THERMOSTAHL PYROGAS 23 User manual

Brand: THERMOSTAHL

Model: PYROGAS 23

Type: User manual

This manual is also suitable for

THERMOSTAHL PYROGAS 23 The THERMOSTAHL PYROGAS 23 is a low-temperature, steel water boiler designed to be fired by wood and briquette. With a power output of 20 kW and a heating surface of 3.00 m2, it is suitable for heating small to medium-sized homes. The boiler operates on the principle of gasification, which involves burning wood in a controlled environment to produce a combustible gas. This gas is then burned to heat the water in the boiler.

The PYROGAS 23 is equipped with a number of features that make it efficient and easy to use. These features include:

A large feeding chamber that allows for long burning times

The PYROGAS 23 is equipped with a number of features that make it efficient and easy to use. These features include:

A large feeding chamber that allows for long burning times

Gasification boiler

PYROGAS

INSTRUCTION MANUAL

ver. 1.1

THERMOSTAHL would like to thank and congratulate you on your purchasing

this boiler device and ensure that you have made a good choice. PYROGAS

boiler is a fail-proof product made of the highest quality materials by the large,

known and reliable production factory. THERMOSTAHL brand guarantees

satisfaction for the customer.

Please read this Operation and Maintenance Documentation (OMD) and get

familiarized with the terms and conditions of the guarantee before installing

and operating the boiler.

1. GENERAL INFORMATION

The Operation and Maintenance Documentation constitutes an integral part of the

boiler and should be delivered to the user with the device.

Installation should be carried out in accordance with the recommendations contained

in this documentation as well as applicable standards and best construction

practices.

Operational use of the boiler based on this documentation shall guarantee safe and

failure-free operation and shall constitute the basis for possible guarantee claims.

The Manufacturer (Thermostahl) shall reserve the right to modify production

engineering, technical data, dimensions, appearance and boiler equipment without

prior notice.

THERMOSTAHL shall not be responsible for damages resulting from improper

installation of the device and for failure to comply with the terms and conditions set

forth in the Operation and Maintenance Documentation.

2. SCOPE OF DELIVERY (SHIPPING CONDITION)

PYROGAS boiler shall be delivered as follows:

1. The complete boiler body with the boiler doors and two ceramic plates,

2. Packaging with the casing, thermal insulation with harnesses and turnbuckles for

its clamping,

3. Control panel (charged separately),

4. Cleaning tools,

5. Technical manual.

3. TECHNICAL CHARACTERISTICS, INTENDED USE OF THE BOILER, TYPES

OF FUELS

PYROGAS boiler type is a low-temperature, steel water. It is designed to be fired by

wood and briquette. Boiler operation is based on the process of gasification. The

woods are placed on the upper combustion chamber of the boiler, where it is the

process of drying and preheating. The fan supplies primary and secondary air

necessary for combustion. The combustion takes place in a direction downwardly

because of reverse flame, in which the wood is gasified by forced air flow from the

primary air. Special ceramic plates accept the thermal loading amounting to 1200oC.

Flue gases are directed by gas tubes into the smoke chamber and subsequently to

the chimney. With the method of gasification achieved efficiency to 92% resulting in

fuel economy by 25-30% compared to a conventional wood boiler. Moreover there is

a very small amount of ash. When loading wood the user should open the damper

(by-pass) by the lever. The smoke will leave by the tamper to the chimney. All boilers

have heat exchanger for cooling the boiler and protect them in case of overheating.

The boiler design allows achieving high efficiency and the efficient combustion

guarantees minimum exhaust emission of harmful substances and fuel economy.

Combustion process

Phase 1: Drying of wood.

Phase 2: Gasification of wood at 450oC.

Phase 3: Burning of mixture of gasified woods with the secondary air at 560oC.

Phase 4: Combusting with increasing flame temperature at 1200oC, at the lower

combustion chamber.

Phase 5: Outlet the exhaust gases through the torch at 165oC.

3.1. Boiler design

 Boiler Body

PYROGAS gasification boiler is made of St 37.2 steel plates according to DIN 1700.

Non-metallic parts are made of special materials with high temperature resistant and

designed in that way to have long life time and strength ant to protect the metallic

parts of boiler against the high temperatures.

The boiler is separated in 3 parts; The upper chamber for wood feeding, drying of

wood and gasification of wood, the ceramic plate where burning the gasified woods

with the secondary air and the lower combustion chamber where the flame transfers

the heat to the water. The produced flue gases are directed by three triangle paths

into the smoke chamber and subsequently to the chimney.

An air fan is equipped at the front side of boiler and supplies with primary and

secondary air the upper chamber and the area around the ceramic plate. The

quantity of air is controlled by two switches with screws, one for the primary and one

for the secondary air. The outer of the boiler body is coved with glass wool insulation

and metallic covers.

 Doors

The boiler has 3 doors. The first one allows the access to the upper chamber. It is

used for the feeding of boiler with woods. The second one is the middle door and is

used for the cleaning of the openings for the primary and secondary air and also for

the inspection of ventilator and finally the third one is the lower door and is used for

cleaning of the bottom ash. The amount of bottom ash in the boiler is about 1 to 2%

of the total amount of fuels. The lower door is also equipped with a window for

inspection of flame during the operation of boiler.

 Ceramic plates

The boiler is equipped with two ceramic plates. The ceramics are constructed to

resist at very high temperature. During the operation the temperature of flame

reaches up to 1200oC. The first one is a ceramic plate with jets where the secondary

air is mixed with the gasified woods. The second ceramic plate is placed at the

bottom of the combustion chamber, receives the flame with the high temperature,

protects the boiler against the high temperatures and transfers the heat equally to the

boiler water.

a. b.

a. ceramic with jets, b. ceramic plate

 Smoke chamber

The smoke chamber is at the back side of boiler. The flue gases are directed down of

the ceramic plate and through an opening goes to the smoke chamber after a route

through 3 triangle paths. The triangle paths are in contact with the boiler water so the

flue gases transfer their heat to the water. After that the flues exhaust to chimney and

then to the environment.

The smoke chamber has also and a damper. The tamper connects the feeding

chamber with the smoke chamber. That helps the exhausts to leave from the feeding

chamber to the chimney and not to the boiler room during the start of boiler and

during the feeding process. The damper opens manually with a lever. Before the user

opens the door to fill the boiler with woods they should pull the lever to open the

damper. Then there is no danger to fill the boiler room with smoke and the user could

fill the boiler. When the user completes the filling of the boiler, closes the door and

pushes the lever. The damper closes and the gasification process starts.

The smoke chamber has four covers for cleaning and inspection.

3.2. Technical characteristics

Control panel

Dumber lever

Feeding door

Air fan

Primary air controller

Middle door

Secondary air controller

Combustion chamber door for inspection and cleaning

Flame inspection window

Smoke chamber

Smoke chamber cleaning cover

Τ1

Input of hot water

Τ2

Output of cold water

Τ3

Drain tap 1/2"

Τ4,Τ5

Safety serpentine connections

Τ6

Connection for temperature sensor

Ø1

Flue diameter

3.3. Technical data

Type

Power

Max

pressure

Water

capacity

Heating

surface

Weight

Combust.

chamber

volume

Wood

max.

length

Mcal/h

bar

lit

PYROGAS 23

136

3,00

348

125

370

PYROGAS 35

154

3,31

390

151

470

PYROGAS 47

172

3,62

436

176

570

PYROGAS 58

191

3,93

482

201

670

PYROGAS 69

210

4,24

527

226

770

PYROGAS 81

238

5,27

581

251

870

PYROGAS 93

257

5,58

656

276

970

PYROGAS 116

100

116

285

6,05

728

314

1120

Type

Cooling

serpentine

(T4-T5)

Back

pressure

Min.water

inlet

temperature

Required

chimney

convection

Exhaust

gases

mass

flow

Internal

water

pressure

drop

(ΔT=20oC)

Max

burning

time

Efficiency

g/sec

mbar

PYROGAS 23

15-20

15-18

14-17

5-7

6-10

PYROGAS 35

17-22

19-22

16-23

5-7

6-10

PYROGAS 47

19-23

22-24

20-30

6-8

8-12

PYROGAS 58

20-23

24-28

25-37

7-9

8-12

PYROGAS 69

23-24

27-30

31-46

8-10

8-12

PYROGAS 81

24-25

28-32

35-52

9-12

9-13

PYROGAS 93

25-26

28-32

40-60

9-12

9-13

PYROGAS 116

25-27

30-35

45-70

10-14

3.4. Dimensions

3.5. Fuels

PYROGAS boiler is designed to burn woods and briquettes. You should be very

carefully with the woods that you use for the boiler. PYROGAS gasification boiler is

designed to burn wood with a percentage of humidity up to 20% and briquettes,

which are made of wood only, with humidity up to 10%. Woods with high amount of

water create condensation in the boiler leading to corrosion. Be sure that the woods

that you will use are dry and the amount of humidity is under the allowable limits. Use

woods from oak, beech or pine and do not mix them in the feeding chamber. Use

only one kind of wood in every feeding. This will provide a constant combustion of

fuel.

Fuel

Heating

Value

Allowable

diameter

Max

percentage

of humidity

Allowable

ash

percentage

kWh/kg

Woods

4 – 4,3

80-150

<20

Wood briquettes

5,2

<10

ATTENTION: Do not use inappropriate fuels. There is danger for the health and for

the boiler. Do not as fuels woods that contain chemicals or explosive materials, MDF,

household waste etc. Use only woods and wood briquette suitable for your boiler.

During the manual feeding of the boiler, you should place the woods with the smaller

diameter at the bottom and after the biggest woods. This will help start the boiler and

offers a smooth operation of boiler.

Type

Φ1

Τ1-

Τ2

T3- T4-

Feeding

Door

Dimensions

670

1290

950

620

1460

1385

690

510

460

160

1¼

350x466

670

1290

1050

620

1460

1385

690

610

560

160

1¼

350x466

670

1290

1150

620

1460

1385

690

710

660

160

1¼

350x466

670

1290

1250

620

1460

1385

690

810

760

180

1½

350x466

670

1290

1350

620

1460

1385

690

910

860

180

350x466

670

1290

1450

620

1460

1385

690

1010

960

200

350x466

100

670

1290

1700

620

1460

1385

690

1260

1210

220

2½

350x466

4. Design and installation recommendations

The boiler (boilers) should be installed in the boiler room specially designated and

adapted for that purpose.

4.1. Boiler placement recommendations

 The boiler should be placed in the vertical position.

 The boiler should be installed as close to the chimney as possible.

All distances of the boiler (boilers) from the boiler room’s walls and the distances

between the boilers should ensure easy access to the boiler (boilers). The distance

of the boiler front from the wall should ensure assembly and disassembly of the

burner and cleaning of the smoke tubes.

4.2. Boiler room recommendations

 The boiler room should comply with the requirements set forth in the PN87/B-

02411standard“Built-insolidfuelboilerrooms”.

Moreover, it should comply with requirements of “Technical conditions relating to

buildings” provided for in the Building Code (Official Journal No. 75 of 2000, item

690).

 The dimensions of the boiler room should comply with the requirements

relating to heat loads, fire protection regulations and allow for them to be fitted out,

operated and maintained in compliance with the OHS regulations.

 The minimum height of the boiler room:

for boilers to 100 kW - 2.5 m

for boilers from 100 to 230 kW - 3.0 m

for boilers from 230 to 400 kW - 3.5 m

for boilers over 400 kW - 4.0 m

 The minimum distances of the boiler from the front wall:

for boilers to 100 kW - 1.5 m

for boilers over 100 kW - 2.0 m

 The distance of the boiler from the rear wall should ensure proper access to

the boiler.

 The minimum distances of the boiler from the side wall:

for boilers to 300 kW - 0.6 m

for boilers over 300 kW - 1.0 m

These distances should be twice as long from the side of the feeder.

 Theboilerroom’sfloor should be:

dust-free and non-flammable (paved with terracotta tiles or painted),

laid out with an inclination to the floor drain or cooling well.

 The boiler room should have natural exhaust ventilation carrying off the air

outside and supply of combustion air (the so-called“Z-shaped”ventilationduct)with

the outlet placed 0.3 m above the floor level.

 The section area of the exhaust opening should be calculated making

allowance for the ventilation air flow to be at least 0.5 m3/h per 1 kW of the installed

nominated power.

 The section area of the air supply duct should be calculated on the basis of

the quantity of air required for combustion, which should be 1.6 m3/h per 1 kW of the

installed nominated power and additional air required for the needs of the natural

ventilation (0.5 m3/h per 1 kW), which in total gives at least 2.1 m3/h per 1 kW of the

installed nominated power in the boiler room.

 Use of mechanical ventilation is not allowed.

 No flammable materials may be stored in the boiler room.

 The boiler room should have window openings of the total area not less than

1/15th of the floor area.

 Theboilerroom’sdoorshouldbemadeofmetal,withoutdoorlock,opening

outside under pressure, with the clear width of min. 0.9 m.

4.3. Hydraulic system installation

The system should be installed in accordance with the applicable regulations

and best construction practices.

The boiler can only be operated in the open system heating installations,

The open pressure vessel should be placed 2-3 m above the highest point of the

central heating system and protected against frost.

No cut-off valves should be installed between the boiler and pressure vessel.

The boiler room’s hydraulic system should ensure minimum temperature of

return water to the boiler (for solid fuel and gas–60oC, for furnace oil-50oC*).

To this end, a mixing valve with the boiler pump must be installed of the capacity

of c. 40% of the nominal flow of water through the boiler.

A desludger or strainer should be installed in the return water system before the

boiler.

The temperature sensors of the systems protecting against exceeding the

allowable temperature should be installed directly on the boiler at its highest

point.

Hydraulic connections of boiler

Installation of boiler with open type expansion tank

Symbols

1,2,3,4,5,6,7,8,9

Ball valve

10,11

Radiator switch

Radiator

13,14,15

Safety valve

Automatic water fill valve

Drain tap

Cold water supply valve

19, 20, 21, 22, 23, 24

Check valve

Buffer tank

Open type expansion tank

PCI

Circulator of heating system

PRC

Recirculation pump

Circulator for buffer tank

Pressure reducer

Y-type strainer

Automatic air vent

Water filter

Symbols

Hot water outlet

Τ2

Return water inlet

Τ3

Drain tap 1/2"

Τ4

Heat exchanger input –

Connection with thermostatic

safety valve

Τ5

Output of hot water from heat

exchanger in case of boiler

overheating

Installation of boiler with closed type expansion tank

Symbols

1,2,3,4,5,6,7,8,9

Ball valve

10,11

Radiator switch

Radiator

13,14,15

Safety valve

Automatic water fill valve

Drain tap

Cold water supply valve

19, 20, 21, 22, 23, 24

Check valve

Buffer tank

Closed type expansion tank

PCI

Circulator for heating system

PRC

Recirculation pump

Buffer tank circulator

Pressure reducer

Y-type strainer

Automatic air vent

Water filter

4.4. Installation safety

 3 bar safety kit

It consists of a collector, manometer, safety valve and automatic air vent. It is fixed to

the input of hot water. For safety reasons, if not installed any of the following

protective systems must be installed and the second valve.

Regularly check the correct operation of safety valves. In case of wear or damage,

replace them immediately with new ones.

3 bar safety kit.

 By-pass system with load units

Boiler has to operate for a temperature difference 10 to 15oC and to insecure that the

temperature of the return water is over 50oC. This insures the smooth operation of

the boiler and generally the right operation, the constant performance and the long

lifetime.

To insure that the temperature difference will be between 10 and 15oC the installation

needs a recirculation pump and a 3-way thermostatic valve. This system insures the

right temperature of return water and also the right temperature of water at the

radiators.

The ESBE series LTC100 is a load unit designed to protect the boiler from return

temperatures that are too low. Maintaining a high and stable return temperature

enables a higher level of boiler efficiency, reduced tarring and increased life span of

the boiler. The integrated pump offers boiler protection and optimal tank loading.

The LTC100 is used in heating applications where solid fuel boilers are used to feed

storage tanks.

The load unit consists of an integrated pump and thermic valve, designed to make

both assembly and handling easy. The load unit is protected by an insulation shell

and is fitted with easily readable thermometers.

The valve regulates on two ports, which makes it easy to install and does not require

any balancing valve in the bypass pipe.

The LTC100 has an integrated auto-circulation function which makes the unit

operational even during power failure or pump failure. The circulation function is

blocked at delivery, but can easily be activated if required.

The valve contains a thermostat which begins to open connection A at an outgoing

mixed water temperature in connection ABof50°C,55°C,60°C,65°C,70°Cor75°C.

Connection B is fully closed when the temperature in connection A exceeds the

nominalopeningtemperaturewith10°C.

ESBE LTC 100, load unit.

 Overheating protection system

In a solid fuels installation with closed type expansion tank it is required to ensure the

protection against overheating, which mainly result from uncontrolled use of wood or

an electrical power failure.

When boiler temperature reaches 90-100oC the valve opens and allows the entry of

cold water into the heat exchanger serpentine. The heat exchanger is connected with

one thermostatic valve. The sensor is positioned into the boiler and when the

temperature of boiler reaches a temperature the valve opens and cold water come

into the serpentine. The cold water into the serpentine takes the heating of the boiler

and as a result the temperature of the boiler decreases. The hot water of the

serpentine goes to the drain. The valve responds directly to temperature differences

and its operation is complete mechanic without electric or spare parts. After the

decrease of boiler temperature under a limit the valve closes again and the water

stops to come into the serpentine.

If the web pressure is over 6 bar it is necessary to install a pressure reducer before

the installation. Noted that this valve does not replace the safety valve and it is

important to install safety valves too (at least 2).

 Temperature and pressure relief valve

The T&P valve has a temperature sensor and provides double safety against

temperature (90oC) and pressure (3 bar). The output of the valve should be

connected with the drain for the disposal of the overheated water. The T&P valve

should be connected nearby to the boiler and necessary at the outlet. It provides

safety in case of closed type expansion tank installation but it is not replace the

overheating safety system.

Technical data:

Temperature (limit)

90οC

Pressure (limit)

3 bar

Connection

½”

Discharge rating:

10 kW

Dimensions

½”

Ø15

102

4.5. Thermal protection of the boiler

The boiler should be operated within the supply and return water temperature

differences in the range of 10 – 15°C.

Because of the lifecycle of the boiler, it should be operated with the return

water temperature not lowerthan60°C.

In practice, it is difficult to meet this condition because the average

atmospheric conditions during the entire heating season “require” lower

settings.

In order to ensure the required return water temperature the following

solutions are suggested:

Higher settings on the boiler (possible only with low external temperatures).

Recommended

use of a mixing system based on the application of a three-way mixing valve

with a boiler circulator (the solution ensuring the proper temperature of both

the return water and the central heating system)

Boiler water requirements:

water for filling up boilers and heating installations should comply with the

requirements of the PN-93/C-04607 standard,

the boiler water should have the following parameters:

- pH value > 8.5

- total hardness < 20of

- free oxygen content < 0,05 mg/l

- chlorides content < 60 mg/l.

the used water treatment technology for filling up the heating installation

should comply with the requirements referred to above,

In the event of failing to comply with the above-mentioned requirements,

THERMOSTAHL may withdraw the guarantee for the installed boiler (boilers).

4.6. Chimney system

It should be installed as an acid-proof, double-wall, insulated chimney, or in

the case of chimneys made of brick, comply with the requirements of the

PN89/B-10425 standard; the technical parameters of the chimney should

ensure its protection against the effects of the condensate resulting from

cooling of the flue gas. Use of acid-proof chimney inserts (tin, stoneware, etc.)

is recommended.

The section of the chimney can be calculated following the formula provided

below:

D = 20(3+P)1/2 [m2]; where: D-diameter in mm, P-boiler power rating in kW.

The chimney diameter may not be less than the diameter of the flue.

Connecting several boilers to one common chimney flue is not recommended.

The connection of the boiler to the chimney should be thermally insulated and

run the shortest possible way with the least possible number of pipe elbows,

with the appropriate height of the flue towards the chimney.

The chimney should be freely open towards the top and built at least 1 m

above the roof,

The diameter of the flue gas duct should be selected (calculated) in

accordance with the recommendations of the manufacturers of the chimney

inserts, however it should not be less than the diameter of the boiler flue.

Installation of an inspection door for removing combustion residues should be

envisaged,

The entire length of the chimney should be maintained clean,

Before connection the boiler to the chimney the user should obtain a positive

opinionofthechimneycleaners’specialist.

A graph for selecting the chimney diameter in relation to the boiler power rating and the chimney height, including

the provided values of the chimney draught.

4.7. Digital Electronic Controller PWC-1000

Operating instructions

Button A1 – A2 : They are used to increase and decrease the desired maximum

water temperature.

Button A3 : It is used for entering and exiting from the menu. For entering into the

menu short pressing is required, and for exiting long pressing.

Button A4 : It is used to turn on and off the controller (long pressing). It is also used

for starting and stopping the ignition process (short pressing).

After entering the menu buttons A1 and A2 are used to change the value of the

selected parameter, and buttons A3 and A4 are used to change the parameter we

want to alter.

Settings

TEMP.WATER

Maximum water temperature.

TEMP.EXHAUST

Maximum exhaust temperature.

TEMP.CIRCULATOR

Water temperature that the circulator pump starts to

operate.

TEMP.Bypass

Water temperature that the bypass valve starts to operate.

FAN AIR MAX

Maximum power amount of the fan (%) in the full burning

process.

DT WATER

Temperature difference below the maximum water

temperature that the fan power starts to decrease.

DT EXHAUST

Temperature difference below the maximum exhaust

temperature that the fan power starts to decrease.

IGNITION TIME

Maximumtimeoftheprocess“ignition”.Fanpoweris

determined onlybythe“ignitionair”settingatthisprocess.

IGNITION AIR

Power amount of the fan (%) in the ignition process.

Off TIME

Timethatexhausttemperaturemustbebelowthe“11-Off

exhaust”sothatthecontrollerissetinto“endoffuel”

process.

Off EXHAUST

Exhaust temperature value that determines when the fuel

has ended.

CONS.PERIOD

Repeatingtimeoftheprocess“flameconservation”.Inthis

processthefanpowerworksat“09-ignitionair”sothatthe

flame is conserved.

CONS.DURATION

Durationoftheprocess“flameconservation”.

5. Operation and maintenance

5.1. Start of the boiler

Before firing the boiler ensure the following:

The installation is complete and correct and there is any problem at the

hydraulic network.

The electrical installation is complete and correct.

The connection of flue gas tube is correct without problems and with the

suitable insulation.

The sensors are well positioned to the boiler.

The hydraulic network is complete and there is the correct pressure.

The circulator is connected and working properly.

The expansion tank is connected properly and ensures enough expansion of

the water.

The boiler valves are open.

There is sufficient ventilation of the installation.

No flammable or explosive materials around the boiler.

If you notice any damage or malfunction at the boiler contact your installer or the

company.

Use as fuel wood or briquettes. Make sure the wood is dry (humidity <20%) to ensure

better combustion, better performance and protect the boiler. Note the size of the

woods. Make sure the length is such that it fits in the feeding chamber. If there are

larger than the length of the chamber cut them.

 First start of the boiler

The ceramic plates which are inside the boiler have a quantity of water inside their

structure from the production process. The water is evaporated during operation of

the boiler. But at the first operations, the boiler should not be working at full load,

because the water content can be vaporized and create gaps in the ceramic structure

that will lead to cracks and possible breakage of the ceramic plates. So it is

recommended the heating of ceramic plates to evaporate the water content and then

operate at full load.

The process for removing humidity from ceramic is as follows: Place a small amount

of kindling and a few small woods into the upper (feeding) chamber. Open the

damper of the upper chamber with the help of the special lever that is on the front

side and the upper right of the boiler. Be sure that you do not fill the boiler with

woods, but put a small quantity of woods, enough for 20 to 30 minutes of

combustion. After the operation allow the boiler to cool for 2-3 hours and repeat the

process. It is recommended to repeat the process 3 times to ensure that the

ceramics are dry.

If the boiler is not used in summer then the process will be repeated again before the

start of use.

 Start of the boiler

Before starting the boiler check the whole installation and that it complies with all

safety rules. Pull the lever at the front and upper - right part of the boiler and open the

damper of the boiler. Open the feeding door and put some firelighters, some twigs

and some thin woods at the bottom of the feeding chamber, on the ceramic plate and

ignite them. Close the feeding door and open the third door to provide air. When the

woods are on fire feed the boiler with woods. During feeding insert woods with

smallest diameter on the bottom and the biggest on the top. Ensure that the woods

are on fire and close tightly the doors of the boiler. Close the dumber pushing the

lever and start the ventilator. Ensure that the doors are closed and there not leave

smoke or sparks.

5.2. Combustion settings

The flame should have suitable dimensions and cover the combustion chamber. The

effective operation of the boiler depends largely on the settings of primary and

secondary air.

If the primary air is excessive, much ash will fall into the combustion chamber. The

flame will be very strong and fast and make noise while wood consumption would be

high.

If the primary air is not enough then the flame will be low and slow and moving by air

currents and will be attracted by the chimney. It will not cover the entire surface of the

chamber, while the production of ash will be small.

If the secondary air is excessive then the flame is small and blue.

If the secondary air is enough then the flame would be great, embracing the entire

combustion chamber and will be red and opaque.

5.3. Maintenance

 Daily maintenance

On a daily basis you need to check the integrity of the boiler room and the correct

operation of the boiler. Check that the pressure in the network is correct and that all

safety devices are in good condition and functioning properly. The boiler should be

cleaned daily by the combustion residues (ash and unburned residues). Clean both

upper chamber and combustion chamber. Clean walls and ceramic plate on the

upper chamber and throw the ash in the combustion chamber. Remove the ash from

the combustion chamber. CAUTION! The ash may contain hot residues which may

cause fire in the final disposal. Finally, check the integrity of the ceramic plates.

 Weekly maintenance

Weekly cleaning of the boiler includes thorough cleaning of the combustion chamber

and the upper chamber. Open the dumber and then open the feeding door, wipe the

ash from the chamber and throw it to the combustion chamber. With a brush clean

ceramic plate lying between the two chambers. Ensure that ashes do not include hot

residues before its disposal. Use a scraper for cleaning the walls of the chambers of

any deposits. If ashes have accumulated underneath the ceramic plate in the

combustion chamber, remove it and clean the chamber. Refit the ceramic in the

chamber with special attention to proper placement. Before you clean, leave the

boiler switched off for at least one or two hours to cool. In continuous operation, it is

recommended to be cleaned once every 4 days.

 Monthly maintenance

During the monthly cleaning clean the smoke chamber. The smoke chamber has

openings for cleaning. Unscrew the screws and clean the deposits of ash. With a

scraper remove smoke and ash from the walls of the smoke chamber. Collect them

of the side opening. After the cleaning, close the openings tight. Check the tightness

of the openings and the condition of the sealing cord. Replace it if it is necessary.

 Season maintenance

Finally, during the annual maintenance of the boiler at the end of the period of use

(spring) check the entire heating system (boiler, piping, connections, valves, etc.) in

order to function correctly. Repair any damages or harms to the network. Clean

thoroughly the boiler, ceramic plates, the smoke chamber, the chimney, and

additionally clean the fan of any existence ashes inside.

6. Defects – Troubleshooting

Type of defect

Cause of defect

Procedure

Backflow of flue gas

into the boiler room

1. Blocked chimney, no or weak chimney

draught.

2. Improper supply and exhaust

ventilation of the boiler room.

3. Incorrectly adjusted boiler fan.

4. Improper boiler start-up.

5. Incorrect connection of the boiler with

the chimney.

6. Incorrectly closed, adjusted boiler door.

1. Measure the chimney

draught, clean the chimney,

check the combustion

parameters, λ=1,8-2,0.

2. Check the operation of the

supply and exhaust ventilation.

3. Adjust the fan.

4. Fire the boiler in accordance

with the manual.

5. Make a proper connection of

the boiler with the chimney.

6. Check whether the boiler door

seal adheres to the boiler on its

entire length.

Low temperature water

in the boiler despite

intensive burning

1. Improper fuel – too low calorific value

or damp fuel.

2. Incorrectly selected boiler in relation to

the size of the building.

3. No/weak chimney draught.

4. Incorrect adjustment of the boiler

settings.

5. Improper or blocked air supply

installation.

6. Too low quantity of primary air.

1. Use fuel of high calorific value

and moisture content in

accordance with the manual.

2. Check selection of the boiler

and the system.

3. Check whether the

combustion chamber, smoke

tubes and chimney are not dirty,

clean them.

4. Adjust the boiler.

5. Check the condition of the air

supply installation.

6. Adjust or clean the fan.

Boiler temperature too

high

1. Water loss in the system.

2. Blocked circulator/ electricity supply

problem.

3. Overloading of boiler.

1. Admit water – after cooling of

the boiler.

2. Check the circulator/check

that the electric parts are

appropriate connected.

3. Do not feed the boiler, wait

until the boiler temperature drop.

Too high temperature

of the flue

1. Too high chimney draught.

2. Incorrect heat transfer due to dirty

combustion chamber.

3. Incorrectly selected, too small boiler

power rating.

1. -Check the chimney system

whether is suitably selected.

- Close the dumber in case that

you forget it open.

2. Clean the combustion

chamber and smoke tubes.

3. Check the appropriateness of

boiler selection in relation to the

building.

Too high consumption

of fuel

1. Incorrectly installed central heating

system.

2. Incorrect selection of the boiler in

relation to the building.

3. Fuel of low calorific value.

4. Improper parameters of boiler

operation.

1. Check the central heating

system.

2. Carry out a short energy audit

3. Replace the fuel with the

appropriate fuel.

4. Set proper parameters for

boiler operation.

Flame image

1. red

2. blue

3.with noise

4.small flame

1. Lack of secondary air.

2. High secondary air supply.

3. High primary air supply.

4. Lack of primary air.

1. Increase the supply of

secondary air.

2. Decrease the supply of

secondary air.

3. Decrease the supply of

primary air.

4. Increase the supply of primary

air.

The chimney smokes

1. Low secondary air supply

2. If it still smokes...

1. Completely open of

secondary air opening

2. …completelyopenof

secondary air opening and

reduce the primary air supply.

Condensation inside

the boiler

1. Condensation of air and exhaust gases

during ignition of the boiler

2. Very low return temperature

3. Fuel with very high amount of moisture

4. Low chimney draft

5. Small section of chimney

6. Faulty connection to the chimney

7. Concentrates or rain entering the

chimney

1. During ignited adjust the

boiler temperature above 70oC

and keep it for a few hours

2. The boiler must be protected

from low return temperature with

a three-way valve. The minimum

return temperature is 50oC.

3. Use dry fuel with

moisture<20%

4. Check the chimney and clean

it if it is necessary

5. Check the sizing of the

chimney in accordance with the

instructions

6. Ensure tight connection of the

boiler to the chimney

7. Check the installation of the

chimney and place protective

hat if it is necessary

The fan does not start

1. Fan failure

2. Burned out fan

1. Check electrical connection of

the fan.

Check the capacitor of the fan

engine.

2. Replace the fan with a new

one.

Poor combustion

1. The fan feeds too little air

2. Too little chimney draught

3. Incorrect air supply system

1. Clean the fan, adjust the

quantity of air with the adjusting

screw.

2. Measure the chimney

draught.

Install a draught generator.

3. Check the patency of the air

supply duct.

THERMOSTAHL PYROGAS 23 User manual

Brand: THERMOSTAHL

Model: PYROGAS 23

Type: User manual

This manual is also suitable for

The PYROGAS 23 is equipped with a number of features that make it efficient and easy to use. These features include:

A large feeding chamber that allows for long burning times

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THERMOSTAHL PYROGAS 23 User manual

This manual is also suitable for

THERMOSTAHL PYROGAS 23 User manual

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