Tetan KP 12S, KP 62S, KP 12-ES, KP 22S, KP 22-ES Service And Operation Manual

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Automatic boiler

KP 12S KP 22S KP 62S KP 12 – ES KP 22 – ES KP 62 - ES

Service and operation manual

Automatic boiler for wood pellets

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

number 1 – Important notes number 6 – Putting the product into operation

number 7 – 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 KP12, KP22 and KP62 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

COntent ...................................................................................................................................................... 2

pictures....................................................................................................................................................... 3

TABle .......................................................................................................................................................... 4

1 IMPORTANT NOTES .............................................................................................................................. 5

2 use of the boiler and its advantages ........................................................................................................ 6

3 Technical data of the boilers KP x2S, KP X2 - ES ...................................................................................... 7

4 structural description of products ............................................................................................................ 8

PICTURE OF PRODUCT AND MAIN PARTS ...................................................................................................... 8

4.1 BOILER BODY, SCHEMA OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS ......................... 9

Boiler body .................................................................................................................................................. 9

4.2 CONTROL UNIT ............................................................................................................................ 10

4.2.1 Boiler Function Module HZS 521-G ........................................................................................ 11

4.2.1.1 Technical base data ......................................................................................................... 13

4.2.2 Terminal HZS 555-S with USB ............................................................................................. 14

4.2.2.1 Description ...................................................................................................................... 14

CLEANING THE TOUCH SCREEN .............................................................................................................. 14

CAUTION! ........................................................................................................................................... 14

Before cleaning the touch screen, the terminal must first be turned off to avoid unintentionally triggering

functions or commands! ....................................................................................................................... 14

4.2.2.2 Technical data ................................................................................................................. 14

4.3 BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE ..................................... 16

CERAMIC PARTS ..................................................................................................................................... 17

4.4 FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)...................................................... 18

4.5 BOILER SHEATHING INCLUDING HEAT INSULATION ....................................................................... 19

4.6 CLEANING SYSTEM ....................................................................................................................... 22

4.6.1 Ash removal ....................................................................................................................... 22

4.6.2 Heat exchanger cleaning ..................................................................................................... 22

4.6.3 External ash container ......................................................................................................... 23

4.7 STANDARD ACCESSORIES ............................................................................................................. 24

4.8 OPTIONAL ACCESSORIES .............................................................................................................. 24

4.9 FUEL BIN ..................................................................................................................................... 24

5 Placement OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION ................................... 26

5.1 PLACEMENT OF PRODUCTS IN BOILER ROOMS ............................................................................... 26

5.2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL ............................................................................ 26

5.3 LEGISLATION IN FORCE ................................................................................................................ 26

4.1.1 Heating system and boiler ................................................................................................... 26

4.1.2 Venting .............................................................................................................................. 26

4.1.3 Fire regulations ................................................................................................................... 27

4.1.4 Electrical ............................................................................................................................ 27

4.1.5 Protection against noise ....................................................................................................... 27

5.4 STORAGE OF FUEL ....................................................................................................................... 27

5.5 BOILER ROOM VENTILATION ........................................................................................................ 27

6 putting the PRODUCTS INTO OPERATION ............................................................................................. 28

6.1 CONNECTION TO THE SYSTEM ...................................................................................................... 28

6.2 INSTALLATION OF THE BURNER .................................................................................................... 29

6.3 INSTALATION OF THE CERAMIC CATALYTIC REFLECTOR ................................................................ 30

6.4 INSTALLATION OF SECONDARY CERAMIC GRATE ........................................................................... 31

6.5 INSTALLATION OF CERAMIC SHIELD ............................................................................................. 32

6.6 CONNECTION OF ELECTRICAL PARTS ............................................................................................ 32

6.7 CHECKING TASKS BEFORE BOILER FIRST OPERATION .................................................................... 33

7 boiler service and maintanance during operation .................................................................................... 34

7.1 SERVICE ...................................................................................................................................... 34

7.1.1 Refueling ............................................................................................................................ 34

7.1.2 Emptying of the external container ....................................................................................... 34

7.1.3 Flue gases exchanger cleaning ............................................................................................. 35

7.2 MAINTANANCE ............................................................................................................................. 35

7.2.1 Burnt gases exchanger cleaning ........................................................................................... 35

7.2.2 Burner grate cleaning .......................................................................................................... 35

7.2.3 Ceramic grate cleaning ........................................................................................................ 35

7.2.4 Annual audit ....................................................................................................................... 36

8 disposal of product after teh end of its service life .................................................................................. 38

8.1 NATURAL PERSON ........................................................................................................................ 38

8.2 LEGAL ENTITY .............................................................................................................................. 38

Automatic boiler for wood pellets

9 control unit operation .......................................................................................................................... 39

9.1 MAIN MENU ................................................................................................................................. 39

9.2 OPERATING CONDITIONS – MAIN MENU ........................................................................................ 40

9.3 MAIN MENU ................................................................................................................................. 41

9.3.1 Setting menu ...................................................................................................................... 41

9.3.1.1 Info menu ....................................................................................................................... 41

9.3.1.2 Menu users settings ......................................................................................................... 42

9.3.1.3 Menu 3 Servis.................................................................................................................. 45

9.3.2 Menu – heating circuits ........................................................................................................ 55

9.3.2.1 Tank ............................................................................................................................... 56

9.3.2.2 Sanitary water ................................................................................................................. 58

9.3.2.3 Heating circuit ................................................................................................................. 60

9.4 ERROR - OVERHEATING, EMERGENCY THERMOSTAT ...................................................................... 63

9.5 ERROR - OVERHEATING, OPERATING THERMOMETER .................................................................... 64

9.6 ERROR – OVERHEATING IN FUEL PATH .......................................................................................... 64

9.7 ERROR FROM LOW TEMPERATURE OF WATER OR COMBUSTION PRODUCTS .................................... 65

9.8 ERROR OF TEMPERATURE SENSOR CONTACT ................................................................................. 65

9.9 ERROR – EXCEEDED ALLOWED TIME OF FEEDER F1 AND F2 RUN .................................................... 66

9.10 ERROR – EXCEEDED ALLOWED TIME OF FEEDER F1 AND F2 RUN ................................................. 66

9.11 ERROR – NOT IGNITED ............................................................................................................. 66

9.12 ERROR – LACK OF FUEL IN THE TANK ........................................................................................ 67

10 Power outage .................................................................................................................................. 67

11 Guarantee and liability for defects ..................................................................................................... 67

PICTURES

Picture No. 1 Picture of product – main parts............................................................................................ 8

Picture No. 2 Boiler body ........................................................................................................................ 9

Picture No. 3 Control unit ................................................................... Chyba! Záložka není definována.

Picture No. 4 Boiler Function Module HZS 521-G .................................................................................... 11

Picture No.5 HZS 532-1 ....................................................................................................................... 12

Picture No. 6 Other modules ................................................................................................................. 12

Picture No. 7 Terminal with USB ............................................................................................................ 14

Picture No. 8 Burner ............................................................................................................................. 16

Picture No. 9 Cer. reflektor KP 12, KP 22 ............................................................................................... 17

Picture No. 10 Two-part cer. reflektor KP 62 ............................................................................................ 17

Picture No. 11 Ceramic secondary grade ................................................................................................. 17

Picture No. 12 Ceramic shield ................................................................................................................. 17

Picture No. 13 Ceramic door casing ......................................................................................................... 17

Picture No. 14 Feeder F1 ....................................................................................................................... 18

Picture No. 15 Jacketing KP 12S, KP 12 - ES ........................................................................................... 19

Picture No. 16 Jacketing KP 22S, KP 22 - ES ........................................................................................... 20

Picture No. 17 Jacketing KP 62S, KP 62 - ES ........................................................................................... 21

Picture No. 18 Ash removal system ......................................................................................................... 22

Picture No. 19 Exchanger ash container .................................................................................................. 23

Picture No. 20 External ash container ...................................................................................................... 23

Picture No. 21 Standard fuel bin sizes ..................................................................................................... 25

Picture No. 22 Assembly guide ............................................................................................................... 25

Picture No. 23 Required chimney draft .................................................................................................... 27

Picture No. 24 Installation dimension of boiler ......................................................................................... 28

Picture No. 25 Burner installation ............................................................................................................ 29

Picture No. 26 Ceramic reflektor ........................................................................................................... 30

Picture No. 27 Parts of secondary ceramic grate ...................................................................................... 31

Picture No. 28 Ceramic grate parts placement guide ................................................................................ 31

Picture No. 29 Ceramic shield ................................................................................................................. 32

Picture No. 30 Ceramic top placement guide ............................................................................................ 32

Picture No. 31 Main menu – sample of visualisation................................................................................. 39

Picture No. 32 Principle of the modulation ............................................................................................... 69

Picture No. 33 Dim. Req. for the placement of KPx2 in boiler room – exam. of using collecting troughs ....... 70

Picture No. 34 Directory information - consuption wood pellets for boiler family KP ..................................... 71

Picture No. 35 Circuit diagram – control unit ............................................................................................ 72

Picture No. 36 Circuit diagram + modul HZS 533 .................................................................................... 73

Picture No. 37 Circuit diagram - HZS 533, HZS 535 ................................................................................ 74

Automatic boiler for wood pellets

TABLE

Table 1 Thermal and technical parameters of products ............................................................................... 7

Table 2 Solid harmful substances in combustion ........................................................................................ 7

Table 3 Technical parameters of products ................................................................................................ 7

Table 4 Electrical parameters of products ................................................................................................. 7

Table 5 Fuel and its parameters ............................................................................................................... 7

Table 6 Settings - Service ..................................................................................................................... 75

Automatic boiler for wood pellets

1 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 a 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 7 - 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 to 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

2 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 watter, 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 a long time maintanance 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.

 Color TFT display 5,7" with touch screen.  Remote control over TCP/IP  USB  User friendly controling  Operation modes: Equitherm, Modulation or Fixed power  Two heating circuits and sanitary water in basic configuration  Possibility to controll acumulation tank or solar system – maximum 7 heating circuits  Upgrading software over USB bootstick

4) PRIORITY HEATING of sanitary water – is secured by the structure and software package of the boiler

without any need for other control elemets.

5) MODULATION PERFORMANCE of the boiler allows adjust production of the heat to an actual needs 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 parametrs with the minimum content of harmful sustances 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) The boiler makes it possible to ensure ANTIFREEZE PROTECTION of heating system in building by a

suitably selected system using electric power.

10) 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 longterm basis. Design of whole solution is using a modern shape elements.

11) This SUBSIDIED ABLE PRODUCT – is fullfilling all required conditions for obtaining subsidies in many

states of the European Union.

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

Automatic boiler for wood pellets

Parameter

Unit

KP 12S

KP 12 - ES

KP 22S

KP 22 - ES

KP 62S

KP 62 - ES

Rated output

Output range

5,5 - 19

8 - 29

18 - 62

Fuel consumption

kg x hrs.-1

~1,3 - 4,4

~1,9 - 6,6

~4,1 – 14,28

Efficiency (rated output)

91,2

90,9

90,6

Efficiency (minimum output)

90,1

Temperature of combustion products

°C

94 - 151

94 - 148

94 - 140

Class of the boiler

Hours of burning - min/max – fuel bin 400L

hrs

213 – 61

142 - 40

64 - 19

Hours of burning - min/max – fuel bin 700L

hrs

373 – 107

249 - 70

111 – 33

Parameter

Unit

KP 12S

KP 12 - ES

KP 22S

KP 22 - ES

KP 62S

KP 62 - ES

Average mass flow rate solid elements pollutions at rated power

g*hrs-1

0,36

0,65

2,2

Exhaust mass flow rate on the outlet-nominal output

kg/s

0,012

0,018

0,034

Exhaust mass flow rate on the outlet-reduced output

kg/s

0,005

0,007

0,016

Parameter

Unit

KP 12S

KP 12 - ES

KP 22S

KP 22 - ES

KP 62S

KP 62 - ES

Weight

310

370

590

Water content

litres

160

Fume duct diameter

130

150

160

Connections: heating and return water

G 1 1/2"

Heating surface

1,8

2,1

3,2

Dimensions (w + d) without ashtray

477x 980

614x980

845x1360

Dimensions (h)

1435

1720

Working overpressure of water

bar

in to 2,5

Hydraul. loss ΔT 10 K

mbar

4,77

10,97

33,7

Hydraul. loss ΔT 20 K

mbar

1,26

2,77

8,3

Required chimney draft

mbar

0,1 – 0,2

0,3 – 0,4

Recom. operating temp. of heating water

°C

60 – 80

Lowest temperature of incoming water

°C

Parameter

Unit

KP 12S

KP 12 - ES

KP 22S

KP 22 - ES

KP 62S

KP 62 - ES

Connecting voltage

230 VAC ± 10%, 50 Hz ± 2 Hz

Electric input (4 motors, fan)

180

210

340

El. Protection of the control unit

---

IP 54

El. Protection of the boiler´s wiring

---

IP 20

Wood pellets diameter

6,0 - 8,5 mm

Caloric value

approximately 16-18 MJ / kg

Water content

Up to 10 %

Ash content

Up to 1 % ( 0,8 – 1,0% )

Bulk weight

0,6 – 0,64 kg / dm3

Fuel delivery system

PE/PP bags 15 – 25 kg,

bags Big Bag by 800 - 1100 kg, cistern filled

3 TECHNICAL DATA OF THE BOILERS KP X2S, KP X2 - ES

Table 1 Thermal and technical parameters of products

*in heating value 17,5MJ/Kg and efficiency 90%

Table 2 Solid harmful substances in combustion

Table 3 Technical parameters of products

Table 4 Electrical parameters of products

Table 5 Fuel and its parameters

As a guaranteed fuels for all KP boilers are wood pellets, with parameters specified in table 5.

Automatic boiler for wood pellets

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

4 STRUCTURAL DESCRIPTION OF PRODUCTS

The structure adheres to the Czech standard ČSN – 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 Picture of product – main parts

Automatic boiler for wood pellets

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

Openig on top for cleaning

covered by a lid of the

boiler´s body

Thermowell for sensor

and thermostat

Emergency thermostat holder

4.1 BOILER BODY, SCHEME OF THE PRODUCTS

AND DESCRIPTION OF THE MAIN PARTS

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

Automatic boiler for wood pellets

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 / acumulation 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

Terminal

HZS 555-S

Boiler function module

HZS 521-G

Extension m.

HZS 532-1

Module

HZS 533

Module

HZS 533

Module

HZS 533

4.2 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 commisioning.

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

Configuration:

HC – heating circuit SWT – sanitary water tank ACU – acumulation tank SOL – solar systém

Automatic boiler for wood pellets

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 1

Impulse sensor 2

Room thermostat 4

Antifrost protection

Servo open

Servo close

SWT pump

Bypass pump

Ignition

HC1 pump

Primary fan

Exhaust fan

Feeder 1

Feeder 2

4.2.1 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. 3 HZS 521-G Connector and terminal electronics layout

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

Automatic boiler for wood pellets

Picture No.4 HZS 532-1

HZS533 HZS533 HZS535

Picture No. 5 Other modules

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

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

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)

4.2.1.1 Technical base data

HZS521-G

Automatic boiler for wood pellets

HZS532-1

HZS533, HZS535

Automatic boiler for wood pellets

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

Stadby

Typically 0.56 W

Starting current

Maximum 25 A for 20 μs

4.2.2 Terminal HZS 555-S with USB

Picture No. 6 Terminal with USB

4.2.2.1 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 an 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.

4.2.2.2 Technical data

Type

5.7" LCD color display

resolution

VGA 640 x 480 Pixel

Color depth

18-bit RGB (262K colors)

LCD Mode

TN / normal white

LCD Polarizer

Transmissive

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°

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)

Délka 11 ms, 18 rázů

Protection Type

EN 60529 Protected through the housing

Front: IP54

Cover: IP20

Display

Environmental conditions

Automatic boiler for wood pellets

4.3.3

4.3.1

4.3.8

4.3.2

4.3.4

4.3.5

4.3.6

4.3.7

4.3 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 resistence spiral for automatic ignition

4.3.7 Cover of spiral

4.3.8 Burner grate

Picture No. 7 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 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 range depending on the required boiler output or the type of fuel being used. (See MENU 11.9 Fans – chapter

9.4.9).

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 an

inclination of minimum 50º (in a relation to horizontal plane).

F2 feeder

driven by an electric motor with a gearbox.

air fan

, whose revolutions can be regulated within a large

Automatic boiler for wood pellets

Attachment to both adaptors must be tight.

Cleaning of KP62 burner provides removal of excessive ash or cinder volume from the burner when burning lower quality fuel. The drive of the cleaning mechanism is works together with ash cleaning.



Note:



Note:

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

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

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

Picture No. 8 Cer. reflektor KP 12, KP 22

Picture No. 10 Ceramic secondary grade

Picture No. 9 Two-part cer. reflektor KP 62

Picture No. 11 Ceramic shield

Picture No. 12 Ceramic door casing

Automatic boiler for wood pellets

4.5.1

4.5.2

4.5.3

4.5.4

4.5.5

4.4 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 12 - ES, KP 22S, KP 22 – ES; diameter 56mm in

KP 62S, KP 62 - ES)

4.5.3 A small bar for mounting of the spiral

4.5.4 Motor and gearbox

4.5.5 Impulse revolution sensor

Picture No. 13 Feeder F1

Automatic boiler for wood pellets

4.6.1

4.6.2

4.6.3

4.6.4

4.6.7

4.6.8

4.6.5

4.6.6

4.5 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 2 or 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 coverí

4.6.6. Back cover – including covering

4.6.7. Door cover

4.6.8. Door

Picture No. 14 Jacketing KP 12S, KP 12 - ES

Automatic boiler for wood pellets

Picture No. 15 Jacketing KP 22S, KP 22 - ES

Automatic boiler for wood pellets

Picture No. 16 Jacketing KP 62S, KP 62 - ES

Automatic boiler for wood pellets

Picture No. 17 Ash removal system

4.6 CLEANING SYSTEM

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

4.6.1 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.

4.6.2 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.

Automatic boiler for wood pellets

Picture No. 18 Exchanger ash container

Picture No. 19 External ash container

4.6.3 External ash container

The external receiver provides space for long-term ash collection outside the burning chamber. It enables longterm 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.

Automatic boiler for wood pellets

4.7 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

4.8 OPTIONAL ACCESSORIES

 Fuel storage (elective size)  Electric heating unit – for tempering of the building in an alternate program. Heating units are

protected from frost damage to the boiler and the heating system. The heating unit - TJ M 48/2 output

2.4; 3; 4; 4.5 a 6 kW.

 Circulatory pump  Three-way (four-way) valve with a servomotor  Flue fan (for KP12, KP22 and KP62 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.

4.9 FUEL BIN

The tank is supplied as optional accessory in sizes 100, 400, 700 and 1 400 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 Bin 1 400 l Bin based on customer request – made to order Bin 400 l - folding Bin 700 l - folding

Chyba!

Picture No. 21 Assembly guide



Note:

Automatic boiler for wood pellets

during operation, the cover must be closed.

Picture No. 20 Standard fuel bin sizes

Automatic boiler for wood pellets

5 PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF

INSTALLATION

5.1 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 ovelap min. 10 cm over the platform of installed quipment. 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 KP62) for cleaning of the boiler.

5.2 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.

5.3 LEGISLATION IN FORCE

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 (CZ - the regulation number 50/1978) 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 yours national equivalents:

4.1.1 Heating system and boiler

ČSN 06 0310 / 1983 – central heating, designing, installation. ČSN – EN 303.5./2000 – boilers for central heating, part 5. ČSN 06 0830 / 1996 – security systems for central heating and heating of hot service water. ČSN EN ISO 12100-2/2004 - structure and versions of boilers.

4.1.2 Venting

ČSN-EN 1443 – Chimneys – general requirements 734200 (9/2004). ČSN 73 42 01 – Chimneys and fume ducts, designing, implementation and connection of fuel consumers

(02/2008) Pressure and temperature conditions necessary for safe operation of heat installations are described in the following standards:ČSN 73 4201 and EN 13 384-1 and EN 13 384-2. Recommended draught of chimney has to be within the range specified by the manufacturer (see picture 27) in connection with the installed power output of the boiler.

Automatic boiler for wood pellets

Picture No. 22 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.)

4.1.3 Fire regulations

ČSN 73 0823 / 1984 – fire and technical properties and combustibility grades ČSN 06 1008 / 1997 – fire safety of heat installations, structure of boilers from fire safety aspect

4.1.4 Electrical

Government Regulation no.17/2003 Coll. ČSN – EN 60 335-1 ed.2.20073– Electrical appliances for domestic and other similar use – Safety - General

requirements. ČSN – EN 60 335-2-102:2007- Safety – Part 2-102: Special requirements for appliences burning gas, petroleum

and solid fuels containing electrical connections.

4.1.5 Protection against noise

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

5.4 STORAGE OF FUEL

Wood pellets have to be in a dry place protected against atmospheric effects because humidity damages the and 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 noncombustible 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.

5.5 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

6 PUTTING THE PRODUCTS INTO OPERATION

6.1 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 pict. no. 40 - 52.



Important:

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

Picture No. 23 Installation dimension of boiler

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. Its hardness has to meet the Czech standard ČSN 07 7401 / 1992 – if the hardness does not meet this standard, it has to be treated with a corresponding softener.

- 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.

Automatic boiler for wood pellets

6.2 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 roupe 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 KP62 attach a security thermostat by two straps on a pipe of the fuel input in to a burner.

Picture No. 24 Burner installation

Automatic boiler for wood pellets

6.3 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.

The 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.

Picture No. 25 Ceramic reflektor

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 regulary!!

Automatic boiler for wood pellets

6.4 INSTALLATION OF SECONDARY CERAMIC GRATE

Individual parts of secondary ceramic grate on the picture.

Picture No. 26 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 surfase is done trought cleaning door of the boiler. Individual parts has 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 than 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:

Picture No. 27 Ceramic grate parts placement guide

Automatic boiler for wood pellets

Picture No. 28 Ceramic shield

6.5 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. 29 Ceramic top placement guide

6.6 CONNECTION OF ELECTRICAL PARTS

The electric parts connections can be performed by qualified personnel only. Connect the particular appliances according with conection 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.

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 Systém 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 termostat X46 Boiler termostat X47 Outside temperature X34 Thermometer behind 3 (4) – way valve X28 Thermometr back water X29



Important note:

With MENU Diagnostics -

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 deaeration Functioning of boiler pump and its deaeration 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 Setting of a proper equithermal curve Setting or changing servomotor timing

Fan and flue fan are controlled proportionally.

direct control

- to be checked by qualified personnel:

6.7 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 – see appendix.

Checking 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 deaeration. 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.

Automatic boiler for wood pellets

7 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.

7.1 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.

7.1.1 Refueling

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 refueling interval by the service technician according to your specific configuration.



Note:

It depends on: Fuel bin size

Anticipated interval – see anticipated burning times in table 1.

The refueling interval cannot be prescribed ambiguously.

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



Note:

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

7.1.2 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.

Před odejmutím nádoby externího popelníku vypněte kotel tlačítkem „STOP“. Zabráníte tak samovolnému spuštění vynášení popele a případně úniku spalin v době, kdy není instalován externí popelník!

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 12S – ES,KP 22S, KP 22 - ES) when using wood pellets

1 × in 2 month (KP 62S, KP 62 - ES) 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:

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



Important note: T

operation.

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

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

Automatic boiler for wood pellets



Important note:

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.

After each visual check of burning or after ash removal you must always make sure that

7.1.3 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:

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

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

7.2 MAINTANANCE

7.2.1 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 when using wood pellets

1 x per month when using alternative pellets

7.2.2 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: 1 x in 3 – 10 day wood pellets 1 x daily alternative pellets

7.2.3 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: 1 x in 4 month wood pellets

1 x month alternative pellets



Note:



Important note:

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

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

Automatic boiler for wood pellets

7.2.4 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 buildups by steel brush from ceramic parts.



Note:

Do not forget that it is about one ceramic. Work carrefully so you do not damage all parts.

Cleaning the draughts of combustion products

If there is automatic cleaning installed, there just has to removed a dust above exchanger by a vacuum cleaner or by forfeiture dust throught 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 exchager



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.

Automatic boiler for wood pellets

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.

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 to place 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 in 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 maitenance is done connect boiler to a power line a trun on main switch. Check if feeders are fill 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

8 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.

8.1 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!

8.2 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 is subject to return collection ehich 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 poduct does not contain lead!

Automatic boiler for wood pellets

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

9 CONTROL UNIT OPERATION

9.1 MAIN MENU

Description of the basic control panel screen

After switch on the main power switch, start program and after severat minutes will show the main menu. For easy operation are used:

- Buttons with names or pictograms

- Buttons with moving (setting of power and temperature)

- Boxis with informations (text, numbers or pictograms)

- Date and time

The data are showed as numbers, diagrams or combination.

Picture No. 30 Main menu – sample of visualisation 

Note: Changes important parameters for combusion quality and safety is alloved after insert

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

Automatic boiler for wood pellets

9.2 OPERATING CONDITIONS – MAIN MENU

SELECTION OF OPERATING MODE

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

FIXED POWER

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

MODULATION

Boiler operating automatically. User can set value temperature (°C). The power is adjusted automatically depend on temperature. User can not change the power.

EKVITERMA

Boiler operating automatically. The power and temperature is adjusted automatically depend on outside temperature and setting of ekviterma diagram. User can not change the power and temperature. This mode user can not chose when the out temperature sensor is not use.

Selection – touch on button:

FIXED POWER » MODULATION » EKVITERMA

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 electic spiral.

Stabilisation

Stabilisation of fire.

Operating

The fire was stabilisated and boiler is normaly working.

Stand-by

quiet mode of the boiler when the boiler is not burning actively. Boiler is ready on the basis of implus from surrounding equipmnts (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 EKVITERMA- control unit automatikally setting power in the

range 0 – 10.



Note:

After „START“ is activatet 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 ongoing 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, EKVITERMA and power supply

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

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

9.3 MAIN MENU

9.3.1 Setting menu

Automatic boiler for wood pellets

9.3.1.1 Info menu

9.3.1.2 Menu users settings

Automatic boiler for wood pellets

Actual time: Hrs:min:sec

Actual date Den.měsíc.rok

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 rihgt – button change on green color

Time, date

Time window setting

Cleaning an ash removeing

Automatic boiler for wood pellets

Skin

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 rihgt – button change on green color

IP Adress

Automatic boiler for wood pellets

9.3.1.3 Menu 3 Servis

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 rihgt – button change on green color

Touch and start functionality

Diagnostics

Automatic boiler for wood pellets

Manual mode



Note:

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!

If you have empty feeders – you must fill fuel into the feeders before START:

Other functionality are used for diagnosing of functionality.

Actual values

Automatic boiler for wood pellets

Configuration

Automatic boiler for wood pellets

Parametres

The setting value of parameters are important for combusion quality, correct function and safety.

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

 Important note:

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

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

Previous page 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

Temperatures

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

Time for pre heating of ignition spirel (without fan)

Control tempereture



Note:

Control temperatur 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

Ignition

Automatic boiler for wood pellets

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 -

Standby mode

Automatic boiler for wood pellets

Programs

 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

Modulation

Automatic boiler for wood pellets

Feeders

Time window setting

Cleaning, Ash removing

Automatic boiler for wood pellets

USB

Load from USB

Automatic boiler for wood pellets

Save on USB

Automatic boiler for wood pellets

Button for open window for addition heating circuits

Button for confirmation

9.3.2 Menu – heating circuits

Demand for heating

Time window setting

Button for settings menu

Button for manual functionality

Visualisation of pump status Green - On Grey – Off

After confirmation:

Automatic boiler for wood pellets

9.3.2.1 Tank

Automatic boiler for wood pellets

Funkcion for setings of parameters

Funkcion for manual control of pump

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

9.3.2.2 Sanitary water

Automatic boiler for wood pellets

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

9.3.2.3 Heating circuit

Automatic boiler for wood pellets

Possible causes

Elimination

Performed by

The boiler water temperature is

set to a high value

(around 90 ° C)

Reduce output water temperature (Menu 2) to f.e. 80 ° C.

user Insufficient heat dissipation from

the boiler

- circulation pump not running

Control of the circulation pump, or switching to higher power.

user

- blocked cleaning strainer

Close the valves and clean the strainer.

installer

- wrong hydraulice of heating circuit (all thermoheads closed)

Check the temperature during Stand – by mode and set a longer period of time

installer

Too short Stand - by time of the

boiler without electric ignition

ExtendStand – by parameter (in the Menu Service)

service

Larger amount of unburned

pellets in the combustion chamber

Carefully clean the burner chamber and professionally set the combustion.

service

Error states

9.4 ERROR - OVERHEATING, EMERGENCY THERMOSTAT

The control unit is equipped with emergency circuit in case of overheating of the boiler. OVERHEATING fault condition occurs when the water temperature at the outlet exceeds a threshold of 95 ° C. In this situation, the emergency circuit is activated by the control unit and the boiler is shut down.

This is indicated by the lighting up of this red box:

Only circulating pump is put into operation for heat dissipation of the heat exchanger. Under normal circumstances, there is no overheating of the boiler, so this condition is considered an emergency. It requires operator intervention (service), which must evaluate why this situation occurred.

Automatic boiler for wood pellets

Possible causes

Elimination

Performed by

defective emergency thermostat

replace emergency thermostat

service

broken wire between the control unit and emergency thermostat

replace the faulty wire

service

emergency thermostat probe is not inserted in the sump

insert and fasten the probe in the sump

service

Commissioning:

In order to put the control unit and the boiler to automatic operation it is necessary that the water outlet temperature fell below 65 ° C. If this condition is not fulfilled, the control unit will not start.

When putting the boiler back into normal operation, proceed as follows:

1. Leave the boiler so long out of operation until the outlet water temperature (see display) drops below 65 ° C.

To accelerate let run the pump.

2. Then press the red reset button of emergency thermostat. Then you must hear a click of the trigger. The

reset button is under the black plastic cap and is accessible without the tool by opening upper boiler door labeled "EMERGENCY THERMOSTAT".

3. After pressing of button and the screen corfirmation, the boiler automatically returns to the original mode.



Comment:

check the emergency thermostat of burner.

If you can not after pressing the trigger to the security thermostat confirm the alarm message,

9.5 ERROR - OVERHEATING, OPERATING THERMOMETER

The control unit is equipped with a programming routine which emergency back-up any control of emergency thermostat. When operating thermometer indicates temperature higher than 100 ° C, the boiler control unit ensures boiler´s shut down.

This is indicated by the inscription on the display:

It is enabled only circulating pump for heat dissipation of the heat exchanger. Under normal circumstances, there is no overheating of the boiler, so this condition is considered an emergency. It requires operator intervention (service), which must evaluate why this situation occurred.

Commissioning:

Is entitled to a professionally trained person.

9.6 ERROR – OVERHEATING IN FUEL PATH

By adding thermostat to the burner in the enter area of fuel we can increase the security of boiler. The boiler is protected against reverse blazing and against reverse thrust of combustion products in the fuel transport path. It is a measure beyond the requirements of ČSN EN 303.5 for more security.

If the temperature at the connecting plastic hose rises to about 85 ° C security thermostat will close its contact and the control unit stops the operation of the boiler. This is indicated as well as overheating of security thermostat.

The temperature rise of burner´s monitored areas should not occur under normal circumstances. Therefore, this condition is considered as an emergency.

It requires operator intervention (service), which must evaluate why this situation occurred.

Automatic boiler for wood pellets

Possible causes

Elimination

Performed by

blocked nozzles in the burner

clean the burner as prescribed annual review

service

dirty heat exchanger

clean heat exchanger

service

insufficient or reverse draft in the chimney

solution is suggested by professional company

chimney service

Possible causes

Elimination

Performed by

low quality fuel

check fuel by specialist company, if necessary, change the fuel

user

lack of fuel

replenish pellets in the fuel bin and fill the transport route by manual override of the feeders

user impassable transport path, etc.

check and remove obstacles which hinder the entry of fuel into the feeder

user

insufficient boiler output

increase the output (max. up to nominal output)

user

wrong choice of boiler output

check the size of the heating system and boiler output, preferably by a specialist company

installation company

Possible causes

Elimination

Performed by

defective sensor

replace the sensor

service

defective connection to the temperature sensor

control of wiring, repair connections

service

Commissioning:

Is entitled to a professionally trained person.

9.7 ERROR FROM LOW TEMPERATURE OF WATER OR COMBUSTION PRODUCTS

During automatic operation is outlet water temperature continuously tested. If the boiler can not reach the temperature of 40 ° C within 30 min. after switching from STAND -BY to automatic

operation or when the water temperature drops during operation below 40 ° C for longer than 30 minutes, the control unit evaluates the situation as substandard condition and operation of the boiler is stopped.

This is indicated on the display with: Stop-non ignition

Commissioning:

Check the burner, remove the residue fuel or ash, run START.

9.8 ERROR OF TEMPERATURE SENSOR CONTACT

The control unit automatically detects the the operation of temperature sensors. In case of failure of the sensor CU will display an error of specific sensor.

If CU loses contact with temperature sensor and the error persists, it is indicated on the display through the message "ERROR TEMP.SENS".

Automatic boiler for wood pellets

Possible causes

Elimination

Performed by

foreign object in fuel

clean fuel path

user

inappropriate fuel (crumbling pellets)

deliver a standard fuel

user

defect in the motor or its electrical supply

check the motor and its connection

service

defective gearbox

replace the gearbox

service

Possible causes

Elimination

Performed by

Insufficient fuel volume in the burner

check fuel supply in the tank

check feeders function check setting of the parameter Period of adding fuel – extend it

service

Too much fuel in the burner

check feeders function

check setting of the parameter Period of

adding fuel – reduce it

service Not ignited pellets in the burner

defective ignition spirals –check or replace

fan output too high – lower it

service

Error indication even when boiler is burning

lower the parameter value

Control

temperature

service

9.9 ERROR – EXCEEDED ALLOWED TIME OF FEEDER F1 AND F2 RUN

Control of feeder F1 is continual and if the running time exceeds running time allowed for more than 10s in particular feeder F1 mode of operation, the boiler will stop and the display will show an error message.



Comment:

9.10 ERROR – EXCEEDED ALLOWED TIME OF FEEDER F1 AND F2 RUN

Feeder´s motor protection by impulse sensors will stop the operation ofcontrol unit if CU does not get the expected number of pulses. The operator is informed about the state of the inscription on the display.

This is the protection of engine from damage and significant element of fire safety (in case of blockage of only feeders - it could lead to filling the whole fuel transport paths and possibly to burn the fuel in the tank).

Detection of error prevent overloading the feeder´s motor and its damage.

Security features in case of infringements of electronic switching element.

Commissioning:

After removing the cause of blocking by operator or authorized service center, boiler can go to the automatic operation by pressing START.



Comment::



Important:

outlet or reliably turn off the circuit breaker in the switchboard.

The work associated with cleaning the routes entrust professional service. At any manipulation of the traffic path is necessary to disconnect the power cord from the wall

9.11 ERROR – NOT IGNITED

Notification of an incorrect function of the boiler, when the process of electrical ignition or transition from STANDBY will not lead to increase the flue gas temperature. This condition is indicated on display.

Automatic boiler for wood pellets

Possible causes

Elimination

Performed by

Insufficient fuel in the tank

adding fuel to the tank

user

9.12 ERROR – LACK OF FUEL IN THE TANK

This will cause boiler fire extinction. This is not a dangerous occurrence. This state is not indicated in any way on the boiler control panel. The boiler will assess the fuel shortage with a certain delay. If the water temperature drops because of boiler fire extinction, this situation is assessed as

Commissioning:

 filling the feeder 2 with fuel trough feeder operation F1 (see MENU-Diagnostics-Manually)  ignite the boiler using routines electric ignition.  Then it is possible go to the automatic operation of the boiler by pressing START.

10 POWER OUTAGE

In case of power failure and following restoration of electricity supply, the control unit continues its work in program mode it was in before the power failure. Configured real time remains unchanged.

11 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, not 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". Regualr annual maitenance has to be done by trained pesrson who is also responsible for the record of it within 14 days (list is part of manual) / service intervention or repaire has to be correctly recorded and sended 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.

Automatic boiler for wood pellets

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 can not take over the guarantee for the functionality of a particular solution of heating system.

Picture No. 31 Principle of the modulation

Picture No. 32 Dim. Req. for the placement of KPx2 in boiler room – exam. of using collecting troughs

Picture No. 33 Directory information - consuption wood pellets for boiler family KP

Picture No. 34 Circuit diagram – control unit

Picture No. 35 Circuit diagram + modul HZS 533

Picture No. 36 Circuit diagram - HZS 533, HZS 535

Menu No.:

Menu - name

Menu – description-meaning

Settings - values

Alloved

MAIN MENU

unit

KP 12S,

KP 12 - ES

KP 22S,

KP 22 - ES

KP 62S,

KP 62 - ES

Info

Informations

1.1.

Info

Only for reading: program version, program visu version, hours of operation

. + +

producer

User settings

Menu for user settings

2.1

Language

Language settings

english

user

2.2

Date/Time

Date and time settings, display saver, lock

+ +

service

2.3

Cleaning

Time window settings

+ +

user

2.4

Skin

Menu for skin setting

+ +

user

2.5

IP adresa

IP adress setting

+ +

user

Service

Menu for diagnosis and pameters settings

. + +

3.1.

Diagnosis

Menu for testing outputs and actual values

. + +

3.1.1

Manual

Testing outputs

. + +

user

3.1.2

Actual values

Visualisation of actual temperatures, sensors of feeders, actual status of room termostat

+ +

3.2

Configuration

Menu for configuration

. + +

service

3.2.1

Model of boiler

Boiler model

. + +

producer

3.2.2

Hardware

Out sensor – activation (Button)

. + +

service

3.3

Parameters

Menu parameters

3.3.1

Boiler temperature

Basic termal parameters setting

Maximum boiler temperature

Upper limit of the temperature fot the parameter Temperature

°C

producer

Minimum exhaust temperature

Minimum exhaust temperature during heating

°C

producer

Maximum exhaust temperature

Maximum exhaust temperature during heating

°C

250

producer

Minimum boiler temperature

Lower limit of the temperature for the parameter Temperature

°C

producer

Delta temperature bypass pump

Delta temperature bypass pump (Only if is used bypass pump)

°C - -

service

Run out time bypass pump

Run out time bypass pump (Only if is used bypass pump)

min - -

service

Electrcal heating is on

Electrcal heating is on – button for activation of electrical heating (Special option)

off

service

Table 6 Settings - Service

Menu No.:

Menu - name

Menu – description-meaning

Settings - values

Alloved

MAIN MENU

unit

KP 12S,

KP 12 - ES

KP 22S,

KP 22 - ES

KP 62S,

KP 62 - ES

3.3.2

Ignition

Menu for ignition parameters setting

Use electrical ignition

Button for activation of electrical ignition (If set OFF boiler is working in Stand By mode)

service

Ignition feeding time

Ignition feeding time (feeder F1) – fuel for ignition

Sec

producer

Fan delay after start

Time electrical ignition (preheating) without fan

Sec

producer

Primary fan level in ignition

producer

Control temperature

Minimum temperature difference exhaust and boiler water in the end ignition

°C

producer

Reignition enable

Permit repetition ignition in case wrong ignition - button

OFF

service

Exhaust fan enable

Exhaust fan enable - button

OFF

service

Exhaust fan level in ignition

Exhaust fan level in ignition - button

% - -

service

Maximum ignition time

Maximum ignition time (activation electrical heating elements)

Min

producer

Burn on time after ignition

Time for stabilization of fire

Min 2 2

producer

Feeding time in burn on

Feeding time (feeder F1) for stabilization of fire

Sec 5 5

producer

Ignition is running in burn on state

Time spiral activation - during stabilisation of fire

Min 1 1

producer

Stabilization time after burn on

Time for prolong of stabilization of fire

Min 2 2

producer

Aplication time during burn on

Aplication time during burn on – additional fuel for burn on

Min 0 0

producer

Start program after ignition

- 3 3

producer

3.3.3

Standby mode

Menu Standby mode parameters setting

Standby time

Time period, in which automatic boiler is not actively burning

Min

producer

Time fire life

Min

producer

Boiler standby temperature

Temperature - desired output

°C

in accordance with

the settings

in accordance with

the settings

in accordance with

the settings

user

Feeder 2 run out in standby

Sec

producer

Maximal burnout time fan

Min 1 1

producer

Stop the fan in burnout at

producer

Feeding worktime in standby

Feeding workintime in standby

Sec 5 7

producer

Feeding breaktime in standby

Sec

producer

Number of cycles

- 2 2

producer

Primary fan if feeding in standby

producer

Exhaust fan if feeding in standby

% 0 0

producer

3.3.4

Programs

Menu programs parameters setting

Program number

Button – No. Program for setting parameters

Program No.1 30% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 5

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Menu No.:

Menu - name

Menu – description-meaning

Settings - values

Alloved

MAIN MENU

unit

KP 12S,

KP 12 - ES

KP 22S,

KP 22 - ES

KP 62S,

KP 62 - ES

Program No.2 40% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 7

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.3 50% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.4 60% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.5 70% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.6 80% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.7 85% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.8 90% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Menu No.:

Menu - name

Menu – description-meaning

Settings - values

Alloved

MAIN MENU

unit

KP 12S,

KP 12 - ES

KP 22S,

KP 22 - ES

KP 62S,

KP 62 - ES

Program No.9 95% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

Program No.10 100% of nominal boiler power

Feeder 1 on

Time for feeding of fuel (feerder 1)

Sec 5 9

producer

Feeder 1 off

Breaktime of feeder 1

Sec

producer

Primary fan

Primary fan settings

producer

Exhaust fan

Exhaust fan settings

% 0 0

producer

3.3.5

Modulation

Menu Modulatin parameters settings

PID modulation

Button - ON

service

Periode time of regulation

Min 1 1

service

Start/actual boilertemp. In program

°C - -

service

Proporcional constant

- 1 1

service

Integrative constant

- - -

service

Derivative constant

- 1 1

service

Start program after ignition

- 3 3

service

3.3.6

Feeders

Menu Feeders parameters settings

Time for checking impulses of F1

Time for checking impulses of feeder F1

Sec

producer

Count of impulses of feeder F1

- 1 1

producer

Number of allowed errors F1

- 3 3

producer

Time for checking impulses of F2

Time for checking impulses of feeder F2

Sec

producer

Count of impulses of feeder F2

- 1 1

producer

Number of allowed errors F2

- 3 3

producer

Run in of feeder F2

Sec 1 1

producer

Run out of feeder F2

Sec 3 3

producer

No.:

Menu - name

Menu – description-meaning

Settings -

values

Alloved

MAIN MENU

unit

KP 12S,

KP 12 - ES

KP 22S,

KP 22 - ES

KP 62S,

KP 62 - ES

3.3.7

Cleaning

Cleaning parameters settings

. + +

service

Time period

Time period (Allowed functionality)

hrs:min

XX:XX

user

Cleaning (exchanger)

Number of cycles

100

producer

Clean time

Min 3 3

producer

Actual number of feeding cycles

Actual number of feeding cycles - information

- - -

Ash sweeping

Number of cycles

250

150

producer

Removal time

min 3 3

producer

Run only in STANDBY

Run only in STANDBY - Button

OFF

producer

3.3.8

USB

Menu USB

3.3.8.1

Load from USB

+ +

service

Load program settings from flash

+ +

Load parameters from flash

+ +

service

Load factory settings

+ +

service

3.3.8.2

Save on USB

+ +

service

Save program settings to flash

+ +

service

Save parameters to flash

+ +

service

Tetan KP 12S, KP 62S, KP 12-ES, KP 22S, KP 22-ES Service And Operation Manual

Specifications and Main Features

Frequently Asked Questions

User Manual