Roca P-10 Installation, Assembly And Operating Instructions

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P-10

Multifuel Boiler

Installation, Assembly
and Working Instructions
for the INSTALLER

GB

Combustibles fluidos

For fluid-fuel firing

Combustibles sólidos

For solid-fuel firing

Caldera policombustible

Instrucciones de Instalación,
Montaje y Funcionamiento
para el INSTALADOR

E

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42 – Interruptor del circulador / Pump On/off switch
43 – Interruptor del quemador / Burner On/off switch
44 – Termostato de regulación / Control thermostat
45 – Termostato de seguridad / Limit termostat
46 – Termohidrómetro / Combined temp./altitude gauge

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53 - Recogedor / Shovel
54 - Rastrillo / Scraper
55 - Atizador / Slice bar
56 - Cepillo rectangular, con mango / Flue brush with handle

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Nota: Si se coloca termostato ambiente, deshacer el puente existente entre los bornes 5 y 6.
Note: Where an ambient thermostat has been installed, remove the jumper across terminals 5 and 6.

Esquema de conexionado / Wiring diagram

Esquema eléctrico de principio

Schematic Wiring Diagram

Interruptor circulador
Pump On/off switch

Circulador
Pump

Termostato ambiente
Ambient thermostat

Interruptor puerta quemador
Burner door microswitch

Interruptor quemador
Burner On/off switch

Termostato regulación
Control thermostat

Termostato seguridad
Limit thermostat

Quemador
Burner

Interruptor circulador
Pump On/off switch

Interruptor quemador
Burner On/off switch

Termostato regulación
Control thermostat

Termostato seguridad
Limit thermostat

Circulador
Pump

Termostato ambiente
Ambient thermostat

Interruptor pta. quemador
Burner door microswitch

Quemador
Burner

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Main features

Constructed basically from cast-iron, which constitutes a guarantee of indefinite continuous use.
It permits fitting the ashpit door and the burner door, with burner assembly at the same time and therefore it is not necessary to
change accessories for adapting the boiler for using different fuels.
The cast-iron sections, joined together by means of push nipples, make up a completely sealed combustion chamber and
flueways, for making full use of the combustion heat and energy consumed.
Combustion chamber with fixed water-cooled grates adapted for burning all types of fuel, with no need of firebrick protection.
It has an ash-pan for quick and clean removal of ashes and cinders.
The boiler body and all the doors are thermally insulated to prevent heat loss and improve efficiency.
Automatic damper regulator, control panel and burner safety microswitch for use according to the chosen fuel.

Dimensions and Technical Features

GB

ORIFICIOS: a = ida 2”

Flow 2”

b = retorno 2”

Return 2”

c = desagüe 1/2”

Drain 1/2”

d = aparatos de regulación y control 1/2”

Comb. gauge & damper regulator 1/2

For solid-fuel firing For fluid-fuel firing

(3) (1) (2) (4)

Boiler

Type

Nº. o f

Sections

Wate r

content

Flueway

Pressure

Drop

Depth

A

Heat Output Net

Effic iency

Fuel Load

Volume

Ashpit

Volume

Approx.

Weight

Anti-

runaway

Equipment

Heat Output Net

Effic iency

Approx.

Weight

Litres mm.w.g. mm kcal/h k W % dm

3

dm

3

kg kcal/h kW % kg

P-10-3 3 13 0,10 309 7.000 8,1 75 12 5,3 118 AE0 10.000 11,6 82 125
P-10-4 4 17 0,15 414 10.000 11,6 75 19 7,6 147 AE1 14.000 16,3 82 154
P-10-5 5 21 0,20 519 13.000 15,1 75 26 10,0 176 AE1 18.000 20,9 82 183

(1) Output obtained with coal

- Granulometry 20 ÷ 60 mm

- Calorific value (net) 7,000 kcal/h
(2) Corresponds to the volume occupied by the fuel from the grates to the bottom of the firedoor.
(3) With excess air e ≈ 25%
(4) Optional

Chimney sizing

To guarantee the necessary negative pressure at the base of the chimney, the diameter should be 17.5cm and the minimum
height 5 m. When fitting approved chimneys, please observe the makers’ directions.

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Delivery

1 - The P-10 boiler for solid fuels is delivered in two packages:

Pack 1 - Fully assembled boiler body, painted with an anti-

rust primer, protected with wooden packing for
transport.
The ash-pan beneath the grates.
The automatic damper regulator, in its packing,
and the shovel inside the combustion chamber.

Pack 2 - The casing unit in a cardboard pack which

contains:
The casing, comprising:

- Top cover

- Right-hand panel

- Left-hand panel

- Back cover

- Firedoor case

- Ashpit door case
Boiler cleaning tools:

- Flue brush

- Brush handle

- Scraper

- Slice bar
Insulating blanket for the boiler.
A plastic bag containing:
The protective cover for the damper regulator, the
screws for fixing it, as well as the screws and
washers for fixing the casing.

2 - The P-10 boiler for fluid fuels comes in three packages.

The contents of two of them are similar to those for the
solid-fuel version, and the other contains the conversion kit
CLS-7 for fluid-fuel firing and comprises:
Pack 3 -Burner door with fitted casing.

- Control panel with burner door microswitch.

- Plastic bag with accessories and nuts & bolts.

Assembly

Checking the material

First we suggest checking the number of packages, that their
contents conforms to those indicated in “Delivery” and that no
incident in transport or lying on site has altered their
composition.
With respect to the boiler, proceed to:
1 - Remove the packing.
2 - Open the ashpit door (1) by means of the handle (2).
3 - Lower the front section grille (3) hinged on the built-in

section brackets (4) and leave it upside down.

4 - Take out the material contained in the combustion chamber

and replace the grille (3) in its original position. Close the
door (1).

5 - Open the firedoor (5) using the handle (6) and check the

flues to make sure that no foreign body has entered them.
It so, it should be removed. Close the door (5).

Location

6 - Check that the P-10 boiler is properly levelled on the base

chosen for its use.

Damper Regulator

7 - Remove the plastic cap that protects the threads of the 1¼”

x ¾” tapping (7) in the front section and fit the body with
handle of the automatic damper regulator (8)* according
to the instructions that come with this accessory.

* This operation can be omitted in boilers intended for continuous use of

fluid fuels and the bushing in the tapping (7) substituted by a 1¼” plug.
Nevertheless, from the aesthetic point of view it is suggested that this
piece be fitted.
In any case, it is preferable not to fit the hexagonal rod and chain
permanently until after assembling the casing.

Controls

8 - If it is decided to fit a combined temperature/altitude gauge

in boilers intended for continuous use of solid fuels*, the
metal plug must be removed from the top tapping (9) in
the front section and the pocket should be screwed into it.
The combined temp./altitude gauge shall be installed after
fitting the casing.
If an altitude gauge and a thermometer are being fitted
separately, the former will have to be screwed into the
same tapping (9) in the front section, after fitting the casing.

* Operation 8 should be omitted in boilers intended for continuous use

of fluid fuels.

Insulating blanket

9 - Cover the body of the boiler with the insulating blanket

(10) passing it between the body and the four tie-rods
(11) to ensure its immobility.

Connecting to the installation

10 - Remove the plastic caps that protect the threads of the

upper (12) and lower (13) tappings in the back section
and make connections to the flow and return circuits
respectively.

11 - Remove the plug from the tapping (14) in the back section

and fit a drain cock.

Safety devices

12 - Fit the specific safety devices for sealed system or open

vented installations (safety valve, sealed or open
expansion vessel).
In any case the diameters of the safety pipes shall comply
with current regulations.

Connecting to the flue duct system

13 - Connect the boiler to the flue duct system through the

smoke hood (15).

14 - Carefully pack round the base of the chimney with putty

and check the sealing of the smoke hood to ensure that
no air can leak in.

Fitting complementary equipment for using fluid fuels

In order to use fluid fuels it is necessary to equip the boiler with
the required components which are:

- Burner door with fitted casing.

- Control panel and microswitch.
15 - Open the ashpit door (1) and lower the front section grille

(3). This action prevents damage to the blast tube (17)

which, on closing the burner door (16) with the burner
fitted, might strike the grille if this were still in its original
position.

16 - Adding the burner door (16) to the boiler does not make it

necessary for the ashpit door (1) to be removed. It is
sufficient to leave the latter open and hang the former
from the hinges (18) after fitting them to the left of the
front section using the four bolts which, together with the
two fixing pins, are supplied in a plastic bag with the door.

17 - Fit the microswitch (20) (a switch necessary for preventing

accidental functioning of the burner when using solid fuels),
with its bracket (21) on the lower right part of the rear
surface of the front section, using the two M4 x 25* bolts
in such a way that the operating lever can be pushed by
the M5 x 55* bolt (22) which will have been fixed in the
hole for this purpose in the burner door, with an M5* nut.

* Supplied in a plastic bag.

18 - Fix the burner to the door (16) with the flange adapted for

“Roca” burners, in accordance with the instructions that
come with it. Close the burner door and immobilize it by
tightening the locking screw (23) with a suitable tool.

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Safety against opening the firedoor

It is impossible to open the firedoor (5) accidentally once the
burner door (16) is immobilized since the flange (24) makes it
impracticable. The firedoor can be opened only after
deliberately loosening bolt (23) and opening the burner door.

Controls

19 - Insert the triple* pocket in the tapping (9) and the pocket

for the control panel altitude gauge in the tapping (25) in
the front section after removing the metal plugs from both
of them.

* Supplied in a plastic bag inside the control panel packing.

Control panel

The control panel that forms part of the complementary
equipment for using fluid fuels has to be installed on the top
casing cover, and so will be fitted after assembling the casing.

Watertight test

20 - Fill the installation with water and check that there are no

leaks in any part of the hydraulic circuit.

Fitting the casing

According to whether the boiler is intended for continuous use
of solid or fluid fuels, it is advisable to open the required number
of pre-punched holes in the top cover, taking into consideration
the apparatuses or control panel that are going to be fitted. In
the latter case, the three knock-outs should be cleared.
21 - Place the top cover (27) on the boiler, introducing the rear

ends of the two tie-rods in the holes provided in the casing.

22 - Situate the right (28) and left* (29) side casing panels in

their respective sides of the boiler. The left panel has an
opening (30) where the cable entry carrying the cable
connecting the burner and the control panel in fluid-fired
boilers should be fitted.

* When the boiler incorporates a burner door, the slots (31) on the front

edge which coincide with the hinges should be left free.

23 - The lower front brackets (32) should be fixed between

the two nuts screwed on the ends of the tie-rods*, while
the rear ones (33) fit on the ends of the tie-rods.

* Where a burner door has been fitted to the boiler, this should be

opened to allow easy manipulation of the nuts.

24 - Insert the side edges of the top cover (27) into the locating

lugs (34) on the upper edges of the side casing panels.
Fasten the two sides to the top cover using the four self­tapping screws provided – two in the front part (26) and
two in the rear (57).

25 - Hang the back cover (35) introducing the four locating

lugs into their respective slots (36) punched on the rear
edge of the side casing panels.

26 - Fit the casing panels (37) and (38) to the firedoor and

ashpit door respectively, using the screws and washers
provided.

27 - Fit* the hexagonal rod (39) and the chain (40) of the

damper regulator as indicated in the instructions that come
with it.

28 - Open the firedoor and fit* the plate (41) for protecting the

damper regulator in the front part of the top casing cover,
using the two M4 screws supplied. Close the firedoor.

* This operation will not be necessary in boilers intended for continuous

use of fluid fuels if a damper regulator has not been fitted.

29 - In boilers designed for solid fuel firing, screw the altitude

or combined temp./altitude gauge, -whichever control unit
is chosen-, in the pocket provided for this purpose in the
front section. (See operation 8 in “Assembly”).

Fitting the control panel

The control panel that is supplied with the complementary
equipment for using fluid fuels incorporates the relative parts,
as well as the terminal strip and the burner door microswitch.
30 - Fit the two fixing brackets for the control panel to the top

casing cover, using the screws provided.

Electrical connections

31 - Before fitting the control panel, make the electrical

connections in accordance with the following diagram.
The burner cable incorporates a multiple connection plug and
a cable entry. The latter should be fitted in the existing opening

(30) in the left-hand side casing panel.

Likewise with the cable that supplies the pump, its cable entry
should be fitted in the exiting opening (58) in the rear part of
the left-hand side casing panel.
The mains power cable is passed through cable entry (47).
If an ambient thermostat is installed, then its cable will pass
through (59).
The different cables from the control panel will come out through
the same knock-out in the top casing cover.
32 - The bulbs for the control thermostat (48), limitthermostat

(49) and the thermometer (50) are inserted* in the triple

pocket which is in turn introduced in the tapping provided

for this purpose in the front section. Fasten the capillaries

with the clip in the pocket.

Screw* the altitude gauge sensor (51) in its pocket, located

in the chosen tapping in the front section. (See “Assembly”

operations).

* Through the knock-outs in the top casing cover which have not been

used for passing electrical cables.

33 - Secure the control panel (52) using the bracket fitted to

the top casing cover and the M6 screws provided.

Operation

Schematic Wiring Diagram

(See Diagram)

Operations prior to the first lighting

1 - Check that the installation is full of water and place the

fixed pointer on the altitude or combined temp./altitude
gauge in the position corresponding to the static head of

the installation.
2 - Check the pump for correct operation.
3 - Bleed the air from the system and radiators.
4 - In installations with a sealed expansion vessel, top up with

water (if necessary) until the mobile pointer on the altitude

or combined temp./altitude gauge is slightly above the fixed

one. Where an open expansion vessel has been installed,

refill until the mobile pointer levels with the fixed one.

First lighting with solid fuels

5 - Check that the smokehood damper is open. (Handle in

position “A”).
6 - Open the ashpit door, lower the front section grille and put

a sufficient amount of straw or paper, kindling or coal so

as to aid lighting up.

While doing this, keep the firedoor and its observation

window closed. The latter will be kept open only when

using fuel with an excessive content of volatile material

requiring a secondary supply of air for burning.
7 - Switch on the system circulating pump.
8 - Following the initial combustion, put the grille back in its

original position and close the ashpit door.
9 - Open the firedoor and stoke with the chosen fuel, loading

it so as not to smother the fire, to an appropriate level.

Close the firedoor and check that there are no leaks of flue

gases.

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10 - Set the automatic damper regulator according to the

instructions that come with it.

11 - Bleed all the radiators and ensure that they reach the

required operating temperature in accordance with that
selected on the damper regulator.

First lighting with fluid fuels

5 - Connect the fuel supply line to the burner.
6 - Check that the smokehood damper is open. (Handle in

position “A”).

7 - Turn ON the main switch for the power supply to reach

the control panel.
8 - Turn ON the switch (42) to start up the system pump.
9 - Turn ON the switch (43) to start up the burner and check

its running against the instructions that come with it.
10 - Set the control thermostat (44) to 80 ºC approximately.

Check that both the control and limit thermostats operate

correctly.

Where an ambient thermostat has been installed, set it to

the required comfort temperature.
11 - Bleed all the radiators and ensure that they reach the

required operating temperature in accordance with that

selected on the control thermostat.
12 - Check that there are no leaks of flue gases.
13 - Check the burner safety devices.

Maintenance

To aid operating and cleaning the boiler, a set of tools is
supplied, comprising:

53 - Shovel
54 - Scraper
55 - Slice bar
56 - Flue brush with handle

The shovel (53) is used in stoking the boiler, for putting solid
fuel in the combustion chamber, as well as for collecting and
removing cinders from the ash-pan.
The scraper (54) permits drawing ashes and slag which might
have fallen onto the base of the boiler, from the back to a more
accessible place for collecting and removing.
The slice bar (55) eases cleaning of the grate bars in such a
way that the cinders which have remained on the surface can
fall onto the ash-pan. It can also be used –if necessary– for
poking the solid fuels.
The flue brush (56) is used for cleaning the flues and the interior
walls of the boiler.

Important recommendations

- If the installation is located in a frost-risk area, some anti-

freeze solution should be added to the water in proportion to
the minimum outside temperature of the place.

- The characteristics of the water in the installation should

preferably be:

pH : 7.5 ÷ 8.5
Hardness: 8 ÷ 12 French degrees*

* One French degree is equivalent to 1 gram of calcium carbonate in 100

litres of water.

- If it were essential to add water to the system, always wait

until the boiler has cooled down completely.

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