Caleffi International NV - Brochure biomassa
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 Caleffi International NV - Brochure biomassa Caleffi International NV - Brochure biomassa Document Transcript

  • COMPONENTS FOR BIOMASS SYSTEMS
  • The Caleffi Biomass product series has been created specifically to be used in circuits of systems with wood solid fuel generators, operating at high temperature with water or glycol solutions as thermal medium. The materials of the components and their performance take account of the specific system needs in terms of efficiency and safety of the generators and systems. BIOMASS LOGS Biomass is “the biodegradable fraction of products, waste and residues from biological origin from agriculture (including vegetal and animal substances), forestry and related industries (including fisheries and aquaculture), as well as the biodegradable fraction of industrial and municipal waste”. Biomass can be in the form of a solid, liquid or gas. This line of Caleffi products has been specifically designed for wood solid biomass (solid fuel). SOLID FUEL GENERATORS PELLETS Solid fuel generators can be classified in two macro-categories: 1) Boilers: generators “for solid fuels, hand and automatically stoked”, to be installed in specific technical rooms. Heating takes place via a hydraulic connection to the heating system. 2) Residential devices: “residential solid fuels burning appliances with boiler, not exceeding a total nominal heat output of 35 kW”, installed directly inside the dwelling. Hand or automatically stoked. Heating takes place via air and water circulation, with a hydraulic connection to the heating system. Residential devices can be classified in three types: - Fireplace heating systems - Thermostoves - Thermocookers WOODCHIPS The generators are further divided according to their fuel stoking system: Hand stoking, typically that of log-burning generators, requires an operator to put the blocks of wood into the generator stoking compartment. Automatic stoking refers to the last device conveying the fuel (for example pellets or woodchips) from the storage tank to the combustion chamber. Hand and automatically stoked boiler Flue gas Thermal exchange Comburent air M Primary and secondary air M M Hand and automatically stoked residential device M 2 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • P T Safety thermostat with manual reset TR TR T Adjustable thermostat with automatic reset Safety relief valve Optical and acoustic alarm AL To storage Near the Comburent air stop device AC REFERENCE STANDARDS PPM Closed expansion hand stocked The standards classify systems according to the (only for and V > 300 l) system (open or closed vessel) and according to the system for stoking fuel into expansion generator boilers vessel TC Control thermostat Temperature gauge the boiler, by hand (logs) or automatic (pellets, woodchips etc.). Temperature relief valve RIARMO SOLID Generator FUEL BOILER Power rating Product standard Boiler Up to 300 kW EN 303-5 (2004) Boiler < 35 kW Boiler > 35 kW Residential Up to 35 kW P PLM Safety pressure switch with manual reset System standard Pressure gauge 542 1 1/2 X 1 1/2 542 EN 12828 (2003) for Three way tap Europe Minimum level protection device Temperature safety relief valve I.S.P.E.S.L. master pressure gauge EN 12828 (2003) Italy PPM Minimum pressure protection device I.S.P.E.S.L. test pocket Temperature relief valve with automatic S Collection R I.S.P.E.S.L. (1982-2005-2009*) Italy filling C EN 13229 (2006) EN 13240 (2006) EN 12815 (2006) EN 12828 (2003) Europe UNI 10412-2 (2009) Italy *In the phase of approval Here we give some significant examples of open and closed vessel systems made in accordance with applicable standards T TR TC P Comburent air stop TR AC device PPM T P Safety thermostat with manual reset Adjustable thermostat with automatic reset TR TR T AL Near Optical and acoustic the TR TL alarm P PPM PLM P generator P PPM Control thermostat To storage (only for hand stocked Closed expansion boilers and V > 300 l) To storage To storage (only for hand stocked (only for hand stocked boilers ToboilersTemperature storageand V > 300 l) and V > 300 l) (only for hand valve stocked boilers and V > 300 l) SOLID FUEL BOILER Safety pressure switch manual reset T vessel Temperature gauge Near the Near generator the generator withNear the generator Pressure T Safety relief valve RIARMO TR relief 542 gauge 542 Three way tap for I.S.P.E.S.L. master pressure gauge FUEL BOILER PPM Minimum pressure protection device TC S C Temperature relief valve with automatic filling Black devices: mandatory according to standards Magenta or “framed” devices: optional or as an alternative according to standards AL TL RIARMO 542 1 1/2 X 1 1/2 542 RIARMO 542 1 1/2 X 1 1/2 542 S C S C T S TC PPM ≤1 m To storage (only for hand stocked boilers and V > 300 l) Near the generator P P PPM generatorC T T Near the ≤1 m TL Near theP PLM To storage (only for hand stocked boilers and V > 300 l) PLM EN 303-5 (2004): Heating boilers for solid fuels, hand and automatically stoked, nominal heat output of up to 300 kW. Open vessel. EN 303-5 (2004): Heating boilers for solid fuels, hand and automatically stoked, nominal heat output of up to 300 kW. Closed vessel. TL RIARMO AL C Near the generator Near the generator SOLID FUEL GENERATOR SOLID FUEL GENERATOR SOLID FUEL BOiLER SOLID FUEL BOiLER PLM AC S generator TC P PPM T SOLID SOLID FUEL FUEL BOILER DOMESTIC GENERATOR DEVICE To storage (only for hand stocked boilers To storageand V > 300 l) (only for hand stocked boilers and V > 300 l) Near the generator Near the generator SOLID FUEL GENERATOR 542 I.S.P.E.S.L. test pocket PLM Near the generator SOLID FUEL BOiLER 542 1 1/2 X 1 1/2 Temperature gaugetap for Three way I.S.P.E.S.L. master Pressure gauge pressure gauge Pressure gauge Three way tap forpocket I.S.P.E.S.L. test I.S.P.E.S.L. master Three way tap for pressure gauge I.S.P.E.S.L. master pressure gauge I.S.P.E.S.L. test pocket TR T P P PPM T TC 542 542 TR SOLID FUEL GENERATOR TR TL RIARMO C 1 1/2 X 1 1/2 P PPM T TC Temperature relief Closed expansion valve vessel Closed expansion vessel Temperature relief Temperature safety valve valve relief Temperature relief valve Temperature relief valve with safety Temperatureautomatic filling relief valve Temperature safety relief valve Temperature relief valve with automatic Temperature relief filling valve with automatic filling EN 12828 (2003): Heating system in buildings - Design for water-based heating systems. Closed vessel. RIARMO PLM AC P Safety relief valve Closed expansion Safety relief valve vessel SOLID FUEL Control thermostatlevel protection Minimum PLM GENERATOR device P Safety pressure switch with manual reset Safety pressure switch with P manual reset P Minimum pressure PLMPM Minimum level protection protection device device PLM Minimum level protection device PPM Minimum pressure protection device PPM Minimum pressure protection device Temperature safety relief valve I.S.P.E.S.L. test pocket TR TL Safety relief valve device thermostat TR Adjustablereset PPM with Optical and acoustic automatic P AL T Safety thermostat with T TC AC Comburent air stop alarm device manual reset Comburent air stop Safety thermostat with AC device manual reset thermostat with TC Adjustable thermostat Control Temperature gauge TR automatic reset Optical and acoustic Near the AL alarm Adjustable thermostat with generator Optical and acoustic with automatic resetpressure switchAL P Safety alarm Pressure gauge manual reset TC Control thermostat Temperature gauge 1 1/2 X 1 1/2 SOLID FUEL SOLID BOiLER FUEL BOILER PLM Minimum level protection device SOLID AC Comburent air stop Safety thermostat with manual reset T TC 542 1 1/2 X 1 1/2 542 TL RIARMO TL T PLM AC PLM AC SOLID FUEL GENERATOR SOLID FUEL GENERATOR SOLID FUEL GENERATOR TC AL RIARMO AL TL 542 ≤1 m 1 1/2 X 1 1/2 542 ≤1 m TC T T TR T L TC P PLM ≤1 m 542 S 1 1/2 X 1 1/2 542 ≤1 m ≤1 m ≤1 m S DOMESTIC DEVICE ≤1 m C Near the generator To storage (only for hand stocked boilers and V > 300 l) S C S C SOLID FUEL DOMESTIC BOiLER DEVICE DOMESTIC DEVICE C DOMESTIC DEVICE Collection R I.S.P.E.S.L. (2009): Applicatory technical specifications of Title II of Italian Ministerial Decree DM 1.12.75 in accordance with art. 26 of the decree. (P>35 kW for Italy). Hand and automatically stoked. Open vessel. UNI 10412-2 (2009): Hot water heating systems - Safety requirements. Part 2: Requirements for systems with residential solid fuels burning appliances with boiler, not exceeding a total nominal heat output of 35 kW. Automatically stoked. Closed vessel. RIARMO PLM AC AL 542 1 1/2 X 1 1/2 542 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003 SOLID FUEL GENERATOR ≤1 m 3
  • SAFETY DEVICES 542 543 tech. broch. 01001 Temperature relief valve, with fail-safe action. Manual reset for burner switch off or alarm activation. Working pressure: 0,3 ≤ P ≤ 10 bar. Working temperature range: 5–100°C. Setting temperature 98°C and 99°C Qualified and calibrated to I.S.P.E.S.L. Discharge rating: 1 1/2” x 1 1/4” - 136 kW. 1 1/2” x 1 1/2” - 419 kW. Code 542870 542880 tech. broch. 01057 Temperature safety relief valve, with double safety sensor, for solid fuel generators. Max. working pressure: 10 bar. Working temperature range: 5–110°C. Setting temperature 95°C Discharge flow rate with ∆p of 1 bar and T=110°C: 3000 l/h Length of capillary: 1300 mm. Certified to EN 14597 standard. Setting 1 1/2” M x 1 1/4” F 1 1/2” M x 1 1/2” F Code 98°C 99°C 543513 Setting 3/4” F 95°C Function Function The temperature relief valve discharges the system water on reaching the setting temperature. Equipped with positive action. It can be used with non-pulverized solid fuel generators with open or closed vessel in accordance with current regulations. The temperature safety relief valve limits the water temperature in solid fuel generators equipped with a built-in storage or emergency exchanger (for immediate cooling). On reaching the setting temperature, the valve opens the flow of mains water through the emergency exchanger or built-in storage unit, so as to draw off the excess heat and thereby lower the temperature of the system water contained in the boiler jacket. I.S.P.E.S.L. reference standards According to the provisions of Collection R Ed. 2009, concerning “central heating systems using hot water with temperatures no greater than 110°C and a maximum nominal heat output greater than 35 kW”, the use of the temperature relief valve is contemplated in the following cases: Open vessel systems - Systems with generators stoked with non-pulverized solid fuel, in place of the consumption water heater or emergency exchanger (chap. R.3.C., point 2.1, letter i2). Closed vessel systems - Thermal systems with generators stoked with non-pulverized solid fuels up to a nominal heat output of 100 kW with partial cut-off in place of the residual power dissipation device (chap. R.3.C., point 3.2). Reference standards Its use is contemplated in the I.S.P.E.S.L. standards, Collection R ed. 2009, chapter R.3.C., point 2.1, letter i2; point 3.1, letter i; point 3.3. The valve complies with EN 14597, it can be combined with solid fuel generators with a heat output of less than 100 kW, used according to the system provisions of the standards EN 12828, UNI 10412-2 and EN 303-5. RIARMO 542 1 1/2 X 1 1/2 542 SOLID FUEL GENERATOR SOLID FUEL GENERATOR 4 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • SAFETY DEVICES 544 529 tech. broch. 01058 Draught regulating valve, with double safety. Male threaded connection. Adjustment range: 30–100°C. Temperature relief valve, with positive action, with automatic filling. For solid fuel generators. Max. working pressure: 6 bar. Max. working temperature: 110°C Working temperature range: 5–110°C. Ambient temperature range: 1–50°C. Setting temperature: 100°C (0/-5°C). Discharge flow rate with ∆p of 1 bar and T=110°C: 1600 l/h Length of capillary: 1300 mm. Code Setting 544400 100°C 1/2” F Code 529500 3/4” Function Function On reaching the setting temperature, the temperature relief valve discharges the water of the system with a solid fuel generator. The device integrates in a single group a temperature relief valve with a positive safety remote sensor and a filling valve. The discharge of water enables limiting the system water temperature, while the filling inlet enables the replacement of the discharged flow rate. The draught regulating valve, installed on the boiler with the thermostatic element immersed in the medium, automatically adjusts the flow rate of the comburent air to provide a more regular and complete combustion. Reference standards Used when there is no emergency exchanger and for heat outputs < 35 kW (Italy). S C RESIDENTIAL DEVICE 5 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • ANTI-CONDENSATION VALVE 280 Function Anti-condensation valve with thermostatic control of the return temperature to solid fuel generators. Brass body. The anti-condensation valve, used in heating systems with a solid fuel generator, automatically regulates at the set value the temperature of the water returning to the generator. Keeping the boiler at a high temperature prevents condensation of the water vapour contained in the flue gas. Condensation produces tarry deposits that, accumulating on the metal surfaces of the flue gas-system water exchanger, cause corrosion, reduce the thermal efficiency of the flue gas-system water exchanger and are a source of danger for the flues as they are flammable. The anti-condensation valve gives the generator a longer life and ensures greater efficiency. Flue gas and emission control Code Connection Kv (m3/h) Settings 3/4” 1” 1 1/4” 3,2 9 12 45°C 55°C 60°C 70°C 45°C 55°C 60°C 70°C 45°C 55°C 60°C 70°C 28005 28006 28007 G G G G Code completion Setting 45°C 55°C 60°C 70°C G 4 5 6 7 Primary and secondary air: • Combustion efficiency Technical Specifications Performance Medium: Maximum percentage of glycol: Max. working pressure: Working temperature range: Setting temperature: Accuracy: By-pass complete closing temperature: SR ANTIAccumulation of ash and residues CONDENSATION water, glycol solutions 30% 16 bar 5–100°C 45°C, 55°C, 60°C, 70°C ±2°C Tset + 10°C Flow by-pass 5 3/4” - 1” - 1 1/4” M with union 2 Thermostat replacement to modify setting The adjustment sensor can easily be removed for maintenance or to change the set, with no need to remove the valve body from the piping. 3 1 Installation in mixing mode (anti-condensation) System return Installation The valve can be fitted on both sides of the generator in any position, vertical or horizontal. Installation is recommended on the return to the generator in mixing mode; it is also allowed on the flow from the generator in diverter mode according to the needs of system control. SOLID FUEL GENERATOR 4 Characteristic components 1) Thermostatic sensor 2) Obturator 3) Spring 4) Plug 5) Valve body Installation in diverter mode (system control) SOLID FUEL GENERATOR 6 M Return to generator Connections: SF Zones of condensation forming: • Deposits and tar • Corrosion • Reduction in heat exchanger efficiency • Flammability SOLID FUEL GENERATOR ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • SOLID SOLID FUEL FUEL GENERATOR GENERATOR ANTI-CONDENSATION VALVE SOLID FUEL FUEL SOLID GENERATOR GENERATOR Operating principle The thermostat, completely immersed in the medium, controls the movement of an obturator that regulates the flows in by-pass and toward the system. On starting up the generator, the anti-condensation valve recirculates the flow water so as to bring the generator up to temperature as quickly as possible (1). When the flow temperature Tf exceeds the set of the anti-condensation valve Tset, the valve’s cold port starts opening to produce the mixing Tmix: in this phase the system loading begins (2). When the generator return temperature Tmix is greater than the setting of the anti-condensation valve by approximately 10°C, the by-pass port gets closed and water returns to the generator at the same temperature of the system return (3 and 4). Tf ≤ Tset SYSTEM START UP TRANSIENT by-pass open system return closed Tf ≤ Tset, Tmix=Tf Tf Tf Tmix Tmix Tf Tf SOLID SOLID FUEL FUEL GENERATOR GENERATOR SOLID FUEL FUEL SOLID GENERATOR GENERATOR 1 Tset Tmix Tmix Tf > Tset START OF SYSTEM LOADING by-pass open system return open Tf > Tset, Tr < Tset, Tmix=Tset Tf Tr Tr SOLID FUEL FUEL SOLID GENERATOR GENERATOR Tset Tr Tf Tmix Tmix Tf SOLID SOLID FUEL FUEL GENERATOR GENERATOR Tf Tset Tmix Tmix Tr Tset Tset Tf SOLID FUEL FUEL SOLID GENERATOR GENERATOR Tf 3 Tf Tmix Tmix Tf Tset Tmix Tmix Tr Tr Tr Tr Tset Tset Tset Tmix = Tset + 10°C BY-PASS CLOSING by-pass closed system return open Tf > Tmix = Tset +10°C, Tmix=Tr SOLID SOLID FUEL FUEL GENERATOR GENERATOR 2 Tmix > Tset + 10°C SYSTEM LOADED by-pass closed system return open Tf > Tmix > Tset +10°C, Tmix=Tr Tf Tr Tr SOLID FUEL FUEL SOLID GENERATOR GENERATOR Tset Tr Tset Tset Tf = Flow temperature Tset = Anti-condensation set temperature Tf Tmix Tmix Tf SOLID SOLID FUEL FUEL GENERATOR GENERATOR Tf Tset Tmix Tmix Tr 4 Tr Tr Tset Tr Tr Tset Tset Tmix = Mixed water temperature of generator return Tr = System return temperature Application diagram System with inertial storage Safety devices to choose according to current regulations M M SOLID FUEL GENERATOR 7 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • ANTI-CONDENSATION CIRCULATION UNIT 282 Function Circulation unit with anti-condensation valve, with thermostatic control of the return temperature to solid fuel generators. With insulation. The anti-condensation circulation unit performs the function of connecting the solid fuel generator to the distribution manifold, controlling the return temperature to the generator, to avoid condensation by means of the built-in thermostatic device. The unit also enables connecting the generator to the inertial storage or directly to the user system. This unit has been specifically designed for the connection to the separator/distribution manifold 559 series, both for the external use and the recess mounting versions. System return System flow 4 Bottom-up flow, supply RH side Top-down flow, supply LH side Code Connection Settings 1”F 45°C 55°C 60°C 70°C 28260 G 1 Bottom-up flow, supply LH side Top-down flow, supply RH side Connection Settings 1”F Code 45°C 55°C 60°C 70°C 28261 G 7 G Code completion 2 Setting 45°C 55°C 60°C 70°C G 4 5 6 7 Technical Specifications Performance Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: Max. recommended flow rate: Temperature gauge scale: Connections: water, glycol solutions 30% 5–100°C 10 bar 2 m3/h 0–120°C - system circuit: - generator circuit: - connection centre distance: Anti-condensation valve Working temperature range: Set temperatures: Accuracy: By-pass complete closing temperature: Pump Three-speed pump: 5 3 1” F with union 1” F 90 mm 5–100°C 45°C, 55°C, 60°C, 70°C ±2°C Tset +10°C Generator return Generator flow Characteristic components model UPS 25-60 Technical specifications of insulation Material: closed cell expanded PE-X Thickness: 20 mm Density: internal part 30 kg/m3 external part 50 kg/m3 Thermal conductivity (DIN 52612): at 0°C 0,038 W/(m·K) at 40°C 0,045 W/(m·K) Coefficient of resistance to the diffusion of water vapour (DIN 52615): > 1.300 Temperature range: 0–100°C Reaction to fire (DIN 4102): class B2 8 6 1) Anti-condensation valve 2) Three-speed pump 3) Shut-off valves 4) Check valve ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003 5) Flow temperature gauge 6) Return temperature gauge 7) Insulation
  • ANTI-CONDENSATION CIRCULATION UNIT Application diagram System with SEPCOLL, solid fuel generator combined with gas generator. 40 0 40 40 60 20 80 60 20 0 80 40 60 20 0 80 60 20 0 80 Configuration with SEPCOLL supplied from right-hand side Configuration with SEPCOLL supplied from left-hand side SOLID FUEL GENERATOR 40 40 60 20 0 80 40 60 20 0 80 40 60 20 0 80 60 20 0 80 SOLID FUEL GENERATOR In the event of multiple presence of generators, apply the current regulations Construction details Compact construction The unit features all the functional components assembled in a kit and ready for installation. The centre distance has been specifically defined for application to the SEPCOLL separator-manifold, 559 series. Anti-condensation valve This device incorporates a thermostatic sensor to control the temperature of the water returning to the generator so as to prevent condensation. The sensor has been specifically realised to be removed from the valve body for maintenance or replacement if necessary. Check valve This device prevents reverse circulation of the medium. The check valve is useful when the circulation unit is used on its own for a direct connection to the system or for the connection to a manifold not equipped with a hydraulic separator. 9 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • 2 ANTI-CONDENSATION RECIRCULATION AND DISTRIBUTION UNIT 281 Function Anti-condensation recirculation and distribution unit, with thermostatic control of the return temperature to solid fuel generators. Brass body. With insulation. The anti-condensation recirculation and distribution unit enables the connection of the solid fuel generator to the user system (direct or with inertial storage). It controls the return temperature to the generator to avoid condensation, by means of the built-in thermostatic device. 5 4 Flow by-pass Ritorno al generatore 4 5 3 1 2 5 Connection 28106 28107 G G G Settings 1” F 1 1/4” F Code 45°C 55°C 60°C 70°C 45°C 55°C 60°C 70°C 5 4 4 Generator return Code completion Setting 45°C 55°C 60°C 70°C G 4 5 6 7 System return 3 Characteristic components Technical Specifications Performance Medium: Max. percentage of glycol: Working temperature range: Max. working pressure: Maximum recommended flow rate: Temperature gauge scale: Connections: water, glycol solutions 30% 5–100°C 10 bar 1,5 m3/h 0–120°C 1” F and 1 1/4” F with union Anti-condensation valve Working temperature range: Setting temperature: Accuracy: By-pass complete closing temperature: Pump Three-speed pump: Technical specifications of insulation Material: Mean thickness: Density: Working temperature range: Thermal conductivity: Reaction to fire (UL94): 5–100°C 45°C, 55°C, 60°C, 70°C ±2°C Tset +10°C RS 4-3 EPP 30 mm 45 kg/m3 -5–120°C 0,037 W/(m·K) at 10°C class HBF 1) Anti-condensation thermostatic device 2) Three-speed pump 3) Valve for natural circulation 4) Union with built-in ball valve 5) Temperature gauge housing Construction details Single casting and reversibility The compact brass single casting, that houses the pump and functional components, enables immediate installation of the device, either on the right or left of the solid fuel generator, respecting the flow directions as shown. The temperature gauges can be extracted from the housings and re-inserted in the same position on the back side of the unit. Anti-condensation valve This device incorporates a thermostatic sensor to control the temperature of the water returning to the solid fuel generator so as to prevent condensation. The sensor has been specifically realised to be removed from the valve body for maintenance or replacement if necessary. Natural circulation valve The function of this clapet device is to ensure natural circulation of the medium in the event of pump stop due to an electric power failure. When the pump is active, the thrust of medium keeps the valve closed, forcing the water to flow through the anti-condensation thermostatic valve. If the event of pump stop, when the water within the boiler is at high temperature, a natural circulation of the water begins, by-passing the anti-condensation valve, thus preventing the temperature in the generator from reaching dangerous high levels. Dirt separator In order to carry out continuous dirt separation in the system it is available the 5462 series DIRTCAL® dirt separator as accessory. 10 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • ANTI-CONDENSATION RECIRCULATION AND DISTRIBUTION UNIT Operating principle The thermostat, completely immersed in the medium, controls the movement of an obturator that regulates the flows in by-pass and toward the system. On starting up the generator, the recirculation unit recirculates the flow water so as to bring the generator up to temperature as quickly as possible (1). When the flow temperature Tf exceeds the set of the anti-condensation valve Tset, the unit’s cold port starts opening to produce the mixing Tmix: in this phase the system loading begins (2). When the generator return temperature Tmix is greater than the set of the anti-condensation valve by approximately 10°C, the by-pass port gets closed and water returns to the generator atTf same temperature of the the Tf Tf Tf system return (3). Tf ≤ Tset SYSTEM START UP TRANSIENT by-pass open Tf system return closed Tf ≤ Tset, Tmix=Tf Tf Tmix Tmix Tmix Tf > Tset START OF SYSTEM LOADING by-pass open Tf Tf system return open Tf > Tset, Tr < Tset, Tmix=Tset 1 Tmix Tmix Tr Tr TsetTset Tmix Tset Tmix > Tset + 10°C SYSTEM LOADED by-pass closed system return open Tf > Tmix > Tset +10°C, Tmix=Tr Tr Tmix Tr Tmix Tr Tr TsetTset Tset Tset PUMP OFF Natural circulation valve open M M Natural circulation of the medium 3 Tf Tf Tf 2 Tr Tr Tset 4 Tf SOLID FUEL GENERATOR Tmix Tmix Tmix Tmix Tf = Flow temperature Tset = Anti-condensation set temperature Tr Tr TsetTset Tr Tr Tmix = Mixed water temperature of generator return Tr = System return temperature Application diagram Tset Tset System with inertial storage Safety devices to choose according to current regulations M M SOLID FUEL GENERATOR 11 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating only version) 2851 Connection and energy management unit, heating only version. Code 28515 Function The connection and energy management unit preassembled in the box enables combining solid fuel generators with another type of generator, which may already be present in the heating system. Main functional features: - connection of new solid fuel generators (both boilers and residential devices, with maximum heat output of 35 kW, both with open or closed vessel) with other closed vessel generators - possibility of not adding the power outputs of the two generators as described in I.S.P.E.S.L. (Italy). - automatic system management with a specific digital regulator with synoptic diagram: generators, mixed heating circuits, solar water storage - built-in anti-condensation system (optional) for solid fuel generator - easy access to components for maintenance - practical installation thanks to the arrangement in a box. 7 5 45°C 55°C 60°C 70°C G G Code completion Setting 45°C 55°C 60°C 70°C G 4 5 6 7 G 3 4 Settings = 0 Without anti-condensation valve 2 1 Technical specifications Performance 6 8 Connections: Regulator Three-point type Power supply: Pumps Three-speed pump: Three-speed pump: Diverter valve with spring return Max. working pressure: ∆p max: Diverter valve actuator with spring return Synchronous motor Normally closed Power supply: Opening time: Closing time: 12 3/4” M 230 V - 50 Hz model UPS 25-60 model UPS 15-60 10 bar 1 bar 1) Grundfos UPS 25-60 pump on primary side for solid fuel generator 2) Grundfos UPS 15-60 pump on secondary side (system) 3) Brazed plate heat exchanger 4) Anti-condensation valve (optional) 5) Three-way diverter valve with spring return 6) Dirt separator 7) Digital regulator 8) Shut-off ball valves 9) Box for exposed mounting ACCREDITED FM 21654 SYSTEM FLOW Characteristic components 230 V - 50 Hz 70–75 s 5–7 s ISO 9001 SYSTEM RETURN SOLID FUEL GENERATOR FLOW Anti-condensation set temperature (optional): 45°C, 55°C, 60°C, 70°C Accuracy: ±2°C By-pass complete closing temperature: Tset + 10°C BOILER RETURN 9 BOILER FLOW solutions 30% 5–100°C 10 bar 35 kW 2,0 m3/h 2,0 m3/h SOLID FUEL GENERATOR RETURN Medium: water, glycol Max. percentage of glycol: Working temperature range: Max. working pressure: Max. heat exchanger net output: Max. recommended primary circuit flow rate: Max. recommended secondary circuit flow rate (system): ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating only version) Operating conditions The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized valve and the generators. The heating circuit is managed according to need. Heating with solid fuel generator K S1 SOLID FUEL GENERATOR RT Open vessel D V1 P1 K Heating system T S1 P2 SOLID FUEL GENERATOR SYSTEM FLOW BOILER RETURN BOILER FLOW BOILER RETURN SYSTEM RETURN SOLID FUEL GENERATOR RETURN HEATING BOILER BOILER FLOW Closed vessel SOLID FUEL GENERATOR FLOW C Phase 1: solid fuel generator active - Coloured components = active, grey components = not active - Pumps P1 and P2 ON - Boiler OFF - Valve V1 connects the system to the solid fuel generator via the heat exchanger Heating with boiler K S1 SOLID FUEL GENERATOR RT Open vessel D V1 P1 K Heating system T P2 S1 Closed vessel SYSTEM FLOW SYSTEM RETURN SOLID FUEL GENERATOR FLOW C SOLID FUEL GENERATOR RETURN SOLID FUEL GENERATOR HEATING BOILER Phase 2: solid fuel generator off or not at temperature - Coloured components = active, grey components = not active - Pumps P1 and P2 OFF - Boiler active - Valve V1 connects the system to the boiler 13 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating and domestic hot water with storage version) 2853 Connection and energy management unit, heating and domestic hot water with storage version. Code 28535 Function The connection and energy management unit preassembled in the box enables combining solid fuel generators with another type of generator, which may already be present in the heating system. The unit is fitted for the production of domestic hot water with a connection to a storage. Main functional features: - connection of new solid fuel generators (both boilers and residential devices, with maximum heat output of 35 kW, both with open or closed vessel) with other closed vessel generators - possibility of not adding the power outputs of the two generators as described in I.S.P.E.S.L. (Italy) - automatic system management with a specific digital regulator with synoptic diagram: generators, mixed heating circuits, solar water storage, domestic water storage - built-in anti-condensation system (optional) for solid fuel generator - easy access to components for maintenance - practical installation thanks to the arrangement in a box. Settings 45°C 55°C 60°C 70°C G G 7 Code completion 3 Setting 45°C 55°C 60°C 70°C G 4 5 6 7 G 4 = 0 Without anti-condensation valve 10 Technical specifications 5 Performance Medium: water, glycol Max. percentage of glycol: Working temperature range: Max. working pressure: Max. heat exchanger net output: Max. recommended primary circuit flow rate: Max. recommended secondary circuit flow rate (system): solutions 30% 5–100°C 10 bar 35 kW 2,0 m3/h 2,0 m3/h 2 1 6 8 9 DHW STORAGE FLOW SYSTEM FLOW SYSTEM RETURN BOILER RETURN Characteristic components Diverter valves with spring return See 2851 series 14 BOILER FLOW 230 V - 50 Hz Pumps See 2851 series Diverter valve actuator with spring return Synchronous motor Normally closed Power supply: Opening time: Closing time: DHW STORAGE RETURN Regulator Three-point type Power supply: 3/4” M SOLID FUEL GENERATOR RETURN Connections: SOLID FUEL GENERATOR FLOW Anti-condensation set temperatures (optional): 45°C, 55°C, 60°C, 70°C Accuracy: ±2°C By-pass complete closing temperature: Tset + 10°C 230 V - 50 Hz 70–75 s 5–7 s 1) Grundfos UPS 25-60 pump on primary side for solid fuel generator 2) Grundfos UPS 15-60 pump on secondary side (system) 3) Brazed plate heat exchanger 4) Anti-condensation valve (optional) 5) Three-way diverter valve with spring return 6) Dirt separator 7) Digital regulator 8) Shut-off ball valves 9) Box for exposed mounting 10) Three-way diverter valve with spring return for priority on domestic water with storage ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating and domestic hot water with storage version) Operating conditions The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized valves and the generators. The heating circuit and the preparation of domestic hot water with storage are managed according to need. NOTE: for heating operation, please refer to the diagrams in “Connection and energy management unit, heating only version” 2851 series Domestic hot water production with solid fuel generator DHW Domestic water system K S2 S1 DCW RT SOLID FUEL GENERATOR TA Open vessel D V2 D V1 P1 S1 DHW STORAGE FLOW DHW STORAGE RETURN SYSTEM FLOW SYSTEM RETURN Phase 1: solid fuel generator active HEATING - Coloured components = active, BOILER grey components = not active - Pumps P1 and P2 ON - Boiler OFF - Valve V1 connects the system to the solid fuel generator via the heat exchanger - Valve V2 diverts the flow of system water towards the domestic water storage BOILER RETURN C Closed vessel BOILER FLOW Heating system P2 SOLID FUEL GENERATOR RETURN T SOLID FUEL GENERATOR SOLID FUEL GENERATOR FLOW K Domestic hot water production with boiler DHW Domestic water system K S2 S1 DCW SOLID FUEL GENERATOR RT TA Open vessel K D V2 D V1 P1 S1 DHW STORAGE FLOW SYSTEM FLOW SYSTEM RETURN 15 ACCREDITED ISO 9001 DHW STORAGE RETURN Phase 2: solid fuel generator off or not at temperature HEATING - Coloured components = active, BOILER grey components = not active - Pumps P1 and P2 OFF - Boiler active - Valve V1 connects the system to the boiler - Valve V2 diverts the flow of system water towards the domestic water storage BOILER RETURN C Closed vessel BOILER FLOW Heating system P2 SOLID FUEL GENERATOR RETURN T SOLID FUEL GENERATOR FLOW SOLID FUEL GENERATOR FM 21654 ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating and instantaneous domestic hot water version) 2855 Connection and energy management unit, heating and instantaneous domestic hot water version. The connection and energy management unit preassembled in the box enables combining solid fuel generators with another type of generator, which may already be present in the heating system. The unit is fitted for the production of instantaneous domestic hot water with a heat exchanger. Main functional features: - connection of new solid fuel generators (both boilers and residential devices, with maximum heat output of 35 kW, both with open or closed vessel) with other closed vessel generators - possibility of not adding the power outputs of the two generators as described in I.S.P.E.S.L. (Italy) - automatic system management with a specific digital regulator with synoptic diagram: generators, mixed heating circuits, solar water storage, instantaneous production of domestic hot water - built-in anti-condensation system (optional) for solid fuel generator - easy access to components for maintenance - practical installation thanks to the arrangement in a box. Settings Code 28555 Function 45°C 55°C 60°C 70°C G G Code completion 10 Setting 45°C 55°C 60°C 70°C G 4 5 6 7 G 7 11 = 0 Without anti-condensation valve 4 3 Technical specifications Performance 1 Medium: water, glycol Max. percentage of glycol: Working temperature range: Max. working pressure: Max. heat exchanger net output: Max. recommended primary circuit flow rate: Max. recommended secondary circuit flow rate (system): Max. domestic hot water heat exchanger net output: Max. domestic hot water flow rate delivery: solutions 30% 5–100°C 10 bar 35 kW 2,0 m3/h 2,0 m3/h 35 kW 1,1 m3/h Anti-condensation set temperatures (optional): 45°C, 55°C, 60°C, 70°C Accuracy: ±2°C By-pass complete closing temperature: Tset + 10°C SYSTEM FLOW SYSTEM RETURN BOILER RETURN BOILER FLOW SOLID FUEL GENERATOR RETURN SOLID FUEL GENERATOR FLOW Characteristic components 156 l/h 108 l/h Diverter valve actuator with spring return See 2851 series 10 bar 10 bar 1) Grundfos UPS 25-60 pump on primary side for solid fuel generator 2) Grundfos UPS 15-60 pump on secondary side (system) 3) Brazed plate heat exchanger for heating 4) Anti-condensation valve (optional) 5) Three-way diverter valve with spring return 6) Dirt separator 7) Digital regulator 8) Shut-off ball valves 9) Box for exposed mounting 10) Three-way three point diverter ball valve for DHW priority 11) Brazed plate heat exchanger for DHW 12) Flow switch Diverter ball valve actuator for DHW priority Synchronous motor Electric supply: 230 V (± 10%) - 50–60 Hz Operating time (angle of rotation 90°): 10 s 16 8 12 230 V - 50 Hz Diverter valve with spring return See 2851 series Diverter ball valve for DHW priority Max. working pressure: ∆p max: 9 3/4” M Pumps See 2851 series Flow switch Contacts normally open (NO) Contacts close with increasing flow at: Contacts open with decreasing flow at: 2 DCW INLET Regulator Three-point type Power supply: 6 DHW OUTLET Connections: 5 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • CONNECTION AND ENERGY MANAGEMENT UNIT (heating and instantaneous domestic hot water version) Operating conditions The digital regulator automatically manages the unit’s operation, receiving the signal from the probes and activating the pumps, the motorized valves and the generators. The heating circuit and the instantaneous preparation of domestic hot water are managed according to need. NOTE: for heating operation, please refer to the diagrams in “Connection and energy management unit, heating only version” 2851 series Domestic hot water production with solid fuel generator RT S3 K SOLARINCAL T D S1 M F SOLID FUEL GENERATOR Domestic water system D V3 P1 Open vessel D V1 K T S1 A Heating system P2 SOLID FUEL GENERATOR SYSTEM FLOW SYSTEM RETURN BOILER FLOW BOILER RETURN SOLID FUEL GENERATOR RETURN DHW DCW INLET HEATING BOILER SOLID FUEL GENERATOR FLOW Closed vessel DHW OUTLET C Phase 1: solid fuel generator active - Coloured components = active, grey components = not active - Pumps P1 ON, P2 OFF - Boiler OFF - Valve V1 connects the system to the solid fuel generator via the heat exchanger - Valve V3, activated by the flow switch F, diverts the flow of the solid fuel generator towards the DHW heat exchanger Domestic hot water production with boiler RT S3 K SOLARINCAL TA D S1 M F SOLID FUEL GENERATOR Domestic water system D V3 P1 Open vessel D V1 K S1 T Heating system P2 DHW SYSTEM FLOW SYSTEM RETURN BOILER RETURN BOILER FLOW SOLID FUEL GENERATOR RETURN HEATING BOILER DCW INLET Closed vessel SOLID FUEL GENERATOR FLOW C DHW OUTLET SOLID FUEL GENERATOR Phase 2: solid fuel generator OFF or not at temperature - Coloured components = active, grey components = not active - Pumps P1 and P2 OFF - Valve V1 connects the system to the boiler - Boiler active for the production of DHW by means of thermal integration via the kit SOLARINCAL 265 series type 17 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • DIGITAL REGULATOR FOR SYSTEMS WITH SOLID FUEL GENERATOR 1522 Function Digital regulator for systems with solid fuel generator. The digital regulator enables controlling and managing heating systems containing a solid fuel generator, which may be combined with another type of generator. The regulator has the following functions: - management of the solid fuel generator combined with another type of generator. - regulation of two secondary circuits by means of the activation of the booster pumps and mixing valves for flow temperature adjustment. - regulation and management of the domestic hot water circuit with storage and recirculation circuit. Code The regulator has 6 pre-set programs that can be adapted by the user to many system situations. 152200 Technical specifications Electric supply: 230 V (ac); ±10%, 50-60 Hz Adjustment range: 20–90°C Protection class: II Protection class: IP 40 Number of probes to choose according to the type of system 1 3 Description of controls 1. 2. 3. 4. 5. Functional status indicator LED. Mini DIN connector on front of panel for PC connection. Display: menu display. Select knob: selection of menu, functions and parameter editing. Function keys. 2 4 5 Program diagrams The regulator enables outside compensated temperature regulation of the mixed circuits, loading the domestic hot water storage unit and managing the energy arriving from the buffer storage. If this is not sufficiently loaded, the regulator activates the boiler integration. T T M T T M M T T SOLID FUEL GENERATOR Diagram of system management with direct connection to the buffer storage, mixed circuits and domestic hot water with dedicated storage. T T T M T T T M T SOLID FUEL GENERATOR Diagram of system management with direct connection to the buffer storage, mixed circuits, domestic hot water with dedicated storage and integration boiler. 18 M T T ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003 T
  • TYPES OF APPLICATION DIAGRAMS OF BIOMASS SYSTEMS Solid fuel generator, direct connection to buffer storage. Safety devices to choose according to current regulations M M D M SOLARINCAL SOLID FUEL GENERATOR T Solid fuel generator, parallel connection to buffer storage. Safety devices to choose according to current regulations M M SOLID FUEL GENERATOR T Solid fuel generator, direct supply to the system. Safety devices to choose according to current regulations M M DOMESTIC DEVICE T We reserve the right to modify our products, make technical improvements and develop them further. None of the illustrations, numerical data, etc., are binding. 19 ACCREDITED ISO 9001 FM 21654 ISO 9001 No. 0003
  • 0318111GB Caleffi S.p.A. S.R. 229 n. 25 28010 Fontaneto D’Agogna (NO) Italy Tel. +39 0322 8491 Fax +39 0322 863723 · www.caleffi.com · info@caleffi.com · © Copyright 2011 Caleffi