®
CENTRAL HEATING BOILER
ON SOLID FUEL
KALVIS-2-16, 2-25, 2-30, 2-40
USERS INSTALLATION
AND OPERATION MANUAL
CERTIFICATE NO. SPSC-5199
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Attention !
Get acquainted with this technical certificate before installing
the boiler.
1. Technical data.
Central heating boiler "Kalvis-2-16, 2-25, 2-30, 2-40" (hereinafteer
referred to as the boiler) is used for heating of various premises where
central heating system with natural or forced circulation is arranged.
Boiler has a socket for mounting 3x1,5…3x2 kW electric heating
devices (with 2“ thread) with temperature control and emergency
thermostats or without them (devices not included).
1 fig.
1.Air supply damper. 2.Service doors. 3.Cast iron doors. 4.smoke exhaust
channel. 5.Fuel loadinjg doors. 6.Thermometer. 7.Draught adjuster. 8.Top loading
cover. 9.Electric heating device socket. 10.Smoke exhaust damper. 11.Service
cover. 12.Chamotte brick. 13.Hot water tube. 14.Ignition damper. 15.Draught
damper. 16.Turbulators. 17.Screen (only for Kalvis-2-16). 18.Secondary air
openings. 19.Combustion chamber. 20.Return water tube. 21.Drainage tube.
22.Ash removal cover. 23.Fire grate mover. 24.Movable fire grate.
Measures designated by letters are included in „main technical data“ table.
KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
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Main technical data:
Boiler type K-2-16 K-2-25 K-2-30 K-2-40
Fuel used Wood, waste wood, peat and
saw dust briquettes, coal
Heated area 80 – 160 150 - 250 200 - 300 250 - 400
Fuel load, dm3 (l) 100 120 175 220
Fire wood length up to , mm 400 350 350 450
Combustion duration*:
- fire wood, h.
- coal, val.
4 - 8
12
Maximum combustion duration.: 12
Fuel consumption per heaqting season,
m³
10 - 15 16 - 20 18 - 28 25 - 35
Nominal capacity, kW 16 25 31,5 40
Efficiency not less than, %:
- fire wood
- coal
82
85
Water volume in the boiler, l 81 84 102 116
Water pressure in the boiler, not
greater than, MPa (kgf/cm
2
)
0,15 (1,5)
Minimum return water temperature 58ºC
Recommended water temperature in
the boiler
70-90ºC
Minimal chimney draught, Pa 14 14 15 16
Loading opening dimensions, mm 290 x 290 290 x 290 290 x 390 290 x 490
Overall dimensions, mm:
H
g
/ H
Bg / B
L
g
/ L
1380 / 1300
760 / 600
1060 / 800
1500 / 1420
590 / 490
1220 / 960
1500 / 1420
690 / 590
1230 / 970
1500 / 1420
790 / 690
1230 / 970
Branching dimensions, mm:
K
M
N
Ø158
G1½-B
G½-B
Ø179
G2-B
G½-B
Other dimensions, mm:
E / G
A / C
D / F
980 / 195
1180 / 330
242 / 325
1050 / 300
1305 / 270
240 / 300
1050 / 350
1305 / 270
240 / 350
1050 / 400
1305 / 270
240 / 400
Mass, not greater than, kg 435 435 490 535
* Combustion duration depends on fuel type, humidity, outdoor conditions etc.
2. Design description
Due to constant development of design, minor inconsistencies with the
manual are possible.
Boiler frame is welded from special sheet steel has water cavities, where
water is heated (see 1 fig.). Internal boiler frame is made of 6 mm thick
steel, external – 3 mm. Exterior of the boiler is covered with insulating
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
Kalvis-2-16
Kalvis-2-25
Kalvis-2-30
Kalvis-2-40
Boiler model mark
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
shoelds. Front side of the boiler has draught adjuster (p.7), which controls
air supply damper (p.1), thermometer (p.6), doors (p.2), behind which there
are servoce doors (p.3). Loading chamber is closed with doors (p.5). In the
boielr there is a smoke exhaust damper (p.10) and ignition damper (p.14),
which allows a direct smoke flow into the chimney, ignition damper is used
for fuel ingition and loading extra fuel; also the fire grate (p.24), secondary
air opening (p.18). Combustion chamber has chamotte bricks (p.19) that
maintain high temperature of combustion. Beneath the shields there is a
servoce cover (p.11) for cleaning the internal surfaces fo the boiler.
On the sides of the boiler there are secandary air controlling dampers.
Rear side of the boiler has drainage tube (p.21), return (p.20) and hot
water (p.13) tubers, smoke pipe with draught damper (p.15).
Boiler heat exchanger (except Kalvis-2-16) has turbulators (p.16) that
ensure a better heat transfer.
If there is an insufficient draught it is recommended to remove
turbulators.
Electric heating devices are automatically switched on when boiler runs
out of fuel and temperature falls beneath the preset waiting mode
tmeperature.
3. Transportation and storage.
Transport boilers only in vertical position by all types of covered
transport. Transporting by not covered transport is possible only when the
weather is dry. Use additional protection means to protect boilers against
fall downing and scratching. Striking, turning over or throwing boilers
during loading, unloading or transportation time is strictly prohibited.
The boilers are to be stored in the dry rooms, where is no vapour of
chemicaly active materials.
4. Mounting
Boiler has to be installed in the premises that meet, RSN-159-95 and
RPST-01-97 requirements or according to similar national regulations.
, RSN-159-95 and
RPST-01-97 requirements or according to similar national regulations.
It is recommended to have mounted a smoke collecting cobver
above boiler. Boiler should be mounted vertically, or with forward
inclination, which would not exceed 1 degree.
4.1 Fire precautions:
* Boiler should be placed on the incombustible material;
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
* If boiler is connected to the chimney by metal pipes, pipes should be not
thinner than 1,5mm and they have to be covered by thermal insulation
Attention !
When chimney’s draught is too great and sawdust is used for fuel sparks
may fly out through the chimney.
It is prohibited to use sawdust for fuel, if the distance between chimney
and flammable roof or other flammable structures is less than 20 m.
4.2. Requirements for chimney
Chimney design and boiler connections into it are shown on the
fig 2 and 3.
Boiler sold:
Company
Sales date:
Address
Phone
Boiler
mounted:
Company
Address
Phone
Foreman
(name, last name, signature)
In case of a
breakdown
contact
Company
Address
Phone
Manufacturer
UAB “Šiaulių tauro kalvis”
Pramonės 15,
LT-78137 Šiauliai, Lithuania
Phone: (+370 41) 540556
E-mail: info@kalvis.lt
• Chimney draught is not less than specified in main technical data
table;
• Chimney hole‘s cross section should be not less than
120x270 mm;
• Boiler needs a separate hole for the chimney connection. No other
connections through that hole are allowed
2 fig. 3 fig.
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9. Complement
1. Boiler "Kalvis-2-_____” 1 vnt.
2. Draught adjusterC20/25 1 vnt.
3. Grinder 1 vnt.
4. Ash scoop 1 vnt.
5. Poker 1 vnt.
6. Manual 1 vnt.
10. Product guarantee
Manufacturer guarantees, that the product meets technical
documentation requirements.
Guarantee time - 24 months from the sale date.
Manufacturer will repair any malfunctions in the product that
appear due to manufacturers fault.
Manufacturer will not acknowledge any quality claims for
products operation and consequences if the product has been wrongly
chosen, mounted, installed or serviced.
Boiler complement has 12 months guarantee and consumables – 6
months.
In case of malfunction, fill in the form and send it to the
manufacturer or authorized guarantee servicing company by a
reistered mail. In emergency cases make a telephone call and give the
form to the company representatives.
I am acquanited with rules of installation and servicing and
guarantee policy.
Purchaser:
(name, last name, signature)
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
Bouiler connection to chimney by elbows.
* not less than 60° A - correct B – incorrect
Chimney insert mounting
• If chimney is connected with additional elbow, it‘s cross section
has to be not less than that of the boiler smoke pipe, and bending
radii not less than 100mm;
• Pipe from the smoke pipe to chimney has to be not longer than 1,5
m and lean upwards toward chimney;
• Joints have to be well sealed;
• Chimney hole has to be well cleaned.
Necessary to know that:
• Smoke continues to cool in the chimney, vapor condenses on the
chimney walls, especially in the unheated loft and on the outside
of the building;
• Condensate acids and erosion may destroy the chimney in few
years;
• Not cleaned soot in the chimney may self-combust and become
the cause of fire.
Recommended:
• Mount an insert into the chimney. Well mounted insert protects
chimney from condensate influence;
• Insert should not significantly decrease the cross section of the
chimney;
• Insert parts should be well joined together (no soldering);
• Condensate collector and drainage should be arranged in the
bottom;
• An incombustible material should insulate the cavity between the
insert and chimney. Top slit should be hermetically sealed;
• In the unheated loft an incombustible material should insulate
chimney.
4.3. Requirements for the connection to the heating system:
Recommended connection schema is shown in the 4 fig.
• Boiler may be connected to the heating system according to the
project prepared by heating equipment specialists or works may be
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performed by a well qualified plumbing welder who is well
acquainted with this manual and boiler design
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
- oak wood - 500 kg;
- birch wood - 450 kg;
- fir wood - 330 kg;
- asp wood - 330 kg.
The higher wood humidity – the less calorie value. Decrease in
calorie value of humid wood in comparison to 20% humidity wood:
- 30 % humidity - 10 ÷ 15 %;
- 50 % humidity - 35 ÷ 40 %.
Fresh cut tree has about 35 ÷ 60 % water. Wood cut in the
beginning of winter or hard wood has least water.
Peat and wood calorie value is similar.
1 kg of coal gives 2 ÷ 3 times more heat than 1 kg of wood.
Combustion of 1 kg of wood requires 4 ÷ 5 m3 of air, coal –
around 10 m3.
The more ash is left – the worse fuel is.
Energy radiation from combusting 1 dm3 of wood of 20 %
humidity:
Wood type Kcal Kwh Comparison to oak %
Oak, maple 2520 2,93 100 %
Ash 2460 2,86 98 %
Birch 2270 2,64 90 %
Alder 1900 2,21 75 %
Pine 1850 2,15 73 %
Asp 1810 2,10 72 %
Polar 1680 1,95 67 %
Fir 1610 1,87 64 %
Average coal caloric value 6500 kcal/kg (7,56 kWh/kg).
8. Receipt note
Central heating boiler "Kalvis-2-____" factory No._________
conforms with manufacturing drawingsand is fit for service.
Manufacturing date______________________
Quality manager__________________________
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
Burner should be cleaned before every start up.
Clean flame sensor when needed.
Use special chemicals for hardened solids cleaning. Use Swedish
„Fasch 300“ or cleaners used for fireplaces glass cleaning.
5.5.Consumables
Fire grate and cast iron door may burn up, especially if user
combusts coal, serivicing door and servicing cover fiber gasket may
wear out.
User may purchase consumables from manufacturer of the boiler.
6. Safety precautions
It is prohibited:
• Disassemble boiler or electric installation;
• Connect boiler to the system without protection valve, that keeps
pressure in the system below 0,15MPa (1,5 kgf/cm2);
• Close hot or return water valves when boiler is operated;
• Store dry fuels or other combustible materials close to or on top of
the boiler;
• Store fuel closer than 500 mm to boiler;
• Ignition fuel with combustible liquids (petroleum, kerosene etc.);
• Operate boiler with doors and covers open;
• Open burner while boiler is operated;
• Allow children to be at the working boiler without adult
supervision;
• Operate boiler without having it grounded;
• Rapidly open loading doors during combustion (open a little, wait,
then slowly open wide);
• Operate boiler with tank cover opened or non hermetic pellet
supply hose;
• Clean or service boiler when electric power is on.
7. Fuel types and properties
Combustion heat of absolutely dry wood does not depend on the
kind of wood and equals 4510 kcal/kg. So in order to compare
different kinds of wood we need to assume their relative weight. 1m3
weighs:
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
- Open damper (p.1) with draught adjuster.
Check the smoek color out of chimney. Smoke should be thin of a
light grey color. If smoke is thick and black it means incomplete
combustion, not enough secondary air. Open secondary air supply
dampers.
As a part of combustion process ash is formed, it blocks the
openings in fire grate, boiler capacity and combuistion intensity
drops. Move the fuel and ash by pressing the pedal of the fire grate
mover. Excess of ash in an ashtray blocks primary air supply, that is
why ash needs removal. Boilers K-2-30 and K-2-40 Bottom doors
have two primary air dampers. Top damper allows air flow even
when ash blocks fire grate openings.
Unless there is a necessity it is not recommended to open fuel
loading doors (p.5 and p.8) during combustion.
Boiler premises have to be well ventilated.
Recommenmded fuel humidity not greater than15-20 %.
Attention! If the boiler combusts humid wood or saw dust,
condensate will form acids which will shorten the life span of the
boiler several times
5.3. Installing and adjusting the draught adjuster
Draught adjusters manufactured by Swedish ESBE C20/25 with
protection from boiler overheating or without it are used. Adjuster is
turned into a socket, scotch tape is used for sealing, Attach chain to
air supply damper.
When boiler heats up to 70°C, adjust adjusters handle to position
"4" and shorten the chain so that, air supply damper is closed.
Turning adjuster to the correspondent position sets desired
temperature. Position "6" corresponds to 90°C. Temperature
increment between positions is 10°C.
5.4.Boiler cleaning.
To ensure optimum boiler performance slag has to be removed
from the burner and ash has to be cleaned from the internal boiler’s
surfaces.
Burner cleaning periods depend on pellet quality. When pellets
with lots of admixtures are combusted burner should be cleaned
every day.
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
• nly persons with necessary qualification are allowed to perform
installation works;
• Installation works should be performed according to the
prepared project;
5. Boiler servicing
Adults that are well acquainted with the design and users manual
may service boiler.
5.1. System preparation for heating
Fill system with water and let the air out. Check if valves
disconnecting boiler from the heating system are fully opened and
remove their handles.
5.2. Combustion (refer to 1 fig.)
Open draught damper (p.15) prior to fuel ignition, ignition damper
(p.14), through doors (p.3) place some dry wood waste and ignite it.
In case of coal combustion 5 - 10 kg of firewood should be covered
by a 10 cm layer of coal. Secondary air dampers (p.18) should be
closed. Dampers are operated when tmeperature in the boiler
reaches 60°C.
Upon fuel ignition chamber may be filled with fuel. Finer fuel
increases boiler capacity.
Wood should be loaded freely, so that it is able to fall down during
combustion.
Coal is addwed in layers, depending on quality and required heat
amount.
When adding fuel:
- Open ignition damper (p.14);
- Open doors (p.2) anmd check if the ash allows air inflow
through teh fire grate openings. Move the fuel and close the
door after 15-20seconds if needed;
- Close the door damper (p.1) with draught adjuster (p.7);
- Slightly open fuel loading door (p.5), fully open them in 5-10
seconds and add fuel;
- Close fuel loading doors and dapers tightly;
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KALVIS-2-16, 2-25, 2-30, 2-40 en 2009.05.18
• Boiler should be connected by hot and return water pipes not
smaller than 1.5’’ in diameter
• Boiler may be connected to the heating system with the expansion
tank, where operating pressure does not exceed 0,15 MPa (1,5
kgf/cm2);
• If system pipes have valves, that disconnect boiler from the
system, mounted, they have to be fully opened. To avoid break
down due to inadvertence, valve handles should be removed.
• It is necessary to mount the protection valve that keeps the
operating pressure in the system not greater than 0,15 MPa (1,5
kgf/cm2).
Notice: To avoid appearance of the condensate, which may shorten
the service time of the boiler several times, 3-way valve,
controlled by the AKR controller should be mounted in the
system. That enables keeping the return water temperature
not lower than 60 degrees.
4.4. Requirements for the electric connections:
If electric heating devices are isntalled
Pos. Name q-ty
F1-F3
Switch
3 16A
E
Heating device
thread G2B
L=400)
1
3x1,5 kW
3x2 kW
5 fig..
Recommended connection for electric heating
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