Schmid UTSR 150 User manual

Schmid AG
energy solutions
Hörnlistrasse 12
8360 Eschlikon
Switzerland
www.schmid-energy.ch
Operating instructions
Translation of the original German version
Version 1.6 en, 06.09.2021
DMoving grate combustion system
UTSR without boiler
Series, Type: UTSR without boiler
Serial number: See nameplate
System name:
Year of manufacture: 2021

Moving grate combustion system UTSR without boiler
1.6 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .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 UTSR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
2.2 Description of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-19
2.3 Design of the moving grate combustion system . . . . . . . . . . . . . . . . . . . . . . .D-21
2.3.1 Automatic ignition (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-23
2.3.2 Automatic radiation-vault cleaning system (optional) . . . . . . . . . . . . . . . . . . .D-23
2.3.3 Flue gas recovery (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-24
2.3.4 Under-grate de-ashing (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-25
2.3.5 Flue gas filter system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-25
2.4 Nomenclature key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-25
2.5 Inlet design variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-26
2.6 Structure of the combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-26
2.7 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-27
2.7.1 Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-27

Moving grate combustion system UTSR without boiler
1.6 en D-3
2.7.2 Combustion chamber weight and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-28
3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-29
3.1 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-30
4 Installation, commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
4.1 Installation, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-31
4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-32
4.2.1 Requirements for circulating water up to 110° . . . . . . . . . . . . . . . . . . . . . . . . D-33
4.2.2 Water treatment for different types of raw water . . . . . . . . . . . . . . . . . . . . . . D-33
4.2.3 Technical safety devices, combustion chamber cooling . . . . . . . . . . . . . . . . D-33
4.2.4 Filling with circulation water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33
4.3 Heating the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35
5.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-35
5.1.1 System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36
5.2 Switching the combustion system on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-37
5.2.1 Correct manual lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38
5.3 Emergency shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
5.4 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
5.4.1 Mains disconnection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
5.4.2 Machine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
5.4.3 Operating mode selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-39
5.5 Recommissioning after a longer interruption . . . . . . . . . . . . . . . . . . . . . . . . . D-40
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
6.2 Maintenance contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-41
6.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-42
6.3.1 Clean ash removal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-43
6.3.2 Clean fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-44
6.3.3 Clean vault/intermediate ceiling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
6.3.4 Clean the moving grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46
6.3.5 Clean lower grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46
6.4 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47

Moving grate combustion system UTSR without boiler
1.6 en
D-4
6.5 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-51
6.5.1 Emissions control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-51
6.5.2 Clean the O2 sensor (lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-51
6.5.3 Check the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-51
6.5.4 Maintenance work on components with drive units . . . . . . . . . . . . . . . . . . . .D-52
6.5.5 Dangers resulting from flue gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-52
6.5.6 Oil hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-53
6.5.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-55
7 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-57
7.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-57
7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-57
8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-58
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-58
8.2 How to order replacement parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-58
8.3 UTSR moving grate combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
8.3.1 UTSR 150 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-60
8.3.2 UTSR 180-240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-61
8.3.3 UTSR 300-360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-62
8.3.4 UTSR 450-550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-63
8.3.5 UTSR 700-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-64
8.3.6 UTSR 995 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-65
8.3.7 UTSR 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-66
8.3.8 UTSR 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
8.3.9 UTSR 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-68
8.3.10 UTSR 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-69
8.3.11 UTSR 3200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-70
8.3.12 UTSR 4200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-71
8.3.13 UTSR 5000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-72
8.3.14 UTSR 6500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-73
8.4 Automatic ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-74
8.5 Back fire protection BRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-75

Moving grate combustion system UTSR without boiler
1.6 en D-5
1 Safety instructions
1 Safety instructions
1.1 Intended use
The moving grate combustion system is intended solely for the combustion of the
contractually specified fuels as bulk materials. This is clearly stated in the order confir-
mation of Schmid AG energy solutions and in the system overview. 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.
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.

Moving grate combustion system UTSR without boiler
1.6 en
D-6
1 Safety instructions
1.1.2 Combustion grate
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)
• Maximum flow temperature (°C)
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.

Moving grate combustion system UTSR without boiler
1.6 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.
The flue gas paths from the combustion chamber to the flue must always be open!
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.

Moving grate combustion system UTSR without boiler
1.6 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.

Moving grate combustion system UTSR without boiler
1.6 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 elec-
trical circuit cabinet
• 5 safety regulations must be com-
plied with when working on the
electrical system.
Signnexttomaintenanceaccesspoints
in the flue gas path and undergrate
doors
• Before opening, the combustion
system must have cooled and the
flue gas path must be sufficiently
purged.
Sign next to service openings
• Before opening, shut down the sys-
tem and secure with the personal
padlock.
Sign near the under-grate door.
• Never open the under-grate door
during operation. Work-free zone –
keep free during operation.
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
Do not open the furnace door
during start-up and ignition!
DANGER OF EXPLOSION/
DEFLAGRATION!
Endangered area - keep clear
during operation.
2000.7377

Moving grate combustion system UTSR without boiler
1.6 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
procedure
Signnextto access door tofuelstorage
room
• Caution fermentation gas choking
hazard
• Lights red / green (permanent) for
access control
• Coupled with the light (the fan
switchesonautomaticallywhenthe
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 installa-
tions such as electrical cables or water
pipes etc.
Designates the position of a covered
maintenance opening. This should nev-
er 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

Moving grate combustion system UTSR without boiler
1.6 en D-11
1 Safety instructions
1.5 Emergency shut down
Themovementofthewoodcombustionsystem canbestoppedatany timebyactivating
the emergency stop button.
Opening the combustion chamber door stops the movement of the system. Exception:
the flue gas fan continues to run.
Removal of the ash container stops the movement of all of the ash removal components.
The emergency cut-off does not immediately stop the combustion process in the
combustion system. The fire continues to burn for a long time (Read
chapter«1.3 Residual risks»).
1.6 Environmental impact
When operated properly, this wood combustion system fulfils the requirements of the
Swiss air quality act LRV 92 and Germany's Federal Emissions Act (BImSchG).
Wood fuel is carbon neutral and there are no risks associated with its transport and
storage, apart from the development of fermentation gases in storage. The useof wood
fuel, therefore, makes sense from an ecological perspective and protects the environ-
ment.
The operator must arrange for the disposal of ash through the responsible authorities.
1.7 Ambient conditions
i DANGER!
Flue gas inhalation hazard!
Lack of air in the boiler room can result inunconsciousness and severe injury to thecen-
tral nervous system.
In the heatingroom the conditions givenin Sections«1.7.1 Combustion airsupply to the
heating room» and «1.7.2 Ambient temperature in the heating room» must be complied
with.

Moving grate combustion system UTSR without boiler
1.6 en
D-12
1 Safety instructions
1.7.1 Combustion air supply to the heating room
Depending on the desired capacity, a certain air flow rate is necessary for wood combus-
tion (combustion air).
The size of the openings is determined during planning in accordance with the valid
local directives (e.g. VKF Directive).
Calculation of the combustion air opening in compliance with VKF:
10.3 x boiler capacity (kW) = free cross-section in cm2
Should forced ventilation (electronically controlled mechanical flaps/fans) be used for
the supply of combustion air, it must be ensured at all times that the required combus-
tion air is available during operation of the system. The valid standards, directives and
regulations such as VKF etc. must be complied with. In addition, it must be ensured
when the boiler has been switched off that combustion air flows into the heating room
for at least 5 hours (systems up to 250 kW) or 10 hours (systems above 250 kW). There
should never be any overpressure (max. +5 Pa in relation to theambient air pressure)or
underpressure (max. -5 Pa in relation to the ambient air pressure) in the heating room.
Never cover or close the air supply vents in the boiler room under any circumstances.
Doing so will cause the combustion system to operate with an inadequate supply of air.
1.7.2 Ambient temperature in the heating room
The ambient temperature in the heating room of +10°C to max. +35°C must be complied
with.
1.7.3 Installing the combustion system
With regard to the design of theheating room, the respective local building regulations,
the applicable standards and fire regulations as well as the fire protection regulations
are decisive. It is not permitted to place the combustion system on a wooden floor or
combustible surface. Observe the respective regulations regarding fire protection as
well as the valid regulations on accident protection and accident prevention. Ensure
sufficient lighting at the installation site.

Moving grate combustion system UTSR without boiler
1.6 en D-13
1 Safety instructions
1.8 Safety and monitoring systems
1.8.1 Overview
Fig. 1 Safety and monitoring systems
The detailed description of the error messages is given in Register "C User manual,
Control unit", section "11 Events".
Item Description Function
1 Limit switch, grate door Only allows the grate door to be opened when the
“Open combustion chamber door” button is
pressed.
2 Combustion chamber under-
pressure monitoring Pressure cell for underpressure monitoring in the combustion chamber
3/4 Air supply monitoring The combustion blowers are monitored with
airflow measurement sensors and pressure cells.
5 Flame temperature sensor Monitoring of the combustion system to ensure
that the basic flame is sufficient to ignite the fuel as
well as monitoring for combustion chamber over-
heating
6O
2sensor (lambda sensor) Measures the oxygen content in the flue gases and
soundsanalarmiftheO2 values are too low,instal-
lation in the flue gas connection or flue gas blower
7 Back fire thermostat In the event of a backfire, switches off the combus-
tion system and generates an alarm.
8 Extinguishing water valve Opens automatically at temperatures > 65°C in the
stoker, the back fire is extinguished.
2
5
6
1
3
4
7, 8

Moving grate combustion system UTSR without boiler
1.6 en
D-14
1 Safety instructions
1.8.2 Thermal extinguishing water valve
The sprinkler connection is equipped with a thermal valve with sensor (electrically
decoupled) and installed directly on the stoker. If the temperature in the stoker exceeds
65°C, the extinguishing water valve automatically opens and the back fire is extin-
guished. The extinguishing water valve closes automatically once the temperature
drops.
Annual function checks must be carried out on the back fire thermostat, the thermal
extinguishing water valve, the safety temperature limiter, the O2sensor as well as on
the back fire protection slide or the rotary valve. This inspection work may only be
carried out by service personnel of Schmid AG energy solutions.
Item Designation
1 Thermal valve
2 Contact sensor
Minimum water pressure 3 bar
Minimum water supply line ½"
12
A water supply must be ensured at all times. If a stop cock is installed, it must always
be open. If necessary, the hand cock on the shut-off valve should be removed to
prevent anybody from interrupting the water supply.
A drinking water separator must be installed in the extinguishing water supply in
compliance with specific national regulations.
An annual functional check must be carried out on the thermal extinguishing water
valve. This inspection work may only be carried out by service personnel of Schmid
AG energy solutions.

Moving grate combustion system UTSR without boiler
1.6 en D-15
1 Safety instructions
1.8.3 O2sensor (lambda sensor)
The O2sensor is a sensor that measures the residual oxygen content in the flue gas. The
signal of the O2sensor can affect the combustion air or the fuel quantity.
The O2sensor must be removed before cleaning the flue gas connection or the flue gas
fan.
Clean with a soft cloth or blow off with compressed air. When blowing off maintain a
distance of 20cm to prevent damage to the sensor.
1.8.4 Emergency stop button and maintenance switch for drive mo-
tors
Position emergency stop buttons:
The customer can provide emergency stop buttons on the access doors and escape
routes to the heating room that can be integrated into the control cabinet front. Actu-
atingtheemergency stop button stops thesystemcontrolledbySchmidAG energysolu-
tions.
Position of the maintenance switches to the electrical drive motors:
Immediatelynearthecorresponding gear motors. When carrying out maintenancework
on the drive motor or the corresponding display element, actuate the maintenance
switch and secure against unauthorised activation.
Operationofthesystemwithdefectivetechnicalsafetycontroldevicesis prohibited.The
device status must be checked daily and the function of the devices must be checked
every six months. Defective devices must be replaced and not bridged.
i WARNING!
Risk of burns, the O2sensor is hot.
Before removal check the temperature of the O2 sensors, always wear gloves during
work.

Moving grate combustion system UTSR without boiler
1.6 en
D-16
1 Safety instructions
1.9 Operator workstations
Access to the system must be possible on all sides for the following tasks:
• General operation
• Fire monitoring
• Flue gas duct cleaning and flue gas recovery
• Cleaning of the combustion chamber
• Maintenance work in the area of the fuel and air intake areas
• Disposal of ash
Fig. 2 Free working area
(x): This work area can be reduced after consultation.
Capacity (kW) BR (mm) LR (mm) HR (mm) 9 (mm)
150 950 1600 1400 950
180 1150 1800 1400 950
240 1150 1800 1400 950
300 1250 1800 1400 950
360 1250 1800 1400 950
450 1440 2300 1600 1150
550 1440 2300 1600 1150
700 1800 2700 1950 1400
900 1800 2700 1950 1400
995 2000 3000 2300 1600
1200 2000 3000 2300 1600
1600 2000 3400 2300 1600
2000 2320 3800 3000 1550
2400 2320 4500 3000 1550
3200 2800 5000 4100 1950
4200 2800 6200 4300 1950
5000 2800 7400 5400 1950
6500 3200 8000 5400 2300
[x]
9
BR LR
HR

Moving grate combustion system UTSR without boiler
1.6 en D-17
2 Description UTSR
2 Description UTSR
2.1 Introduction
This automatic moving grate combustion system is designed for economical and low-
emission combustion of forest woodchips and pellets. The energy released by combus-
tion is used thermally.
Depending on the heat requirements, the combustion system adjusts its capacity within
a range of 30 to 100 percent. Depending on the required capacity, the air and fuel quan-
tities are adjusted automatically. The amount of fuel is regulated depending on the
combustion temperature. The feeding unit transports the dosed fuel onto the combus-
tion grate. A rotary valve or a backfire protection slide is installed upstream from stoking
to protect it against backfire.
The fuel supplied runs through the four phases required for optimum combustion -
drying, gasification (pyrolysis), combustion (oxidation) as well as the charcoal burnout
on the flat moving grate. The flat grate cooled with the primary air is constructed of cast
ribs arranged in rows. Each second cast rib row is controlled by a joint hydraulic drive
and transports the fuel or the combustion residues to thegrate de-ashing screw. Four to
five different air supplies are provided for control of the combustion process. Two to
three primary air zones below the grate for drying, gasification and burnout as well as
two secondary air zones in the combustion chamber for combustion of the gases. The
combustion process is monitored via air flow measurements in the primary and
secondary air ducts, measurement of the combustion temperature as well as the O2
measurement. The secondary air injection 1 is effected from three sides, offset by 90° in
the upper part of the combustion chamber to achieve optimum mixture of the wood
gases with the combustion air and therefore full burnout with low CO values. The
secondary air 2 is injected above the vault in the burnout zone. This construction
complies with the low NOx process with air stages. The combustion chamber is lined
with fireproof concrete on the combustion chamber side, on the one hand to protect the
steel construction, on the other for storing the temperature required for optimum
combustion.The vaultedceilingsaremade of shaped bricks andserveto dry the fuel effi-
ciently. The combustion chamber is back-cooled with air to minimise radiation losses
and protect personnel and prevent physical contact, and it is insulated with a 100 mm
thick layer of mineral mats and clad with a powder-coated metal sheet. At the same time
air cooling serves to pre-heat the secondary combustion air.
The heat energy in the hot flue gases is normally transferred to a medium in the down-
stream boiler.
Thesolidsformed during combustionflowwiththe hotfluegasthrough theboiler.After-
wards the particles are separated in a multi-cyclone that runs in accordance with the
centrifugalforce principle. The multi-cyclone is also insulated andclad with sheet metal.
To lower dust emissions even further, the gases can be additionally cleaned by a down-
stream filter system. The flue gas fan is installed in accordance with the filter type on the
inlet or outlet side of the filter.
The flue gas fan draws off the combustion gases through the boiler and the multi-
cyclone and transfers these to the flue gas pipe that leads to the stack. An underpressure
measurement system combined with an electronic control unit regulates the speed of
the fan to ensure the underpressure required in the combustion chamber.

Moving grate combustion system UTSR without boiler
1.6 en
D-18
2 Description UTSR
Fig. 3 Cross-section of the moving grate combustion system

Moving grate combustion system UTSR without boiler
1.6 en D-19
2 Description UTSR
2.2 Description of functions
To ensure optimal combustion, the fuel, which is dosed with the stoker screw or pusher,
undergoes four phases.
•Drying
• Gasification (pyrolysis)
• Combustion (oxidation)
• Charcoal burnout
In order to control this process, the system has two different air supply zones.
• Primary air zone under the grate for drying and gasification
• Secondary air zone in the combustion chamber for burnout
Fig. 4 Basic construction
Item Designation
1 Primary air duct 1 + 2
2 Primary air zones under the grate
3 Secondary air duct 1 + 2
4 Secondary air nozzles
5 Combustion chamber
6 Moving grate
7 Ash chute
5
6
7
134
2

Moving grate combustion system UTSR without boiler
1.6 en
D-20
2 Description UTSR
The following measurements control the combustion process:
• Primary air quantity
• Secondary air quantity
• Combustion temperature
• Excess air measurement (O2sensor)
• Underpressure in the combustion chamber
• Temperature of the refractory lining (UTSR 700 and larger)
• Temperature near the lower grate (UTSR 2000 and larger)
• Fuel bed control (optional on UTSR 700 and larger)
The combustion grate is filled with refractory concrete.
• To protect the steel structure
• As thermal insulation
The combustion grate is insulated with 100 mm insulation mats covered by a sheet-
metal cladding in order to minimise radiation losses and as burn protection.
Flue gas dedusting
Combustion of solids produces fly ash which is released in the hot flue gas.
Thefly ashisnormallyseparatedoutof thegasvia multi-cyclones(centrifugalprinciple).
The result is a flue-gas reference value of less than 150 mg/Nm3 following separation.
To lower dust emissions even further, the flue gases can be additionally cleaned by a
downstream filter system.
Flue gas fan
The flue gas fan is especially designed for the respective system in accordance with the
order confirmation and the project planning documents. Additional information is given
in the separate instruction manual.
Thefluegas fanextractscombustiongasesthroughtheboiler and the multi-cyclone and
conveys the gases to the flue gas pipe and then the stack.
Fine particle filter
A fine particulate filter can be optionally integrated into the system. Additional informa-
tion is given in the separate instruction manual.
The flue gas is further purified through a fine particle filter. If the filter is operated with
underpressure, it is installed upstream of the flue gas fan.
Mechanical de-ashing system
The automatic de-ashing feature is especially designed for the respective system in
accordance with the order confirmation and the project planning documents. Additional
information is given in the separate instruction manual.
The residues of combustion such as grate and fly ash as well as fuel contaminants are
automatically discharged with screws out of the combustion system and the multi-
cyclone. The ash is routed into a container of 50, 240 or 800 litres.