ZMM Haskovo PYROTHERM Series User manual

User manual
Green ECO Therm
for installation and exploitation
of wood gasification hot water boiler of series :
PYROTHERM
http:// www.greenecotherm.eu

p. 2/69
Thank You for buying the wood gasification boiler of series “Pyrotherm”.
This manual will help You to use and maintain the unit properly.
The user manual applies to the following types of hot water boilers:
“Pyrotherm 25”, “Pyrotherm 32 and “Pyrotherm 52”.
This document is intended to be used as additional information for the
service team, which will install and adjust the boiler, as well as maintenance
information, which will help the end user.
The producer requires the service staff, which will perform the above
mentioned procedures, to get training course at the producer’s training center
and get certified as well.
ATTENTION! In interest of your personal security it is
obligatory to read thoroughly and carefully this instruction
manual before proceeding with any actions with the system –
mounting, connecting, etc. its elements. In case that
requirements, depicted in this manual are not satisfied,
failures of any element of the system could be expected, or
even fatal consequences, for which the boiler’s producer does
not take responsibility;
Producer ZMM Haskovo Plc.
Address Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd.
Phone [phone]
Fax [phone]
e-mail [e-mail]
home page www.greenecotherm.eu
User manual for installation and exploitation of wood gasification hot water boiler of
series „Pyrotherm” (Document version: 16.11.2011 13:32:00)

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CONTENTS
p.
1. Main properties and advantages of the wood gasification hot water
boiler of series “Pyrotherm” ..............................................................................5
1.1. Basic information for the hot water boiler..................................................5
1.2. Basic information for the pyrolisis process................................................5
2. Technical data of wood gasification hot water boiler of series серията
“Pyrotherm” ........................................................................................................8
3. Description of the wood gasification hot water boiler of series
“Pyrotherm”. .....................................................................................................12
4. Installation of the hot water boiler of series “Pyrotherm”.................18
4.1. Basic requirements for installation of wood gasification hot water
boiler of series “Pyrotherm”:........................................................................18
4.2. Basic requirements for installation of wood gasification hot water
boiler of series “Pyrotherm”, considering it’s easy maintenance and
servicing:.........................................................................................................19
5.1. Basic fuel requirements.......................................................................26
5.2. Basic requirements for exploitation of the hot water boiler,
connected to a heating system.......................................................................26
5.3. Starting wood gasification hot water boiler of series “Pyrotherm”
procedure........................................................................................................28
5.3.1. Interface control board of wood gasification hot water boiler
of series “Pyrotherm” .......................................................................................30
5.3.2. Start-up initialization of the boiler..........................................32
5.3.3. Ignition of the fuel and boiler’s heating up ............................33
5.3.4. Adjustment of the air flow rate control thermovalve............36
5.3.5. Nominal operating mode of the boiler.....................................37
5.3.6. Fuel hopper charging................................................................39
5.3.7. Adjustment of the operating parameters of the boiler..........41
5.3.8. Estimating the thermal capacity of the boiler........................47
5.3.8.1. Decreasing the thermal capacity of the boiler........................48
5.3.8.2. Increasing the thermal capacity of the boiler.........................48

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5.4. Operation of the boiler in “stand-by” mode.....................................49
5.5. Stopping the operation of the boiler..................................................50
5.6. Turning OFF the boiler.......................................................................51
•Emergency boiler stop..........................................................................51
5.7. Cleaning the ash of the boiler.............................................................52
5.8. Showing and teaching the end user about the maintenance and
adjustment procedures of the boiler............................................................59
5.9. Safety and unexpected risks ...............................................................60
5.10. Operation faults and their repairing.................................................61
5.11.Hot water boiler warranty form completion......................................64
5.12. Actions, after the unit is not in exploitation anymore......................64
6. Electrical scheme of control board of wood gasification hot water
boiler of series “Pyrotherm”............................................................................65
QUALITY CERTIFICATE .............................................................................66
WARRANTY CONDITIONS..........................................................................67
WARRANTY SERVICE PROCEDURES LIST...........................................69

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1. Main properties and advantages of the wood gasification hot
water boiler of series “Pyrotherm”
1.1. Basic information for the hot water boiler
The wood gasification hot water boiler of series “Pyrotherm” is steel-plate
hot water boiler, which uses solid biomass fuel in shape of wood logs. The
boiler is designed to be connected to local hot-water heating systems, as well
as heating up domestic hot water. The boiler uses wood logs with moisture
content up to 20% (the parameters of the fuel are described below), the
resulting heat energy from thermo-chemical conversion (i.e. combustion
process) is transmitted to the circulation water in its water jacket and the heat
energy is transported to the heating system/consumer. The design of the
boiler is optimized in order to achieve high efficiency and low cost heating
process, as well as easy maintenance, ash removal and servicing. The hot
water boiler of series “Pyrotherm” is manually fuel fed boiler. The
combustion process is organized in the combustion chamber of the boiler.
The set of the hot water wood gasification boiler of series
“Pyrotherm” consists of the following :
•Hot water boiler of series “Pyrotherm” - 1 sp;
•Combustion chamber ceramic directing element - 1 sp;
•Thermovalve for control of air flow rate – 1 sp;
•Steel ash cleaning brush – 1 sp;
•Ash scrapper – 1 sp;
•User manual for installation and exploitation of hot water boiler of
series “Pyrotherm” – 1 sp;
1.2. Basic information for the pyrolisis process.
The pyrolisis process is chemical decomposition of the biomass through
heating of the matter. The word pyrolisis is coined of two Greek words
„pyro” – fire and „lysis” – decomposition. The wood pyrolisis process is
realized at certain conditions, the products of this process are volatile gases,
which are utilized like gas combustion process. The pyrolisis gases are
extracted out of the fuel chamber and are directed through a ceramic nozzle
and oxidized in the combustion chamber, reaching high intensity of the
combustion process and high efficiency. This process have many advantages
– the combustion process could be optimized and allows efficient utilization
of the fuel material. The design of the how water boiler of series “Pyrotherm”
allows optimal conditions for the above mentioned process, so they are

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named “pyrolisis” hot water boilers. The fuel ignition, as well as the fuel
charging is done manually, the ash deposition cleaning is also done
periodically by hand – this allows achieving optimal combustion process and
efficient and low cost heat energy for the heating system.
The boiler could utilized the following fuel – wood logs, preferably
chopped wood logs, having the following properties:
oPure wood, contaminated (i.e. painted, chemically treated as well as
other mineral or organic substances) wood is not allowed;
oThe length of the wood logs should correspond with the depth of the
fuel chamber of the boiler – see the specification of boiler;
oThe cross section (the diameter) of the wood logs should be : D ≤
200mm;
oThe moisture content of the raw material should be less than 20%
(W
r
≤20%);
oIt is possible along with the wood logs to utilize other wood based
fuel – like saw dust, shavings and other small fuel particles, but their
quantity should be less than 20% of the total charged fuel in the
chamber of the boiler;
The boiler consists of
•Steel plate heat exchanger, which transfers the heat energy from the
flue gases to the heating media (in most cases this is circulating water);
•Flue gas fan, which extracts the exhausted gases out of the boiler;
•Fuel chamber;
•Ignition flap, utilized at the initial phase of fuel ignition and boiler
heating up;
•Ceramic insulated combustion chamber;
•Convective duct, which also heats up the air, consumed for the
combustion process;
•Dash board for control and monitoring of the operating parameters of
the boiler;
•Thermal insulation – made of mineral wool;
The boiler is equipped with
•Thermo-manometer, which indicates both the operating temperature
and the operating overpressure of the circulating water;
•Operating thermostat, which controls the flue gas fan;

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•Thermostat, which indicates the thermal condition of the boiler and
indicates if the boiler needs to be cleaned of the accumulated ash -
option;
•Alarm thermostat, which switches off the power supply of the boiler in
alarm overheating mode of the boiler;
•Emergency cooling coil, utilized in case of alarm overheating of the
boiler;
Advantages of the boiler
•The boiler is designed to utilize wood biomass, which makes it
ecologically clean and environmentally friendly and its operation does not
contribute to the global warming of the Earth;
•The price of the thermal energy, derived by utilizing the boiler like local
energy source is less influenced by the world prices of the other fuels and
energy sources, which makes it attractive and competitive, compared with
the common known energy sources;
•The manual feeding of the fuel in the boiler allows easy control of its
thermal capacity, which guaranties high thermal comfort and fuel savings;
•High efficiency;
•Low pollutants;
•Opportunity to heat up domestic hot water (DHW);
•Simplified maintenance and service;
•Minimal running costs;

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2. Technical data of wood gasification hot water boiler of series
“Pyrotherm”
•Thermal and technical data for the wood gasification hot water
boiler of series “Pyrotherm” are given in Table 2.1;
•Dimensions and technical data for the wood gasification hot
water boiler of series “Pyrotherm” are given in Table 2.2;
•Parameters of the recommended fuel are given in Table 2.3;
•Low heating value of wood logs is given in Table 2.4;
Parameter Dimension
Value
Model 25 32 52
Nominal thermal capacity kW 25 32 52
Thermal capacity
operation range kW 13 - 25 16 - 32 26 - 52
Utilized fuel Wood logs for heating purposes, water
content up to 20%
Wood logs consumption
rate at nominal thermal
capacity kg/h 7.9 10.2 16.5
kg/h 93 120 195
Fresh air flow rate,
required for effective
combustion process and
boiler operation m
3
/h 81 104 169
Flue gases mass flow rate g/s 28.1 36.1 58.6
Averaged wood logs
consumption rate (the boiler
is operating in a popular heating
system) kg/h 5.5 7.0 11.5
Thermal efficiency at
nominal capacity ℅85
Flue gasses temperature
at nominal thermal
capacity ºC 180 – 250
Solid fuel residue ash
The quantity depends on the ash
contents in the raw fuel, as well
as operating conditions
Table 2.1. Thermal and technical data for the wood gasification hot
water boiler of series “Pyrotherm”;

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Parameter Dimension
Value
Model 25 32 52
Weight 330 330 330 450
water jacket capacity 60 59 59 89
100 100 100 170Fuel chamber capacity 16 - 20 16 - 20 16 - 20 25 - 30
Interval of time for nominal
thermal capacity after fuel
chamber charging hours 2 - 3
Maximal wood log length mm 330 330 700
W - width 780
D - depth 975 975 1321
Overall
dimension of the
system: (WxDxH) H - height mm 1282
Operating overpressure of the
circulating water MPa 0.2
Hydraulic losses of the
circulating water at nominal
thermal capacity hPa 3.54 5.27 8.37
Heating system expansion
vessel type - opened or closed
Factory tested overpressure MPa 0.4
Recommended circulating
water temperature in the boiler ºC 80 - 85
Minimal recommended return
water temperature in the boiler ºC 60
Draught hPa 0.18 - 0.24
Supply/return
flow G 1½” 2”
Drainage G 3/4”
Emergency
cooling coil G
½ ”
Connections
Flue gases duct
mm 150
Power supply - L1, N, PE, 50Hz; 230V;
Power supply cable - 3 x 1.5mm
2
Electrical capacity VA 32 32 65
Electric protection - IP20
Class of the boiler
(according to EN 303-5) - 3
Table 2.2. Dimensions and technical data for the wood gasification
hot water boiler of series “Pyrotherm”;

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Parameter Dimension Value
Fuel type Wood logs
Length of the wood logs mm See Table 2.2.
Moisture content % ≤20%
MJ/kg >13.9Low calorific value of the fuel (LHV) kWh/kg >3.9
Table 2.3. Proximate parameters of the recommended fuel – predried
and chopped wood logs;
EXPLANATION: one of the most important parameters of the fuel is its
calorific value (its heat content). The calorific value (also known as heating
value) is function of the moisture content of the wood logs (the moisture is
mechanically conserved water in the fuel. The biomass is a natural product and
the moisture content of a raw material could be 40 to 60% (the just cut down
material can contain up to 80%).
In order to achieve economic operation of the boiler and to achieve
efficient combustion process, it is necessary to supply fuel with minimal water
content, for pyrolisis types of boilers it is recommended the moisture content to
be up to 20%, which is practically realized by natural drying of the material (at
ambient conditions) for a relatively long period of time (at least for a year),
during the summer period the drying is high intensified. The fuel should be
protected from accident moistening (from example by rain or snow). In order to
achieve uniform and intensive during it is highly recommended to chop the wood
logs into smaller pieces. However, it the wood logs are stored for a longer
period (more than two years), its calorific value is also decreased due to
devolatilization of the biomass;
The so called Low Calorific Value of the fuel (LHV) – the heat energy,
achieved at combustion, but the latent heat of the water vapor in the flue gases
is not retrieved could be calculated from the following equation:
(
)
100
44.2100*
rr
WWHHV
LHV −− = , [MJ/kg], where :
LHV – Low Heating Value of the fuel, [MJ/kg];
HHV = 18.0 [MJ/kg] – High Heating Value of the fuel (this is the energy of the
fuel, which includes the latent heat of evaporation of the water vapor in the flue
gases, i.e. the water has been condensed);
The dependency of the Low Heating Value as function of the moisture
content W
r
is given on the following figure:

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0.000
2.000
4.000
6.000
8.000
10.000
12.000
14.000
16.000
18.000
20.000
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 85
Съдържание на влага
Figure 2.1. Low heating value of wood log (abscise – moisture content W
r
, [%],
ordinate – low heating value LHV);
Moisture content Low heating value
W
r
LHV
[%] [MJ/kg] [kWh/kg]
0 18.000 5.000
5 16.978 4.716
10 15.956 4.432
15 14.934 4.148
20 13.912 3.864
25 12.890 3.581
30 11.868 3.297
35 10.846 3.013
40 9.824 2.729
45 8.802 2.445
50 7.780 2.161
55 6.758 1.877
60 5.736 1.593
65 4.714 1.309
70 3.692 1.026
75 2.670 0.742
80 1.648 0.458
85 0.626 0.174
Table 2.4. Low Heating Value of wood logs as function of moisture content W
r
of the raw fuel % (w.b.);
Low heating
value , [MJ/kg]
Low heating
value, [kWh/kg]

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3. Description of the wood gasification hot water boiler
of series “Pyrotherm ”.
The heat exchanger of the hot water boiler of series “Pyrotherm” complies
with the acting requirements for such kind of units, defined in operating norm :
EN 303-5/2000 – „Heating boilers for solid fuels, hand and automatically fired,
nominal heat output up to 300 kW. Terminology, requirements, testing and
marking”.
The hot water boiler consists of the following elements/modules:
•Heat exchanger is steel plate welded construction. In the upper section of
the boiler is the fuel hopper, which is manually fed with wood logs. This
fuel chamber makes optimal conditions for fuel pyrolisis process and the
volatile gases are directed to the lower section of the boiler, where they
are oxidized in the combustion chamber. In the combustion chamber is
positioned ceramic lining – a nozzle and a flue gas directing element,
which allow efficient combustion process;
•Combustion nozzle, produced from ceramic material, placed in the lower
section of the fuel hopper, which ensures optimal conditions for efficient
combustion process;
•Ceramic directing element,which is positioned in the combustion
chamber of the boiler, allowing high temperature levels and ensures
optimal fuel oxidation;
•Flue gases fan is installed in the back side of the boiler – it transports the
exhausted flue gases out of the boiler and controls the operation of the
boiler;
•Air distribution box, which has primary air control valve. This box also
serves as heat exchanger and preheats the ambient air before being
consumed in the combustion chamber of the boiler. The inlet of this box
has inflow control flap, which is driven by thermovalve and controls the
total mass flow rate of the air, sucked in the boiler;
•Inflow orifice has internal thread (for the size see table 2.2) and is
positioned on the back left lower side of the heat exchanger, the outflow
orifice has internal thread as well (for the size see table 2.2) and is
positioned in the back left upper side of the boiler. Use this orifices in
order to connect the boiler to the heating system;
•Drainage orifice has internal thread (for the size see table 2.2), which
should be connected to a drainage valve;

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•Emergency cooling coil is utilized for alarm cooling of circulating water
in the boiler’s heat exchanger in case that the water temperature has
reached high levels. This coil has connecting thread of size G½”;
•The flue exit duct (the external diameter is described in table 2.2) is
positioned in the back upper of the boiler and extracts the flue gases out of
the convective section of the boiler;
•The heat exchanger is thermally insulated with mineral wool, which
allows lower heat loses to the surrounding atmosphere;
•The doors of the fuel hopper and the combustion chamber are fabricated
from cast iron, which allow high thermal resistance and air tightness of
the boiler;
•The outer covers of the boiler are manufactured from steel plates and are
finally color painted;
The next figures show the dimensions and the design of the wood gasification
hot water boiler of series “Pyrotherm”.
Figure 3.1 Side view of wood gasification hot water boiler of series
“Pyrotherm” – the main elements of the boiler are described;
Control board of the boiler
Fuel hopper door
Combustion chamber door
Thermovalve for
controlling the air flow rate

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Figure 3.2. View of the wood gasification hot water boiler of series
“Pyrotherm” – front view;
Figure 3.3. View of the wood gasification hot water boiler of series
“Pyrotherm” – side view;
EXPLANATION : the value of the dimensions, marked with :W, H иD are
given in table 2.2;
W
H
D

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Figure 3.4. View of the wood gasification hot water boiler of series
“Pyrotherm” – back side view;
Figure 3.5. View of the wood gasification hot water boiler of series
“Pyrotherm” – top view;
D
W
W

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Figure 3.6 Cross section view of wood gasification how water boiler of series
“Pyrotherm”;
Fuel hopper
Orifice for extracting the gasses
of the fuel chamber at ignition
Combustion nozzle
Combustion chamber
Flue gas directing profiled
ceramic in the combustion
chamber
Primary air inlet orifice
Flue gasses outlet (directed to the
convective duct of the boiler);

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Figure 3.7. Longitudinal section of wood gasification hot water boiler of series
“Pyrotherm”;
The producer reserves the right to make any changes of the design and
construction of the boiler without obligation to inform the end user.
Flue gas exit duct
Control box of the boiler
Combustion nozzle
Flue gas fan
Flue gases directing ceramic
profiled element
Upper lid of the convective duct of the
boiler
Lower lid of the convective duct of the
boiler

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4. Installation of the hot water boiler of series
“Pyrotherm”
Norms and requirements.
4.1. Basic requirements for installation of wood gasification hot water
boiler of series “Pyrotherm”:
•The room, dedicated to mount the hot water boiler should be supplied
with fresh air supply duct, necessary for optimal combustion process as
well as room ventilation;
•Installation of the hot water boiler in inhabitable premises, including
dwelling corridors, is not allowed;
•The hot water boiler should be connected to the heating system by
authorized personal only;
•Installation and service procedures of the hot water boiler should be
performed by authorized qualified and certified personal ONLY;
•The wood gasification boiler of series “Pyrotherm” could be attached to a
heating system, equipped with opened or closed expansion vessel, which
should be designed for the water capacity of the entire heating system (its
capacity is calcutated at the step of heating system project development);
•Both the entire heating system and the hot water boiler should be totally
filled with circulating fluid (water) and air-free before operating the
boiler;
•Maintenance procedures of the boiler (as well as the heating system)
should be performed by trained adult persons, which have read the user
manual of the unit;
ATTENTION: at the transport of the boiler, take care to preserve the ceramic
element, mounted in the combustion chamber of the boiler not to be cracked or
damaged (secure the detail, or even transport it separately from the boiler);
Installation procedure of the hot water boiler requires engineering project
for the heating system, prepared according to the acting local norms and
recommendations as follows:
•To the heating system - EN 303-5/2000 - „Heating boilers. Part 5 :
Heating boilers for solid fuels, hand and automatically fired, nominal
heat output of up to 300 kW. Terminology, requirements, testing and
marking”;

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•To the chimney;
•Fire prevention requirements;
•To the power circuit - EN 60335-1/1997- “Household and similar
electrical appliances – safety, Part 1 – General requirements”;
•The ambient air inflow orifice of the boiler’s room should have cross
section of minimum 0.04 m
2
;
4.2. Basic requirements for installation of wood gasification hot water
boiler of series “Pyrotherm”, considering it’s easy maintenance and
servicing:
oThe boiler should be installed on thermally safe and
noncombustible pad, which should have height of 50 mm;
oThe minimal space in front of the boiler for cleaning, maintenance
etc, should be 1000 mm;
oThe minimal distance allowed between the back side of the boiler
and a wall should be 400 mm;
oThe minimal distance from the boiler’s side and a wall should be
500 mm, in order to allow easy maintenance and servicing
procedures of the boiler’s convective heat exchanger and back side
of the unit;
oThe minimal distance between the opposite side of the boiler and a
wall should be 500 mm in order to ensure easy access to the heat
exchanger and to allow easy cleaning of the deposited ash;
oThe minimal distance between the top side of the boiler and a wall
(ceiling) should be 600 mm, in order to ensure easy access to the
control board of the unit, for attachment of the emergency coil, as
well as for the cleaning and maintenance procedures of the heat
exchanger;
EXPLANATION: after the hot water boiler is positioned, the following
procedures of the installation process should be performed:
oThe ceramic flue gas directing element should be placed in the
combustion chamber of the boiler;

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Figure 4.1. Ceramic flue gases directing element, which should be
positioned in the combustion chamber of the boiler;
Figure 4.2. Ceramic flue gases directing element is positioned in the
combustion chamber of the boiler;
ATTENTION: at the mounting and installation of the ceramic element
should be done with care and preventive measures should be taken in
order to keep this element’s integrity. After the element has been installed
in the combustion chamber, it should be pushed backwards in order to
touch the back vertical plate of the heat exchanger.
oInstall the thermovalve, which controls the air flow rate;