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Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
Woodpecker training workshop jan'11 presentation
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Woodpecker training workshop jan'11 presentation

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Transcript

  • 1. EnsightBioenrgy
    Woodpecker Boiler Training Workshop
    Charlottetown, PEI
    24th January, 2011
  • 2.
  • Bruce McCallum
    President
    Ensight Bioenergy
  • 32. Declan Crosse
    Research & Development Director
    Woodpecker Energy
  • 33. Woodpecker Product Range
    Woodpecker Self Cleaning / De-Ashing
  • 34. Woodpecker Product Range
    Woodpecker Self Cleaning / De-Ashing 25kW / 45 kW with Fillomatic
  • 35. Woodpecker Product Range
    Thermon 150 / 300kW
  • 36. What New
    Thermon Commercial Boiler 150/300kW
    Reference Site – 2012 London Olympic Atheletes Village
    Fillomatic Pellet Transport System
    Control System Functions
    Buffer Management
    Remote Access and Monitoring
  • 37. Domestic Range
  • 38. Boiler Construction
    LCD controller
    110 Kg Hopper
    Combustion Chamber
    Automatic Cleaning
    5 Stage Modulating Burner
  • 39. Boiler Construction
    94% Efficient
  • 40. Burner Construction
  • 41. Burner Construction
    Ignitor holding cone and holder
    Ignitor Hole
  • 42. Self Cleaning - Boiler
  • 43. Self Cleaning - Burner
    Air Compressor
    Air Cleaning Pipe
  • 44. Self Cleaning - Burner
  • 45. Self Cleaning - Burner
  • 46. Self Cleaning - Burner
  • 47. Controller Capabilities
  • 48. Controller Capabilities
    Combustion Control
    Auto Ignition
    Standby Mode
    Cleaning Control
    Diagnostics
    Remote Control
    Remote Access
    Pump Management
    UPS
  • 49. Commissioning
    Commissioning can be divided into 3 separate tasks :
    • Pre-commissioning checks
    • 50. Start up check
    • 51. Run mode check and flue gas analysis
  • Commissioning
    Pre-commissioning checks
    These checks include :
    • Electrical installation – Ensure the permanent live and timed/switched live are configured correctly
    • 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. 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. Unlock the controller – Unlocking code can be advised by Woodpecker Energy.
    • 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. Check the alignment of the element – See section on the ignition element in the appendix.
    • 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
  • Commissioning
    Start Up Check
    • 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. Monitor draft - Adjust at each stage of ignition (20Pa min.)
    • 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. 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. 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.
    Draft Sampling Point
  • 62. Commissioning
    Check Up
    Variable Ignition
    Pre-Heat
    Pre-Load
    Stabilisation
    Run Mode
    35 sec
    (t08)
    40 sec
    (t00)
    40 sec
    (t38)
    4 min
    (t01)
    90 sec
    (t02)
    TIMERS
    100
    LIGHT
    30%
    30%
    0
    Draught 20 Pa min.
    20 Pa min.
    20 Pa min.
    Light may dip slightly
    at this point
    At this stage :
    Light > 30%
    F.G.T > 10C
    At this stage :
    Light > 30%
    F.G.T > 10C
    Correct Level of Pellets
  • 63. Commissioning
    Run mode check and flue gas analysis.
    • Ensure boiler reaches power 5.
    • 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. 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. 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. 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. 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.
  • Commissioning
    Flue Gas Analysis Sampling Point
  • 69. Commissioning
    Run mode check and flue gas analysis.
    • Ensure boiler reaches power 5.
    • 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. 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. 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. 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. 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.
  • Servicing
    Servicing can be divided into 3 separate tasks :
    • Boiler Servicing
    • 75. Burner Servicing
    • 76. Hopper and Auger Cleaning.
  • Boiler Servicing
    F
    E
    A Combustion Chamber Door
    B Ceramic Board
    C De-Ash Auger
    D De-Ash Auger Motor
    E Boiler Cleaning Solenoid Valves
    F Boiler Cleaning Pipes
    G Boiler Cleaning Spirals x 8
    B
    A
    A
    D
    C
    G
  • 77. Burner Servicing
    Pellet Feed Pipe
    Separate Inner and Outer Tubes
    Photocell
    Clean cresote deposits from plates
  • 78. Burner Servicing
    Change Igniter
  • 79. Hopper / Auger Cleaning
    Pellet Level Sensor
    Auger Bearing
    Larger slot in plate to allow motor to move before full load is exerted.
  • 80. Troubleshooting
  • 81. Venting / Buffer Tanks
    Venting – Direct Vent / Conventional Chimney - Discussion
    Buffer Tank - Size is important. - Discussion
  • 82. Fillomatic
  • 83. Fillomatic Auger Options
    Standard Auger
  • 84. Fillomatic Auger Options
    Floor Track System
  • 85. FillomaticController
    Diagnostics
    Night time refill
    External Alarm
  • 86. Q&A
    Questions Please !
  • 87. Thank You

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