Schmid UTSR 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 1.8 en, 20.01.2022
DUTSR moving grate combustion
system
Series, Type: UTSR-
Fabrication number: See nameplate
System name:
Year of manufacture: 2022

UTSR moving grate combustion system
1.8 en
D-2
Table of Contents
1 Safety instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
1.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
1.1.1 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-6
1.1.2 Combustion grate and boiler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
1.2 Reasonably foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-7
1.3 Residual risks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-8
1.3.1 Danger when entering the combustion chamber. . . . . . . . . . . . . . . . . . . . . . . .D-9
1.4 Warning signs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-10
1.5 Emergency shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.6 Environmental impact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.7 Ambient conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-12
1.7.1 Combustion air supply to the heating room . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
1.7.2 Ambient temperature in the heating room . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
1.7.3 Installing the combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-13
1.8 Safety and monitoring systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-14
1.8.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-14
1.8.2 Thermal extinguishing water valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-15
1.8.3 O2 sensor (lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-16
1.8.4 Emergency stop button and maintenance switch for drive motors . . . . . . . .D-16
1.9 Operator workstations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-17
2 Description UTSR. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-19
2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-19
2.2 Heat storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-20
2.3 Description of functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-21
2.4 Design of the moving grate combustion system . . . . . . . . . . . . . . . . . . . . . . .D-24
2.4.1 Automatic boiler tube cleaning (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-26
2.4.2 Automatic ignition (optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-27
2.4.3 Automatic radiation-vault cleaning system (optional) . . . . . . . . . . . . . . . . . . .D-27
2.4.4 Temperature safety valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-28
2.4.5 Flue gas recovery (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-30
2.4.6 Under-grate de-ashing (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-31
2.4.7 Economiser (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-31
2.4.8 Flue gas filter system (option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32
2.5 Nomenclature key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-32

UTSR moving grate combustion system
1.8 en D-3
2.6 Inlet design variants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33
2.7 Structure of the combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-33
2.8 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
2.8.1 Dimensions (subject to technical changes) . . . . . . . . . . . . . . . . . . . . . . . . . . . D-34
2.8.2 Connection sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-36
2.8.3 Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-37
2.8.4 Planning values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-38
3 Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-43
3.1 Lifting loads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-45
4 Installation, commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46
4.1 Installation, assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-46
4.2 Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-47
4.2.1 Requirements for circulating water up to 110° . . . . . . . . . . . . . . . . . . . . . . . . D-48
4.2.2 Water treatment for different types of raw water . . . . . . . . . . . . . . . . . . . . . . D-48
4.2.3 Technical safety equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
4.2.4 Filling with circulation water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-48
4.3 Heating the combustion chamber . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-49
5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-50
5.1 General instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-50
5.1.1 System operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-51
5.2 Switching the combustion system on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-52
5.2.1 Correct manual lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-53
5.3 Emergency shut down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54
5.4 Operating and display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54
5.4.1 Mains disconnection devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54
5.4.2 Machine control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54
5.4.3 Operating mode selector switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-54
5.5 Recommissioning after a longer interruption . . . . . . . . . . . . . . . . . . . . . . . . . D-55
6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-56
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-56
6.2 Maintenance contract . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-56
6.3 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-57

UTSR moving grate combustion system
1.8 en
D-4
6.3.1 Clean boiler passes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-58
6.3.2 Clean upper vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-59
6.3.3 Clean ash removal box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-60
6.3.4 Clean fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-60
6.3.5 Clean lower vault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-61
6.3.6 Clean the moving grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-62
6.3.7 Clean lower grate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-62
6.4 Maintenance overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-63
6.5 Maintenance tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
6.5.1 Emissions control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
6.5.2 Clean the O2 sensor (lambda sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
6.5.3 Check the doors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-67
6.5.4 Maintenance work on components with drive units . . . . . . . . . . . . . . . . . . . .D-68
6.5.5 Dangers resulting from flue gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-68
6.5.6 Oil hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-69
6.5.7 Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-71
7 Disassembly and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-73
7.1 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-73
7.2 Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-73
8 Spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-74
8.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-74
8.2 How to order spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-74
8.3 UTSR moving grate combustion system . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-75
8.3.1 UTSR 180-240 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-76
8.3.2 UTSR 300-360 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-77
8.3.3 UTSR 450-550 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-78
8.3.4 UTSR 700-900 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-79
8.3.5 UTSR 1200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-81
8.3.6 UTSR 1600 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-82
8.3.7 UTSR 2000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-83
8.3.8 UTSR 2400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-85
8.3.9 UTSR 3200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-86
8.3.10 UTSR 4200 - 6500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-87
8.4 Automatic boiler tube cleaning unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-88
8.5 Automatic ignition unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-90
8.6 Back fire protection BRA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-91
8.7 Flue gas recovery (recirculation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-92

UTSR moving grate combustion system
1.8 en D-5

UTSR moving grate combustion system
1.8 en
D-6
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. It is recommended to
operate the combustion system with fuel of the quality listed in section 2.8.4.
Thesystemis not intendedforcombustionof any fuel otherthanvirginwood or residual
wood from the wood processing industry. Other fuels, such as waste wood, contami-
nated wood waste, etc. do not conform to the intended use of the 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.

UTSR moving grate combustion system
1.8 en D-7
1 Safety instructions
1.1.2 Combustion grate and boiler
Also refer to «2.8.4 Planning values» of the UTSR 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)
• Maximum flow 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 inconformity 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 changestothemachineryundertakenindependentlyshall void the
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.

UTSR moving grate combustion system
1.8 en
D-8
1 Safety instructions
1.3 Residual risks
The machine is built to the state of the art and in conformity withrecognized safety stan-
dards. The following residual risks exist and should be kept in mind when operating the
machinery.Residual risksassociatedwithspecificphasesoftheservicelife ofthesystem
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
the mains with the master switch. The master switchmust be secured against accidental
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 combustionsystem 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.

UTSR moving grate combustion system
1.8 en D-9
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 chamberdoor 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.

UTSR moving grate combustion system
1.8 en
D-10
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 maintenance access points in
the flue gas path and undergrate doors
• 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.
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.
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AUTOMATIC START-UP!
Before opening, shut down the
system and secure against restart
with the personal padlock.
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Do not open the furnace door
during start-up and ignition!
DANGER OF EXPLOSION/
DEFLAGRATION!
Endangered area - keep clear
during operation.
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