Schmid UTSK-180 User manual

Schmid AG
energy solutions
Hörnlistrasse 12
8360 Eschlikon
Switzerland
www.schmid-energy.ch
Operating instructions
Translation of the original German version
Version 1.10 en, 20.01.2022
DUnderfeed grate UTSK
Series, Type: UTSK-
Fabrication number: See nameplate
System name:
Year of manufacture: 2022

Underfeed grate UTSK
1.10 en
D-2
Table of Contents
1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
1.1.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-5
1.1.2 Combustion grate and boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
1.2 Reasonably foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
1.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
1.3.1 Danger when entering the combustion chamber. . . . . . . . . . . . . . . . . . . . . . . .D-8
1.4 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-9
1.5 Emergency shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
1.6 Environmental impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
1.7 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-11
1.7.1 Combustion air supply to the heating room . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.7.2 Ambient temperature in the heating room . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.7.3 Installing the combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.8 Safety and monitoring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
1.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
1.8.2 Thermal extinguishing water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-14
1.8.3 O2 sensor (lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-15
1.8.4 Emergency stop button and maintenance switch for drive motors . . . . . . . .D-15
1.9 Operator workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
2 Description UTSK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
2.2 Heat storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-18
2.3 Description of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-19
2.4 Structure of the wood combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-22
2.4.1 Automatic boiler tube cleaning (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24
2.4.2 Automatic ignition (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24
2.4.3 Temperature safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-25
2.4.4 Flue gas recovery (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-27
2.4.5 Active postcombustion grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-28
2.4.6 Economiser (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-28
2.4.7 Flue gas filter system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-29

Underfeed grate UTSK
1.10 en D-3
2.5 Nomenclature key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
2.6 Inlet design variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
2.7 Structure of the combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
2.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
2.8.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
2.8.2 Connection sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
2.8.3 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33
2.8.4 Planning values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-37
3.1 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
4 Installation, commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-40
4.1 Installation, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-40
4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
4.2.1 Requirements for circulating water up to 110° C . . . . . . . . . . . . . . . . . . . . . . . D-41
4.2.2 Water treatment for different types of raw water . . . . . . . . . . . . . . . . . . . . . . D-42
4.2.3 Technical safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-42
4.2.4 Filling with circulation water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-42
4.3 Heating the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-43
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
5.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
5.1.1 System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
5.2 Switching the combustion system on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46
5.2.1 Correct manual lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47
5.3 Emergency shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
5.4 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
5.4.1 Mains disconnection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
5.4.2 Machine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
5.4.3 Operating mode selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
5.5 Recommissioning after a longer
interruption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49

Underfeed grate UTSK
1.10 en
D-4
6 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-50
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-50
6.2 Maintenance contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-50
6.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-51
6.3.1 Clean boiler passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-52
6.3.2 Clean the vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-53
6.3.3 Clean ash removal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-54
6.3.4 Clean fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-54
6.4 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-55
6.5 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
6.5.1 Emissions control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
6.5.2 Clean the O2 sensor (lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
6.5.3 Check the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
6.5.4 Maintenance work on components with drive units . . . . . . . . . . . . . . . . . . . .D-60
6.5.5 Dangers resulting from flue gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-60
6.5.6 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-61
7 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-63
7.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-63
7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-63
8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-64
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-64
8.2 How to order spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-64
8.3 Underfeed combustion system UTSK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-65
8.3.1 UTSK 180 - 240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-66
8.3.2 UTSK 300 - 360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
8.3.3 UTSK 450 - 550/500 - 550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-68
8.3.4 UTSK 700 - 900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-69
8.4 Automatic boiler tube cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-70
8.5 Automatic ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-71
8.6 Back fire protection BRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-72
8.7 Flue gas recovery (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-73

Underfeed grate UTSK
1.10 en D-5
1 Safety instructions
1 Safety instructions
1.1 Intended use
The underfeed combustion system is only provided for combustion of the contractually
specified fuels as bulk materials. This is clearly stated in the order confirmation of
Schmid AG energy solutions and in the project design. Any other use, or the use of any
other fuels is considered contrary to the intended use. The manufacturer is not liable for
any damage resulting from such use. The user alone bears the risk of such unintended
use.
1.1.1 Fuel
The fuel specifications are defined during system project design. It is recommended to
operate the combustion system with fuel of the quality listed in section 2.8.4.
Thesystemisnotintendedfor combustionofanyfuelother than virgin woodorresidual
wood from the wood processing industry. Other fuels, such as waste wood, contami-
nated wood waste, etc. do not conform to the intended use ofthe system and can result
in damage to the system, such as corrosion, mechanical defects, and environmental
damage (e.g. emissions of heavy metals).
Special fuels must be coordinated with Schmid AG energy solutions. Furthermore, the
system must always be operated in conformity with applicable air quality laws.
The defined fuels according to the order confirmation and project design must be
complied with.
The introduction of any foreign objects, such as stones, nails, soil, and metal objects
may result in severe damage to the transport assemblies and combustion system.
Never under any circumstances exceed the specified moisture content of the fuel.
Excessive moisture content will result in improper combustion. If moisture content is
too high, the combustion temperature will not reach the proper level, causing exces-
sive flue gas emissions. There is also a risk that the combustion system will become
over-filled, smothering combustion.
Failure to adhere to these guidelines voids the warranty on system parts, mechanics
and emissions.

Underfeed grate UTSK
1.10 en
D-6
1 Safety instructions
1.1.2 Combustion grate and boiler
Also refer to «2.8.4 Planning values» of the UTSK series.
This applies to the following values in particular:
• Nominal heat capacity (kW)
• Heat capacity range (kW)
• Permissible operating pressure (bar)
• Maximum permissible operating temperature (°C)
To prevent corrosion damage on the boiler resulting from condensation, the minimum
return line temperature in the boiler (boiler admission temperature) must be main-
tained. The system must be operated in conjunction with a return temperature
controller.
1.2 Reasonably foreseeable misuse
Any use not in conformity with the specified "intended use" or any use beyond such use
shall be considered a violation of the intended use of the system and is prohibited. Any
other use must be coordinated with the manufacturer.
Modifications and changes:
Anymodificationsor changes to the machinery undertakenindependentlyshallvoidthe
liability and warranty of the manufacturer.
Spare parts, wear parts and auxiliary materials:
Use of spare parts or wear parts from other manufacturers can involve risk. Use only
original or manufacturer-approved parts.
The values specified on the nameplate must be adhered to.
Failure to adhere to these specifications voids the warranty on system parts,
mechanics and guaranteed emissions.

Underfeed grate UTSK
1.10 en D-7
1 Safety instructions
1.3 Residual risks
The machine is built to the state of the art and in conformity with recognized safety stan-
dards. The following residual risks exist and should be kept in mind when operating the
machinery.Residual risksassociatedwithspecificphasesoftheservicelifeofthesystem
are detailed in the corresponding chapters of these instructions.
The system may only be operated in good condition.
i DANGER!
When working on live electrical parts, there is the risk of death, serious injury and
damage to equipment.
Switch off the machinery/system in the event of a fault in the power supply.
If work is necessary on voltage-carrying parts, the system must be disconnected from
themainswith the masterswitch.The masterswitchmust be securedagainstaccidental
activation (e.g. with a personal padlock).
Only professional electricians should perform work on electrical systems and operating
media.
Never remove any covers. The door of the control cabinet must be kept closed at all
times.
i WARNING!
High flue gas concentrations in the air can result in unconsciousness and the risk of suf-
focation.
Take the following precautions before working on the flue gas system:
Ensure that the combustion system has been stopped and that no flue gases are coming
from the combustion system.
Ensure that the flue gas system has cooled down.
Ensure adequate ventilation.
Ensure that the combustion system is secured against unauthorised operation.
Operation without a connection to the flue gas pipes is prohibited.
Always close cleaning openings after cleaning.
i WARNING!
There is a risk of falling when climbing on the system. Never climb on the system.
Do not use system parts for climbing. Wear fall-protection equipment during mainte-
nance work at high elevations.
During work at heights of more than 1.8 m (6'), use safe climbing equipment or work
platforms.

Underfeed grate UTSK
1.10 en
D-8
1 Safety instructions
1.3.1 Danger when entering the combustion chamber.
i DANGER!
Risk of explosion (deflagration)!
Risk of flame exposure when opening the combustion chamber door!
In the event of faulty pre-ventilation or incomplete combustion, an explosive atmo-
sphere can occur in the combustion chamber due to the formation of carbon monoxide
(CO). This can ignite when the burner is repeatedly started, when the combustion cham-
ber or maintenance doors are opened and cause deflagration. This can result in death,
serious injury or damage to equipment.
Before lighting the fuel, close all maintenance doors. Lighting may only be performed
manually through the combustion chamber door.
Never open the combustion chamber door after lighting the fuel or during the automatic
lighting procedure.
It is prohibited to open the combustion chamber door during start-up and operation as
well as after shutdown for faster cooling.
The combustion chamber door and the maintenance doors may only be reopened after
pre-ventilation, especially after a power failure.
It is prohibited to bridge safety switches.
i WARNING!
Obstruction of the respiratory tracts by dust!
Dust, ash and fly ash from the multi-cyclone or electrostatic precipitator can negatively
affect breathing.
In the event of high dust concentrations (especially from the ash from the multi-cyclone
or electrostatic precipitator), respiratory protection of class P3 or FFP3 must be worn.
Caution! Respirator masks for fine dust do not provide protection against hazardous or
suffocating gases and vapours.
i WARNING!
Danger from heat and hot surfaces!
The combustion chamber, combustion chamber and maintenance doors, fuel supply
and flue gas pipes can be hot.
Do not touch during operation. Wear gloves and protective gear.
i WARNING!
Risk of injury when entering the combustion chamber. Always secure the combustion
chamber door.
Before entering the combustion chamber always secure the combustion chamber door
with the personal padlock.

Underfeed grate UTSK
1.10 en D-9
1 Safety instructions
1.4 Warning signs
i WARNING!
Risk of injury due to rotating parts.
Before entering the combustion chamber, switch off the grate de-ashing screw on the
maintenance switch and secure with the personal padlock to prevent reactivation.
Sign below the main switch of the electri-
cal circuit cabinet
• 5 safety regulations must be complied
with when working on the electrical
system.
Sign next to the maintenance openings in
the flue gas path
• Before opening, the combustion sys-
tem must have cooled and the flue gas
path must be sufficiently purged.
Sign next to service openings
• Before opening, shut down the system
and secure with the personal padlock.
2000.8407
RISK OF FATAL ELECTRIC SHOCK
5 compulsory safety rules for working
with electrical equipment:
ƔSwitch off the power and disconnect
mains.
ƔLock against reclosure.
ƔCheck the absence of voltage.
ƔGround and short circuit.
Ɣ
Protect against neighbouring, live parts.
RISK OF SUFFOCATION /
RISK OF EXPLOSION
Before opening the maintenance
door, the combustion system must
be cooled down and the flue gas
system fully ventilated.
2000.8411
AUTOMATIC START-UP!
Before opening, shut down the
system and secure against restart
with the personal padlock.
2000.7369

Underfeed grate UTSK
1.10 en
D-10
1 Safety instructions
Missing or unreadable pictograms must be replaced.
Sign next to combustion chamber door
• Do not open during start-lighting pro-
cedure
Sign next to access door to fuel storage
room
• Caution fermentation gas choking haz-
ard
• Lights red / green (permanent) for ac-
cess control
• Coupled with the light (the fan switch-
es on automatically when the light is
switched on)
Sign next to the hot maintenance open-
ings
• Do not open during operation
Designates a maintenance zone. This
should never be blocked by installations
such as electrical cables or water pipes etc.
Designates the position of a covered main-
tenance opening. This should never be
blocked by installations such as electrical
cables or water pipes etc.
DANGER OF EXPLOSION/
DEFLAGRATION!
Do not open the furnace door
during start-up and ignition!
FIRE HAZARD/
RADIANT HEAT!
Only open the furnace door briefly
and never leave unsupervised.
HOT SURFACES!
Always wear full protection gear
(gloves, goggles, long-sleeved
cotton garments).
SECURE FURNACE DOOR!
Secure furnace door with the per-
sonal padlock before entering the
furnace.
ROTATING ELEMENTS!
Before entering the furnace, secure
the grate de-ashing screw against
reactivation with the personal padlock.
2000.7365
FERMENTATION GAS -
RISK OF SUFFOCATION!
Ventilate the room before
entering!
2000.7373
HOT SURFACES!
2000.7389
Always wear full protection gear
(gloves, goggles, long-sleeved
cotton garments).
Maintenance area - please
keep clear!
2000.7385
Maintenance opening behind
the cover!
2000.7381