CN 80, 120 User Manual

Page 1

User Manual

for CN Boilers

Type

80 / 120

Machine no.

Date

CN Maskinfabrik A/S

Skovløkkevej 4, Tiset
6510 Gram, Denmark

Tel.: [phone]
Fax: [phone] Version: April 2005

Page 2

CONTENTS

Page 1. Front page
Page 2. Contents
Page 3. Function
Page 4. Dimensions
Page 5. Rating plate / Boiler with Cooling Spiral / Responsibilities / Safety
Page 5. Startup, Manual Stoking
Page 6. Installation and Assembly Guide
Page 7. Installation and Assembly Guide
Page 8. Installation and Assembly Guide
Page 9. Installation and Assembly Guide
Page 10. Maintenance, Cleaning and Frost Protection
Page 11. Technical Information. / Warranty Claims
Page 12. Check List, End User
Page 13. Check List, Supplier
Page 14. Check List, CN MASKINFABRIK A/S.
Page 15. Warranty Certificate, Customer Copy
Page16. 5 Year Warranty Certificate CN MASKINFABRIK A/S.
Page 17. Principle Diagram Overflow Valve / Cooling Spiral
Page 18. Principle Diagram Open Expansion with Accumulation Tank.
Page 19. Principle Diagram Pressure Expansion Without Accumulation Tank
Page 20. Principle Diagram Open Expansion Without Accumulation Tank.
Page 21. Principle Diagram Open Expansion Without Accumulation Tank.

Accessories supplied with the boiler

1. Probe (dip pipe, valve, sensor)

2. Cleaning brush

3. Scraping tool

Page 3

All CN boilers must be installed according to the Installation and Assembly
Guide below.
If the boiler is not installed in accordance with the installation instructions in the
user manual, it is the responsibility of the installation engineer to submit the
boiler unit to a construction test (module B1) or install the boiler unit in
accordance with a system of full quality assurance (module H) according to the
Pressure Equipment Directive 97/23/EEC. In both cases, an authorised body after
your own choice must be contacted.

Function

• The CN boiler is a triple-flue boiler constructed on the basis of many years’ experience and testing.

• The CN boiler is constructed with a large cylindrical fire chamber, specially developed for firing with

stoker, wood, wood chips, saw dust, peat, paper, coal or coke etc.

• The convection part of the CN boiler is placed on top of the fire box in the hottest part of the boiler,
which consists of many smoke gas sections surrounded by water.

• The construction and dimensions of the CN boiler thus create an efficient use of the smoke gas
before it reaches the smoke outlet

• The large doors of the CN boiler, which open both the fire chamber and the smoke ducts, make
cleaning the boiler very efficient and easy.

• Optimal, environmentally friendly and highly efficient burning of the wood requires correct ratio
between the combustion air and the smoke gasses from the fuel.

• The boiler is constructed with a large door to enable the burning of large objects.

• Acidifying substances such as plastic (PVC) must not be burned in the boiler, as they produce

hydrochloric acid fumes during combustion (HCL).

• Basifying substances must not be burned in the boiler, as they corrode the boiler during combustion.

•

It is important that the feeding of fuel is adjusted to allow the heat from the wood to be contained in
the heat reservoir at all times. The stoking should be adjusted so that the fuel has just been burned
when the heat reservoir reaches its maximum temperature.

• The boiler efficiency is larger when the boiler can deliver the heat without having to shut off the air
supply too much.

Page 4

Key CN 80 CN 120

A mm 1700 1780
B mm 1540 1540
C mm 1800 1800
D mm 2130 2130
E Return pipe mm 2” 2”
F Smoke outlet mm 250 250
G mm 300 310
H mm 1400 1480
I mm 980 1180
J Supply / Return inches

2” 2”

L Expansion vessel inches

1” 1”

M Flue regulator inches

1” 1”

Yield wood

kW

65 100

Yield automatic stoking

kW

80 120

Heat surface m2 7.5 9.6
Volume fire chamber m2 0.75 1.07
Test pressure bar 4 4
Water content litre 490 560
Fire box diameter mm 815 970
Fire box depth mm 1450 1450
Smoke tube stub

diameter

mm 250 250

Page 5

Boiler type Production year

Serial no.
Yield
Max. op. temperature
Test pressure

Oper. pressure

Boiler with cooling spiral

Boilers can be ordered with a cooling spiral, and this must be used for installation with pressure expansion,
and in open systems if the pressure in the boiler is above 0.5 bar over pressure.
The cooling spiral must only be used as a cooling spiral; it must not be used for heating up water for other
use. Therefore the cooling spiral must be left empty during operation. Water supply for cooling spiral
maximum 15 °C. Pressure for cooling spiral minimum 2 bar, maximum 10 bar.

Responsibilities

The user is responsible for the operation of the boiler and ensuring compliance with the operational
guidelines supplied by CN MASKINFABRIK A/S. Failure to comply with the guidelines may result in reduced
efficiency and increased negative effects on the environment, as the boiler will not achieve as clean emission
gasses as intended. Furthermore, incorrect operation can reduce the working life of the boiler.
Correct operation and installation are the best guarantees for a well-functioning boiler with a long life and a
good environment. The user needs to have the necessary willingness and correct attitude to burning wood,
as it does, after all, take a bit of work to ”yield the crops” of this environmentally friendly and financially
profitable type of heating

Safety

If any faults or failures are found, they must be repaired as soon as possible by a boiler engineer. Flue pipes,
ventilation ducts, air holes etc. must not be closed off or blocked. Flammable liquids or combustible
substances must not be placed in dangerous proximity to the boiler.
For systems with an operational pressure above 0.5 bar over pressure (closed system with pressure
expansion or open system where the height from the boiler to the highest water surface is more than 5
meter), the boiler must be equipped with a cooling spiral connected to a cold water supply.
Boilers equipped with a cooling spiral must not be used (should be switched off) if the water supply is out of
order, or the water supply to the boiler is shut off (e.g. on the main tap).

Startup, manual stoking

1. Fill the boiler with the required amount of combustible material.

2. Light the fuel from below.

3. Adjust the air supply hatches (only until the right air supply level is found) only during manual stoking
without stoker.

• Note. Be very careful when opening the door to the boiler during operation due to extreme heat

inside the boiler and smoke emission.

Stop: When the fuel material has been burned, the heat supply from the boiler stops.

Page 6

Installation and Assembly Guide:

Norms and Directions

• It is the responsibility of the installation engineer that he has the necessary training and authorisation

to install the boiler. The size of the boiler should be based on the heating needs of the house rather
than the size of the fuel container.
The installation must fulfill the requirements described in the directions of the Health and Safety at
Work Act 1974, iincluding the following regulations: The Electricity at work Regs 1989, The Provision
and Use of Work Equipment Regs 1998, The Personal Protective Equipment Regs 1992,
The Fire Precautions (Workplace) (Amendments) Regs 1999, The construction Design and
Management Regs 1994. Current Institute of Electrical Engineers regulations. “The Pressure
Equipment Directive 97/23/EEC” and UK Building Regulations 2000 (as amended). See in particular
the following approved documents:
A: structure 2004 + amendments
B: fire safety 2000 edition + amendments
F: ventilation 2006 edition
J: combustion appliances and fuel storage systems 2002 edition
J: Guidance and supplementary information on the UK implementation of European standards for
chimneys and flues 2002 edition
L1A; L1B; L2A;L2B: Conservation of fuel and power 2006 edition.
M: Access to and use of buildings 2004 edition
P: Electrical Safety – Dwellings – 2006 edition

• If the boiler is used for burning straw, the installation must furthermore fulfill the requirements

described in the specific directions of The Health and Safety at Work Act 1974

• All smoke pipes must have an uphill gradient of minimum 1 %, and all joints must be tight. Never use

a smaller diameter smoke pipe as the boiler outlet pipe. Always use elbows with a bending and flap as
bent joints, as they provide the best flue. All smoke pipes must be insulated, also when the boiler

is used with stoker feeding.

• The combustion must not be carried out until the boiler is installed and fully connected.

• A probe must always be installed on the boiler, and the return pipe (pages 9/11) must always be

minimum 60° C during operation. See the assembly guide drawing.

• If the right physical conditions are present, the boiler may be installed on a base (approximately

400 mm high) to make the operation and removal of ashes easier.

Open or closed system

• CN boilers type 80 and type 120 are approved for installation as open or closed systems.

• When used as a closed system (with pressure expansion) and open system with a height above 5

meters, the boiler must be equipped with a cooling spiral and a thermal over temperature valve
(pages 7 & 8).

Safety valve requirements in closed systems

• With boilers > 60 kW every boiler must have at least 2 safety valves. The safety valves must be able

to, in combination at the chosen blow-off pressure, blow off at least 1.5 times the boiler heat yield in
the form of steam. They must, however, have a minimum internal diameter of 20 mm.

• The inlet and outlet hoses of the safety valves must be of sufficient dimensions for the capacity of the

safety valves not to be noticeably reduced. The inlet pipe must not contain blocking devices, pumps,
boiler mountings, restrictions or water sacks.

• All inlet and outlet hoses to and from safety valves must be run through pipes approved for 120 °C

and minimum 10 bar over pressure.

Page 7

Safety hose open systems (open expansion)

• All the system boilers must have a connection to the atmosphere through a safety hose which cannot

be blocked.

• Safety hoses must depart from the top of the system boiler(s). They must run at an uphill gradient to

the open expansion vessel and from there run at a steady downhill gradient, at a suitable distance
from a drain and in such a way that the outlet of hot water does not result in a risk of injury. The outlet
point must be cut at an angle.

• At the highest point of the safety hose there must be an internal diameter of minimum 15 mm as a

siphon break.

• The vertical distance from the highest point of the system to the boiler must not exceed 10 meters.

• The total length of the safety hose must not exceed 20 meters.

• For boilers > 60 kW the safety hose must have a minimum internal diameter of 35.5 mm

• All pipes must be approved for 120 °C and minimum 10 bar over pressure.

For installation with operational pressure >0.5 bar and open expansion principle diagram pages

17 & 20 must be used

• If the operational pressure of the boiler exceeds 0.5 bar over pressure, the boiler unit (the installed

boiler including fittings and safety equipment) is covered by the Pressure Equipment Directive
97/23/EEC ”Installation of pressurised equipment”, which requires that the boiler unit must fulfil
certain essential safety requirements regarding the safety equipment of the boiler etc. The boiler
must be fitted with a cooling spiral

• Expansion vessel: The vessel must be installed in accordance with the directions of The Health and

Safety at Work Act 1974.

• The bottom of the expansion vessel should be installed only above pipes/radiator of the central

heating system and with an open expansion vessel. Block valves must under no circumstances be
placed between the boiler and the expansion vessel. There must under no circumstances be any

circulation in the expansion vessel.

The boiler must be installed with pos. nos. 1, 2, 3, 4, 5, 7, 9, 10, 13 (drawings pages 17 & 20)

Description Type / Requirements Draw. Pos no. Supplier
Shunt valve TA type TRV 300 1 CN (supplied)
Oper. thermostat BC components type NTC-2322 2 CN (supplied with stoker)
Overheat. thermostat Honeywell type L6188 3 CN (supplied with stoker)
Boiler thermometer 0-120 degrees 4 Installation engineer
Pressure gauge
(manometer)

0-3 maximum 5 bar, red mark at 2.5 bar 4 Installation engineer

Expansion vessel CE labeled, minimum 8 % of total system

water volume

5 Installation engineer

Safety valve
CE approved

2 pces., 2.5 bar, clearance minimum 20 mm

7

Installation engineer

Cooling spiral
CN80:

Wieland heat exchanger type WRK 13

9

CN (supplied)

Cooling spiral
CN120:

Wieland heat exchanger type WRK 13

9
Safety thermostat Honeywell type TS130, CE approved 10 CN
Water shortage protection RT 200 Pressostat 13 Installation engineer