Kovarson PREDATOR, PREDATOR 20, PREDATOR 25, PREDATOR 30, PREDATOR 35 Series Manual
...
KOVARSON s.r.o.
Lhota u Vsetína 4
755 01, Vsetín
tel. ČR: +420 571 420 926
tel. SR: +421 949 176 717
email: info@kovarson.cz
Manual for combi boiler
PREDATOR
Dear customer,
Thank you for purchasing pyrolytic boiler MAKAK and the trust you have put in
KOVARSON s.r.o.
The boiler you have purchased has been comprehensively tested by our development
department and. We believe that you will be satisfied with our product. To avoid any
problems, we advise you to read carefully the installation manual of the boiler, before you
start using it.
If you have any questions, please do not hesitate to contact our service engineers who will
help you with your inquiries and always resolve your issue quickly.
Comfortable heating by
KOVARSON s.r.o.
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Content
1) Boiler application and benefits ................................................................................... - 4 -
2) Boiler description ..................................................... Chyba! Záložka není definována.
2.1 Boiler construction ............................................... Chyba! Záložka není definována.
2.2 Function parts of boiler ................................................................................................ 6
2.3 Boiler accesories ................................................... Chyba! Záložka není definována.
3) Technical parameters ................................................ Chyba! Záložka není definována.
4) Recommended fuel ................................................... Chyba! Záložka není definována.
5) Boiler installation ..................................................... Chyba! Záložka není definována.
5.1 Rules and regulations ................................................................................................. 11
5.2 Placement options ................................................. Chyba! Záložka není definována.
5.3 Connecting the boiler to the chimney and outlet of combustion products ....... Chyba!
Záložka není definována.
5.4 Air supply to the boiler ......................................... Chyba! Záložka není definována.
5.5 Connecting the boiler to the heating system .............................................................. 14
5.6 The cooling loop connection ................................ Chyba! Záložka není definována.
5.7 Connection to the mains ....................................... Chyba! Záložka není definována.
5.8 Boiler parts installation ......................................... Chyba! Záložka není definována.
5.8.1 Installation of the boiler casing and thermostatic valve ........................................... 16
5.8.2 Exhaust fan connection ............................................................................................. 16
5.8.3 Universal burner connection ..................................................................................... 17
5.8.4 Fan and screw feeder installation ............................................................................. 17
5.8.5 Installation of the tank .............................................................................................. 17
5.8.6 Control unit FOX installation .................................................................................... 18
6 Boiler operation by user ................................................................................................ 18
6.8 Verification activities before usage of the boiler .. Chyba! Záložka není definována.
6.9 Firing ......................................................................................................................... 19
6.10 Stoking .................................................................. Chyba! Záložka není definována.
6.11 Combustion control ................................................................................................... 21
6.12 Power settings and regulation .................................................................................... 22
6.13 Ash removal .......................................................... Chyba! Záložka není definována.
6.14 Boiler cleaning ........................................................................................................... 23
6.15 Maintance and inspection of the boiler ...................................................................... 23
7 Control unit FOX .......................................................................................................... 24
7.8 Control unit FOX description .................................................................................... 24
7.9 Operation of the controller ................................... Chyba! Záložka není definována.
7.10 Temperature sensors installation .......................... Chyba! Záložka není definována.
7.11 Technical data ....................................................... Chyba! Záložka není definována.
7.12 A wiring diagram of the controller ............................................................................ 26
7.13 Commissioning .......................................................................................................... 26
8 Important alerts ............................................................................................................. 27
9 Disposal of the product after its service life .................................................................. 27
10 Warranty and liability for defects .................................................................................. 28
11 Warranty does not cover ............................................................................................... 28
11 Trouble shooting ........................................................................................................... 28
12 Recommended connection of the boiler ........................................................................ 30
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EC DECLARATION OF CONFORMITY .............................................................................. 31
1) Boiler application and benefits
Czech boiler PREDATOR is designed for economical and ecological heating of family
houses, business premises and medium – sized objects, including the ability to heat the water.
2) Boiler description
2.1 Boiler construction
The boiler is based on the principle of two-stage combustion at a high temperature
during a process is a wood gasification followed by combustion flue gases with an exhaust fan
which exhausts gases from the boiler. Universal burner is placed under the boiler for brown
coal combustion.
Boiler PREDATOR is welded boiler plate of high quality. The upper internal part of
the boiler consists of a fuel hopper, which is at the bottom equipped with a heatproof pipe
fitting having an elongated hole for the passage of gases. In the space below the fitting is a
burn-out area and below this ares is placed universal burner, below burner is an ashtray. At
the rear of the vertical flue gas heat exchanger which is in the upper part of the collecting
channel through which cold gases coming into the chimney.
Most strongly stressed part of the boiler by a high temperature, corrosive gases, acids
and condensates is the upper chamber, which is equipped with stainless steel inserts, which
protects the combustion chamber of the boiler and increases the durability of the boiler.
The inner part of the boiler is made of sheet metal with a thickness of 6mm, flue gas
heat exchanger at the back of the boiler is constructed by 5-exchanger tubes with inner
diameter of 6mm. The boiler has double casing, the inner part is made of 6 mm high quality
steel and any areas which might be in contact with the flame are reinforced by 8mm plate.
The outer part of the boiler is made from metal sheet 4mm.
In front of the boiler are upper stoking door, middle cleaning (ignition) door, bottom
cleaning (ignition) door and bottom door for the ash.
On the back of top boiler cover is a removable casing under which you will find
cleaning access for flue gas chamber. On the side of the boiler is located a handle for cleaning
turbulators.
The feeder shaft extends into the burner, where it is fastened on the far side. The screw
feeder extends to the combustion chamber and pushes against a counter screw, which forces
the fuel upwads.
The upper part of the burner is made of two cast iron rings.
The burner is fed air by a fan placed on the flange of the burner under the fuel hopper.
The fan can be regulated electronically.
The screw feeder is placed next to the covered fuel hopper. Boilers can be ordered in
two variations:
• Right fed – The fuel hopper is on the right side of the boiler.
• Left fed – The fuel hopper is on the left side of the boiler.
There is wax plug inside the burner, which is the emergency extinguisher.
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The boiler body, base and doors are insulated with non-toxic mineral insulation to
minimize heat transmission losses to the surroundings.
The body is insulated with mineral wool 40 mm thick and shielded by metal plating.
Pic. No. 1 Main boiler dimensions
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Pic. No. 2 Main parts of the boiler
1) Control unit display
2) Control unit
3) Handle for cleaning
4) Upper casing
5) Side Casing
6) Stoking door
7) Cleaning door
8) Middle door - burner
9) Exhaust fan
10) Flue outlet
11) Back casing
12) Heating water inlet
13) Drain valve
14) Top cover – heat exchanger
15) Heating water outlet
16) Cooling loop, waste connection
17) Primary air intake
18) Secondary air intake
19) Hopper
20) Ash door
21) Fan
22) Cleaning tank lid
23) Gearbox
24) Engine
25) Tank lid
26) Screw feeder tube
2.2 Function parts of boiler
Filling chamber – here is the primary combustion (gasification) process and it also serves as
the fuel hopper.
Refractory concrete fitted with nozzle – intake of secondary air to the nozzle.
Post - combustion area – there is a secondary combustion process and area which serves for
the collection of ash.
Main tube exchanger – transmitting the heat from the flue gases to heated water.
Fan – blows the air which is required for the combustion process, divided into:
a) Primary – air intake to the filling chamber supports the primary combustion.
b) Secondary – air intake into the nozzle is mixed with the woodgas.
Antismoke flap – system using a flap which draws smoke when you open the filling door.
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Universal burner – combustion of the brown coal supported by a fan.
Fan – supports combustion of fuel in the universal burner.
Fan flap – must close this valve during manual heating to avoid sucking air through the
burner.
Hopper – reservoir volume 350 liters.
Vermiculite plates – during the manual heating it is neccesary to place this plates above the
burner.
Boiler regulation – regulates the amount of air using the fan speed control, regulates the
efficiency of the boiler on the basis of the output temperatures. Controls pump and mixing
valve + it can also monitoring the storage tank.
Heatexchanger turbulators – additional device, which is located in the rear exchanger tubes.
Turbulators increasing efficiency and simplify cleaning of the boiler.
Cooling loop – The loop should be permanently connected to a water order and to the waste.
This system is monitoring a temperature using a bimetallic sensor to prevent overheating of
the boiler. In case that the boiler is overheated system is able to cool him quickly.
2.3 Boiler accesories
The boiler is delivered with the following accessories:
Steel brush 1pc
Scraper 1pc
Exhaust fan 1pc
Flange 2pc
Boiler manual 1pc
Manual FOX 1pc
Filling valve 1pc
Fan VPA06 1pc
3) Technical parameters
Chart, No. 1 – Dimensions and technical parameters of the boiler
PREDATOR
Boiler Type
Wood efficiency %
Coal efficiency –
nominal power %
Coal efficiency –
Minimal power %
Weight kg 750
Water volume l 140
Flue diameter mm 156
Combustion chamber depth mm 550
Combustion chamber
volume
Coal hopper volume dm3 350
Boiler dimensions mm See Figure 1
Size of hopper loading
window
Size of coal hopper loading
window
EN 303-5 boiler class wood
EN 303-5 boiler class –
brown coal
dm3 135
mm 440x300
mm 370x335
- 4 5 5 5 5
- 4 4 4 4
20
84,9 86,2 87,5 88,8 90,25
86,23 87,16 88,1 89,96
68,47 68,47 68,47 68,47
PREDATOR
25
PREDATOR
30
PREDATOR
35
PREDATOR
40
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-
1
Maximum operating
excess water pressure
Tested operating excess
water pressure tolerance
Recommended operating
tem. of heating water
bar 2
bar 2
°C 50-85
Hydraulic boiler loss mbar
Recommended operating
temp. of heating water
Minimum temperature of
returning water
°C 70 - 90
°C 55
Noise level dB < 60
Chimney draft during the
exhaust fan running at a
rated power
Pa
20
Boiler connections - water
heating, return water
DN G 2"
Returning water DN G 2"
Filling, Draining DN G 1"
Cooling loop DN G 1/2"
Supply voltage V 230
Electric load W 60
International protection - IP20
Chart. No.2 Thermal technical parameters of the boiler when burning wood and coal
Boiler Type
PREDATOR
20
Nominal power - wood kW 20 25 30 35 40
Nominal power - coal kW 20 25 30 35 36
Minimum power - coal kW 6,5 8 10 12 12
Fuel consumption at rated
power - coal
Fuel consumption at
minimal power - coal
Fuel consumption - wood kg.h
Burning time at nominal
power - wood
Burning time at nominal
power - coal
Flue gas temperature -
wood
Flue gas temperature – coal,
Nominal power
Flue gas temperature – coal,
Minimal power
Flue gases mass flow –
wood, Nominal power
Flue gases mass flow –
coal, Nominal power
Flue gases mass flow –
coal, Minimal power
kg.h-1 4,738 5,2395 5,741 6,7 6,744
kg.h-1 1,658 1,658 1,658 1,658 1,658
5,694 6,72 7,746 9,78 9,798
h 2,1 2,1 2,2 2,2 2,3
h >6 >6 >6 >6 >6
°C 73,1 87,3 101,5 115,8 130
°C 118,1 124,4 130,7 140 140,3
°C 60,4 60,4 60,4 60,4 60,4
kg.s-1 0,016
kg.s-1 0,016 0,017 0,018 0,020 0,020
kg.s-1 0,006 0,006 0,006 0,006 0,006
PREDATOR
25
PREDATOR
30
PREDATOR
35
0,019 0,022 0,025 0,028
PREDATOR
40
8
The values need adjustment depending on quality and type of fuel. Therefore, it is necessary
to make corrections during adjustment of feeding cycle, fan speed or exhaust fan speed,
possibly setting primary and secondary air. For example, if during the automatic combustion
occurs the unburned fuel in the ashtray it is necessary to either increase or decrease the fan
speed or fuel feeding cycle. In the event that the fuel drops into the burner below the
recommended limit, it is necessary to reduce the fan speed or increase fuel level.
4) Recommended fuel
Ruční provoz - zplyňování:
It is recommended to burn wood in maximum lengths according to the parameters of the
boiler. It is neccesary to burn the wood with a maximal dampness up to 20%. When damp
wood is burned it releases the water that condenses on the walls of a body and chimney. This
combustion reduces the durability and performance of the boiler due to the formation of
aggressive substances.
The vertical axis shows the calorific value of wood kWh/kg and the horizontal axis shows
percentually the water content in wood. Moreover the comparison between coniferous and
deciduous trees.
Pic. No. 3 Calorific value of wood material in dependence on the water content
Automatic operation:
Warranty fuel parameters – fuel with which the tests are carried out in TSU:
• Water volume
• Volatile matter volume
• Temperature of ash deformation caused by melting
• Low caking
9
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1
Chart. No. 2 Záruční palivo v automatickém provozu
Fuel Fuel Type Operation Granularity [mm] Calorific Value [MJ.kg
Brown coal
Nut 2 Automatic
10.25 18,2
]
Chart. No.4 Warranty fuel – brown coal (automatic operation)
Tar
content
in dry
matter
[%]
Fuel
Granularity
[mm]
Calorific
Value
[MJ.kg-1]
Ash
content
[%]
Water
content
[%]
Sulfur
content
[%]
Specific
sulphur
content
[g/MJ]
Graded brown
coal from down
Bílina (coal
10,25 18,2 9,8 Max.20 0,76 0,44 15,1 15,71
elaboration
Ledvice) - nut 2
5) Boiler installation
When handling and storing of the product you must be careful to avoid any breaches of
boiler.
Tar content
in
combustible
[%]
The boiler has to be installed by heating specialists with a valid license for the installation
and maintenance of such equipment. The installation project must be undertaken according to
valid regulations.
Before the installation, check the completeness and integrity of the boiler package, if they
are correct with the data according to the product label.
Before commissioning a boiler, it meets the requirements of CSN. (e.g. chimney revision,
approval of the boiler by chimney office, heating system project, heating test, etc.)
The main condition for boiler installation is the involvement of the mixing valve in the
boiler circuit and wiring of the cooling loop. If there will be no cooling loop connected, it is
necessary to ensure heat dissipation during a blackout which will block the pump and the
mixing valve actuator.
Before the heating season it is necessary to check the water pressure and bleed the heating
system.
The manufacturer is not responsible for demages of the boiler caused by errorneous
installation!
10
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