Tradgardsteknik NPS 35 User guide

SOLID FUEL HEATING UNIT

TYPES NPS 35 AND NPS 70

ORIGINAL INSTRUCTION MANUAL

1. General information

The Original Instruction Manual constitutes an

integral and material part of the product, and is to be

transferred to the user with the transfer of

ownership. It needs to be studied thoroughly and

retained for future reference, as all remarks included

in it provide important hints on safety during

installation, use and maintenance of the appliance.

The heating unit needs to be assembled and

installed with adherence to the standards in force in

the country of operation, according to indications of

the manufacturer, and operated by trained

professionals. Improper device installation might be

the cause of injury to people and animals and of

material damage, for which the manufacturer is not

liable.

The air heating unit may be used exclusively for the

purpose for which it was clearly designed. Any other

use shall be considered improper, and,

consequentially, hazardous.

In case of errors during installation, use or

maintenance that were caused by negligence in

terms of the law in force, of provisions in force or the

Original Instruction Manual (or any different manual

supplied by the manufacturer), the manufacturer is

not liable for any contract or other responsibility for

the arising damages, and the equipment warranty

becomes void.

The choice of heating units for heating buildings is

conducted based on a building thermal heat balance

sheet, with particular consideration of losses

stemming from the transfer of heat to buildings.

2. Foreseen use of the heating unit

The NPS series heating units are foreseen for

heating air in small to medium-sized rooms, in

buildings without a water-based central heating

system.

Thermal heat is generated as a result of combustion,

and the thermal energy is transferred through the

combustion chamber walls and the heat exchanger.

The air heaters are devices ideally suited for:

industrial halls, workshops

warehouses, shops, megastores,

wholesalers

swimming pools, tennis courts, sports halls

exhibition tents, trade fair stands

religious sites.

The NPS series heater is a device generating

thermal heat through combustion of solid fuel

(wood, coal, following the installation of an

additional burner - pellets) directly from the heat

exchanger tube to the outside environment,

without any intermediate liquid. During

combustion, smoke and other gases are

generated, which are ventilated by the chimney

line.

NOTE!

Due to the specifics of operation of the solid

fuel-fired air heater, operation supervision in

the form of operation parameter control is

necessary.

3. Heater description

The NPS series air heated is composed of the

following parts:

combustion chamber with thermal heat

exchanger (body)

covers

ash tray

cast iron grid

ventilator system

electric switch box with thermostat

air blower.

Thermal heat is generated as a result of combustion

in the combustion chamber, which is equipped with a

cast iron grid. The thermal energy is transferred from

the combustion gases to the ambient fresh air by

means of natural and forced convection.

The air and combustion gases are passed through

different ducts, which are welded and properly

insulated. The emerging combustion gases, after

cooling, are led out through a duct that must be

connected to a chimney or gas duct. The chimney or

gas duct diameter must be sufficiently large to

guarantee effective combustion gas removal. The air

used in the combustion process is taken directly

from the room or building being heated. For this

reason, it is of paramount importance to provide

appropriate ventilation for the heated room or

building that will guarantee the provision of an

appropriate volume of fresh air. The ash emerging in

the combustion process falls to the ash tray, from

which it can be removed without difficulty. The

heated air is distributed around the room through a

rotating blower, which is mounted in the top area of

the air heater.

The electric switch box with thermostat is

responsible for the assurance of electric energy to

the heater fan. When the heater outer casing

reaches the set temperature (35 °C), the fan is

switched on and warm air is distributed around the

room, in which the heater was installed.

The ventilator is automatically shut down if the

heater casing cools down to less than 35 °C.

4. Fuel parameters

The basic fuel for NPS heaters is fuel wood in

chunks. It should be seasoned under a roof for a

period of at least two years at a humidity level of 15-

20%.

HINT!

The wood should be seasoned for at least a

year. Wood humidity exceeding 25% can

cause energy losses and damage to the

heater body.

It is permitted to use replacement fuels with different

quality parameters and of a different granularity as

additions to the basic fuel (up to 10% with respect to

the wood chunk volume), such as waste wood.

When burning small pieces of fire wood note that

they should be separated by large fuel wood chunks.

NOTE!

The NPS series heater is not a furnace for

burning waste, and fuel that is forbidden may

not be burned in it.

NOTE!

Permanent use of certain wet fuel types, with

simultaneous maintenance of low combustion

gas temperature (less than 160 °C) will cause

faster

wear of the heater body, corrosion of the

convection ducts, the flue and tar deposits in the

combustion chamber. This is caused by

condensation of the combustion products: water,

nitrogen oxides and sulphur oxides, which

together form a very aggressive environment

facilitating faster corrosion.

As replacement fuel for NPS type air heaters,

energy coal may be used, nut type, classes 24/12,

type 31-2, according to standard PN-91/G-04510.

The indicated designation of 24/12 concerning fuel

characteristics determines the calorific value to be

approx. 24000 kJ/kg with an ash content of 12%.

This type of fuel guarantees the maintenance of the

declared power values.

As replacement fuel there may also be used a mix of

nut coal of class 24/12 at 70% with coal dust

of class

21/15 at 30% according to the standards indicated

above.

5. Heater technical data

Air heater

NPS 35

NPS 70

Rated power

35 kW

70 kW

Power supply

230 V 50 Hz

400 V 50 Hz

Energy consumption

1.2 A

1.6 A

Fan air flow

5500 m3/h

12500 m3/h

Width

600 mm

780 mm

Length

1000 mm

1250 mm

Height with head

1400+500 mm

1720+550 mm

Combustion rack chamber dia.

450 mm

620-mm

Combustion rack chamber height

680 mm

860 mm

Smoke stack diameter

150 mm

180 mm

Weight

200 kg

280 kg

Ventilation head rotation

Yes

Fuel

Wood/coal

Burner installation option

Yes

6. Heater transport and assembly

6.1. Transport and storage

The heater units are delivered assembled on pallets,

packed in film.

Use appropriate lifting equipment to raise and lower

the heater. Before transporting the heater, it should

be protected against shifting and tilting on the

vehicle platform by means of belts, chocks or

wooden blocks

HINT!

The heater should be transported in a vertical

position!

NPS series heaters may be stored in unheated

rooms that are necessarily covered with a roof and

provided with ventilation.

Before installation, the completeness of the scope of

delivery and its technical condition need to be

inspected.

6.2. Assembly requirements

Before installation of the heater, one needs to

acquaint themselves with the requirements of this

manual and the requirements of the relevant national

provisions.

Adherence to requirements included in the manual

during assembly and use of the heater shall enable

long-term and trouble-free operation of the heater,

and shall allow one to achieve optimum thermal

parameters.

It is suggested for the heating system to be

designed, the individual devices to be chosen and

assembled by a specialised plumbing company

having appropriate permits. The installation of the

device should be preceded by consultation with a

chimney specialist and a fire safety specialist.

It is recommended, before assembly begins, to hold

a written expert opinion on the building insulation

and ventilation and a chimney opinion concerning

the ventilation of fumes (of the chimney).

NOTE!

The heater should be installed by a

professional plumbing company according to

the standards in force!

NOTE!

It is forbidden to install the heater outside of

the building (in the open).

Fuel

The fuel should be stored in a separate technical

storage room, close to the heater or in the room,

where the heater is located, however, not closer

than 0.5 m (two feet) from the heater.

NOTE!

It is forbidden to install a forced ventilation

system in the heater room.

Ventilation

It is forbidden to use forced ventilation in the

installation room of the heater, taking in air for

combustion from its room, and with a gravitational

combustion gas removal, and in the room in which

the intake ducts for the combustion gas lines are

located.

The use of individual forced ventilation units in

rooms directly adjacent to the room of installation of

the heater may also cause the emergence of

underpressure and uncontrolled outflow of

combustion gases from the heater into the room.

In the installation room of the heater, there must be

ensured a gravitational air supply and exhaust

system. This system may not cause the emergence

of underpressure in the room.

The air supply system should ensure an inflow or

combustion air in a volume not less than 10 cu m

per hour for each kW of installed nominal burner

power and not less than 20 cu m per hour for each

person foreseen to permanently remain in the room.

The air supply and ventilation ducts should be

protected by steel mesh and constructed in such a

way that they cannot be clogged. The placement of

the mesh units should not cause draughts to

emerge.

NOTE!

The supply of a sufficient volume of fresh air

to the heater room needs to be ensured. Lack

of sufficient fresh air supply produces the risk

of incomplete combustion and the formation

of carbon monoxide.

6.3. Arrangement of heater in the room

NPS series heaters require no special foundations,

however, care must be taken for them to be

precisely levelled. The heater should stand on an

even, stable surface with sufficient load bearing

capacity. In case of insufficient load bearing capacity,

measures need to be undertaken for the required

load bearing capacity to be achieved.

The floor in the heater installation room should be

made of non-combustible materials. Should the floor

be made out of combustible materials, it should be

covered with a steel sheet with a thickness of at

least 1 mm, up to a distance of at least one metre

(three feet) from the heater outline.

When arranging the heater setup, consider fire

safety conditions. It is recommended that

a safe distance of at least 1.5 metres (five

feet) be maintained from combustible

materials during installation and operation of

the heater,

for combustible materials with a flammability

rating of C3, which burn away quickly and

easily even after the flame source is

removed, this distance increases twofold, i.

e. to at least three metres (ten feet),

if the combustibility level is not known, the

safety distance also needs to be doubled.

Combustibility of

construction materials

and related products

Construction materials

and products

A - non-combustible

Sandstone, concrete,

bricks, fire-safe plaster,

masonry mortar, ceramic

tiles, granite

B - difficult to combust

Wood-cement planks,

fibreglass, mineral

insulation

C1 - difficult to

combust

Beechwood, oak wood,

plywood

C2 - combustible with

medium difficulty

Pine, larch, spruce, cork,

sawn timber, rubber floor

covering

C3 - easily combusting

Asphalt-plywood,

cellulose masses,

polyurethane,

polystyrene,

polyethylene, plastic,

PVC

The placement of the heater should take into

account the possibility of unimpeded cleaning and

direct access from all sides.

The distance of the heater front face from the

opposing wall should not be less than two metres

(seven feet), and the sides of the boiler to the walls -

not less than half a metre (two feet).

6.4. Selecting the right heater

The heating system at an industrial plant should

provide appropriate thermal comfort. According to

relevant provisions, in the working rooms a

temperature level must be secured appropriate for

the type of work being executed (according to the

work methods and the physical effort required to

carry it out), however, not being lower than 14 °C. In

working rooms, in turn, in which light physical work

is carried out, and in office rooms, the temperature

may not be lower than 18 °C. In order to choose the

heating unit correctly, the heat requirement must be

determined.

The first step is to determine the building's thermal

balance, meaning, to determine the heat losses

through walls, doors, windows, entry gates, etc.,

considering the thermal gains that may arise due to

the machinery operating inside the building, the

people or animals (i. e. in a stall) residing inside.

This procedure is quite complicated, therefore, a

formula was devised that enables one to choose a

heater properly.

P = [qv W (tw - tz)] 0.001

Where:

P- thermal heat requirement [kW]

qv - unit thermal heat power dependent on the

building's volume and estimated insulation capacity

of walls (W/m3K)

W- building volume (m3)

tw - temperature required inside the building (°C)

tz - calculated external temperature for the individual

region of the country, for Poland in line with standard

PN-82/B-02403 (°C)

Care must be taken to properly determine the unit

thermal capacity for a building. It is dependent on

the building's volume and insulation capacity.

1- increased thermal insulation capacity

2- small total window and door surface

3- large total window and door surface

Fig. 1. Unit thermal capacity depending on the

building volume and the insulation capacity of

construction divisions.

Design outside temperature and mean annual

outside temperature value depending on the

climate zone

Climate zone

Design outside

temperature in

°C

Mean annual

outside

temperature in

°C

-16

7.7

-18

7.9

III

-20

7.6

-22

6.9

-24

5.5

Example: Building volume 1200 cu m. Required

internal temperature is 16 °C.

We read from the curve the value for qv = 1.5

W/m3K

from the map we read out that Gdańsk is

located in climate zone I, so the design outside

temperature is -16 °C. We calculate:

Q = 1.5 x 1200 x [16 -(-16)] x 0.001 = 57,6 [kW]

Accordingly, one can choose either one heater with

a capacity of 60 kW or two with a capacity of 30 kW

each. Such a solution would permit flexible

placement of the heaters and directing the air flow

so that better efficiency is achieved.

This information is only general in character. We

recommend choosing a professional systems

company to select the heater unit with the right

capacity.

6.5. Connection to the electric grid

The electric grid, to which the heater shall be

connected, should terminate in an earthed socket.

Grid voltage values required by the heaters

NPS 35

230 V / 50 Hz

NPS 70

400 V / 50 Hz

NOTE!

Using a socket without an earth connector is

risking an electric shock!

The socket should be located at a safe distance from

the heat source. It is recommended for a separate

electric system circuit to be provided to power the

heater.

NOTE!

All electric system connections are to be

made by an electrician with the appropriate

permits.

NOTE!

The user is forbidden from any interference or

making any changes to the electric

connections!

6.6. Connecting the heater to the chimney

The device may not be connected to a chimney

together with other burners.

In case of installation of the heater in a country, the

heater chimney connection should conform to

requirements of standards and legal provisions

presently in force in the relevant target country.

The heaters should be connected to chimneys using

profiles with an appropriate cross section and shape,

made of sheet steel, insulated at the heater exhaust

gas exit

and at the chimney exit, the length of which

should not exceed one metre. The connection

should have a fall towards the heater.

The height and cross-section of the chimney, and

the precision of its construction, should ensure the

maintenance of the required draught value. The

usefulness of the chimney should be confirmed by a

certified chimney specialist.

Heater

NPS35

NPS70

Minimum chimney height (m)

Dimensions (cm x cm)

Diameter (mm) 18x18

210 25x25

290

NOTE!

A weak draught shall cause the condensation

of water vapour on the exchanger walls, which

will bring about quick wear and damage to the

heater.

This can also cause the emergence of smoke

from behind the door and cleaning openings

of the heater.

The formula below permits easy selection of the

chimney cross-section.

F = 0.03 x Q x 0.86 / √h

Where:

F - chimney cross-section (sq m)

Q - heater thermal capacity (kW)

h - height of chimney measured from the burner

level to the exit (m)

It is important for the chimney to start at floor level,

as the exhaust fumes emerging from the heater

should have the option of 'bouncing back'. It is also

important for the lower part of the chimney to have

an inspection opening that can be sealed tight.

The chimney should stand at least 1.5 metres (five

feet) above the roof surface. The walls of the

chimney should be smooth, tight, without any narrow

passages or turns and free from any other

connections. A new chimney needs to be dried and

heated sufficiently before the heater is fired. In case

of doubt, the technical condition shall be evaluated

by a chimney specialist. Steel pipe chimneys should

be taller than masonry chimneys by 15-20%.

Maintenance of the chimney duct within its

recommended limits is one of the more important

factors guaranteeing the achievement of appropriate

technical and operational parameters of the heater.

NOTE!

Due to their high effectiveness, it is

recommended to use chimney liners made of

stainless steel thermal heat-resistant steel for

the NPS series heaters.

7. Heater operation and maintenance

7.1. Initial heater start-up

Before start-up of the heater, inspect as follows:

chimney system tightness

chimney connection correctness

tightness of ventilator contact surfaces and

inspection openings

manner of connection to the electric grid

The boiler start-up procedure is as follows:

switch on the heater

light up the burner according to this manual

recheck heater tightness

acquaint the user with the operation of the

unit

note data in the warranty card

HINT!

The conclusion of installation and the

execution of a heating trial need to be noted in

the warranty card. The completed warranty

card should be sent by the user, as copy, to

the address of the manufacturer so the user is

registered in the company system.

7.2. Heater start-up and use (User instructions)

Before commencing burner start-up, check:

that system ducts are free from

obstructions

that the ventilation system works

properly.

1. If this is a repeated start-up, remove the ash

collected in the loading chamber. The charcoal

remaining in the chamber can form the first start-up

layer.

2. Lay out on the remains of the charcoal a layer of

wood, not filling more than 50% of the grid.

3. From the topside, lay out a layer of minute pieces

of wood with some bunched-up paper. Afterwards

add a layer of wood chippings and some pieces of

soft wood.

4. The heater should be started up by switching the

control unit on.

5. Light the paper, and after it catches fire, close the

loading door, leaving it slightly open for a few

seconds.

6. In order to ease distribution of a higher volume of

air during start-up, set the volume of primary air by

extracting and pushing in the ash tray.

7. When the wood catches fire well (after about 20-

30 minutes), fill the chamber with an appropriate

amount of wood so that the loading chamber is

approx. 60% full, and close the loading door.

8. The next steps in the burning process entail

continued supply of fuel and controlling the burning

process by adjusting the primary air volume by

extracting and pushing in the ash tray.

9. Never leave the heater unattended!

NOTE!

It is forbidden to disconnect the power supply

from the device when it is hot, because the

collected energy can damage the ventilator

and heat exchanger!

NOTE!

Components of the heater -

in particular outer

covers -

are hot during operation. Appropriate

caution is advised!

NOTE!

Never stand straight before the boiler when

opening doors. Risk

of burns!

NOTE!

The grid chamber should always be closed,

save for a start-up period, for loading and the

removal of grid contaminants.

7.3. Periodic heater maintenance -

cleaning and

upkeep

HINT!

In order to maintain appropriate combustion

efficiency, keep the convection ducts and

sheet metal inside the grid chamber

appropriately clean. Soot, dust and ash from

combustion shall reduce effectiveness and

capacity of the combustion process.

NOTE!

The operating temperature of the individual

heater units can reach up to 600 °C.

In order to clean the heater,

shut it down and

wait out the time necessary for the heat

exchanger to cool down.

NOTE!

Before commencement of maintenance

procedures, disconnect the heater power

supply!

NOTE!

All activities

need to be carried out with

particular care. They can only be executed by

adults. Ensure for children to stay clear and

away from the heater during its cleaning

procedure. Use

gloves, safety goggles and

head protection when servicing the heater.

In the grid chamber of the heater, pay particular

attention to the precise removal of ash and slag

from the grid grooves and chamber walls. Such

cleaning should be carried out each time the

heater is started up. Before cleaning, shut off the

heater with its main switch, and wait out the

period necessary for the heat exchanger to cool

down.

The exhaust ducts, in which volatile ashes

gather, should be carried out through the

inspection openings every seven to fourteen

days, depending on the fuel quality and humidity.

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