Kovarson TIGER Installation And Operation Manual

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KOVARSON s.r.o.

Lhota u Vsetína 4

755 01, Vsetín

tel. ČR: [phone]

tel. SR: [phone]

email: [e-mail]

Installation and operation manual automatic

boiler

TIGER

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Dear customer,

Thank you for purchasing an automatic solid fuel TIGER boiler and the trust you have
put in KOVARSON s.r.o.

Please read this manual before putting your new boiler into operation to avoid
unnecessary complications resulting from handling issues. Section 7 – Operating the
Boiler by the User, Section 8 – Important Instructions, Section 9 – Maintenance and
the Operation Manual for the LIDER Control Unit are particularly important.

To ensure a long and trouble-free boiler life, please follow the manufacturer’s
instructions as well as those of the authorized installation company that sets up your
boiler.

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Content:

1. Boiler uses and benefits ..................................................................................... - 4 -

2. Boiler technical specifications ............................................................................. - 4 -

3. Recommended fuel............................................................................................. - 6 -

4. Description .......................................................................................................... - 7 -

4.1 Boiler construction ......................................................................................... - 7 -

4.2

Control, regulation and safety elements ...................................................... - 10 -

5. Location and installation ................................................................................... - 11 -

5.1 Regulations and Requirements ................................................................... - 11 -

6. Boiler installation .............................................................................................. - 15 -

6.2 Installation procedure .................................................................................. - 16 -

7.1 Electrical Wiring .......................................................................................... - 20 -

7.2 Pre-fire-up check list ................................................................................... - 21 -

7.3 Control unit parameters setting ................................................................... - 22 -

7.4 Putting the boiler into operation - Firing up ................................................. - 23 -

7.5 superior regulation – room thermostat ............................................................ - 25 -

8. Important instructions ....................................................................................... - 26 -

9. Maintenance ..................................................................................................... - 27 -

10. Disposal of the product after a period of his life .............................................. - 28 -

11. Guarantee and liability for defects .................................................................. - 28 -

12. Trouble shooting ............................................................................................. - 29 -

EC DECLARATION OF CONFORMITY ............................................................... - 30 -

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1. Boiler uses and benefits

The TIGER boiler is designed to heat households, commercial buildings and other
medium-sized structures economically and ecologically using an automatically
controlled feeder for solid fuels and with minimal servicing. It can also be used as a
boiler for domestic hot water (DHW).
Boiler benefits:

− high efficiency

− cast iron body manufactured by a well-known Czech producer

− high exchanger durability

− universal burner - burns brown coal or wood pellets

− simple boiler controls

− unattended operation, boiler maintenance takes 10 minutes every 3 days

− electronically controlled fan speed managed by the control unit

− low power consumption

− in warm seasons, it can be used to heat DHW only

− controlled by a room thermostat

− option to order the boiler with the large hopper on the right or left

2. Boiler technical specifications

Tab.1 Dimensions and technical parameters of the boiler

Boiler model

TIGER

20

TIGER

25

TIGER

30

TIGER

35

TIGER

40

TIGER

48

TIGER

55

Number of sections pcs

4 5 6 7 8 9 10

Weight kg

384 438 547 594 634 713 778

Water volume l

33.3 35 44.7 50.4 56.1 61.8 67.5

Flue diameter mm

160 160 160 160 180 180 180

Combustion chamber
volume

dm3

37.5 51 64.5 78 91.5 105 118.5

Combustion chamber
depth

mm

295 405 515 625 735 845 955

Hopper capacity dm3 290 290 290 290 290 290 290
Boiler dimensions mm see Figure 1
Size of hopper loading

window

mm 370x335 370x335 370x335 370x335 370x335 370x335 370x335

EN 303-5 boiler class - 3 3 3 3 3 3 3
Maximum operating
excess water pressure

tolerance

bar 3

Tested operating excess
water pressure tolerance

bar 6

Recommended operating
temperature of heating
water

°C 60 - 85

Minimum temperature of
returning water

°C 60

Hydraulic pressure loss in
the boiler at ΔT= 20/10K

mbar

0.55÷1.82 0.76÷2.635 0.97÷3.45 1.15÷4.23 1.29÷5.08 1.5÷5.9 1.74÷6.71

Noise level dB 67
Flue draw when the

emissions fan is running
and system is at nominal
output

Pa 14 14 14 14 17 19 22

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Boiler connections - water
heating

Js G 2"

- returning
water

Js G 2"

Supply voltage V 230
Electric load
(fan + motor)

W 170 170 170 170 170 210 210

International protection
rating

- IP20 IP20 IP20 IP20 IP20 IP20 IP20

Tab.2 Thermal technical parameters of the boiler (brown coal combustion)

Boiler model

TIGER

20

TIGER

25

TIGER

30

TIGER

35

TIGER

40

TIGER

48

TIGER

55

Number of sections pcs

4 5 6 7 8 9 10

Nominal output kW 20 25 30 35 40 50 55
Minimum output kW 6 7.5 9 10.5 12 15 16.5
Consumption of fuel at

nominal output

kg.h

-1

4.2 4.9 5.5 6.8 8.1 9.4 10.7

Consumption of fuel at
minimum output

kg.h

-1

1,2 1,4 1,7 2,0 2,3 2,7 3,0

Burning time at nominal
output

h > 6 > 6 > 6 > 6 > 6 > 6 > 6

Efficiency % 79.9 79.5 79.2 78.8 78.5 78.3 78.1
temperature of emissions

at nominal output

°C 182 172 166 157 163 169 175

temperature of emissions
at reduced output

°C 97 101 105 109 106 103 100

Volume of emissions
output at nominal level

kg.s

-1

0.018 0.020 0.022 0.024 0.031 0.038 0.045

Volume of emissions
output at reduced level

kg.s

-1

0.008 0.010 0.012 0.013 0.017 0.020 0.024

Thermal technical parameters of the boiler (wood pellets combustion)

Boiler model

TIGER

20

TIGER

25

TIGER

30

TIGER

35

TIGER

40

TIGER

48

TIGER

55

Number of sections pcs

4 5 6 7 8 9 10

Nominal output kW 20 25 30 35 40 50 55
Minimum output kW 6 7.5 9 10.5 12 15 16.5
Consumption of fuel at

nominal output

kg.h

-1

5.0 6.1 7.3 8.4 10.2 12.1 14.0

Consumption of fuel at
minimum output

kg.h

-1

1.5 1.8 2.2 2.6 3.0 3.4 3.8

Burning time at nominal
output

h > 6 > 6 > 6 > 6 > 6 > 6 > 6

Efficiency % 83.4 83.0 82.6 82.2 82.2 82.1 82.1
temperature of emissions

at nominal output

°C 157 155 152 150 150 150 150

temperature of emissions
at reduced output

°C 96 97 99 102 98 94 91

Volume of emissions
output at nominal level

kg.s

-1

0.014 0.017 0.021 0.024 0.030 0.036 0.041

Volume of emissions
output at reduced level

kg.s

-1

0.008 0.010 0.012 0.013 0.014 0.015 0.016

These values vary depending on the quality and type of fuel. Therefore, it is necessary
to make corrections when adjusting the feeding cycle and fan speed. If, for example,

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there is unburned fuel in the ash pan, the fan speed or feeding cycle needs to be
adjusted. Or, conversely, if the burning fuel in moves toward the feeder, the fan speed
should be reduced or more fuel added!

3. Recommended fuel

Warranty fuel parameters– fuel with which the tests were carried out in the National
Testing Facility:

• Moisture content

• The content of volatile matter

• Ash fusion temperature

• Low sintering capacity

• Low expansion capacity

Tab.3 Fuel tested

Fuel Fuel type Operation

Granularity

[mm]

Heating value

[MJ.kg-1]

Brown coal

nut 2 Automatic 10.25 16,5 - 19,5

B

iomass

Wood pellets Automatic Ø6-8 15 - 19

Tab.4 Fuel tested - brown coal (automatic operation)

fuel

Diameter

[mm]

Heating

value

[MJ.kg-1]

the ash
content

[%]

moisture

content

[%]

sulfur

content

[%]

specific

sulfur

content

[g/MJ]

Tar

content

in dry

matter

[%]

Tar content

in

combustible

elements

[%]

Sorted brown

coal from the

Bílina Mine

(Úpravna uhlí

Ledvice) - nut 2

10.25 17.6 9.8

maximum

20

0.77 0.44 15.1 15.71

Wood pellets must satisfy at least one of the following specifications or standards:

• Specification number 14-2000 MŽP ČR

• DIN 517 31

• ÖNORM M 7135

Prescribed diameter of pellets 6 – 8 mm
Moisture content in a fuel maximum 12%
Ash content maximum 1.5%

CAUTION! Poor quality pellets may negatively affect output and boiler emission
parameters.

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4. Description

4.1 Boiler construction

The boiler construction meets ČSN EN 303-5 : 2000 requirements:

- boiler for CH - Part 5: boiler for DHW using solid fuel with manual or automatic
feeding, at a nominal heat output of up to 300 kW ­Terminology, requirements, testing and marking.

The core of the boiler is the cast-iron body. The body is composed of front, rear and

middle sections. The main function of the boiler body is to transfer thermal energy from
the exhaust gas to heat water. The upper cleaning door and the middle door are
located on the front section. The smoke extension that funnels emissions to the flue is
located on the back section.

The cast iron body is set on the base. The base is made from a 5mm-sheet of steel.

The ash pan door is on the front of the base.

The burner is placed into the side wall of the base. 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
upwards. The upper part of the burner is made from two cast-iron rings.

Two ceramic plates are positioned inside the boiler body in front of the cleaning door
to improve combustion.

The burner’s ash pan is placed at the bottom of the base.

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 body from the front

perspective

• left fed – The fuel hopper is on the left side of the boiler body from the front

perspective

There is wax plug inside the burner, which is the emergency extinguisher.

The boiler body, base and doors are insulated with non-toxic mineral insulation to
minimize heat transmission losses to the surroundings.

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Figure1 Main boiler dimensions (right fed)

A B C D E F G H

dimension

4-7čl

1530 1445 1245 600 500 147

mm

8-10čl

1630 1545 1295 600 500 147

I J K L M N O P

dimension

4-7čl

620 1225 1400 1350 1710 158 2" 2"

mm

8-10čl 720 1325 1500 1450 1810 178 2" 2"

Boiler

TIGER

20

TIGER

25

TIGER

30

TIGER

35

TIGER

40

TIGER

48

TIGER

55

Number of

sections

4 5 6 7 8 9 10

C 493 603 713 823 933 1043 1153
D

640 750 860 970 1080 1190 1300

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1. LIDER control unit

2. boiler cover

3. flue damper

4. fuel hopper cover

5. top cleaning door

6. fuel hopper

7. middle door

8. base

9. lower door

10. fan

11. fuel hopper cleaning plate

12. feeder motor

13. fuel feeder

14. output of heating water

16. input for heating water

18. boiler body

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4.2

Control, regulation and safety elements

The LIDER electronic control unit manages and controls the system - see separate
manual.

Safety elements:

• An emergency heating system thermostat safeguards against overheating. It is set

at 90° C by the manufacturer, above which temperature the fan shuts down for a
certain time while the feeder works in cycles to smother the fire.

• A fuel tank temperature sensor safeguards the system against fuel back-burn. The

factory setting is at 70°C, but the user may reset the temperature according to
his/her needs. If the temperature is higher than the setting, the feeder motor is
started up according to the time set in the control unit to smother the fire. This
function is only available if the boiler is connected to a power source.

• There is an overheating safeguard for the motor. The normal operating temperature

is anything below 80°C.

• Fire extinguishing equipment is included as an element of the safety system in case

of back-burn. The system is triggered if the wax plug is melted – this happens if the
temperature in the feeder exceeds 90°C. Water will be released from the plastic
tank.

4.3 Boiler accessories

Standard accessories:

• Boiler operation and installation manual

• Control unit manual

• 2 ceramic top tiles ( 2 tiles)

• Ash pan

• Ash brush

• Poker

• emergency fire extinguisher with wax plug

• 2 flanges (upper and lower)

• 2 ¾” plugs

• fill/drain valve

• 2 shear fuses

• 2 reservoirs for sensors