Protection and Control of Solid Fuel Boiler Catalogue

8/10/2019 Protection and Control of Solid Fuel Boiler Catalogue

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Protection and Control

of Solid Fuel Boilers

Catalogue

Energy-saving solutions



BOILER OVERHEATING PROTECTION

BOILER PROTECTION AGAINST CLOGGING AND HEAT TRANSFER SURFACE CORROS

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 ver y aggressiveesp. 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 waterfrom the boiler outlet. This way the whole heat exchanger (heat transfer surfaces) is kept warmer, at temperaturesthat will not allow condensation to occur and so fouling and quick corrosion will be prevented. Fouled heat transfersurfaces deteriorate boiler efficiency substantially and increase the risk of scale formation. Quick corrosion andfouling will not occur if the heat transfer surfaces are warm enough as condensation will not occur above certaintemperatures. The heat transfer surfaces will be warmer, making their service life longer and the boiler efficiencyhigher. 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 othercomponents.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 .

Thermostatic draft regulators keep the outgoing temperature from a solid fuel boiler at the value selected by theregulator knob. They operate combustion air dampers by chains, controlling this way the boiler output. Theiradvantage is a robust build, mechanically sturdy and thermally resistant. Their double scale enables horizontal aswell 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 boileron electric signal. This way the boiler temperature and output can be controlled by a room thermostat or otherelectronic controller.

BOILER OUTPUT CONTROL

Solid fuel boilers may get overheated during operation, mostly due to a power failure. The boiler circulation pumpstops while there is glowing fuel inside and the heating water temperature starts rising quickly as the heat is notbeing removed. This danger can be prevented in two ways: either by recooling the boiler via a thermostatic valvethat needs no energy for its operation, or by a backup source that supplies energy for the circulation pump.



1


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





Regulus Thermovar LK 810 Thermostatic Pump Station ................... 12

Regulus CS TSV Pump Station ................................................... 13

Regulus CS TSV MIX Pump Station .............................................. 14


RT3E Thermostatic Draft Regulator, electric operated .................... 15

RT3 Thermostatic Draft Regulator ............................................. 16

CONTENTS



2

DBV1SpecificationOpening temperature (limit) 97 °C ±2 °CMax. temperature 120 °CMax. pressure on boiler side 4 barMax. pressure on water side 6 barKvs 1.80 m3 /h at heating water temp. of 110 °CConnection to a heat source ¾“ MConnection to cooling water pipe ¾“ MConnection to sewer ¾“ MCode 8066

For boilers with no recooling heat exchanger

DBV1 Thermostatic ValveThis 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 inst alled to a place where the highes t temperature is reached in case ofoverheating - 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 thermostaticelement is located directly in heating water, its reaction to water temperature fluctuations is immediate. The valve hasno 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

» 100 % function controlled in production

The valve is patented in many European countries.Examples of patents issued:


A B

C 1 9 9

6 1

, 5

G ¾ "

G

¾ "

G

¾ "

28

3 5

, 5

56

5 2

COLDWATER

INCOLD WATERTO THE BOILER

HOT WATERTO SEWER

SENSOR AND HOTWATER FROM THE BOILER

SENSOR AND HOTWATER FROM THE BOILER

TO SEWERBOILER

TOHEATING

SYSTEM

FROMHEATINGSYSTEM

COLDWATERIN

KEY:shut-off valve

pressure reducing valve

strainer

check valve (in pipe)

safety valve

pump



3

For boilers with a recooling heat exchanger

JBV1 Thermostatic ValveThis 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 wateris discharged into a sewer.

In order to work properly, the valve shall be ins talled to a place where the highest temperature is reached in case ofoverheating - 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 thermostaticelement is located directly in heating water, its reaction to water temperature fluctuations is immediate. The valve hasno 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 » 100 % function controlled in production

The valve is patented in many European countries.Examples of patents issued:

JBV1SpecificationOpening temperature (limit) 97 °C ±2 °CMax. temperature 120 °CMax. pressure on boiler side 4 barMax. pressure on water side 6 barKvs 1,80 m3 /h at heating water temp. of 110 °CConnection to a heat source ½“ MConnection to cooling water pipe ¾“ MCode 8877

A B 1 7 9

6 3

3 0

G ½ "

G

¾ "

56

9 3

COLDWATEROUT

COLDWATER

IN

TO SEWER

BOILER

TOHEATINGSYSTEM

FROMHEATINGSYSTEM

COLDWATERIN

KEY:shut-off valve

pressure reducing valve

strainer


safety valve

pump



4

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 intoa 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 caseof overheating - usually directly in a top section of the boiler or on an outlet pipe close to the boiler. The valveinstalls on a cooling water pipe and is currently supplied with a 1.3m or 4m capillar y.

» a push button for manual opening like in safety valves

» the valve is not installed directly on a boiler or outlet piping

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 m3

/hSensor 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

1 1 7

3 1

G

¾ "

Ø 30,5

60

G

¾ "

Ø 19,5

Ø 24

Ø 8

1 3 0

G ½ "

Ø 16

10115 - Length: 1,3 m10114 - Length: 4,0 m10113 - Length: 1,3 m

TO SEWER

BOILER

TOHEATING

SYSTEM

FROMHEATINGSYSTEM

COLDWATERIN

KEY:shut-off valve

strainer


safety valve

pump

COLDWATER

IN



5

Backup Sources

PG 500 Backup Source for Solid Fuel BoilersPG 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 specialbattery, 44 Ah. Unlike a current automotive battery, this one is designed for a smaller current to be drawn for a longertime. 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

230V socket(for a pump)

230V socket for a powercord, integrated fuse

screw terminals toconnect the battery

1 6 5 1 9 5

1 7 0

2 2 2

8 0

2 5 5

PG 500Capacity 44 AhCode 9140



6

Thermostatic mixing valves

BOILER PROTECTION AGAINST CLOGGING AND HEAT TRANSFERSURFACE CORROSION

TSV Thermostatic mixing valves keep boiler return water temperature at a preset temperature, preventing low-temperature corrosion and boiler clogging. The boiler then works with a higher efficiency and its service life isextended.

The valve contains a thermostatic element made by a renowned French manufacturer that facilitates mixing hotoutlet 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 ofan 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 gettingclogged 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 replacedby 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 adjus t properly the balancing valve mounted in the by-pass pipe br inging hotwater from the boiler outlet into the valve.

TSV3B and TSV5Bmodels do not need a balancing valve, automatic balancing of hot water incoming via a bypassis incorporated inside the valve. Its installation is so easier and control more precise. Especially in a situationwhen the return water temperature from a heating system or accumulation tank is close to the valve nominaltemperature or higher, the valve res tricts hot water flow from the bypass to complete tight closing. Due to this, theoutgoing temperature from a boiler does not rise too much and so the boiler can work at full power even under theseconditions.

Model TSV3 TSV3B TSV5 TSV5B TSV6 TSV8 TSV2 TSV2 TSV2Nominal 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 [m3 /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 TSV245 °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

BOILER

ACCUMULATION

TANK

HEATING SYSTEM

THERMOSTATICVALVE TSV

BALANCINGVALVE



7

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 pumpof 4m head is sufficient (e.g. Wilo RS 25/4) and valve temperature of 65°C. For boilers of higher output valves areused 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.

TSV3Nominal temperature (outlet „AB“) [°C] 45 °C 55 °C 65 °C 77 °C

Flow coefficient Kvs [m3 /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

TSV3 Valve

TSV3B Valve

This valve is equipped with automatic balancing of bypass flow, so no manual balancing valve is needed. The controlis 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 thatprevent microcirculation and heat loss via a chimney in periods when the boiler is extinguished.

A AB

B

94

G

1 "

G

1 "

G 1"

1 0 6

6 0

TSV3BNominal temperature (outlet „AB“) [°C] 45 °C 55 °C 65 °C




Weight [kg] 0.75


Code 11282 11281 10080



9

TSV6Nominal temperature (outlet „AB“) [°C] 55 °C 61 °C 65 °C




Weight [kg] 1.6

Connection size [”] 6/4” F

Code 11820* 11525 11821*

* available from 09/2012

TSV6 Valve has 6/4“ connections and due to its high Kvs value (22 m3 /h) it is used for boilers of 100 kW output oreven more. Nowadays it is available with a 61°C thermostatic element, from September 2012 the offer will includealso 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.

TSV6 Valve

AB

B

A

G 6/4"

G 6 / 4 "

G 6 / 4 "

7 7

140

1 3 7



10

TSV8 Valve has 2“ connections and is the biggest model of TSV line. It will be available from September 2012 with45°C, 55°C and 65°C thermostatic elements with rubber gasket that prevents microcirculation and heat loss via thechimney in periods when the boiler is extinguished.

TSV8 Valve

TSV8*Nominal temperature (outlet „AB“) [°C] 55 °C 65 °C




Weight [kg] 1.75


Code 11818* 11819*

* available from 09/2012

AB

B

A

G 2"

G 2 "

G 2 "

152

7 1

1 3 1



11

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 elementreplacement. It comes with a 61°C thermostatic element, standard tightness.

Due to its high Kvs value of 20.4 m3 /h it is used for boilers of output up to 100 kW.

TSV2 Valve

TSV2Nominal temperature (outlet „AB“) [°C] 61 °C




Weight [kg] 1.96

Connection size 3× F [”] 5/4“ 6/4“ 2“

Code 6544 6563 6564

G 5 / 4 "

G 5 / 4 "

G 5/4"

8 1

157

6544 - Thermostatic valve, 61°C, DN50 2" + 5/4" ttings

G 6 / 4 "

G 6/4"

G 6 / 4 "

215

1 1 0

6563 - Thermostatic valve, 61°C, DN50 2" + 6/4" ttings

G 2 "

G 2"

G 2 "

192

9 8

6564 - Thermostatic valve, 61°C, DN50 2" + 2" ttings

G 2 "

G 2 "

G 2"

103

5 4

Thermostatic valve, 61°C, DN 50 - 2"



12

BOILER

HEATING SYSTEM

ACCUMULATION

TANK

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 boilerflow 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 caseof 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

Max. flow rate set

on the switch

3……2800 l/h2……2200 l/h1……1400 l/h

Connection 5/4“ F

Body material brass

Dimensions 210 × 210 × 110 mm

Weight 4.8 kg


LK 810Model LK810 - 55 LK810 - 65 LK810 - 70

Min. water temperature entering boiler 55 °C 65 °C 70 °CMax. boiler output 90 kW 60 kW 45 kW

Code 10550 10302 10551

AB

B

A

G 5/4"

G 5 / 4 "

G 5 / 4 "

205

210

2 0 5

2 6 5



13

Regulus CS TSV Pump Station

Regulus CS TSV pump station is designed for use with solid fuel boilers with no accumulation tank, DHW possible. Waterentering the heating system is mixed automatically to the temperature corresponding to the boiler per formance. Itcan 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 withRT3-E regulator.

CS TSV involves:» Circulation pump

» Boiler pump

» TSV3 thermostatic mixing valve

» 2 ball valves for connection to heating system

CS TSV

A storage water heater can be connected to the pumpstation.

Safety assembly for heating systems, code 8063.The assembly contains a pressure gauge, air release

valve and a safety valve. In case these componentsare already fitted on the boiler, this assembly is notneeded.

CS TSV Code

Pump station with TSV 7699

2

1

BOILER

STORAGEWATERHEATER

HW

CW



14

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 heatingsystem (i.e. heat output for heating system) is mixed in a 3-way mixing valve, either with manual or electroniccontrol.

Boiler heat surplus is stored into an accumulation t ank 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)

CS TSV MIX

BOILER

ACCUMULATIONTANK

STORAGEWATERHEATER

HW

CW

A storage water heater can be connected to the pumpstation.

Safety assembly for heating systems, code 8063.The assembly contains a pressure gauge, air release

valve and a safety valve. In case these componentsare already fitted on the boiler, this assembly is notneeded.

CS TSV MIX

Codeno mixing valve el. actuator, 65 °C 7700with el. actuator for 3-way valve, 65 °C 8118no mixing valve el. actuator, 55 °C 11605with el. actuator for 3-way valve, 55 °C 11606

2

1



15


Electric operated regulator works in the same manner as RT3, moreover it can reduce outgoing temperature froma boiler on electric signal. This way the boiler temperature and output can be controlled by a room thermostat orother 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 maint ained.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 electronicprogrammable (TP07) room thermostat.

RT3E Thermostatic Draft Regulator, electric controlled

roomthermostat

12V powersupply

RT3E

1 2 6 0

- 0 2

0

+

4 3

1 7 9

7 3

, 7

G ¾ "

1 2 0 0

- 2 0

4 0

+

Ø 24,1

1 7

RT3E

RT3E - TP07

RT3E - TP546

RT3E

RT3E Regulator is patented.

178

1 2 8

Code

RT3E RT3E+TP07 RT3E+TP546

7191 9138 9139



16

Draft regulator keeps the outgoing water temperature from a boiler at the value selected by the knob by controllingcombustion air damper. This way the boiler output is increased or reduced. The damper is operated by a lever andchain.

The controller features elegant appearance thanks to its chrome-plated body and long lifetime. Its heart is a high-quality and precise thermostatic element made by a renowned French manufacturer. Its sturdy metal body offers highmechanical resistance and the materials used guarantee high temperature resistance. Its body height facilitatesinstallation 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 isproved by the fact that we manufactured over 200 000 RT draft regulators in our Czech production plant in 2011.

1 6 6

6 1

G ¾ " (G 1" on request)

Ø 21

Ø 17

1 2 6 0

- 0 2

0

+

1 2 0 0

- 2 0

4 0

+

4 3

RT3

178

1 2 8

RT3 Thermostatic Draft Regulator



17

1 2 6 0

- 0 2

0

+

6 2 1

7 9

4 1

1 1 8 0

- 2 0

4 0

+

Ø 25

G ¾ "

Ø 21

Ø 17

1 6 6

6 1


Ø 21

Ø 17

1 2 6 0

- 0 2

0

+

1 2 0 0

- 2 0 4 0

+

4 3

1 6 6

6 1

4 3


Ø 21

Ø 17

1 2 6 0

- 0 2

0

+

1 2 0 0

- 2 0

4 0

+

RT3T, RT3L and RT3S Thermostatic Draft Regulators

RT3T

RT3L

RT3S

313

1 2 1

213

1 2 8

178

1 2 8

CodeRT3 RT3T RT3L RT3S

8486 11211 8763 8787



v1.1-03/2012

Regulus spol. s r.o., Czech RepublicDo Koutů 1897/3, 143 00 Praha 4Tel.: ++420 241 765 191, Fax: ++420 241 763 976

Protection and Control of Solid Fuel Boiler Catalogue

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