Pyronox LR, LR-NT 21 – 32 LRK, LRK-NT 21 – 32 Installation and operating instructions Manual LR-LRK GB.doc Ygnis Article number: 406784 edition 30.10.
LR, LRK, LR-NT, LRK-NT 21 - 32 Table of Contents 1. Precautions 2 2. Description 2.1. General information 2.2. Conformity and certificates 3 3 4 3. Scope of supply 4 4. Technical data 4.1. Main data / operating conditions 4.2. Minimum operating pressure 4.3. Required water quality 4.4. Dimensions 4.5. Dimensions of custom made models 4.6. Technical data 4.7. Additional data for Pyronox LRK and LRK-NT 4.8. Correction values for different operating conditions 5 5 5 5 6 8 10 22 28 5.
LR, LRK, LR-NT, LRK-NT 21 - 32 1. Precautions STEPS TO BE TAKEN IN CASE OF DANGER Close fuel supply, disconnect unit from mains using emergency stop or main switch (outside of the boiler room). Use suitable fire extinguishers to extinguish flames. Occurrence of gas smell (gas units) - Ventilate the affected rooms thoroughly by opening doors and windows. - Do not use any electronic devices (mobile phone, etc.). - Do not activate any electrical contacts (light, motor, lift, door bell, etc.).
LR, LRK, LR-NT, LRK-NT 21 - 32 2. Description 2.1. General information Pyronox LR boilers are high efficiency, power-saving boilers ranging from 530 to 3000 kW and from 450 to 2600 kW for low-NOx applications. They can be operated in combination with oil or gas burners. The Pyronox LR boiler range are three pass, smoke tube boilers with combustion chamber and flue way using the Low-Nox technology.
LR, LRK, LR-NT, LRK-NT 21 - 32 2.2. Conformity and certificates These boilers fulfill the requirements of the low voltage directive 73/23/EEC, of the EMC-directive 89/336/EEC and the efficiency directive 92/42/EEC. The LRK boiler range as well as the LR range with ECA-rating have efficiencies in conformity with the requirements of the Enhanced Capital Allowance Scheme (ECA). 3.
LR, LRK, LR-NT, LRK-NT 21 - 32 4. Technical data 4.1. Main data / operating conditions Max. operating pressure (standard model) Test pressure (other pressures on request) 6,0 bar g 9,0 bar g Boiler supply and return pipe flanges PN 6 Max. operating temperature (safety cut-out) 110°C Min.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.4. Dimensions 4.4.1.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.4.2.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.5. Dimensions of custom made models The following custom made models are available on request. They are however subject to different delivery times! 4.5.1.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.5.4. Version with flue gas recirculation (ARF) For connection dimensions see chapter 6.7. 4.5.5. Divided version Also available as a custom made option is a divided version of the boiler. Thanks to the inferior dimensions of the individual parts, this version is most suitable when bringing-in conditions are tight. The individual prefabricated parts must be welded together in the boiler room.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6. 4.6.1. Technical data Pyronox LR Technical specifications LR (fuel oil) LR Power Boiler nominal power qN (80/60°C) Calorific power qF max. min. kW max. min. Modulation rate at 80/60 °C Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 50 / 70 °C Overall efficiency 60 / 80 °C Efficiency DIN4702-8, 60 / 75 °C Mass flows Fuel oil flow 100% 30% min qF ηN max. min. max. wet min.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR (natural gas) LR Power Boiler nominal power qN (80/60°C) max. min. Calorific power qF kW max. min. 3 3 Modulation rate Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 60 / 80 °C Overall efficiency 60 / 80 °C Efficiency DIN4702-8, 60 / 75 °C 100% 30% min qF ηN Mass flows Gas flow, NG type E kW % % % % 1,2 max. 3 nm /h 1,2 min. max. wet kg/s min.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6.2. Pyronox LR, ECA-rating Technical specifications LR (fuel oil, ECA-rating) LR Power Boiler nominal power qN (80/60°C) Calorific power qF max. min. kW max. min. kW 100% 30% % % Modulation rate at 80 / 60°C Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 50 / 70 °C Mass flows Fuel oil flow max. min. max. wet min. wet Exhaust gas mass flow Exhaust gas data, losses Overpressure combustion chamber Exhaust gas temperature at 80/60 °C 1 1 kg/s max.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR (natural gas, ECA-rating) LR Power Boiler nominal power qN (80/60°C) Calorific power qF max. min. kW max. min. kW 100% 30% % % Modulation rate Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 60 / 80 °C Mass flows Gas flow, NG type E 1,2 max. 3 nm /h 1,2 min. max. wet kg/s min. wet Exhaust gas mass flow Exhaust gas data, losses Overpressure combustion chamber Exhaust gas temperature ati 80/60 °C max.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6.3. Pyronox LR (low-NOx version) Technical specifications LR (fuel oil, low NOx) LR Power Boiler nominal power qN (80/60°C) Calorific power qF max. min. min. max. min. min. Modulation rate at 80/60 °C Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 50 / 70 °C Overall efficiency 60 / 80 °C Efficiency DIN4702-8, 60 / 75 °C Mass flows Fuel oil flow 100% 30% min qF ηN 2 3 2 3 2 3 3 3 3 kW kW % % % % 1 max. kg/h 1,3 min. max. wet kg/s min.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR (natural gas. low NOx) LR Power Boiler nominal power qN (80/60°C) max. min. Calorific power qF max. min. Modulation rate Efficiencies Overall efficiency 60 / 80 °C Overall efficiency 60 / 80 °C Overall efficiency 60 / 80 °C Efficiency DIN4702-8, 60 / 75 °C kW kW 3 3 100% 30% min qF ηN Mass flows Gas flow, NG type E % % % % 1,2 max. 3 nm /h 1,2 min. max. wet kg/s min.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6.4. Pyronox LR (low-NOx version with internal flue gas recirculation, ARF) Technical specifications LR (fuel oil, low NOx) with ARF LR Power Boiler nominal power qN (80/60°C) Calorific power qF 4 2,4 3,4 max. min. min. max. min. min.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR (natural gas, low NOx) with ARF LR Power Boiler nominal power qN (80/60°C) Calorific power qF 21 22 23 24 25 26 27 28 380 84 430 108 470 108 585 148 600 148 755 215 935 263 935 263 413 88 21% 463 113 24% 509 113 22% 632 155 25% 649 155 24% 814 224 28% 1009 1009 1285 1577 2011 2535 275 275 321 406 584 594 27% 27% 25% 26% 29% 23% 92.0 95.4 92.8 95.5 92.4 95.5 92.6 95.6 92.4 95.6 92.7 95.8 92.6 95.8 92.6 95.8 92.2 95.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6.5. Pyronox LR-NT Technical specifications LR-NT (fuel oil) LR-NT Power Boiler nominal power qN (80/60°C) max. min. Calorific power qF 2 2 Modulation rate at 80/60 °C 100% 30% min qF ηN Mass flows Fuel oil flow Exhaust gas data, losses Overpressure combustion chamber 1 1 Exhaust gas losses at 80/60 °C max. min. max.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR-NT (natural gas) LR-NT Power Boiler nominal power qN (80/60°C) 21 22 23 24 25 26 530 89 580 115 630 115 700 145 800 145 895 232 1150 1300 1650 1900 2500 2750 287 287 331 419 629 633 593 94 16% 639 120 19% 700 120 17% 767 152 20% 887 152 17% 981 242 25% 1266 1446 1851 2116 2781 3085 299 299 345 437 654 660 24% 21% 19% 21% 24% 21% 89.4 95.6 95.5 94.2 90.8 95.9 95.6 94.7 90.1 95.8 95.6 94.5 91.3 96.1 95.7 95.0 90.3 96.0 95.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.6.6. Pyronox LR-NT (lox NOx version) Technical specifications LR-NT (fuel oil, low NOx) LR-NT Power Boiler nominal power qN (80/60°C) max. min. min. Calorific power qF max. min. min.
LR, LRK, LR-NT, LRK-NT 21 - 32 Technical specifications LR-NT (natural gas. low NOx) LR-NT Power Boiler nominal power qN (80/60°C) Calorific power qF max. min. max. min. Modulation rate Efficiencies Overall efficiency 60 / 80 °C Overall efficiency @ tm = 58 °C Overall efficiency 60 / 80 °C Efficiency DIN4702-8, 60 / 75 °C Mass flows Gas flow, NG type E 100% 30% min qF ηN kW 3 3 3 kW % % % % 1,2 max. 3 nm /h 1,2 min. max. wet kg/s min.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7. 4.7.1. Additional data for Pyronox LRK and LRK-NT Pyronox LRK Technical specifications recuperator (fuel oil) LRK Power Nominal power qN (30 / 35°C) Efficiencies Overall efficiency 30 / 35 °C Overall efficiency 30 / 35 °C Efficiency DIN4702-8, 60 / 75 °C Exhaust gas data, losses Additional exhaust gas pressure drop Total combustion space overpressure Exhaust gas temperature at 30 / 35 °C max. min. 1 1 100% 30% ηN 1 2 max max Exhaust gas losses at 30 / 35 °C max.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7.2. Pyronox LRK (low-NOx version) Technical specifications recuperator (fuel oil, low NOx) LRK Power Nominal power qN (30 / 35°C) Efficiencies Overall efficiency 30 / 35 °C Overall efficiency 30 / 35 °C Efficiency DIN4702-8, 60 / 75 °C Exhaust gas data, losses Additional exhaust gas pressure drop Total combustion space overpressure Exhaust gas temperature at 30 / 35 °C max. min. 1 1,3 kW 100% 30% ηN 1 2 3 % % % max max Exhaust gas losses at 30 / 35 °C max. min.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7.3. Pyronox LRK (low-NOx version with ARF) Technical specifications recuperator (fuel oil, low NOx) with ARF LRK Power Nominal power qN (30 / 35°C) Efficiencies Overall efficiency 30 / 35 °C Overall efficiency 30 / 35 °C Exhaust gas data, losses Additional exhaust gas pressure drop Total combustion space overpressure Exhaust gas temperature at 30 / 35 °C max. min. 1 1,3 kW 100% 30% 1 2,3 % % max max Exhaust gas losses at 30 / 35 °C max. min. max.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7.4. Pyronox LRK-NT Technical specifications recuperator (fuel oil) LRK-NT Power Nominal power qN (30 / 35°C) Efficiencies Overall efficiency 30 / 35 °C Overall efficiency 30 / 35 °C Efficiency DIN4702-8, 60 / 75 °C Exhaust gas data, losses Additional exhaust gas pressure drop Total combustion space overpressure Exhaust gas temperature at 30 / 35 °C max. min. 1 1 100% 30% ηN 1 2 max max Exhaust gas losses at 30 / 35 °C max. min. max.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7.5. Pyronox LRK-NT (low-NOx version) Technical specifications recuperator (fuel oil, low NOx) LRK-NT Power Nominal power qN (30 / 35°C) Efficiencies Overall efficiency 30 / 35 °C Overall efficiency 30 / 35 °C Efficiency DIN4702-8, 60 / 75 °C Exhaust gas data, losses Additional exhaust gas pressure drop Total combustion space overpressure Exhaust gas temperature at 30 / 35 °C max. min. 1 1,3 100% 30% ηN 1 2,3 max max Exhaust gas losses at 30 / 35 °C max. min. max.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.7.6. Water resistance of recuperators for LRK and LRK-NT 1000 LRK 21 22 & 23 24 & 25 26 27 & 28 29 30 31 32 500 400 300 mbar 200 100 50 20 10 1 4 6 8 10 15 20 30 40 50 70 100 m3 / h Pressure resistance in relation to water flow of the recuperators LRK et LRK-NT We reserve the right to make changes to dimensions and construction 27 edition 30.10.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.8. 4.8.1. 4.8.2. Correction values for different operating conditions Flue gas temperature correction values LR, LR-NT Average boiler water temperature tm °C 50 60 70 80 90 100 Flue gas temperature difference ∆t K - 16 -8 ±0 +8 + 16 + 24 Excess air λ 1.10 1.15 1.20 1.25 1.30 1.35 Flue gas temperature difference ∆t -6 -3 ±0 +3 +6 +8 K Modulation range In chapter 4.
LR, LRK, LR-NT, LRK-NT 21 - 32 4.8.4. Recuperator data for different operating conditions Operation on fuel oil: 1.6 1.4 kWh/kg Brst/Fioul/Oil 1.2 1.0 200 °C 180 °C 0.8 160 °C 180 °C, 50% 0.6 0.4 0.2 0.0 10 20 30 40 50 60 70 TR (°C) Recuperator power output per kg of fuel oil for different flue gas inlet temperatures and recuperator return temperatures TR at boiler nominal loads as well as 50% load (for 180°C nominal inlet temperature) Values at: - CO2 = 12.7% − Δt water = 5 K - Rel.
LR, LRK, LR-NT, LRK-NT 21 - 32 Operation on natural gas: 1.6 1.4 kWh/nm3 Gas/Gaz 1.2 1.0 200 °C 180 °C 0.8 160 °C 180 °C, 50% 0.6 0.4 0.2 0.0 10 20 30 40 50 60 70 TR Recuperator power output per nm3 of gas for different flue gas inlet temperatures and recuperator return temperatures TR at boiler nominal loads as well as 50% load (for 180°C nominal inlet temperature) Values at: - CO2 = 10% − Δt water = 5 K - Rel. humidity = 60%, p-baro = 100 kPa 1.6 90 1.4 80 1.2 70 1.0 60 0.
LR, LRK, LR-NT, LRK-NT 21 - 32 5. Boiler control panel 5.1. Description A wide range of system controls has been designated for Pyronox LR boilers. In the basic version, the panel allows for operation with a two-stage burner. The enlarged modular version of the control system allows users to freely choose the best accessories for their system among a range of modern digital microprocessor governors for boiler, burner, heating line and consumable water control. The panels are ready to be connected.
LR, LRK, LR-NT, LRK-NT 21 - 32 6. Installation guide 6.1. Boiler room and boiler room ventilation The boiler room must be arranged in compliance with local regulations and installation specifications. Particular attention should be paid to the ventilation of the boiler room. Supply of combustion air must be guaranteed (non-shut opening). Minimum air requirement is 1.6 m3/h for each kW of boiler power. Minimum free section of combustion air opening is 6 cm2 for each kW of boiler power.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.2.3. Boiler support It is possible to mount the boiler on vibration dampers (available as option) to reduce noise transmission caused by vibrations. b b B A B e A l l ca.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.3. 6.3.1. Hydraulic connection General notice For the hydraulic connection of the heating system and water heaters– in particular with regards to technical safety devices such as safety valves, expansion tanks, etc. – refer to generally accepted engineering rules as well as locally applicable standards, specifications and regulations.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.4. 6.4.1. Electrical installation General notice The electrical installation must be carried out by an authorised electrician from beginning to end. In carrying out the electrical installation, local regulations as well as any standards and specifications in force must be complied with. The wiring diagram is joined with the control panel.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.6. Boiler control panel and casing assembly Please refer to the separate assembly guide enclosed with the supply. The boiler casing should only be assembled after the boiler has been hydraulically connected otherwise, there is a risk of damage of the casing. However, the casing must be mounted prior to connecting the unit to the flue! 6.7. Connecting the burner and ARF-blower 6.7.1.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.7.2. Burner assembly The front door is provided with a norm-conform flange for fitting the burner. An additional, intermediate flange may be necessary to fit the burner. The intermediate flange and relative screws must be supplied by the burner manufacturer. Attention: The intermediate space between the burner tube and door hole must be filled with the supplied insulating material before the burner is commissioned (see separate assembly guide). 6.7.3.
LR, LRK, LR-NT, LRK-NT 21 - 32 6.8. Flue gas system The pertinent rules of technology and good practice as well as the country-specific regulations and valid standards must be observed. The Pyronox LR boilers have been developed using the latest technologies. The perfect balance existing between boiler and chimney ensures optimal fuel use and economical system operation as a result. 6.8.1. Section determination Sections must be calculated for boilers without draught.
LR, LRK, LR-NT, LRK-NT 21 - 32 7. Operating conditions 7.1. Fuels The Pyronox LR boiler is designed for operation with fuel oil EL and natural gas. Attention: 7.2. The use of other fuels such as for example biogas is only permitted with the express approval of the manufacturer. Combustion air The combustion air must not have high dust concentrations. Important: 7.3. Furthermore, it must be free of halogens (chlorine and fluorine compounds).
LR, LRK, LR-NT, LRK-NT 21 - 32 8. Operation Read this section of the manual with great care and get an installer to explain the heat producing system in all its different aspects: regulation and control. If you suspect that the boiler or other part of the system is frozen, do not start the system. Please also note the operating conditions described in chapter 7. 8.1.
LR, LRK, LR-NT, LRK-NT 21 - 32 8.3. First steps to take in case of failure In the event of system operational failure, perform the checks in the table below. Also check the governor set-up. If the failure cannot be eliminated, call a reliable engineer or your support service. Problem Possible cause Solution Burner not functioning No power Check fuse, switch on main or safety switch.
LR, LRK, LR-NT, LRK-NT 21 - 32 9. Maintenance To maintain the high degree of efficiency of the unit, it is necessary to service it regularly. Depending on the type of operation, annual or semi-annual servicing is recommended. The boiler and firing must be inspected by a qualified specialist in accordance with the official regulations. Before performing any work on the unit, it must be disconnected from the mains and the fuel supply must be shut off.
LR, LRK, LR-NT, LRK-NT 21 - 32 10. Spare parts 10.1. Pyronox LR 21-26 We reserve the right to make changes to dimensions and construction 43 edition 30.10.
LR, LRK, LR-NT, LRK-NT 21 - 32 Pyronox LR, LR-NT Designation 21 22 Pos. 23 24 N° Art.
LR, LRK, LR-NT, LRK-NT 21 - 32 10.3. Pyronox LR 27-32 We reserve the right to make changes to dimensions and construction 45 edition 30.10.
LR, LRK, LR-NT, LRK-NT 21 - 32 Pyronox LR, LR-NT Designation 27 28 Pos. 29 30 N° Art.
