal eating power [kW]
Class of t e boiler class 4
Class of fuel Wood - A
Boiler efficiency [%] >80
Working pressure [bar] 0,2÷2
Testing pressure [bar] 5
Testing date
Water capacity [l]
Working temperature [ o C] 60÷95
DGR 97/23/EG
Norm PN-EN 303-5
Serial number
Power consumption: 0,24 kW, Voltage: 230 V 