Viessmann KOB PYROMAT DYN Manual

5726 783 Original German version Issue 1.0 Please keep safe!
Operating
and maintenance instructions
for plant operators
DYN 45 to DYN 85
Group

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Issue Date Comment
1.0 27.03.2009 Release

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1 Important basic information
This chapter will familiarise you with the layout of the operating and maintenance
instructions so that you will be able to find information in this document quickly and with
assurance.
The operating and maintenance instructions use symbols and signs that make it easier
for you to locate information. Please read the explanations for the symbols in the
following section.
Read all of the safety notices in this operating and maintenance instructions with
particular care.
Safety notices are found in chapter "General safety regulations" and before the
handling instructions.
1.1 Explanation of the symbols and signs
Symbols and signs are used in these operating and maintenance instructions to enable
you to find information quickly.
1.1.1 Symbols and signs in the text
LWherever this symbol is shown you are provided with useful information for the safe
and fault-free operation of the heating system.
1. Multiple step operating procedure:
This sign shows an operating action. Carry out the stages of the operating action in
the sequence given.
Bullet points:
There are no activities linked to bullet points.
1.1.2 Symbols and signs in figures
A, B, C, …:
Items in the figures are identified with these letters.
1.2 Purpose of the operating and maintenance instructions
LThese operating and maintenance instructions are a part of the safety concept of
your heating system. Ensure that all personnel that work on the heating system
have read and understood the contents of this document.
LThese operating and maintenance instructions contain important information to
enable the safe and professional operation and maintenance of the heating system,
and to facilitate the rectification of simple faults yourself.
These operating and maintenance instructions are a part of the heating system.
Retain these operating and maintenance instructions for the entire service life of the
heating system.
The operating and maintenance instructions must be passed on to any future owner
or user of the heating system.

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1.3 Legal notes
1.3.1 Liability, warranty and guarantee
Liability
The information, data and instructions provided in the operating and maintenance
instructions were up-to-date at the time of printing. Claims can not be raised for heating
systems previously supplied, on the basis of the information, diagrams and descriptions
in this document.
Köb Holzheizsysteme GmbH accepts no liability for damage and operational faults that
have occurred as a result of:
Improper use.
Unauthorised alterations to the heating system.
Unprofessional work on or with the heating system.
Operating errors.
Disregard of the operating and maintenance instructions.

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Table of Contents
1Important basic information..........................................3
1.1 Explanation of the symbols and signs.............................. 3
1.1.1 Symbols and signs in the text............................................................3
1.1.2 Symbols and signs in figures.............................................................3
1.2 Purpose of the operating and maintenance instructions 3
1.3 Legal notes..........................................................................4
1.3.1 Liability, warranty and guarantee.......................................................4
2Safety notice...................................................................7
2.1 Meaning of warnings:.........................................................7
2.2 Target groups......................................................................7
2.3 Use in accordance with the regulations ........................... 8
2.4 Improper use.......................................................................8
2.5 Other applicable documentation.......................................8
2.6 General safety regulations................................................. 9
2.6.1 Over-temperature or electrical outage behaviour..............................9
2.6.2 What to do if you smell exhaust gas................................................10
2.6.3 What to do in the event of fire..........................................................10
2.6.4 Conditions in the heating room........................................................10
2.6.5 Accessory parts, replacement and wearing parts............................10
2.7 Qualifications of the personnel ....................................... 11
2.8 EC Declaration of Conformity.......................................... 12
2.9 Placards on the PYROMAT DYN...................................... 13
2.10 Safety devices................................................................... 14
2.10.1 Automatic fuel feed..........................................................................15
3Product information .....................................................16
3.1 Model description............................................................. 16
3.2 Workplace.......................................................................... 18
3.3 Fuels .................................................................................. 18
4Commissioning.............................................................19
5Operation.......................................................................20
5.1 Basic menu navigation - ECOTRONIC ............................ 20
5.2 Factory settings................................................................ 22
5.3 F3 key "PYROMAT Parameter"........................................ 23
5.4 F4 key "PYROMAT loading"............................................. 26
5.5 Keys F5 to F8 "Extended control system"...................... 27
5.6 Operation with automatic fuel feed ................................. 28
5.6.1 Heating system with storage as hydraulic switcher.........................28
5.6.2 Filling fuel storage with rotary sweep extractor and spring core
extractor .......................................................................................................28
5.6.3 Filling fuel storage with sliding barextractor.....................................29
5.6.4 Filling fuel storage with hopper extractor.........................................29
5.6.5 Filling fuel storage by blowing in......................................................30
5.6.6 Heat-up in automatic mode..............................................................30
5.6.7 Stop heating operation.....................................................................32
5.7 Log operation.................................................................... 33
5.7.1 Fill wood...........................................................................................33
5.7.2 Heat-up in log operation ..................................................................35
5.7.3 Check the heating operation............................................................36

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6ECOTRONIC control system extensions................... 37
6.1 Room unit...........................................................................37
6.2 Utility water heater ............................................................42
6.3 Air heating apparatus........................................................44
6.4 Annexes .............................................................................46
6.4.1 Utility water heater.......................................................................... 48
6.5 Remote supply line ...........................................................49
6.6 Auxiliary heat generator ...................................................50
7Servicing, cleaning...................................................... 54
7.1 Safety regulations .............................................................54
7.2 Annual general inspection................................................55
7.3 Maintenance overview ......................................................55
7.4 Maintenance activities ......................................................57
7.4.1 Clean ash pan, combustion chamber bottom (1)............................ 57
7.4.2 Clean bottom ash pan (2) ............................................................... 58
7.4.3 Clean sight glasses (3) ................................................................... 58
7.4.4 Clean pipe heat exchanger (4)........................................................ 59
7.4.5 Clean exhaust blower (5)................................................................ 59
7.4.6 Clean top combustion chamber (6)................................................. 60
7.4.7 Clean exhaust gas deduster (optional)........................................... 60
7.4.8 De-ashing into ash box (optional)................................................... 61
8Error correction ........................................................... 63
8.1 Safety regulations .............................................................63
8.2 Procedure for error correction.........................................63
8.3 Error report table...............................................................64
8.3.1 Heat generation .............................................................................. 64
8.3.2 Loading ........................................................................................... 66
8.3.3 heat distribution............................................................................... 67
8.4 Error correction on feed systems(optional)....................68
8.4.1 Error correction on de-ashing system (optional)............................. 68
9De-commissioning for an extended break in heating69
9.1 De-commissioning ............................................................69
9.2 Recommissioning .............................................................69
10 Disposal........................................................................ 70
11 Notes............................................................................. 71
12 Appendix ...................................................................... 72

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2 Safety notice
In these operating and maintenance instructions warning notices are provided ahead of
an operating procedure where there is a risk of injury to persons or property damage.
The measures described for hazard prevention must be adhered to.
2.1 Meaning of warnings:
The hazard symbols always appear in conjunction with a signal word. The signal words
provide information on the extent of the danger.
Please also note that a hazard symbol can never replace the text of a safety notice -
therefore, the safety notice text must always be read in full!
The meanings of the signal words are as follows:
Danger!
Immediate danger!
Failure to observe carries risk of death or serious injuries
Warning!
Potential danger!
Failure to observe can carry risk of death or serious injuries.
Caution!
Hazardous situation!
Failure to observe can lead to minor injuries or damage to property.
2.2 Target groups
These operating and maintenance instructions are addressed to the operator of the
heating system.

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2.3 Use in accordance with the regulations
The heating system and its components are designed and constructed in accordance
with the latest technology and in compliance with all recognised safety regulations.
Nevertheless when such machinery is deployed, severe hazards, which could be fatal
or cause injury to users and others can arise, or the heating system or other property
may be adversely affected.
Appropriate use also includes observing the operating and maintenance instructions as
well as adhering to the inspection and maintenance conditions.
The heating system and its components must be used only when in technically perfect
condition, and must also be used for its proper purpose and with an awareness of
safety and of hazards, and always in consideration of the operating and maintenance
instructions. In particular any faults that could have an effect on safety must be
remedied without delay.
The intended purpose of the PYROMAT DYN is the burning of wood fuels.
The appropriate use of the PYROMAT DYN is defined:
In the regulations in the assembly and installation instructions.
Through the limit values in the technical data.
In data sheet 1010/1 + 2 "Wood fuels minimum requirements - Information".
With the safety regulations in these operating and maintenance instructions.
2.4 Improper use
Unless there is written approval from the manufacturer, any alternative or additional use
of the PYROMAT DYN is considered inappropriate use. The manufacturer is not liable
for damage resulting from this action. The user is solely responsible for the risk
incurred.
The following, amongst other things, are considered improper use:
Operation of the PYROMAT DYN by unqualified personnel, without schooling or
knowledge of the operating and maintenance instructions.
Disabling of safety or monitoring devices on the PYROMAT DYN.
Removal of protective covers and fairings on the PYROMAT DYN by unauthorised
personnel.
Carrying out modifications or alterations on the PYROMAT DYN without the
agreement of the manufacturer.
Use of replacement parts or accessories from external manufacturers without the
approval of the manufacturer.
2.5 Other applicable documentation
Data sheet 1010/1 + 2 "Minimum requirements, wood fuels - Information" in chapter
"Appendix".
Data sheet 3010/1 - 5" Boiler systems loading PYROMAT DYN“ in chapter
"Appendix".

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2.6 General safety regulations
LAll personnel who carry out tasks on the heating system must ensure that they are
familiar with the documentation provided which relates to these tasks.
LIn addition to the safety regulations stipulated in these instructions, also observe
the country-specific safety regulations.
General hazard!
Serious injuries due to operating error by insufficiently trained personnel.
Warning! 1. Only trained and experienced personnel may operate the heating system.
2. Personnel requiring training may only operate the heating system whilst under
supervision.
Electric shock!
Risk of fatal injury due to electricity.
Danger! 1. When working on the heating system it must be de-energised either at the separate
fuse or a main switch.
2. Secure heating system against being switched on again.
3. Electrical work must be carried out by electricians exclusively.
2.6.1 Over-temperature or electrical outage behaviour
Danger of deflagration!
In the event of a power outage the exhaust blower stops and the fresh air supply to the
combustion chamber is interrupted. Low temperature gas forms and this can lead to a
deflagration.
Danger! 1. Leave all covers closed.
2. Ventilate affected area.
3. Identify and rectify source of electrical outage.
Risk of burning due to hot system parts!
Caution! 1. You should touch the unit only at the handles and other identified parts.
2. Never touch the flue ducts or their mountings.

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2.6.2 What to do if you smell exhaust gas
Exhaust gas can lead to life endangering poisoning!
Danger! 1. Switch off the heating system.
2. Ventilate affected area.
3. Close doors in living spaces.
2.6.3 What to do in the event of fire
In the event of fire there is a risk of being burned and a danger of
explosion!
Danger! 1. Switch off the heating system.
2. Leave all covers closed.
3. Call the fire service.
4. If it is still possible to tackle the fire yourself without risk of personal injury:
Use a fire-class ABC certified fire extinguisher for fire-fighting.
2.6.4 Conditions in the heating room
General hazard!
Improper environmental conditions can cause damage to the heating system and
endanger the operational safety.
Caution! 1. Ensure ambient temperatures warmer than 0°C and colder than 40°C.
2. With air contaminated by easily inflammable materials:
Remove paint, varnish and other easily inflammable materials from the area around
the heating system.
3. Prevent extended periods of high humidity - risk of corrosion.
4. Do not block the existing air supply apertures.
2.6.5 Accessory parts, replacement and wearing parts
General hazard!
Components that have not been tested with the heating system can cause damage to the
heating system or adversely affect its function.
Caution! 1. When replacing parts, use only original parts or parts approved by the manufacturer.
2. Under no circumstances should changes or amendments to the heating system be
carried out without the prior written consent of the manufacturer.
3. Additions or replacements must be undertaken out exclusively by specialists.

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2.7 Qualifications of the personnel
Activity Personnel Qualification
Installation Köb personnel, installation
specialists, heating system
operators
Knowledge of operating and maintenance
instructions, installation instructions
Hydraulics knowledge
Experience in installation
All work on the electrical
system Electrician Qualified electrician with experience in
dealing with machinery
Transportation Köb personnel (loading), external
transport personnel, installation
specialists
Experience in machinery transport
Commissioning Köb personnel, installation
specialists, heating system
operators
Electrical knowledge
Knowledge of the operating and
maintenance instructions
Hydraulics knowledge
General technical knowledge
Operation Heating system operator Knowledge of the operating and
maintenance instructions
Service / maintenance Köb personnel, installation
specialists, heating system
operators
Knowledge of the operating and
maintenance instructions
Hydraulics knowledge
General technical knowledge
Fault fixing Köb personnel, installation
specialists, heating system
operators
Knowledge of the operating and
maintenance instructions
General technical knowledge
Electrical knowledge
Hydraulics knowledge
Experience in handling the machine
Repair Köb personnel, installation
specialists
Experience in metal working
Experience in installation
Electrical knowledge
Knowledge of the operating and
maintenance instructions
Hydraulics knowledge
General technical knowledge
Disassembly Installation specialists, heating
system operators, unskilled workers
Knowledge of the operating and
maintenance instructions
Hydraulics knowledge
General technical knowledge
Disposal Installation specialists, heating
system operators
Knowledge of local waste disposal
regulations

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2.8 EC Declaration of Conformity
Starting up the heating boiler is prohibited until it has been determined that the facility
into which this heating boiler is installed complies with the regulations of the applicable
machinery directive.

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2.9 Placards on the PYROMAT DYN
Fig. 1 Overview of placards on the PYROMAT DYN
A Comply with operating and maintenance instructions!
B Danger of deflagration!
C Risk of burns!
D
Example: PYROMAT DYN45 type plate
E Risk of crushing and being drawn in!

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2.10Safety devices
LThe components listed in the following are a part of the safety concept.
Modifications and/or changes on this component are prohibited without exceptions.
Defective components may only be replaced by original replacement parts of the
same design.
Main switch The heating system can have all poles disconnected
from the electrical mains by means of the main
switch, delivered loose.
Triggering the function Actuating the main switch results in all drives being
de-energised.
LThe recirculating pumps for the water circulation
are supplied by a separate electrical circuit.
Cancelling the function Switch on the main switch.
Temperature limiting safety
switch (TLSS) The TLSS is located in the front panel underneath the
firebox door.
LIf the TLSS has been triggered then it must be
manually unlatched.
Triggering the function The TLSS is triggered if the boiler temperature
exceeds 100°C.
Cancelling the function LResetting is only possible after the boiler
temperature has dropped below approx. 70°C.
1. Unscrew fastener on temperature limiting safety
switch and press button.
2. Screw fastener back on again.
Thermal run off safety valve
(optional) The thermal run off safety valve is installed in the rear
area of the boiler.
LAdhere to the instructions in the manufacturer's
documentation for the thermal run off safety valve!
Triggering the function The thermal run off safety valve is triggered if the
boiler temperature exceeds 100°C. Cold mains water
flows through the safety heat exchanger. The boiler is
cooled and the heated water is conducted to the
drain.
Cancelling the function LResetting occurs automatically, depending on the
thermal run off safety valve installed, if the boiler
temperature has dropped below the triggering
temperature.
LAfter every triggering be sure to check the
resetting of the thermal run off safety valve!

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2.10.1 Automatic fuel feed
With feeding burners there is a connection, created by the transport path, between the
burning material in the boiler and the fuel store.
With the PYROMAT DYN heating boiler, the feed auger is also the dosing screw and is
therefore always completely filled with material during operation.
To prevent back burn the following safety devices must be installed, according to the
country-specific regulations:
Temperature sensor If the temperature sensor on the feed auger detects an increased temperature then the
supply to the feed auger is interrupted and the material in the feed auger is fed into the
combustion chamber.
Slide valve
(optional) Closes when the system is shut down, if there is a danger of back burn or if there is a
power outage (spring return motor).
Rotary valve
(optional) Engagement of the slide valve in the silo with pressure application.
Drop The burning material connection is broken by a vertical drop.
Extinguishing device
(optional) This device, which operates independently of electrical power, floods the fuel material
in the feed auger.

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3 Product information
3.1 Model description
Description: PYROMAT DYN
Manufacturer: Köb Holzheizsysteme GmbH
Flotzbachstraße 33
A-6922 Wolfurt
T 0043 / (0) 5574 / 6770 – 0
F 0043 / (0) 5574 / 65707
[email protected]
www.kob.cc, www.koeb-holzheizsysteme.com
Viessmann Group
Overview
PYROMAT DYN
Fig. 2 Overview PYROMAT DYN front
A Firebox door, feeder chute
underneath B Top opening cleaning lid
C Sight glass D Lock for cleaning lid
E Combustion chamber maintenance
cover F Exhaust gas sensor, lambda sensor
G Feed auger gearing H Feed auger motor
K Dosing container L Feed auger
M Lower cleaning door N Automatic ignition system
O Ash pan door P Temperature limiting safety switch
Q Firebox door lock

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Overview
PYROMAT DYN
Fig. 3 Overview PYROMAT DYN rear
A Boiler pump B Burner control valve with actuating
drive
C Return D Flow
E Safety heat exchanger, thermal run
off safety valve sensor F Combustion chamber maintenance cover
G Automatic combustion chamber
maintenance cover (opposite feed),
combustion chamber light barrier
H Cleaning de-ashing drive (opposite
feed)
K Exhaust blower L Light barrier dosing container

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3.2 Workplace
The following areas around the heating system must be freely accessible:
All doors and covers.
All inspection hatches.
LThe heating system must be switched off during any cleaning, servicing or repair
activities on the system so that safe working conditions are guaranteed.
LYou must ensure that the heating system and the surrounding area are kept clean
and tidy.
3.3 Fuels
LKöb provides no guarantee for the function and service life of the boiler if fuels
other than those specified under the point “Appropriate Use” are used. See the
"Guarantee" point in the general delivery conditions.
Fuels (bulk material) The PYROMAT DYN is suitable exclusively for burning the materials specified in data
sheet 1010/1 + 2 "Wood fuels minimum requirements".
Logs for
manual loading Air dried, natural logs such as e.g.: Split, cut or round logs.
Hardwood: max. ∅15 cm
Softwood: max. ∅12 cm
Recommended storage value (dry storage)
Hardwood: 2 to 2½ years
Softwood: 1 to 1½ years

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4 Commissioning
General hazard!
Serious injuries due to untrained personnel.
Warning! 1. Only trained and experienced personnel may perform the commissioning of the
heating system.
2. Training personnel may only work on the heating system whilst under supervision.
3. Commissioning work may only be carried out by Köb installation specialists or by
persons authorised by Köb.
LThe commissioning of the complete heating system is carried out by Köb
installation specialists or your installation specialists. The heating system is set up
in such a way that the fuel available, in conjunction with the air intake volume, will
provide an optimum burn.
LAs the operator of a new heating system you are obligated to register this
immediately with the authority responsible for your property. The authority will also
provide you with information regarding further activities pertaining to your heating
system (e.g. regular measurements, cleaning).
LThe instructions for commissioning are contained in the assembly and installation
instructions for specialists.

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5 Operation
5.1 Basic menu navigation - ECOTRONIC
The ECOTRONIC controller gathers all data relevant for operations and regulates the
heat output and heat consumption.
The boiler system is continuously monitored in all phases of operation and is kept in the
optimised emissions zone.
Fig. 4 ECOTRONIC overview
A Display B Navigation buttons
C Increase/decrease parameter,
confirm input D Function keys with built-in LEDs:
Selection of the various menus.