EnsightBioenrgy<br />Woodpecker Boiler Training Workshop<br />Charlottetown, PEI<br />24th January, 2011<br />
<ul><li>Registration
Introduction
About Bioscan Tech
About Woodpecker Energy
Product Range
What’s New
Domestic Range
Boiler Construction
Pellet Burner
Self Cleaning Systems
Controller Capabilities
Commissioning
Pre-Commissioning Checks
Start Up
Draft / Underpressure Adjustment
Flue Gas  Analysis
Servicing
Troubleshooting
Flues / Venting
Buffer Tanks
Commercial Range
Explore the Thermon 150 / 300
Feeding Systems
Remote Monitoring
Fillomatic Pellet Transport System
Fillomatic or Transvac ?
Auger Options
Controller Capabilities
Q&A
Conclusion</li></li></ul><li>Bruce McCallum<br />President<br />Ensight Bioenergy<br />
Declan Crosse<br />Research & Development Director<br />Woodpecker Energy<br />
Woodpecker Product Range<br />Woodpecker Self Cleaning / De-Ashing<br />
Woodpecker Product Range<br />Woodpecker Self Cleaning / De-Ashing 25kW / 45 kW with Fillomatic<br />
Woodpecker Product Range<br />Thermon 150 / 300kW<br />
What New<br />Thermon Commercial Boiler  150/300kW<br />Reference Site – 2012 London Olympic Atheletes Village<br />Fillom...
Domestic Range<br />
Boiler Construction<br />LCD controller<br />110 Kg Hopper<br />Combustion Chamber<br />Automatic Cleaning<br />5 Stage Mo...
Boiler Construction<br />94% Efficient<br />
Burner Construction<br />
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Woodpecker training workshop jan'11 presentation

  1. 1. EnsightBioenrgy<br />Woodpecker Boiler Training Workshop<br />Charlottetown, PEI<br />24th January, 2011<br />
  2. 2. <ul><li>Registration
  3. 3. Introduction
  4. 4. About Bioscan Tech
  5. 5. About Woodpecker Energy
  6. 6. Product Range
  7. 7. What’s New
  8. 8. Domestic Range
  9. 9. Boiler Construction
  10. 10. Pellet Burner
  11. 11. Self Cleaning Systems
  12. 12. Controller Capabilities
  13. 13. Commissioning
  14. 14. Pre-Commissioning Checks
  15. 15. Start Up
  16. 16. Draft / Underpressure Adjustment
  17. 17. Flue Gas Analysis
  18. 18. Servicing
  19. 19. Troubleshooting
  20. 20. Flues / Venting
  21. 21. Buffer Tanks
  22. 22. Commercial Range
  23. 23. Explore the Thermon 150 / 300
  24. 24. Feeding Systems
  25. 25. Remote Monitoring
  26. 26. Fillomatic Pellet Transport System
  27. 27. Fillomatic or Transvac ?
  28. 28. Auger Options
  29. 29. Controller Capabilities
  30. 30. Q&A
  31. 31. Conclusion</li></li></ul><li>Bruce McCallum<br />President<br />Ensight Bioenergy<br />
  32. 32. Declan Crosse<br />Research & Development Director<br />Woodpecker Energy<br />
  33. 33. Woodpecker Product Range<br />Woodpecker Self Cleaning / De-Ashing<br />
  34. 34. Woodpecker Product Range<br />Woodpecker Self Cleaning / De-Ashing 25kW / 45 kW with Fillomatic<br />
  35. 35. Woodpecker Product Range<br />Thermon 150 / 300kW<br />
  36. 36. What New<br />Thermon Commercial Boiler 150/300kW<br />Reference Site – 2012 London Olympic Atheletes Village<br />Fillomatic Pellet Transport System <br />Control System Functions<br />Buffer Management<br />Remote Access and Monitoring<br />
  37. 37. Domestic Range<br />
  38. 38. Boiler Construction<br />LCD controller<br />110 Kg Hopper<br />Combustion Chamber<br />Automatic Cleaning<br />5 Stage Modulating Burner<br />
  39. 39. Boiler Construction<br />94% Efficient<br />
  40. 40. Burner Construction<br />
  41. 41. Burner Construction<br />Ignitor holding cone and holder<br />Ignitor Hole<br />
  42. 42. Self Cleaning - Boiler<br />
  43. 43. Self Cleaning - Burner<br />Air Compressor<br />Air Cleaning Pipe<br />
  44. 44. Self Cleaning - Burner<br />
  45. 45. Self Cleaning - Burner<br />
  46. 46. Self Cleaning - Burner<br />
  47. 47. Controller Capabilities<br />
  48. 48. Controller Capabilities<br />Combustion Control<br />Auto Ignition<br />Standby Mode<br />Cleaning Control<br />Diagnostics<br />Remote Control <br />Remote Access<br />Pump Management<br />UPS<br />
  49. 49. Commissioning<br />Commissioning can be divided into 3 separate tasks :<br /><ul><li>Pre-commissioning checks
  50. 50. Start up check
  51. 51. Run mode check and flue gas analysis</li></li></ul><li>Commissioning<br />Pre-commissioning checks<br />These checks include :<br /><ul><li>Electrical installation – Ensure the permanent live and timed/switched live are configured correctly
  52. 52. Flue installation – The flue must always run vertically with no 90 degree bends. Check the end of the flue for an anti-downdraught cowl if lower than the roof apex. Twin walled insulated flue pipe only.
  53. 53. Plumbing at the boiler – The pump is recommended to be on the return side. The expansion must be sized correctly – Min. 20 litres and 1 litre for every 1kW thereafter. Additional expansion will be required if using a buffer tank or a high volume circuit.
  54. 54. Unlock the controller – Unlocking code can be advised by Woodpecker Energy.
  55. 55. Boiler system test – Run a test on the auger, combustions fan, exhaust fan, pump, element, Belimo valve, boiler cleaning, burner cleaning (if applicable) and de-ash system. SYSTEM MENU > OUTPUTS TEST > AUGER ……………..
  56. 56. Check the alignment of the element – See section on the ignition element in the appendix.
  57. 57. Load boiler hopper with pellets – Prime the auger with pellets. Make sure the burner tube is cleared of pellets when this operation is finished. USER MENU > LOAD</li></li></ul><li>Commissioning<br />Start Up Check<br /><ul><li>Turn on boiler- The boiler should be turned on with the time clock to check that the signal is being received by the controller. (See configuration of controls in appendix)
  58. 58. Monitor draft - Adjust at each stage of ignition (20Pa min.)
  59. 59. Ensure all functions are operating correctly – Make sure that the water, flue gas temp and photocell are giving correct readings. This can be viewed in the SYSTEM MONITOR of the USER MENU.
  60. 60. Monitor photocell and flue gas temperature reading during start up – At the end of Variable ignition and Stabilisation the light level (L01 – THERMOSTATS MENU – factory set at 30) should be over 30%and the flue gas temperature (S18 – THERMOSTATS MENU – factory set at 10C) should be over 10C.
  61. 61. Monitor the transition from start up to running mode – Once draught adjustments have been set for ignition monitor the light reading near the end of stabilisation and transition into run mode. If the light level reads < 30% see section on Er12/Er13 in the Errors section of this manual.</li></ul>Draft Sampling Point<br />
  62. 62. Commissioning<br />Check Up<br />Variable Ignition<br />Pre-Heat<br />Pre-Load<br />Stabilisation<br />Run Mode<br />35 sec<br />(t08)<br />40 sec<br />(t00)<br />40 sec<br />(t38)<br />4 min<br />(t01)<br />90 sec<br />(t02)<br />TIMERS<br />100<br />LIGHT<br />30%<br />30%<br />0<br />Draught 20 Pa min.<br />20 Pa min.<br />20 Pa min.<br />Light may dip slightly<br />at this point<br />At this stage :<br />Light > 30%<br />F.G.T > 10C<br />At this stage :<br />Light > 30%<br />F.G.T > 10C<br />Correct Level of Pellets<br />
  63. 63. Commissioning<br />Run mode check and flue gas analysis.<br /><ul><li>Ensure boiler reaches power 5.
  64. 64. Set boiler to manually adjusted power levels – in ENABLES MENU set P45 to 0. This will allow you to set the boiler to run at a particular Power Level. This Power Level can be adjusted in the USER MENU > Power. To start with set this to 5.
  65. 65. Check draught. – Wait until the water temperature has reached 55C then check the draught at the draught sampling point. Adjust the speed of the exhaust fan (SYSTEM MENU > EXHAUST FAN > (Select code for the relevant power level) until min. 20Pa is reached ( any value draught value between 20Pa and 40Pa is o.k.). Let each power level settle for 2-3 minutes before dropping to the next and repeating the process. Once power level 1 is reached let the system settle for 5-10 minutes.
  66. 66. Carry out flue gas analysis. - Adjust combustion fan (SYETM MENU > COMBUSTION FAN > (Select code for relevant the relevant power level) to achieve CO2 reading of approx 12% and CO of less than 100 ppm. Let each power level settle for 5-10 minutes before increasing to the next power level. Repeat the process for power levels 2,3,4 and 5. At the lower power level if CO2 of 12% is difficult to achieve adjust the combustion fan to keep the CO (ppm) under 100.
  67. 67. Return the boiler to automatically adjusted power levels. – Always return the value P45 in the ENABLES MENU to 1 once the flue gas analysis and draught setting has been completed. This will allow the power levels to be managed automatically.
  68. 68. Wait until boiler reaches the water temperature – The boiler should enter the modulation range, modulate successfully and once it reaches the water set temperature it will shut down.</li></li></ul><li>Commissioning<br />Flue Gas Analysis Sampling Point<br />
  69. 69. Commissioning<br />Run mode check and flue gas analysis.<br /><ul><li>Ensure boiler reaches power 5.
  70. 70. Set boiler to manually adjusted power levels – in ENABLES MENU set P45 to 0. This will allow you to set the boiler to run at a particular Power Level. This Power Level can be adjusted in the USER MENU > Power. To start with set this to 5.
  71. 71. Check draught. – Wait until the water temperature has reached 55C then check the draught at the draught sampling point. Adjust the speed of the exhaust fan (SYSTEM MENU > EXHAUST FAN > (Select code for the relevant power level) until min. 20Pa is reached ( any value draught value between 20Pa and 40Pa is o.k.). Let each power level settle for 2-3 minutes before dropping to the next and repeating the process. Once power level 1 is reached let the system settle for 5-10 minutes.
  72. 72. Carry out flue gas analysis. - Adjust combustion fan (SYETM MENU > COMBUSTION FAN > (Select code for relevant the relevant power level) to achieve CO2 reading of approx 12% and CO of less than 100 ppm. Let each power level settle for 5-10 minutes before increasing to the next power level. Repeat the process for power levels 2,3,4 and 5. At the lower power level if CO2 of 12% is difficult to achieve adjust the combustion fan to keep the CO (ppm) under 100.
  73. 73. Return the boiler to automatically adjusted power levels. – Always return the value P45 in the ENABLES MENU to 1 once the flue gas analysis and draught setting has been completed. This will allow the power levels to be managed automatically.
  74. 74. Wait until boiler reaches the water temperature – The boiler should enter the modulation range, modulate successfully and once it reaches the water set temperature it will shut down.</li></li></ul><li>Servicing<br />Servicing can be divided into 3 separate tasks :<br /><ul><li>Boiler Servicing
  75. 75. Burner Servicing
  76. 76. Hopper and Auger Cleaning.</li></li></ul><li>Boiler Servicing<br />F<br />E<br />A Combustion Chamber Door<br />B Ceramic Board<br />C De-Ash Auger<br />D De-Ash Auger Motor<br />E Boiler Cleaning Solenoid Valves<br />F Boiler Cleaning Pipes<br />G Boiler Cleaning Spirals x 8<br />B<br />A<br />A<br />D<br />C<br />G<br />
  77. 77. Burner Servicing<br />Pellet Feed Pipe<br />Separate Inner and Outer Tubes<br />Photocell<br />Clean cresote deposits from plates<br />
  78. 78. Burner Servicing<br />Change Igniter<br />
  79. 79. Hopper / Auger Cleaning<br />Pellet Level Sensor<br />Auger Bearing<br />Larger slot in plate to allow motor to move before full load is exerted.<br />
  80. 80. Troubleshooting<br />
  81. 81. Venting / Buffer Tanks<br />Venting – Direct Vent / Conventional Chimney - Discussion<br />Buffer Tank - Size is important. - Discussion <br />
  82. 82. Fillomatic<br />
  83. 83. Fillomatic Auger Options<br />Standard Auger<br />
  84. 84. Fillomatic Auger Options<br />Floor Track System<br />
  85. 85. FillomaticController<br />Diagnostics<br />Night time refill<br />External Alarm<br />
  86. 86. Q&A<br />Questions Please !<br />
  87. 87. Thank You<br />

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