Ponast KP 82S, KP 52S, KP 22S, KP 12S, KP 62S Service And Operation Manual

Automatic boiler for wood pellets

Manufacturer address:

PONAST spol. s.r.o., Na Potuckach 163, 757 01 Valasske Mezirici, CZECH REPUBLIC http://www.ponast.cz

We would like to focus your attention mainly on the following chapters:

No. 1 – Important notes No. 5 – Putting the product into operation No. 6 – Maintenance and attendance of the boiler during operation

The boiler has been approved for operation in the Czech Republic and in 27 EU countries by the State Testing Institute, state testing plant number 202.

General information on CAA and smoke control

The Clean Air Act 1993 and Smoke Control Areas

Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if located in a designated smoke control area. It is also an offence to acquire an "unauthorised fuel" for use within a smoke control area unless it is used in an "exempt" appliance ("exempted" from the controls which generally apply in the smoke

control area).

The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have been "authorised" in Regulations and that appliances used to burn solid fuel in those areas (other than "authorised" fuels) have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved administrations.

The KP12S, KP22S, KP52S, KP62S , KP82S boilers have been recommended as suitable for use in smoke control areas when burning wood pellet.

Further information on the requirements of the Clean Air Act can be found here: http://smokecontrol.defra.gov.uk/

Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of smoke control areas and you can contact them for details of Clean Air Act requirements.

Automatic boiler for wood pellets

CONTENT

1 USE OF THE BOILER AND ITS ADVANTAGES ...................................................................................................... 5

2 STRUCTURAL DESCRIPTION OF PRODUCTS ....................................................................................................... 6

3 BOILER BODY, SCHEME OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS ......................................... 7

3.1 BOILER BODY............................................................................................................................................ 7

3.2 CONTROL UNIT ......................................................................................................................................... 8

3.2.1 Boiler Function Module HZS 521-G ..................................................................................................... 9

3.2.1.1 Technical base data .................................................................................................................... 11

3.2.2 Terminal HZS 555-S with USB ......................................................................................................... 12

3.2.2.1 Technical data ............................................................................................................................ 12

3.3 BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE ................................................ 14

3.4 CERAMIC PARTS ...................................................................................................................................... 15

3.5 FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)................................................................. 15

3.6 BOILER SHEATHING INCLUDING HEAT INSULATION .................................................................................. 17

3.7 CLEANING SYSTEM .................................................................................................................................. 18

3.7.1 Ash removal .................................................................................................................................. 18

3.7.2 Heat exchanger cleaning ................................................................................................................ 18

3.7.3 External ash container .................................................................................................................... 19

3.8 STANDARD ACCESSORIES ........................................................................................................................ 20

3.9 OPTIONAL ACCESSORIES ......................................................................................................................... 20

3.10 FUEL BIN ............................................................................................................................................. 20

4 PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION ............................................ 22

4.1 PLACEMENT OF PRODUCTS IN BOILER ROOMS .......................................................................................... 22

4.2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL ....................................................................................... 22

4.3 LEGISLATION IN FORCE ........................................................................................................................... 22

4.3.1 Heating system and boiler .............................................................................................................. 22

4.3.2 Venting ......................................................................................................................................... 22

4.3.3 Fire regulations .............................................................................................................................. 23

4.3.4 Electrical ....................................................................................................................................... 23

4.3.5 Protection against noise .................................................................................................................. 23

4.4 STORAGE OF FUEL .................................................................................................................................. 23

4.5 BOILER ROOM VENTILATION ................................................................................................................... 23

5 PUTTING THE PRODUCTS INTO OPERATION .................................................................................................... 24

5.1 CONNECTION TO THE SYSTEM ................................................................................................................. 24

5.2 INSTALLATION OF THE BURNER ............................................................................................................... 24

5.3 INSTALATION OF THE CERAMIC CATALYTIC REFLECTOR ........................................................................... 25

5.4 INSTALLATION OF SECONDARY CERAMIC GRATE ...................................................................................... 26

5.5 INSTALLATION OF CERAMIC SHIELD ........................................................................................................ 28

5.6 CERAMIC DOOR JACKETING ..................................................................................................................... 28

5.7 CONNECTION OF ELECTRICAL PARTS ....................................................................................................... 29

5.8 CHECKING TASKS BEFORE BOILER FIRST OPERATION ............................................................................... 31

6 BOILER SERVICE AND MAINTANANCE DURING OPERATION .............................................................................. 31

6.1 SERVICE ................................................................................................................................................. 31

6.1.1 Refuelling ...................................................................................................................................... 31

6.1.2 Emptying of the external container .................................................................................................. 31

6.1.3 Flue gases exchanger cleaning ........................................................................................................ 32

6.2 MAINTANANCE ........................................................................................................................................ 32

6.2.1 Burnt gases exchanger cleaning ...................................................................................................... 32

6.2.2 Burner grate cleaning ..................................................................................................................... 33

6.2.3 Ceramic grate cleaning ................................................................................................................... 33

6.2.4 Annual audit .................................................................................................................................. 34

7 DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE......................................................................... 36

7.1 NATURAL PERSON ................................................................................................................................... 36

7.2 LEGAL ENTITY ......................................................................................................................................... 36

8 CONTROL UNIT OPERATION ........................................................................................................................... 37

8.1 MAIN MENU ............................................................................................................................................ 37

8.2 OPERATING CONDITIONS – MAIN MENU ................................................................................................... 38

8.3 MAIN MENU ............................................................................................................................................ 39

8.3.1 Setting menu ................................................................................................................................. 39

8.3.1.1 Info menu .................................................................................................................................. 39

8.3.1.2 Menu users settings .................................................................................................................... 40

8.3.1.3 Menu Service .............................................................................................................................. 43

8.3.2 Menu – heating circuits ................................................................................................................... 53

8.3.2.1 Tank .......................................................................................................................................... 54

Automatic boiler for wood pellets

8.3.2.2 Sanitary water ............................................................................................................................ 56

8.3.2.3 Heating circuit ............................................................................................................................ 58

9 GUARANTEE AND LIABILITY FOR DEFECTS ...................................................................................................... 61

10 APPENDIX 1 - TECHNICAL DATA OF THE BOILERS KP X2S................................................................................. 67

10.1 INSTALLATION DIMENSION OF BOILER ................................................................................................. 67

10.2 TECHNICAL DATA ................................................................................................................................. 69

11 APPENDIX 2 - REPORT ON THE PUTTING THE BOILER KP INTO OPERATION ...................................................... 72

12 APPENDIX 3 - SELF-ADHESIVE LABEL - IMPORTANT SAFETY INFORMATION ....................................................... 73

PICTURES

Picture No. 1 Boiler body ................................................................................................................................6

Picture No. 2 Boiler body – description of the main parts .............................................................................7

Picture No. 3 Control unit - configuration ......................................................................................................8

Picture No. 4 HZS 521-G Connector and terminal electronics layout ............................................................9

Picture No. 5 Module HZS 532-1.................................................................................................................. 10

Picture No. 6 Other modules ........................................................................................................................ 10

Picture No. 7 Terminal with USB ................................................................................................................. 12

Picture No. 8 Burner ..................................................................................................................................... 14

Picture No. 9 Feeder F1 ................................................................................................................................ 16

Picture No. 10 Jacketing KP 12S .................................................................................................................. 17

Picture No. 11 Ash removal system ............................................................................................................. 18

Picture No. 12 Heat exchanger cleaning ...................................................................................................... 19

Picture No. 13 External ash container ......................................................................................................... 19

Picture No. 14 Standard fuel bin sizes ......................................................................................................... 21

Picture No. 15 Assembly guide ..................................................................................................................... 21

Picture No. 16 Required chimney draft ........................................................................................................ 23

Picture No. 17 Burner installation ................................................................................................................ 24

Picture No. 18 Ceramic reflector .................................................................................................................. 25

Picture No. 19 Parts of secondary ceramic grate ........................................................................................ 26

Picture No. 20 Ceramic grate parts placement guide .................................................................................. 27

Picture No. 21 Ceramic shield ...................................................................................................................... 28

Picture No. 22 Ceramic top placement guide .............................................................................................. 28

Picture No. 23 Main menu – sample of visualisation ................................................................................... 37

Picture No. 24 Principle of the modulation .................................................................................................. 62

Picture No. 25 Directory information - consumption wood pellets for boiler family KP ............................ 63

Picture No. 26 Circuit diagram – control unit .............................................................................................. 64

Picture No. 27 Circuit diagram + module HZS 533...................................................................................... 65

Picture No. 28 Circuit diagram - HZS 533, HZS 535 .................................................................................... 66

Automatic boiler for wood pellets

IMPORTANT NOTES

This product may only be put into operation by an installation organization trained by the manufacturer.

This product may only be operated by adult persons, duly acquainted with the way the product is controlled and duly acquainted also with these Instructions. If you adhere to the below mentioned principles, the product will serve you reliably to your full satisfaction.

1) It is prohibited to intervene in any way in the structure or electrical installation of products. Having the

equipment been disconnected from the electric network, the power supply cord has to be plugged from the mains outlet.

2) It is prohibited to use inflammable liquids for ignition.

3) No inflammable materials may be stored on the boiler; neither may they be stored within the distance of 1,500

mm from the boiler (except for operating metal fuel bin).

4) In order to preserve long-term service life of the boiler body, it is not recommended to operate the boiler

frequently under the temperature of 55°C, if the boiler is not protected with a primary circuit. The temperature of 55°C should be considered as the minimum temperature.

5) The check how the boiler is filled with fuel is only visual. Any verification with touch is prohibited as it may result

in injury.

6) Never open door of the boiler if there is an ignition process.

7) The door of the boiler has to be always tightly closed. If you´ll perform any check, open the door carefully to

prevent from getting jeopardized by gathered products of combustion or to prevent any sparks flying out from the boiler from being the cause of any accident. Open the door slowly in order to get the combustion chamber aerated towards the chimney. This procedure has to be adhered to when the ash is being removed from the ash pan's space.

8) If any work which generates inflammable vapours takes place in the boiler room (glueing the floor, etc.), the

boiler has to be out of operation and the fire has to be burnt out in the boiler.

9) Having the heating season been finished, clean the boiler thoroughly as per the chapter Maintenance. Products of

combustion stuck to the walls of the exchanger may act corrosively for the whole period of time when the boiler will be out of operation. If the burner is not cleaned, this may have effect on faulty combustion. We recommend hire a specialized company to perform this work.

10) If you work on or near to the mechanically movable parts (fuel feeder, etc.), ensure safe disconnection of the

equipment from electric voltage. There is a risk of injury.

11) You should always operate the boiler only under parameters and in harmony with recommendations given in

these instructions for installation and operation. If the boiler works in the AUTO mode and if there is a failure of current, the boiler will start operation again with the electric firing programme (if this programme has been installed) after the delivery of electric current is restored.

12) The manufacturer does not assume any liability for errors and subsequent damage caused by unskilled operation

of the equipment or by infringement of principles given in these instructions for installation and operation or by infringement of generally binding standards and regulations or by using inadequate fuel.

13) If the boiler is moved or otherwise handled with, safety regulations which apply to handling with heavy loads

have to be adhered to.

14) It is prohibited to place heavy loads on jacketing boiler and to step on it. It is recommended to remove the

protective foil after all the building and installation work has been completely finished.

15) External ashtray has to be firmly connected to a boiler fitting while in the operation. Cover of this ashtray has to

be tightly closed. There could be a dangerous escape of combustion gases into a boiler room.

Automatic boiler for wood pellets

1 USE OF THE BOILER AND ITS ADVANTAGES

The series of automatic hot-water boilers for wood pellets is designed mainly to heat family houses, small municipal buildings, cottages and small plants or business buildings.

The main advantages of products:

1) AUTOMATIC OPERATION ensured by the control unit which cooperates with the indoor thermostat, thermostat of

SW tank for hot water, outside thermometer in the mode of equitherm regulation, eventually by superior control system, which ensures comfort for the user including maximum saving of fuel.

2) Automatic ASH REMOVING and heat EXCHANGER CLEANING ensures long time maintenance free and maximum

comfort of heating while keeping high burning efficiency.

3) CONTROL UNIT with modern design – controls operation of the boiler, ensures automatic operation, high

operational reliability and long distance control.

 Colour TFT display 5.7" with touch screen.  Remote control over TCP/IP  USB  User friendly controlling  Operation modes: Equitherm, Modulation or Fixed power  Two heating circuits and sanitary water in basic configuration  Possibility to control accumulation tank or solar system – maximum 7 heating circuits  Upgrading software over USB stick

4) PRIORITY HEATING of sanitary water – is secured by the structure and software package of the boiler without

any need for other control elements.

5) MODULATION PERFORMANCE of the boiler allows adjusts production of the heat to an actual need of the

building.

6) Heating in EQUITHERM regulation mode lowers the cost of the heating.

7) The burner system used with two independent feeders and with a system of ceramic catalytic reflector and grate

ensures perfect SMOKELESS FUEL COMBUSTION, which supports high thermal efficiency of the product and also excellent ecological parameters with the minimum content of harmful substances in combustion products (20-50x less than conventional boilers).

8) SAFETY OF OPERATION ensured by separated structure of fuel transport routes and by the selected transport

mode.

9) DESIGN AND SURFACE – jacketing of the products is coated with a heavy-duty COMAXITE COATING which is

perfectly resistant to environment effects and ensures perfect appearance of products on long-term basis. Design of whole solution is using modern shape elements.

10) This SUBSIDIED ABLE PRODUCT – is fulfilling all required conditions for obtaining subsidies in many states of the

European Union.

11) LONG DISTANCE CONTROL and monitoring by internet or GSM connection.

Automatic boiler for wood pellets

2 STRUCTURAL DESCRIPTION OF PRODUCTS

The structure adheres to the standard EN 303.5 / 2000 i.e. boilers for central heating - part 5 (boilers for central heating with automatic fuel feed of rated heat output up to 300 kW).

PRODUCT MAIN PARTS – FRONT SIDE

PRODUCT MAIN PARTS – BACK SIDE

Picture No. 1 Boiler body

Control unit – boiler function modules

External ashtray

Connection flexible hose

Primary fan

Boiler cover

Terminal with USB

Cleaning mechanism

Inspection door

Cleaning motor

Feeder F2

Exhaust pipe

Heating water output

Feeder F1

Backwater input

Automatic boiler for wood pellets

3 BOILER BODY, SCHEME OF THE PRODUCTS

AND DESCRIPTION OF THE MAIN PARTS

3.1 BOILER BODY

is made of top-quality steel metal sheets and pipes for boiler in form of a weldment. Its shape is adapted in such a way so that combustion products are cooled down efficiently at individual levels of power output, which is, moreover, assisted by a system of turbulators. The exchanger is shaped in such a way so that the exhaust pipes of combustion products can be cleaned individually and efficiently.

Picture No. 2 Boiler body – description of the main parts

Steel weldment

with heat exchanger

Inspection door

Exhaust pipe  130, 150 or 160 mm

Heating water output water G 1½“

(inside thread)

Backwater input water G 1½“(inside thread)

Rear flanged hole to install the burner system

Pipe G ½“to install filling valve

Pipe with inside thread M48x2

mm to install an electrical

heating unit (optional)

Flanged hole to install ash removing system

Opening on top for

cleaning covered by a lid

of the boiler´s body

Thermo well for sensor

and thermostat

Emergency thermostat holder

Automatic boiler for wood pellets

3.2 CONTROL UNIT

Boiler is equipped with the control system with touch screen. This control system enables automatic boiler operation through the control and regulation features (thermostats, sensors, etc.) in the requested modes. It also enables Diagnostics mode of control, which can be used for instance for boiler commissioning.

The control system construction and its electrical shielding (IP 45) make safe and reliable operation possible even under the demanding operational and climatic conditions common to boiler rooms.

Basic configuration Optional configuration

Picture No. 3 Control unit - configuration

Configuration:

Name

Type

Options

Order code

Control unit - boiler function module

HZS 521-G

Standard

Terminal (touchscreen)

HZS 555-S

Standard

Module extension

HZS 532-1

Standard

Module heating circuit / accumulation tank

HZS533

Optional

Module solar

HZS535

Optional

Type and number of circuit

Type and number of module

HC1

SWT

HZS 521-G

HZS532-1

HC1

HC2

SWT

HZS 521-G

HZS532-1

HC1

HC2

HC3

SWT

HZS 521-G

HZS532-1

1 pc

HZS 533

HC1

HC2

HC3

HC4

SWT

HZS 521-G

HZS532-1

2pcs

HZS 533

HC1

HC2

HC3

HC4

HC5

SWT

HZS 521-G

HZS532-1

3pcs

HZS 533

HC1

HC2

HC3

HC4

HC5

ACU

HZS 521-G

HZS532-1

3pcs

HZS 533

HC1

HC2

HC3

HC4

ACU

SOL

HZS 521-G

HZS532-1

2pcs

HZS 533

HZS 535

HC – heating circuit SWT – sanitary water tank ACU – accumulation tank SOL – solar system

Automatic boiler for wood pellets

3.2.1 Boiler Function Module HZS 521-G

The heating system is modularly constructed. The HZS 521-G is a module for the boiler, which communicates with the CPU module and executes the transmitted instructions. The HZS is a simple component that is used to control automated processes in a heating system.

All interfaces and connections for controlling of the boiler are located on the control board.

Picture No. 4 HZS 521-G Connector and terminal electronics layout

Ambient temperature sensor

HC1 mix temp

Backwater temp

Sanitary water temp

Exhaust temp

Sanitary water top

Sanitary water bottom

Room thermostat 3

Room thermostat 2

SWT thermostat

Room thermostat 1

Impulse sensor 2

Impulse sensor 1

Room thermostat 4

Antifrost protection

Servo open

Servo close

SWT pump

Bypass pump

Ignition

HC1 pump

Primary fan

Exhaust fan

Feeder 1

Feeder 2

Automatic boiler for wood pellets

The control unit always contains modules HZS 521-G and HZS 532-1.

Picture No. 5 Module HZS 532-1

HZS533 HZS533 HZS535

Picture No. 6 Other modules

Automatic boiler for wood pellets

3.2.1.1 Technical base data

HZS521-G

Supply voltage

230 V AC +/- 10 %

(Input voltage for the power transformer on the power board, input

voltage for the STB, phase for the phase angle, relays and Triac outputs)

Power supply frequency

45 - 65 Hz

Current consumption of supply (230 V AC)

Total current consumption 200 mA + current consumption of the

connected loads (max. 16 A)

Power supply transformer

Supply for the power board and CPU electronics

Supply for Heater Lambda sensor: 200 mA

The power supply is switched of STB, L-STB

Loads connected over fuse F4 (3,15 AT):

X11 primary fan: maximum

690 W/ maximum 3 A

Loads connected over fuse F5 (10 AT):

X14

Screw: maximum 690W/ maximum 3 A

Loads connected over fuse F6 (10 AT):

X9 Turbine: maximum 2300 W/ maximum 10 A

Loads connected over fuse F7 (10 AT):

X8 Ignition: maximum 2300 W/ maximum 10 A

Loads connected over fuse F8 (10 AT):

X5 heat exchange cleaner: maximum 690 W/ maximum 3 A X6 grate open: maximum 690 W/ maximum 3 A

X7 grate closed: maximum 690 W/ maximum 3 A

The power supply not switched over STB, L

Loads connected over fuse

F9 (10 AT):

X10 boiler circuit return flow pump: maximum 2300 W/ maximum 10 A

HZS532-1

Internal electronics power supply

+24 V (from HZS 511), must be connected to the expansion controller

Relay power supply

230 VAC

Fuse

10 A for relay outputs

+24 V current consumption

HZS 532-1: maximum 60 mA (without relays) Maximum 120 mA (with relays) HZS 532-1 with 5 expansion modules, maximum 350 mA

HZS533, HZS535

Internal electronics power supply

+24 V (from HZS 511), must be connected to the expansion controller

Relay power supply

230 VAC

Fuse

5 A for relay outputs and/or 3 A for solar module

+24V current consumption

HZS 533 maximum 15 mA (without relays) Maximum 40

mA (with relays)

Automatic boiler for wood pellets

3.2.2 Terminal HZS 555-S with USB

Picture No. 7 Terminal with USB

Description

The HZS 555-S is an intelligent terminal for programming and visualization of automated processes. Process diagnosis as well as operating and monitoring automated procedures is simplified using this terminal.

A touch screen serves as the input medium for process data and parameters. The output is shown on a 5.7" SVGA TFT color display.

Cleaning the Touch Screen

CAUTION! Before cleaning the touch screen, the terminal must first be turned off to avoid unintentionally triggering functions or commands!

The terminal's touch screen can only be cleaned with a soft, damp cloth. To dampen the cloth, a screen-cleaning solution such as antistatic foam, water with detergent or alcohol should be used. First spray the cleaning fluid on the cloth and not directly on the terminal. The cleaning solution should not be allowed to reach the terminal electronics, for example, through the ventilation slots.

No erosive cleaning solutions, chemicals, abrasive cleansers or hard objects that can scratch or damage the touch screen may be used.

If the terminal is soiled with toxic or acidic chemicals, quickly and carefully clean the terminal to prevent corrosion.

3.2.2.1 Technical data

Supply voltage

Typically +24 V DC

MIN +18V DC MAX +30V DC

Current consumption of voltage supply

Typically 440 mA (pro + 24 V) ,

Maximum 650 mA

Standby

Typically 0.56 W

Starting current

Maximum 25 A for 20 μs

Automatic boiler for wood pellets

Display

Type

5.7" LCD colour display

resolution

VGA 640 x 480 Pixel

Colour depth

18-bit RGB (262K colours)

LCD Mode

TN / normal white

LCD Polarizer

Trans missive

Pixel size

0.18 mm x 0.18 mm

Active surface

115.2 mm x 86.4 mm

Background lighting

LED

Contrast

600

Brightness

Typically 350 cd/m²

Angle CR >= 10

Left, right, below 75°, above 60°

Environmental conditions

Storage temperature

-10 – +85 °C

Operating temperature

0 – 50 °C

Humidity

10 - 90 %, uncondensed

EMV stability

EN 61000-6-2: noise immunity EN 61000-6-4: noise emission

Vibration - tolerance

EN 600068-2-6

2 - 9 Hz: Amplitude 3.5 mm

9 – 200 Hz: 1 g (10 m/s²)

Shock resistance

EN 60068-2-27

15 g (150 m/s²)

Protection Type

EN 60529 Protected

through the housing

Front: IP54

Cover: IP20

Automatic boiler for wood pellets

3.3 BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE

The heating chamber is depicted in picture Nr. 1 and is comprises of these parts:

4.3.1 The burner body

4.3.2 Feeder F2 including the drive

4.3.3 Impulse sensor

4.3.4 Flexible hose

4.3.5 Primary fan

4.3.6 Electric resistance spiral for automatic ignition

4.3.7 Cover of spiral

4.3.8 Burner grate

Picture No. 8 Burner

The burner body – is a hollow weldment made from highly legated material with a bottom transversal fuel inlet. The

fuel is delivered by a built-in

F2 feeder

driven by an electric motor with a gearbox.

A set of slit and round jets in the burning grill ensures inflow of air in order to facilitate controlled full burning of delivered fuel during its stay in the burner chamber. The burned out fuel is subsequently pushed over the edge of the chamber into the ash receiver.

The inner space of the burner body is connected to an

air fan

, whose revolutions can be regulated within a large range

depending on the required boiler output or the type of fuel being used.

Impulse revolution sensor

The gearboxes of the F1 and F2 feeders are equipped with impulse sensors, which ensure safe operation of the boiler.

Connecting hose to the F1 feeder made of inflammable material connect Feeder F1 and Feeder F2. It is part of the

transfer fuel lines. It must meet strict installation rules:

It cannot have significant folds, which would block smooth fuel movement and must be built with inclination of minimum 50º (in a relation to horizontal plane).

Attachment to both adaptors must be tight.

Cleaning burner provides removal of excessive ash or cinder volume from the burner when burning lower quality fuel. The drive of the cleaning mechanism works together with ash cleaning.

4.3.3

4.3.1

4.3.8

4.3.2

4.3.4

4.3.5

4.3.6

4.3.7

Automatic boiler for wood pellets



Note:

Use of alternate fuels requires change of the burner type and also change of boiler program setup.



Note:

The cleaning mechanism burner drive and its installation are depicted in chapter 4.7 – Cleaning system.

3.4 CERAMIC PARTS

These parts are an inseparable component of the combustion chamber of the boiler and they have a major influence on the quality of burning.

4.4.1 Ceramic reflector – placed on the top of the burner

4.4.2 Ceramic secondary grate – placed in the boiler body above the burner heating chamber

4.4.3 Ceramic plate – placed above the door

4.4.4 Ceramic door jacketing– mounted on the door, or on the sides of the boiler body (at KP 82)

(See cap. 5.3 – 5.6)

3.5 FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)

F1 feeder delivers fuel from fuel storage to the burning chamber. It comprises of a pipe delivery path with an overflow part and an end sleeve. The feeder is built into the fuel storage under an angle, which cannot exceed 45º. If the angle was any bigger, fuel could be dispensed inaccurately. The transporter has its own electric drive, which is controlled by the control unit. The feeder is supplied in various lengths accommodating specific types of storage tanks.

Feeder F1 and F2 gearboxes are equipped with impulse sensors, which ensure safe operation of the boiler.

Feeder F1 set comprises of:

4.5.1 Body of feeder with flange

4.5.2 Axle-less spiral (diameter 38mm in KP 12S, KP 22S, KP 52S; diameter 52mm in KP 62S, KP 82S)

4.5.3 A small bar for mounting of the spiral

4.5.4 Motor and gearbox

4.5.5 Impulse revolution sensor

Automatic boiler for wood pellets

Picture No. 9 Feeder F1

4.5.1

4.5.2

4.5.3

4.5.4

4.5.5

Automatic boiler for wood pellets

3.6 BOILER SHEATHING INCLUDING HEAT INSULATION

The product sheathing is manufactured from steel sheet metal. It is painted with durable paint applied with the powder painting technology (KOMAXIT), which is highly resistant to outside conditions and ensures long-term perfect look of the product. Heat insulation 8 cm thick is done with heat insulation ROCKWOL boards.

The sheathing consists of the following parts:

4.6.1. Left side plate – including coverings

4.6.2. Right side plate – including coverings

4.6.3. Upper cover

4.6.4. Front lower cover

4.6.5. Front upper cover

4.6.6. Back cover – including covering

4.6.7. Door cover

4.6.8. Door

Picture No. 10 Jacketing KP 12S

4.6.1

4.6.2

4.6.3

4.6.4

4.6.7

4.6.8

4.6.5

4.6.6

Automatic boiler for wood pellets

3.7 CLEANING SYSTEM

The automatic cleaning system of the boiler significantly affects time of service-free operation of the boiler.

3.7.1 Ash removal

Ash removal is a complex set of technical and program means, which ensure ash removal from burner heating chamber to external ash receiver in a regular intervals. The ash is taken out by a spiral conveyor. It is driven by an electric motor through a toothed chain transmission.

The ash removal system can be mounted on the left or on the right side. Assembly of the particular version is done in the manufacturing facility based on an order. A professional service firm can perform a change (left/right) at the boiler location.

The motor is connected to the control unit.

3.7.2 Heat exchanger cleaning

Heat exchanger cleaning is a complex set of technical and program means, which ensure removal of solid waste from warm water boiler exchanger pipes in regular intervals. The cleaning is performed by linear movement of turbulators in the exchanger pipes. It is driven by an electric motor through a lever gearbox.

The heat exchanger cleaning system can be mounted on the left or on the right side. Assembly of the particular version is done in the manufacturing facility based on an order. A professional service firm can perform a change (left/right) at the boiler location. The drive motor is connected with the control unit.

Picture No. 11 Ash removal system

Automatic boiler for wood pellets

3.7.3 External ash container

The external receiver provides space for long-term ash collection outside the burning chamber. It enables long-term service-free operation even when using fuel with high ash content. It is attached to the boiler with a detent lever. During boiler operation the lever must be in the lower position and the connecting piping between the boiler and the ash receiver must be tight. Also the receiver cover must be tightly closed. Both of these requirements prevent burning fumes release to the boiler room.

The receiver is removed by moving the detent lever to the upper position and pulling it away from the boiler.

Dispensing of the contents to the waste disposal container is best done by two people because of its weight.

Picture No. 12 Heat exchanger cleaning Picture No. 13 External ash container

Automatic boiler for wood pellets

3.8 STANDARD ACCESSORIES

 Feeder F1 (the feeder length corresponds to the fuel bin and the particular installation used)  Outside temperature sensor for equithermal regulation  Surface temperature sensor – measuring of temperature behind the mixing valve  Surface temperature sensor – measuring of temperature of returning water  Cleaning tools (scraper for manual cleaning of the boiler body)  Outlet/inlet valve ½ “  KP boiler operation and service manual  Quality and completeness certificate of the product – Warranty Certificate

3.9 OPTIONAL ACCESSORIES

 Fuel storage (elective size)  Circulatory pump  Three-way (four-way) valve with a servomotor  Flue fan (for KP12S, KP22S, KP52S, KP62S, KP82S boilers)  Digital room thermostat  Tank for heating warm water (80 – 350 l)  Accumulation vessels (for instance 500 l, 750 l, 1 000 l)  Seasonal large volume fuel storage tanks  Spiral fuel feeder from seasonal tank – ensures automatic fuel refilling in the daily tank.  Automatic fuel feeding from the seasonal tank – ensures automatic operations of the spiral feeder from

seasonal tank.

 Pneumatic fuel feeder from seasonal tank – for fuel refilling in the daily tank from a longer distance.  Automatic control of another three loops (circulatory pump)  GSM modem – for remote control and monitoring of boiler operation.  Module for boiler connection to Ethernet communication network (Internet)  Outside temperature sensor for equithermal regulation  Surface temperature sensor – in the fuel intake area.  Surface temperature sensor – temperature measuring behind the mixing valve.  Surface temperature sensor – temperature measuring of returning water.  Connector outlet 2 pin  Connector outlet 4 pin  Compact hydraulic modules REGPON SYS  Compact hydraulic modules REGPON SWH  Compact hydraulic modules REGPON F



Note:

Optional accessories are not included in the boiler price.

3.10 FUEL BIN

The tank is supplied as optional accessory in sizes 100, 400, 700 and 1 000 l. The 400 l tank has a special modification for pneumatic transfer. Atypical tank finish can be delivered based on special order after consultation with the manufacturer. The tank can be refilled up to full volume without limitations. Fuel refilling of tanks supplied by the boiler manufacturer is safe, because the tank construction ensures safe distance of the operator from moving parts. During automatic boiler operation the filling tank cover must be closed.

Bin 100 l Bin 400 l for pneumatic transfer Bin 400 l Bin 700 l Bin1000 l Bin based on customer request – made to order Bin 400 l - folding Bin 700 l - folding



Note:

during operation, the cover must be closed.

Automatic boiler for wood pellets

Picture No. 14 Standard fuel bin sizes

Chyba!

Picture No. 15 Assembly guide

Automatic boiler for wood pellets

4 PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF

INSTALLATION

4.1 PLACEMENT OF PRODUCTS IN BOILER ROOMS

Minimum distances determine the space necessary to perform the operation and maintenance of the equipment. Boiler must be placed on horizontal non-flammable material, which overlaps min. 10 cm over the platform of installed equipment. Floor in front of the cleaning door has to be out of non-flammable material and min. 60 cm.

The necessary height over the boiler to the ceiling of the boiler room is approximately 450 mm (600mm with KP52S, KP62S, KP82S) for cleaning of the boiler.

4.2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL

COMBUSTIBILITY GRADE OF MATERIALS:

Grade A – non- combustible: stone, concrete, bricks, plasters, etc. Grade B – hardly combustible: inorganic insulation – rotoflex, glass wool, basalt insulation, wood wool slabs, etc. Grade C1 – low combustible: Formica, versalit, fibreboard, hardwood (beech, oak). Grade C2 – moderately combustible: soft wood (spruce), chipboard, rubber, floor covering. Grade C3 – easily combustible: asphalt, tar paper, PVC, paper --- etc.

Minimum safe distance from bulk flammable materials of the type B, C1 and C2 is 200 mm in course of installation of the boiler (as well as during its operation).

This distance is double - i.e. 400 mm for easily combustible materials C3.

As regards relation to the electrical network – it is necessary to ensure that the wall socket where the boiler is connected is always accessible.

4.3 LEGISLATION IN FORCE

Installed system is able to meet the installation requirements of Building Regulations in Northern Ireland (2010 No. 382).

Installed system is able to meet the installation requirements of Building Regulations in Wales (The Building Regulations

2010).

Installed system is able to meet the installation requirements of Building Regulations in Scotland [Building (Scotland) Act 2003 and the Building (Procedure) (Scotland) Regulations 2004.]

Installed system is able to meet the installation requirements of Building Regulations in England.

The product may only be installed by an organization trained by the manufacturer with authorization.

Electric parts may only be connected by an authorized person on professional competence in electrical engineering and trained by a manufacturer.

Installation company or person installing the boiler has to adhere the following standards and regulations, apart from other things or your national equivalents.

4.3.1 Heating system and boiler

EN 12828 – Heating systems in buildings – Design for water-based heating systems EN 303.5./2000 – boilers for central heating, part 5. EN ISO 12100-2/2004 - structure and versions of boilers.

4.3.2 Venting

EN 1443 – Chimneys – general requirements 734200 (9/2004). Pressure and temperature conditions necessary for safe operation of heat installations are described in the following standards: EN 13 384-1 and EN 13 384-2.

Automatic boiler for wood pellets

Recommended draught of chimney has to be within the range specified by the manufacturer in connection with the installed power output of the boiler.

Picture No. 16 Required chimney draft

Chimney systems resistant to humidity in which condensation of water vapour is permitted are recommended in order to ensure long-term trouble-free and safe operation of the boiler. (Chimneys resistant to humidity are recommended for appliances with temperature of combustion products from 30°C to 100°C.)

4.3.3 Fire regulations

EN 13501-1 Fire classification of construction products and building elements – Part 1: Classification using data from reaction to fire tests EN 13501-2 Fire classification of construction products and building elements – Part 2: Classification using data from fire resistance tests, excluding ventilation services

4.3.4 Electrical

EN 60 335-1 ed.2.20073 – Electrical appliances for domestic and other similar use – Safety - General requirements.

EN 60 335-2-102:2007- Safety – Part 2-102: Special requirements for appliances burning gas, petroleum and solid fuels containing electrical connections.

4.3.5 Protection against noise

Government Regulation no. 148/2006 Coll. – product is fulfilling all requirements.

4.4 STORAGE OF FUEL

Wood pellets have to be in a dry place protected against atmospheric effects because humidity damages the aggravates their burning parameters. Excessive humidity completely destroys pellets. They should be stored in a different room than the boiler or at least 1,500 mm from the boiler.

Operating stock of fuel may be stored in a special central bin which has to be manufactured from non-combustible material. Bins supplied by the manufacturer meet operating and safety requirements. They may be filled without any limits up to their total volume.

Large-volume bins have to meet corresponding fire and safety regulations. The supplier is obliged to work out working regulations and instructions for operation and maintenance of large-volume bins.

4.5 BOILER ROOM VENTILATION

Permanent ventilation of the boiler within approximately 75 m3 x hour-1 of fresh air has to be ensured, if a boiler of approximately 20 kW of power output is operated.

Automatic boiler for wood pellets

5 PUTTING THE PRODUCTS INTO OPERATION

5.1 CONNECTION TO THE SYSTEM

Connection to the system is performed in a usual manner - see the below given installation dimensions of products. Recommended connection of the boiler to the heating system – see section picture.



Important:

With boilers KP 52S, KP 62S, KP 82S – it is important to have both water output connect!

Installation dimension of boiler – See APPENDIX 1 - Technical data of the boilers KP X2S

Filling the system with water takes also place in a standard way and the following principles have to be adhered to at the same time:

Water for the heating system has to be clean, free from any admixtures.

If extremely hard water is used, there is a risk of "scale" formation - which is to the detriment of heat exchange and causes tension in the boiler body and this tension may cause damage to the homogeneity of the body.

Attention!

Impurities and sediments which might jeopardize failure-free operation of pumps have to be thoroughly rinsed before the system is finally filled with water.

5.2 INSTALLATION OF THE BURNER

The burner of the boiler is configured into one unit – the body of the burner + screw feeder + gear unit + motor + 2 spirals for electric ignition including needful cable.

Burner has to be placed in a flange on the back side of the boiler and fasten it by nuts M 10 with washers so, that the non-flammable rope is fitting evenly and very closely around circumference of the flange.

Connect the cable of the feeder F2 , of the fan. Place the fan in flange.

On the flange determined to a pellet supply connect by flexible hose and attach with fastener.

Insert a boiler thermostat sensor in to a tube placed on flange for pellet supply.

With burner KP52S, KP62S, KP82S attach a security thermostat by two straps on a pipe of the fuel input in to a burner.

Picture No. 17 Burner installation

Automatic boiler for wood pellets

5.3 INSTALATION OF THE CERAMIC CATALYTIC REFLECTOR

The ceramic catalytic reflector is manufactured from highly heat-resistant material (1800°C). It has two functions:

- directs the flow of combustion products through the boiler body

- assists very efficiently to burn out carbon substances and thus to reduce considerably harmful substances in combustion products.

Tne reflector is placed outside the combustion space during transport in order to prevent from any damage. The shape of the reflector reminds a hollow semi cylinder with one face closed - see picture.

KP 12S, KP 22S, KP 52S KP 62S, KP 82S

Picture No. 18 Ceramic reflector

The reflector is installed into the boiler on the surface of the burner boiler with the stop on its rear side and symmetrically to its centre line.

While in operation ceramic reflector has to touch the back part of isolation desk of the burner.



Note:

If you do not keep it, there is a chance of burner damage or a Boiler!! Check regularly!!

Automatic boiler for wood pellets

5.4 INSTALLATION OF SECONDARY CERAMIC GRATE

Individual parts of secondary ceramic grate on the picture.

KP 12S

KP 22S

KP 52S, KP 62S

KP 82S

Picture No. 19 Parts of secondary ceramic grate

Function as such of these parts is as follows:

- increase turbulence of combustion products before entry to the exchanger

- use additionally the so far unburnt residues of the gaseous combustible on the ceramic burning surface

- direct the flow of combustion products through the exchanger.

Installation of grate in to working surface is done through cleaning door of the boiler. Individual parts have to lift in the angle and place in back part of the burning chamber upwards. After is pushed all the way up to ceiling of a burning chamber the front side of the ceramic has to lift up in to a horizontal level and then place the ceramic part downwards in to s grooves. Grooves of the ceramic grate are in front and back side of a burning chamber.

Steps:

Chyba!

Automatic boiler for wood pellets

Picture No. 20 Ceramic grate parts placement guide

Automatic boiler for wood pellets

5.5 INSTALLATION OF CERAMIC SHIELD

Insert the ceramic shield flatways across the boiler space and fit the part on holders over the door from inside.

Steps:

Picture No. 22 Ceramic top placement guide

5.6 CERAMIC DOOR JACKETING

Ceramic door jacketing – attached to the door from the manufacturer

Picture No. 21 Ceramic shield

Chyba!

Automatic boiler for wood pellets

Picture No. 29 Ceramic door jacketing

5.7 CONNECTION OF ELECTRICAL PARTS

The electric parts connections can be performed by qualified personnel only. Connect the particular appliances according with connection diagram. During connecting the equipment must be shut down with the main switch or disconnected from power supply by pulling the electric cord from the outlet.

Relay for electric ignition

Burner thermostat

Cover control unit

2x M4

Boiler thermostat

Control unit

Automatic boiler for wood pellets

Connect:

Connection terminal Feeder motor F2

X14- L, N, PE

Impulse sensor F2

X45

Electric ignition spiral

X4-L, N, PE

Primary Fan

X11-L, N, PE

Flue Fan (if used)

X12-L, N, PE

Feeder motor F1

X13- L, N, PE

Impulse sensor F1

X44

Flue thermometer

X31

System pump

X10-L, N, PE

Boiler pump

X7-L, N, PE

Servo 3 (4) – way valve

X5-L, N, PE, X6-L, N, PE

Room thermostat

X46

Boiler thermostat

X47

Outside temperature

X34

Thermometer behind 3 (4) – way valve

X28

Thermometer back water

X29



Important note:

Fan and flue fan are controlled proportionally.

With MENU Diagnostics -

direct control

- to be checked by qualified personnel:

F1 feeder motor function and correct rotation direction F2 feeder motor function and correct rotation direction Correct functioning of F1 feeder impulse sensor and simultaneously Correct functioning of F2 feeder impulse sensor Functioning of fan and linearity of its regulation Functioning of flue fan and linearity of his regulation (if used) Functioning of system pump and its venting Functioning of boiler pump and its venting Functioning of motor and correct rotation direction of ash removal spiral screw Functioning of exchange cleaning motor Functioning and correct rotation direction of servomotor Functioning and timing of servomotor between limit positions and agreement of timing with SW setting Correct functioning of electric ignition spirals Correct functioning of attached thermometers

Automatic boiler for wood pellets

Setting of a proper equithermal curve Setting or changing servomotor timing

5.8 CHECKING TASKS BEFORE BOILER FIRST OPERATION

The authorized service technician preparing the boiler for its initial operation must perform the following tasks before start-up. He will record results of all checking tasks – will fill a Certificate of Introduction to Service (Putting boiler into operation) – see appendix 1 - Report of putting the boiler KP into operation.

Check water volume in the heating system and corresponding water pressure. Check whether fittings between the boiler and the heating system are open. Check the heating system for leaks at all new connections – pressure test done by a professional firm. Check the chimney connection (must be tight and safe to prevent escape of flue gases). Chimney and boiler connection must have valid inspection. Check functionality of circulatory pump and its venting. The electrical grid outlet must be always accessible. New electrical outlet must have a valid inspection.. Check the heating chamber and ash receptacles. Clean from possible dirt. Check tank filling by specified fuel. Check operating parameters for the specific boiler type. Confirm that installation meets building regulations for the country in which it is installed – by providing of Building Regulations Compliance Certificate or a Local Authority Building Notice. When flue or chimney is provided as part of the installation the installer must provide information essential to its correct application with permanently displayed way.

6 BOILER SERVICE AND MAINTANANCE DURING OPERATION

Service and maintenance intervals are directly dependent on the type and quality of used fuel. If recommended fuel – wood pellets with clearly guaranteed quality parameters is used, service and maintenance of the product during operation is very simple.

6.1 SERVICE

Pellet boiler service comprises of only two tasks. The necessary presumption is use of guaranteed fuel endorsed by the manufacturer. As a standard, use wood pellets with the 6mm or 8mm diameter.

6.1.1 Refuelling

The fuel level must be maintained in such height that there is always a minimum of 10cm pellets above the F1 feeder inlet. Insufficient pellet volume may result in irregular dispensing or boiler fire extinction.

You will be told the presumed refuelling interval by the service technician according to your specific configuration.



Note:

The refuelling interval cannot be prescribed ambiguously.

It depends on: Fuel bin size

The average boiler output in the particular time interval Quality of used fuel

Anticipated interval – see anticipated burning times in table 1.



Note:

A seasonal tank may be installed to the boiler. Refuelling is controlled automatically or manually.

6.1.2 Emptying of the external container

It is generally true that ash must be removed any time the ash level exceeds 2cm level below the side edges of the external ash container.

Automatic boiler for wood pellets

Before remove the external tank boiler ash off button "STOP". Prevent spontaneous start taking out ash and flue gas leakage or when not installed external ashtray!

Before you remove the external ash container, switch „down“ the boiler „STOP“ button. This way you will avoid spontaneous commencement of ash removal and escape of burnt gases during time when there is no external ash container in place.

Anticipated intervals:

1 × in 6 month (KP 12S, KP 22S) when using wood pellets 1 × in 2 month (KP 52S, KP 62S, KP 82S) when using wood pellets

It is also possible to remove ash from the burning chamber by turning on the ash removing drive in the Menu.



Note

: The ash container removal interval depends on the following: Equipment output (volume of used fuel per given time period) Quality of fuel.

When using alternative fuel, this interval shortens significantly.

Correct boiler adjustment. Type of boiler installed.



Important note:

After checking the ash volume in the container or after ash removal, always close the receptacle

cover carefully. This way you will prevent escape of burnt gases to the boiler room.



Important note: T

he external ash container must be tightly attached in the right place to the boiler during

operation.



Important note:

After each visual check of burning or after ash removal you must always make sure that the boiler door is tightly closed to avoid being stricken by flames from the burning chamber!!! Ajar or slightly opened door will cause increased fire hazard and also negatively affect the fuel burning processes.

6.1.3 Flue gases exchanger cleaning

Cleaning of the gas flue is done automatically in intervals set by the control unit program. Proper setting is done in the manufacturing facility or later by an authorized service technician. Exchanger cleaning is performed repeatedly several times per day depending on burning intensity. Exchanger cleaning can be limited by time. It is not feasible to use exchanger cleaning for instance during night time.



Note:

In case the boiler shows signs of faulty burning, smokes when the door is open or the burnt gases temperature

is rising, check the efficiency of exchanger cleaning. Change the cleaning interval.

6.2 MAINTANANCE

6.2.1 Burnt gases exchanger cleaning

Is done automatically, electric motor drives lever cleaning mechanism.

Operation interval: set by the program, differs by fuel types.

It is also possible to remove ash from the burning chamber by turning on the ash removing drive in the Menu Diagnostics…

The service technician checks correct function of the equipment, checks turbulators for damage, correct function of the drive and lever mechanism and must lubricate cleaning drives if needed.

Anticipated intervals: 1 x per year

Automatic boiler for wood pellets

6.2.2 Burner grate cleaning

During checking it is necessary to pay attention to burning grate cleaning in order to avoid plugging of the burner air jets. Always perform cleaning, when a continuous layer of ash exceeds 4cm. Clean the burner grate with jets simply by moving a scraper along the burner grate area.

Anticipated intervals: inspection once every 10 days

6.2.3 Ceramic grate cleaning

The ceramic grate construction has a self-cleaning feature. Dust particles do not stick to the grate after burning pellets. Nevertheless check cleanliness of these parts. If needed, you can get rid of the dust particles by slightly shaking the individual parts of the ceramic grate. After this procedure check correct placement of ceramic parts.

Anticipated intervals: inspection once every 4 month

Inspection once every 10 days



Note:

Perform this check when the burned gases temperature repeatedly or permanently exceeds 200ºC.



Important note:

Ceramic parts could be extremely hot. Use a proper tool or protective gloves.

Automatic boiler for wood pellets

6.2.4 Annual audit

Every boiler of the KP series should undergo annual audit after the end of the main heating season. This audit is necessary in order to prevent from possible non-standard conditions in the next year of operation of the equipment. If the annual audit is not performed as per the below mentioned programme, this may be considered by the manufacturer to be the reason for rejection of guarantee conditions in the second year of use. At the same time, the user gets exposed to a risk of any failure which may cause loss of operating certainty or large physical damage.

Annual audit - due to demanding activities - has to be entrusted to a trained servicing company which will make record of the audit in the documentation of the boiler.

We proceed as follows during the annual audit:

Turn off the main switch of the control unit

Disconnect the boiler from network by pulling the mains cord from the wall socket or by turning the socket circuit

off in the switchboard.

As we will also work inside the boiler, let us the boiler 2 - 3 hours to cool down before we start next work.

After the boiler gets cooled down

We will start dismantling of ceramic parts through the burner door - i.e.:

Remove the ceramic shield over the burner door (by gradual moving to the left and

Release it then to the bottom right side from the fixation aperture)

Remove the ceramic reflector by simple pulling forward

Remove all parts of ceramic burning out grate. Lift the back side to a maximum possible hights, front side lower down and remove the part out.

Now remove all ash build-ups by steel brush from ceramic parts.



Note:

Do not forget that all parts are made of ceramic. Work carefully so you do not damage all parts.

Cleaning the draughts of combustion products

If there is automatic cleaning installed, there just has to remove a dust above exchanger by a vacuum cleaner or by forfeiture dust through pipes of heat exchanger in to a burning chamber.

Proceed as follows:

Close the burner door so that the boiler does not contaminate the boiler room too much when we will clean the draughts,

Remove lid of the jacketing,

Dismantle the lid of the boiler body (4 screws) and place it on the floor. When you mount it back later, remove slightly ash from it and be careful not to damage insulation during this operation.

Now release ash from turbulators and

Vacuum dust from the space above exchanger



Note:

With advantage we use ash separator and regular vacuum cleaner

Dismantling of the burner

Remove the fan from the extension pipe on the flange of the burner,

Dismantle the flanged joint (4 screws) from the drive of the spiral-chute Feeder F2, remove the complete feed screw and place aside. Check it for wear and tear at the same time.

Dismantle now the whole burner flange (4 screws) and remove the burner. Clean the whole inside surface of the burner carefully with a wire brush, mainly in the place of the feeder's outlet and also in all places of round and slotted nozzles. These places are most susceptible to sedimentation of solid products of burning.

Finally, remove all solid waste located inside the air box of the burner. Tilt the burner gradually in order to pour out all impurities from the burner through the pipe of the fan. Work until the burner is completely cleaned.

Automatic boiler for wood pellets

if automatic ignition is installed on the burner, dismantle both spirals and remove all impurities from the air box of the burner through the installation apertures.

Cleaning of burning chamber

In order to prevent from increased dustiness, we recommend placing the lid of the boiler body on the boiler for this time.

While cleaning, we may not forget about the placement bars of the extension grate which have to be perfectly cleaned so that individual parts of the extension grate can be precisely placed on them back.

After complete assembly of all boiler parts remove ash to the external ash container by manually turning on the ash removal drive in manual control in Menu Diagnostics.

Remaining ash can be removed by scraper from a burning chamber in to a auger.

Back installation of all parts

Should be done reverse order. Ensure mainly the following in course of this activity:

Electric resistance coils - Maximum tightness has to be ensured between the flange of spirals and the wall of the burner.

The flange of the burner has to be put precisely so that the packing cord of the flange fits tightly on the protruding ribs of the body all over the circumference.

The spiral-chute feeder should be anchored precisely in the axis of the pipe and should not thus drag against the wall of the pipe (which is one of reasons why smooth operation is blocked).

The joint has to be treated with a sealing paste before the flange of the drive is installed, which is an important measure against smoke penetration.

Individual part of the extension grate, have to be placed precisely in their correct order.

The ceramic reflector has to be placed symmetrically in the corresponding bed of the burner and plugged in the stop to the rear side. Individual bearing surfaces (of the burner and reflector) have to be in mutual contact.

Having the back installation been done completely, check via gradual visual check whether all parts are installed correctly. Finally, try operation of the spiral-chute feeder. Its operation has to be calm and without any disturbing noise.

Re-entry into service

After the maintenance is done connect boiler to a power line a turn on main switch.

Check if feeders are filling with a fuel and that the pellets are transported in to a burner.

Press button START and check right functionality…

If the boiler is not going to be used in summer time (like heating of service water), we keep the main switch off.

Automatic boiler for wood pellets

7 DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE

Product is made out of materials the waste of which does not have any hazardous properties.

The following main kinds of waste will be generated after the end of the product´s service life: Steel exchanger, jacketing, feeders, bin – waste code 170405, category O. Heat insulation (ROTAFLEX, SIBRAL) – waste code 170604, category O. Ceramic grate, reflector and plates on door – waste code 170103, category O. Control unit with sensing and control elements – waste code 200136, category O.

7.1 NATURAL PERSON

Shall perform disposal of the product as follows:

8.1.1 Steel waste shall be sold to the nearest scrap-yard.

8.1.2 Heat insulation and ceramic parts shall be disposed of as mixed municipal waste.

8.1.3 The control unit with sensing and control elements is subjeck to return collection.

Return collection takes place in seller´s plant, where was this product purchased or at the manufacturer of the boiler. Return collection is free of charge.

In accordance with current requirements of environmental protection the electronic parts of the poduct does not contain lead!

Still do not dispose el. equipment as a municipal waste!

7.2 LEGAL ENTITY

Shall perform disposal as per act no. 185/2001 – act on wastes as amended. Waste shall be sorted as per the kind and category (see main kinds of waste) and handed over to an authorized entity for disposal.

Exception is represented by control with sensing and control elements are subject to return collection which is directly performed by the seller´s plan where the product was bought or by the manufacturer of the boiler. Return collection is free of charge.

In accordance with current requirements of environmental protection the electronic parts of the product does not contain lead!

Automatic boiler for wood pellets

8 CONTROL UNIT OPERATION

8.1 MAIN MENU

Description of the basic control panel screen

After switch on the main power switch, start program and after several minutes will show the main menu.

For easy operation are used:

- Buttons with names or pictograms

- Buttons with moving (setting of power and temperature)

- Boxes with information’s (text, numbers or pictograms)

- Date and time

The data are showed as numbers, diagrams or combination.

Picture No. 23 Main menu – sample of visualisation



Note: Changes important parameters for combustion quality and safety is allowed after insert

password according with table No.6 (In the end of this manual).

Button:

Information and Service menu

Button: Heating circuit setting

Button: Move to second screen

Button SELECTION OF OPERATING MODE

Actual status

Button: START/STOP

Button:

Power setting (required power)

Button: Temperature setting (required temperature)

Information space: Boiler temperature - actual Exhaust temperature - actual

Information: Date Time

Automatic boiler for wood pellets

8.2 OPERATING CONDITIONS – MAIN MENU

SELECTION OF OPERATING MODE

User - before start operation of boiler, have to select operation mode – touch on the button is automatically changed mode:

FIXED POWER

Operate boiler automatically on the fixed power. User can set value of power (% or kW) and temperature (°C).

MODULATION

Operate boiler automatically. User can set value temperature (°C). The power is adjusted automatically depend on temperature. User cannot change the power.

EQUITHERM

Operate boiler automatically. The power and temperature is adjusted automatically depend on outside temperature and setting of equitherm diagram. User cannot change the power and temperature. This mode user cannot chose when the out temperature sensor is not use.

Selection – touch on button:

FIXED POWER » MODULATION » EQUITHERM

START

After touch on the button START boiler is working automatically. The display shows step by step actual operation:

Ignition

Fuel is burn on by electric spiral.

Stabilisation

Stabilisation of fire

Operating

The fire was stabilised and boiler is normally working.

Stand-by

Quiet mode of the boiler, when the boiler is not burning actively. Boiler is ready on the basis of impulse from surrounding equipment (thermostats, GSM Modem) to restore the supply of heat.



Note:

Change –SELECTION OF OPERATING MODE – is possible to make at any time during operation.



Note:

If boiler is working in -MODULATION or EQUITHERM - control unit automatically setting power in the range 0

– 10.



Note:

After „START“ is activated automatic ignition. Auto ignition runs for several minutes. The programme routine of Automatic Ignition has absolute priority to be carried out in full extent. If the routine is activated, it is not possible to interrupt or stop it in any way. This fact is an important condition for reliable operation of the boiler because it is then possible only to ascertain indirectly from further behaviour of the boiler whether it is burning or not. The on-going routine of Automatic Ignition may be terminated only by the operator by switching STOP. Service is than responsible for the correct set up to a automatic operation.



Note:

If the boiler is working in the mode FIXED POWER, MODULATION, EQUITHERM and power supply is

interrupted the boiler will start with the electric ignition routine after the power supply is resumed.

Automatic boiler for wood pellets

8.3 MAIN MENU

8.3.1 Setting menu

8.3.1.1 Info menu

Button: Back on the previous screen

Button: Alarm list

Software version No. dated

Software version visualisation No. dated

Operating hours

Button: Move to second screen

Automatic boiler for wood pellets

8.3.1.2 Menu users settings

Automatic boiler for wood pellets

Time, date

Current time HH:MM:SS

Current date DD.MM.YY

Tine without screensaver

Button: Password

Showed:

„Please insert your password“

After touch on the box for password: Insert password and enter. In the end confirm: OK

If is password right – button change on green colour

Automatic boiler for wood pellets

Cleaning an ash removing

Skin

Time window setting

Automatic boiler for wood pellets

IP Adress

8.3.1.3 Menu Service

Button: Password

Showed:

„Please insert your password“

After touch on the box for password: Insert password and enter. In the end confirm: OK

If is password right – button change on green colour

Automatic boiler for wood pellets

Diagnostics

Manual mode



Note:

If you have empty feeders – you must fill fuel into the feeders before START: The operator can directly control the startup fuel feeders. It is possibilities to fuel filling Feeder F1. Turn on Feeder F1 depend on Feeder F2. Steps for turn on Feeders:

1. Feeder F2

2. Feeder F1

The rotation is signalized by two small red windows – blinking. When fuel is falling down from Feeder F1 into Feeder F2 – immediately stop Feeders! Overfilling of fuel is dangerous!

Other functionality are used for diagnosing of functionality.

Button: Password

Showed:

„Please insert your password“

After touch on the box for password: Insert password and enter. In the end confirm: OK

If is password right – button change on green colour

Touch and start functionality

Automatic boiler for wood pellets

Actual values

Configuration

Automatic boiler for wood pellets

Parameters

The setting value of parameters is important for combustion quality, correct function and safety.

The producer saves changes of parameters by password. Is prohibited to make unqualified changes.

 Important note:

The value of parameters on the pictures below is ONLY SAMPLES!

Actual setting depend on the type of boiler! Producer and qualified service can make changes only!

Automatic boiler for wood pellets

Temperatures

Maximum boiler temperature

Minimum exhaust temperature for heating

Button for activate electric heating

Maximum exhaust temperature

Temperature for activate pump

Temperature for activate bypass pump

Automatic boiler for wood pellets

Ignition

Button for activate electric ignition. Boiler is operating in Stand-by and keeps the fire Fuel for ignition

Time for pre heating of ignition spiral (without fan)

Control temperature



Note:

Control temperature is important for fire control

Fan revolution

Time limit for ignition

Time for stabilisation of fire

Fuel for stabilisation of fire

Time spiral activation - during stabilisation of fire

Time for prolong of stabilisation of fire

Time feeder F1 during burn on fuel

Automatic boiler for wood pellets

Standby mode

Programs

Button to select programs for settings

Parameters for chosen program above

Actual program for fix power

 Note

Is possible to set here but main settings is on the main menu

Time period, in which automatic boiler is not actively burning

Time – fire life

Setting temperature

Time -

Automatic boiler for wood pellets

Modulation

Feeders

 Note

If it is set „0“ then there is no control of the motor

PID regulation recommended

Parameters for regulations

Time count impulses

Allowed errors

On time feeder F2 before F1

Off time feeder F2 of F2

Automatic boiler for wood pellets

Cleaning, Ash removing

USB

Time window setting

Automatic boiler for wood pellets

Load from USB

Save on USB

Automatic boiler for wood pellets

8.3.2 Menu – heating circuits

Button for open window for addition heating circuits

Button for confirmation

Automatic boiler for wood pellets

After confirmation:

8.3.2.1 Tank

Demand for heating

Time window setting

Button for settings menu

Button for manual functionality

Visualisation of pump status Green - On Grey – Off

Automatic boiler for wood pellets

Function for settings of parameters

Function for manual control of pump

Automatic boiler for wood pellets

8.3.2.2 Sanitary water

Demand for heating Blue – heating Red – not heating

Time window setting

Button for settings menu

Button for manual functionality

Visualisation of pump status Green - On Grey – Off

Automatic boiler for wood pellets

8.3.2.3 Heating circuit

Demand for heating Blue – heating Red – not heating

Time window setting

Button for settings menu

Button for manual functionality

Visualisation of pump status Green - On Grey – Off

Button for ekviterm parameters

Servo location: White: closed Black: opened

Servo control: White: Off Green: On

Automatic boiler for wood pellets

9 GUARANTEE AND LIABILITY FOR DEFECTS

The manufacturer provides guarantee:

- for the boiler on a period of 24 months from the date of putting into operation, however, no longer than 30 months from the date of shipment from the manufacturing plant

- for the boiler body on a period of 60 months from the date of putting into operation

- ceramic parts are not covered by the warranty. Its durability is dependent on the way of operation of boiler and their guaranteed durability is 12 months.

GUARANTEE CONDITIONS

1) User is obliged to ensure installation of the boiler and putting it into operation only by an authorized servicing organization which has the manufacturer's accreditation and the user is also obliged to send the letter of guarantee number 1 to the manufacturer's address immediately after the product has been put into operation.

2) The boiler has to be operated only within these Instructions for operation and only prescribed fuel may be used (wood pellets - 6-8.5 mm), free from any admixtures and foreign object. Alternative fuel must be approved by the boiler manufacturer.

3) If the user wants to claim any form of guarantee, he/she has to submit duly filled in letter of

guarantee number 2.

4) The user is obliged to demonstrate that the product was maintained in regular intervals which are described in the chapter "MAINTENANCE". Regular annual maintenance has to be done by trained person who is also responsible for the record of it within 14 days (list is part of manual) / service intervention or repaired has to be correctly recorded and sanded to a manufacturer.

5) Every notification of defect has to be done in writing to the address of the manufacturer immediately after having been ascertained.

The manufacturer reserves the right of product innovations, which may not be part of this manual.



Important:

Recommended hydraulic connections are principled diagrams created by manufacturer on the basis of practical experience in the operation of boilers KP.

The user can use the application unchanged as well as in particular modification to the best solution of heating system.

This is primary responsibility of the designer and implementer of the heating system - which is why the Ponast company cannot take over the guarantee for the functionality of a particular solution of heating system.

Picture No. 24 Principle of the modulation

Picture No. 25 Directory information - consumption wood pellets for boiler family KP

Picture No. 26 Circuit diagram – control unit

Picture No. 27 Circuit diagram + module HZS 533

Picture No. 28 Circuit diagram - HZS 533, HZS 535

10 APPENDIX 1 - TECHNICAL DATA OF THE BOILERS KP x2S

10.1 INSTALLATION DIMENSION OF BOILER

Type

Picture No

KP 11

KP 11.1

KP 12

KP 12S

KP 21

KP 22

KP 22S

KP 51

KP 52S

KP 61

KP 62

KP 62S

KP 82

KP 82S

Legeng:

KP xxx

Water output G 1 1/2"

Flue ducting Ømm (by type KP)

Water input G 1 1/2"

Outlet valve G 1/2"

Semiautomatic cleaning

Type

Picture No

KP 11

KP 11.1

KP 12

KP 12S

KP 21

KP 22

KP 22S

KP 51

KP 52S

KP 61

KP 62

KP 62S

KP 82

KP 82S

Legeng:

KP xxx

Water output G 1 1/2"

Flue ducting Ømm (by type KP)

Water input G 1 1/2"

Outlet valve G 1/2"

Semiautomatic cleaning

10.2 TECHNICAL DATA

Thermical and technical parameters of products

Parameter

Unit

KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Rated output

kW 14,9

19,5

49,5

Rated power (thermal)

kWt 16,4

21,5

31,9

54,7

68,9

Output range

kW 4,5-14,9

5,8 – 19,5

8,6 - 29

14,6-49,5

18,6 - 62

24,5 - 82

Fuel consumption

kg/hour-1

1,1-3,51

~1,3 - 4,4

~1,9 - 6,6

3,44-11,63

~4,1 – 14,28

~5,7 – 18,8

Efficiency at rated output

% 90,8

90,5

90,9

90,4

90,0

90,1

Efficiency at minimal output

% 90,6

88,9

88,5

89,6

89,7

Flue gas temperature at minimal output

°C 79

101

110

101

Flue gas temperature at nominal output

°C 126

127

141

153

160

147

Boiler class - 5 5 5 5 5 5 5 5 5 Output temperature of water

°C 55-80

55-80

Burning time - min/max power - container 400l

hour 250-78

213 – 61

142 - 40

80-24

64 - 19

Burning time- min/max power - container 700l

hour

439-137

373 – 107

249 - 70

140-41

111 – 33

92-28

Solid harmful substances in combustion

Parameter

Unit

KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Average dust emissions at nominal power

g/hour-1 0,36 0,65

2,2 Flue gas mass flow rate at nominal power

kg/sec 0,009

0,009

0,016

0,028

0,035

0,048

Flue gas mass flow rate at minimal power

kg/sec 0,003

0,003

0,007

0,012

0,015

0,021

Technical parameters of products

Parameter

Unit KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Weight

kg 255

255

310

335

370

495

520

590

700

Water content

l 103

103

140

200

210

220

260

Flue pipe diameter

mm 130

130

150

160

200

Minimal chimney draught for operation

Pa 8 8 8 8 8

Flow and return manifold diameter

G 1 1/2"

Heating surface

m2 1,8

1,8

2,1

3,2

3,6

Dimensions (W x L) without ash pan

565x1078

537x1066

693x1100

674x1146

823x1102

816x1078

816x1198

816x1348

Dimensions (H)

mm 1440

1440

1444

1440

1444

1590

1595

1744

Working overpressure of water

bar up 3

up 3

Hydraulic loss ΔT 10 K

mbar 4,77

4,77

10,97

33,7 Hydraulic loss ΔT 20 K

mbar 1,26

1,26

2,77

8,3 Required draught

mbar

0,1 – 0,2

0,1 – 0,3

0,3 – 0,4

Minimal return water temperature

°C 55

Recommended operating temperature of heating water

°C 60 – 80

60 – 80

Noise level

dB 57

As a guaranteed fuels for the boilers KP are wood pellets with parameters specified in table Fuel and its parameters

Wood pellets diameter

6,0 - 8,5 mm

Caloric value

Approx. 16-18 MJ / kg

Water content

up 10 %

Ash content

up 1 % ( 0,8 – 1,0% )

Bulk weight

0,6 – 0,64 kg / dm3

Fuel delivery system

plastic bags 15 – 25 kg, Big Bags 800 - 1100 kg, filled from tank

Electrical parameters of products

Parameter

Unit

KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Mains voltage

230 V AC ± 10%, 50 Hz ± 2 Hz

Standby power consumption

W 4 4 4 4 4 4 4 4 4

Standart power consumption (2 motors & fan)

W 173

173

193

210

193

210

340

400

Maximal power consumption

W 1300

1300

Average power consumption

W 212

212

217

225

Electric protection of the control unit

---

IP 54

Electric protection of the boiler´s wiring

---

IP 20

Average values of emissions O2, CO2, CO, OGC, Nox and dust

Re-counted values of emissions O2, CO2, CO, OGC, Nox and dust

revison 9.7.2013

Parameter

Unit KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

[%]

7,34/10,46

7,65/13,91

7,40/14,82

5,42/11,10

6,62/12,67

6,91/11,55

CO2

[%]

13,18/10,15

11,66/6,36

11,94/5,39

14,59/9,45

12,53/7,24

13,41/9,12

[ppm]

68/259

48/143

165/197

10/78

144/367

184/310

OGC

[ppm] 6/4

1/1

3/9

1/3

1/5

3/5

NOx

[ppm] 98/64

98/41

103/33

130/63

110/45

119/61

Dust

[mp/m3]

34/24

32/6

40/19

40/24

48/32

40/24

18/24

[mg/m3] O

2 =

68/338

49/277

167/439

9/108

137/606

180/451

OGC

[mg/m3] O

2 =

8/6

1/3

4/17

4/27

1/6

1/10

3/9

NOx

[mg/m3] O

2 =

162/138

166/132

171/121

188/144

173/121

190/147

Dust

[mg/m3] O

2 =

28/25

27/9

27/11

32/38

34/35

31/33

14/28

Parameter

Unit

KP11.1

KP11

KP 12S

KP21

KP 22S

KP51

KP52S

KP 62S

KP 82S

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

Nominal/

Lower output

[mg/MJ]

34/170

26/145

87/229

5/54

72/230

90/225

OGC

[mg/MJ] 4/3

0/0

1/5

1/3

0/2

2/5

NOx

[mg/MJ] 81/69

87/69

89/63

94/72

90/64

95/73

Dust

[mg/MJ] 14/13

14/5

17/23

17/18

16/17

7/14

11 APPENDIX 2 - REPORT ON THE PUTTING THE BOILER KP INTO OPERATION

12 APPENDIX 3 - SELF-ADHESIVE LABEL - IMPORTANT SAFETY INFORMATION

Ponast KP 82S, KP 52S, KP 22S, KP 12S, KP 62S Service And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual