Protection and Control of Solid Fuel Boilers

Protection and Control of Solid Fuel Boilers Catalogue Energy-saving solutions

BOILER OVERHEATING PROTECTION Solid fuel boilers may get overheated during operation, mostly due to a power failure. The boiler circulation pump stops while there is glowing fuel inside and the heating water temperature starts rising quickly as the heat is not being removed. This danger can be prevented in two ways: either by recooling the boiler via a thermostatic valve that needs no energy for its operation, or by a backup source that supplies energy for the circulation pump. BOILER PROTECTION AGAINST CLOGGING AND HEAT TRANSFER SURFACE CORROSION Burning causes releasing of water, among others, from the fuel in the form of steam. If the flue gas is hot enough, the steam leaves through the chimney together with flue gas. However, if the flue gas gets cooler at some spot, condensation of water vapor occurs there. The condensate contains products of burning that can be very aggressive esp. when burning wood or solid fuel and thus cause fast corrosion and deposit formation on heat transfer surfaces (tarring). TSV thermostatic mixing valves mix cool return water from a heating system or accumulation tank with hot water from the boiler outlet. This way the whole heat exchanger (heat transfer surfaces) is kept warmer, at temperatures that will not allow condensation to occur and so fouling and quick corrosion will be prevented. Fouled heat transfer surfaces deteriorate boiler efficiency substantially and increase the risk of scale formation. Quick corrosion and fouling will not occur if the heat transfer surfaces are warm enough as condensation will not occur above certain temperatures. The heat transfer surfaces will be warmer, making their service life longer and the boiler efficiency higher. These valves are fitted with thermostatic valves made by a renowned French manufacturer. PUMP STATIONS WITH THERMOSTATIC VALVES Pump stations with thermostatic mixing valves serve for the same purpose of boiler protection as TSV valves, making installation easier as they are fitted also with circulation pumps for the boiler/heating circuit and other components. Regulus CS TSV Pump station involves also components needed for proper operation of both heating and DHW. Installation time and price is reduced this way. They are designed for installation directly on the boiler outlet pipe or on a wall. BOILER OUTPUT CONTROL Thermostatic draft regulators keep the outgoing temperature from a solid fuel boiler at the value selected by the regulator knob. They operate combustion air dampers by chains, controlling this way the boiler output. Their advantage is a robust build, mechanically sturdy and thermally resistant. Their double scale enables horizontal as well as vertical installation. High quality thermostatic elements made by a renowned French manufacturer offer precise operation and a long service life. Electric operated regulators work in the same manner, moreover they can reduce outgoing temperature from a boiler on electric signal. This way the boiler temperature and output can be controlled by a room thermostat or other electronic controller.

CONTENTS BOILER OVERHEATING PROTECTION DBV1 Thermostatic Valve... 2 JBV1 Thermostatic Valve... 3 BVTS Valve with Capillary... 4 PG 500 Backup Source for Solid Fuel Boilers... 5 BOILER PROTECTION AGAINST CLOGGING AND HEAT TRANSFER SURFACE CORROSION TSV3 and TSV3B - DN 25 Thermostatic Mixing Valves... 7 TSV5 - DN 32 Thermostatic Mixing Valve... 8 TSV6 - DN 40 Thermostatic Mixing Valve... 9 TSV8 - DN 50 Thermostatic Mixing Valve... 10 TSV2 - DN 50 Thermostatic Mixing Valve... 11 PUMP STATIONS WITH THERMOSTATIC VALVES Regulus Thermovar LK 810 Thermostatic Pump Station... 12 Regulus CS TSV Pump Station... 13 Regulus CS TSV MIX Pump Station... 14 BOILER OUTPUT CONTROL RT3E Thermostatic Draft Regulator, electric operated... 15 RT3 Thermostatic Draft Regulator... 16 1

52 35,5 61,5 G ¾" 199 G ¾" BOILER OVERHEATING PROTECTION For boilers with no recooling heat exchanger DBV1 Thermostatic Valve This temperature-controlled two-way valve, working without any electricity, opens and lets cold water from the mains in at 97 C, cooling down the boiler and preventing its overheating. Hot water is discharged into a sewer. In order to work properly, the valve shall be installed to a place where the highest temperature is reached in case of overheating - usually directly in a top section of the boiler or on an outlet pipe close to the boiler. The valves are fitted with a thermostatic element from a renowned French manufacturer. Since the thermostatic element is located directly in heating water, its reaction to water temperature fluctuations is immediate. The valve has no capillary that could be damaged during installation. Functional tests are performed on each valve in production.» a reliable thermostatic element made by a renowned French manufacturer» a quick reaction to temperature fluctuations, the sensor and hot water outlet in one place» a knob for manual opening like in safety valves» no capillary - easy installation, no risk of damage 56» 100 % function controlled in production The valve is patented in many European countries. Examples of patents issued: COLD WATER IN A COLD WATER TO THE BOILER B HOT WATER TO SEWER C G ¾" 28 DBV1 Specification SENSOR AND HOT WATER FROM THE BOILER SENSOR AND HOT WATER FROM THE BOILER Opening temperature (limit) 97 C ±2 C Max. temperature 120 C Max. pressure on boiler side 4 bar Max. pressure on water side 6 bar Kvs 1.80 m 3 /h at heating water temp. of 110 C Connection to a heat source ¾ M Connection to cooling water pipe ¾ M Connection to sewer ¾ M Code 8066 COLD WATER IN TO HEATING SYSTEM KEY: shut-off valve pressure reducing valve strainer check valve (in pipe) BOILER TO SEWER safety valve FROM HEATING SYSTEM pump 2

63 30 93 179 G ¾" For boilers with a recooling heat exchanger JBV1 Thermostatic Valve This temperature-controlled two-way valve, working without any electricity, opens and lets cold water from the mains in at 97 C, cooling down the boiler via a recooling heat exchanger and preventing its overheating. Hot water is discharged into a sewer. In order to work properly, the valve shall be installed to a place where the highest temperature is reached in case of overheating - usually directly in a top section of the boiler or on an outlet pipe close to the boiler. The valves are fitted with a thermostatic element from a renowned French manufacturer. Since the thermostatic element is located directly in heating water, its reaction to water temperature fluctuations is immediate. The valve has no capillary that could be damaged during installation. Functional tests are performed on each valve in production.» a reliable thermostatic element made by a renowned French manufacturer» a quick reaction to temperature fluctuations» a knob for manual opening like in safety valves» no capillary - easy installation, no risk of damage 56» 100 % function controlled in production The valve is patented in many European countries. Examples of patents issued: COLD WATER IN A COLD WATER OUT B G ½" JBV1 Specification Opening temperature (limit) 97 C ±2 C Max. temperature 120 C Max. pressure on boiler side 4 bar Max. pressure on water side 6 bar Kvs 1,80 m 3 /h at heating water temp. of 110 C Connection to a heat source ½ M Connection to cooling water pipe ¾ M Code 8877 COLD WATER IN TO HEATING SYSTEM KEY: shut-off valve pressure reducing valve strainer check valve (in pipe) BOILER safety valve TO SEWER FROM HEATING SYSTEM pump 3

31 G ¾" G ¾" 117 130 BVTS Valve with Capillary This single-way capillary valve, working without any electricity, opens and lets cold water from the mains in at 97 C, cooling down the boiler via a recooling heat exchanger and preventing its overheating. Hot water is discharged into a sewer. Model with opening temperature 108 C is usually used for fire protection of pellets or coal. In order to work properly, the capillary shall be located in a place where the highest temperature is reached in case of overheating - usually directly in a top section of the boiler or on an outlet pipe close to the boiler. The valve installs on a cooling water pipe and is currently supplied with a 1.3m or 4m capillary.» a push button for manual opening like in safety valves» the valve is not installed directly on a boiler or outlet piping 10115 - Length: 1,3 m 10114 - Length: 4,0 m 10113 - Length: 1,3 m Ø 8 G ½" Ø24 Ø 19,5 Ø16 Ø30,5 60 Specification Opening temperature (limit) 97 C ±2 C 95 C ±2 C 108 C ±2 C Max. temperature 122 C 122 C 133 C Max. pressure on boiler side 4 bar Max. pressure on water side 10 bar Kvs 2.40 m 3 /h Sensor connection to a heat source ½ M Connection to cooling water pipe 2 ¾ F Capillary length 1.3 m 4 m 1.3 m Code 10113 10114 10115 COLD WATER IN KEY: shut-off valve COLD WATER IN TO SEWER TO HEATING SYSTEM strainer check valve (in pipe) BOILER safety valve FROM HEATING SYSTEM pump 4

80 Backup Sources PG 500 Backup Source for Solid Fuel Boilers PG 500 Backup Source for solid fuel boilers is intended to power-supply a boiler circulation pump in case of a power breakdown. This way boiler recooling is ensured and overheating avoided. PG 500 is supplied together with a special battery, 44 Ah. Unlike a current automotive battery, this one is designed for a smaller current to be drawn for a longer time. This kit will keep running* a Wilo 25/4 circulation pump for at least 5 hours. * speed 3, pump power input of 68W» the course of outlet voltage is optimized for use in circulation pump backup» indication of backup source momentary state, acoustic alarm» wide range of power supply voltage» vertical and horizontal operation possible» installation and commissioning can be done by the user» intelligent charging in two steps, protecting the battery 255 170 222 165 195 screw terminals to connect the battery PG 500 Capacity 44 Ah Code 9140 230V socket for a power cord, integrated fuse 230V socket (for a pump) 5

BOILER PROTECTION AGAINST CLOGGING AND HEAT TRANSFER SURFACE CORROSION Thermostatic mixing valves TSV Thermostatic mixing valves keep boiler return water temperature at a preset temperature, preventing lowtemperature corrosion and boiler clogging. The boiler then works with a higher efficiency and its service life is extended. The valve contains a thermostatic element made by a renowned French manufacturer that facilitates mixing hot outlet water with return water from a heating system or accumulation tank. In new valve models a thermostatic element with rubber gasket is used that guarantees high tightness of the valve, preventing microcirculation in periods when the boiler is extinguished. Microcirculation via a boiler is the reason of an accumulation tank getting cooled down due to heat loss via the chimney. All valves feature robust design with large cross sections for heating water flow. They are not inclined to getting clogged when installed into already operated heating systems. Sludge can be easily drained from valves of the TSV3-8 line as well as the thermostatic element cleaned or replaced by unscrewing the plug, no need to remove the valve from a heating system. TSV2 valve can be easily taken out from a heating systems due to the fitting kit supplied. During installation, it is necessary to adjust properly the balancing valve mounted in the by-pass pipe bringing hot water from the boiler outlet into the valve. TSV3B and TSV5B models do not need a balancing valve, automatic balancing of hot water incoming via a bypass is incorporated inside the valve. Its installation is so easier and control more precise. Especially in a situation when the return water temperature from a heating system or accumulation tank is close to the valve nominal temperature or higher, the valve restricts hot water flow from the bypass to complete tight closing. Due to this, the outgoing temperature from a boiler does not rise too much and so the boiler can work at full power even under these conditions. Model TSV3 TSV3B TSV5 TSV5B TSV6 TSV8 TSV2 TSV2 TSV2 Nominal diameter DN [-] 25 25 32 32 40 50 50 50 50 Max. working pressure [bar] 6 6 6 6 6 6 6 6 6 Connection fittings supplied - - - - - - YES YES YES Connection size [ ] 1 F 1 F 5/4 F 5/4 F 6/4 F 2 F 5/4 F 6/4 F 2 F Flow coefficient Kvs [m 3 /h] 10.2 8.2 12.6 8.7 22.2 31.5 20.4 20.4 20.4 Automatic bypass balancing - YES - YES - - - - - Weight [kg] 0.75 0.75 0.85 0.85 1.6 1.75 1.96 1.96 1.96 Specific codes TSV3 TSV3B TSV5 TSV5B TSV6 TSV8 TSV2 TSV2 TSV2 45 C - high tightness 10741 10282 11802* 11806* * * - - - 55 C - high tightness 10348 10281 11803* 11807* 11820* 11818* - - - 61 C - standard tightness - - - - 11525-6544 6563 6564 65 C - high tightness 10347 10080 11804* 11808* 11821* 11819* - - - 77 C - standard tightness 10742-11836* - - - - - - * available from 9/2012 - not available in this version HEATING SYSTEM BOILER BALANCING VALVE ACCUMULATION TANK THERMOSTATIC VALVE TSV 6

G1" G1" 106 60 B TSV3 Valve This is the mostly used valve, suitable for boiler of output up to 35 kw or more. For boiler output up to 35 kw a pump of 4m head is sufficient (e.g. Wilo RS 25/4) and valve temperature of 65 C. For boilers of higher output valves are used with lower temperature and stronger circulation pumps. Higher valve temperature brings better resistance to corrosion and tarring. The right adjustment of a balancing valve is essential for a proper operation of TSV valves. TSV3B Valve This valve is equipped with automatic balancing of bypass flow, so no manual balancing valve is needed. The control is more precise and that is why this valve is currently used for boilers of 40 kw output and more. Valves with temperatures of 45 C, 55 C and 65 C are fitted with thermostatic elements with rubber gasket that prevent microcirculation and heat loss via a chimney in periods when the boiler is extinguished. G1" AB A 94 TSV3 Nominal temperature (outlet AB ) [ C] 45 C 55 C 65 C 77 C Flow coefficient Kvs [m 3 /h] 10.2 Max. working pressure [bar] 6 Nominal diameter DN [mm] 25 Weight [kg] 0.75 Connection size [ ] 1 F Code 10741 10348 10347 10742 TSV3B Nominal temperature (outlet AB ) [ C] 45 C 55 C 65 C Flow coefficient Kvs [m 3 /h] 8.2 Max. working pressure [bar] 6 Nominal diameter DN [mm] 25 Weight [kg] 0.75 Connection size [ ] 1 F Code 11282 11281 10080 7

G5/4" G5/4" 60 B TSV5 and TSV5B Valves These are new models in TSV line of valves, relating to TSV3 valve. Their connection size is 5/4 and flow rate Kvs is higher. They will be available from September 2012 in the basic version and in the version with automatic bypass balancing. For temperature of 45 C, 55 C and 65 C new thermostatic elements with rubber gasket are used that prevent microcirculation and heat loss via the chimney in periods when the boiler is extinguished. G5/4" AB A 94 TSV5* Nominal temperature (outlet AB ) [ C] 45 C 55 C 65 C 77 C Flow coefficient Kvs [m 3 /h] 12.6 Max. working pressure [bar] 6 Nominal diameter DN [mm] 32 Weight [kg] 0.85 Connection size [ ] 5/4 F Code 11802* 11803* 11804* 11836* * available from 09/2012 TSV5 B* Nominal temperature (outlet AB ) [ C] 45 C 55 C 65 C Flow coefficient Kvs [m 3 /h] 8.7 Max. working pressure [bar] 6 Nominal diameter DN [mm] 32 Weight [kg] 0.85 Connection size [ ] 5/4 F Code 11806* 11807* 11808* * available from 09/2012 8

G 6/4" G6/4" 137 77 B TSV6 Valve TSV6 Valve has 6/4 connections and due to its high Kvs value (22 m 3 /h) it is used for boilers of 100 kw output or even more. Nowadays it is available with a 61 C thermostatic element, from September 2012 the offer will include also temperatures of 45 C, 55 C and 65 C with rubber gasket that prevents microcirculation and heat loss via the chimney in periods when the boiler is extinguished. G6/4" AB A 140 TSV6 Nominal temperature (outlet AB ) [ C] 55 C 61 C 65 C Flow coefficient Kvs [m 3 /h] 22.2 Max. working pressure [bar] 6 Nominal diameter DN [mm] 40 Weight [kg] 1.6 Connection size [ ] 6/4 F Code 11820* 11525 11821* * available from 09/2012 9

G2" G2" 131 71 B TSV8 Valve TSV8 Valve has 2 connections and is the biggest model of TSV line. It will be available from September 2012 with 45 C, 55 C and 65 C thermostatic elements with rubber gasket that prevents microcirculation and heat loss via the chimney in periods when the boiler is extinguished. G2" AB A 152 TSV8* Nominal temperature (outlet AB ) [ C] 55 C 65 C Flow coefficient Kvs [m 3 /h] 31.5 Max. working pressure [bar] 6 Nominal diameter DN [mm] 50 Weight [kg] 1.75 Connection size [ ] 2 F Code 11818* 11819* * available from 09/2012 10

G6/4" G6/4" G2" G2" 110 98 G5/4" G5/4" G2" G2" 81 54 TSV2 Valve The valve has 2 M connections but it is always supplied with fittings that change the connection to 5/4 F, 6/4 F, 2 F. The connection fittings enable easy valve removal from a heating system for cleaning or thermostatic element replacement. It comes with a 61 C thermostatic element, standard tightness. Due to its high Kvs value of 20.4 m 3 /h it is used for boilers of output up to 100 kw. Thermostatic valve, 61 C, DN 50-2" G2" 6544 - Thermostatic valve, 61 C, DN50 2" + 5/4" fittings G5/4" 103 157 6563 - Thermostatic valve, 61 C, DN50 2" + 6/4" fittings G6/4" 6564 - Thermostatic valve, 61 C, DN50 2" + 2" fittings G2" 215 192 TSV2 Nominal temperature (outlet AB ) [ C] 61 C Flow coefficient Kvs [m 3 /h] 20.4 Max. working pressure [bar] 6 Nominal diameter DN [mm] 50 Weight [kg] 1.96 Connection size 3 F [ ] 5/4 6/4 2 Code 6544 6563 6564 11

G5/4" G5/4" 265 205 B PUMP STATIONS WITH THERMOSTATIC VALVES Regulus Thermovar LK 810 Thermostatic Pump Station In Thermovar LK 810 pump station, return water from a heating system (or accumulation tank) is mixed with boiler flow water which ensures the preset minimum temperature of the return water be maintained (55 C, 65 C, 70 C - model dependant). The pump station involves an extra floating check valve that enables boiler cooling through gravity circulation in case of a power failure, and at the same time, it prevents accumulation tank cooling down via an extinguished boiler. Thermovar LK 810 involves:» Grundfos UPSO 65 Low Energy circulation pump» Thermostatic mixing valve» Automatic balancing valve for bypass» Floating check valve» 3 thermometers» 3 ball valves with cap nuts, 5/4» Neat insulation for minimum heat loss Specification Voltage 230V 50 Hz Max. working temperature 110 C Max. working pressure 10 bar Circulation pump Grundfos UPSO 65 Low Energy G5/4" Max. flow rate set on the switch 3 2800 l/h 2 2200 l/h 1 1400 l/h Connection 5/4 F AB A Body material brass Dimensions Weight 210 210 110 mm 4.8 kg 205 210 LK 810 Model LK810-55 LK810-65 LK810-70 Min. water temperature entering boiler 55 C 65 C 70 C Max. boiler output 90 kw 60 kw 45 kw Code 10550 10302 10551 HEATING SYSTEM ACCUMULATION TANK BOILER 12

Regulus CS TSV Pump Station Regulus CS TSV pump station is designed for use with solid fuel boilers with no accumulation tank, DHW possible. Water entering the heating system is mixed automatically to the temperature corresponding to the boiler performance. It can work at low boiler output e.g. with temperatures of 75/65 C at the boiler, 50/40 C in the heating system. Heat output is controlled directly at the boiler, e.g. with RT3 thermostatic regulator or with a room thermostat with RT3-E regulator. CS TSV involves:» Circulation pump» Boiler pump» TSV3 thermostatic mixing valve» 2 ball valves for connection to heating system HW STORAGE WATER HEATER CW CS TSV BOILER 1 2 Safety assembly for heating systems, code 8063. The assembly contains a pressure gauge, air release valve and a safety valve. In case these components are already fitted on the boiler, this assembly is not needed. A storage water heater can be connected to the pump station. CS TSV Code Pump station with TSV 7699 13

Regulus CS TSV MIX Pump Station CS TSV MIX Pump Station is intended for solid fuel boilers with an accumulation tank, DHW possible. Water for heating system (i.e. heat output for heating system) is mixed in a 3-way mixing valve, either with manual or electronic control. Boiler heat surplus is stored into an accumulation tank and used later automatically when the boiler goes out. CS TSV MIX involves:» Circulation pump» Boiler pump» TSV3 thermostatic mixing valve» 2 ball valves for connection to heating system» 3-way mixing valve for heating system» Mixing valve actuator (only versions with actuator, code 8118 and 11606) HW STORAGE WATER HEATER CW ACCUMULATION TANK CS TSV MIX BOILER 1 2 Safety assembly for heating systems, code 8063. The assembly contains a pressure gauge, air release valve and a safety valve. In case these components are already fitted on the boiler, this assembly is not needed. A storage water heater can be connected to the pump station. CS TSV MIX Code no mixing valve el. actuator, 65 C 7700 with el. actuator for 3-way valve, 65 C 8118 no mixing valve el. actuator, 55 C 11605 with el. actuator for 3-way valve, 55 C 11606 14

73,7 + 179 43 BOILER OUTPUT CONTROL RT3E Thermostatic Draft Regulator, electric controlled Electric operated regulator works in the same manner as RT3, moreover it can reduce outgoing temperature from a boiler on electric signal. This way the boiler temperature and output can be controlled by a room thermostat or other electronic controller. It is fitted with a 3m silicone cable. When 12V voltage is applied, the regulator reduces temperature of heating water from the boiler. If no voltage is applied, the preset temperature is maintained. The regulator can also be controlled continuously, with 0-12V voltage. The regulator is supplied separately or in set with 12V power source and either mechanical (TP546) or electronic programmable (TP07) room thermostat. room thermostat 12V power supply RT3E G ¾" +40 1200-20 128 17 RT3E Regulator is patented. RT3E RT3E - TP546 RT3E - TP07 RT3E 1260-0 20 Ø 24,1 178 Code RT3E RT3E+TP07 RT3E+TP546 7191 9138 9139 15

61 1260-0 20 + 128 166 43 RT3 Thermostatic Draft Regulator Draft regulator keeps the outgoing water temperature from a boiler at the value selected by the knob by controlling combustion air damper. This way the boiler output is increased or reduced. The damper is operated by a lever and chain. The controller features elegant appearance thanks to its chrome-plated body and long lifetime. Its heart is a highquality and precise thermostatic element made by a renowned French manufacturer. Its sturdy metal body offers high mechanical resistance and the materials used guarantee high temperature resistance. Its body height facilitates installation on boilers with thicker insulation. A version for boilers with extremely high insulation and mantle is also available. The standard connection size is ¾, on request 1 (not for RT3T). For 10 years we supply our RT draft regulators to dozens of manufacturers worldwide. Our customers satisfaction is proved by the fact that we manufactured over 200 000 RT draft regulators in our Czech production plant in 2011. RT3 G ¾" (G 1" on request) Ø21 Ø17 +40 1200-20 178 16

1260-0 20 41 + 1180-20 166 61 43 1260-0 20 + 121 61 1260-0 20 + 128 166 43 128 62 179 RT3T, RT3L and RT3S Thermostatic Draft Regulators RT3T Ø25 G ¾" Ø21 Ø17 +40 178 RT3L G ¾" (G 1" on request) Ø21 Ø17 +40 1200-20 213 RT3S G ¾" (G 1" on request) Ø21 Ø17 +40 1200-20 313 Code RT3 RT3T RT3L RT3S 8486 11211 8763 8787 17

Regulus spol. s r.o., Czech Republic Do Koutů 1897/3, 143 00 Praha 4 Tel.: ++420 241 765 191, Fax: ++420 241 763 976 E-mail: sales@regulus.cz Web: www.regulus.eu v1.1-03/2012