BioCalora KP Series Workbook Download | Manualshive

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Summary of Contents for KP Series

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Page 2: ... 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...

Page 3: ...eight and diameter of the chimney 18 Chimney draft flue gas path 19 STORAGE OF FUEL 21 BOILER ROOM VENTILATION 21 6 COMISSIONING OF THE PRODUCT 21 CONNECTION TO THE SYSTEM 21 INSTALLATION OF THE BURNER 21 INSTALATION OF THE CERAMIC CATALYTIC REFLECTOR 21 INSTALLATION OF SECONDARY CERAMIC GRATE 23 INSTALLATION OF CERAMIC SHIELD 23 CONNECTION OF ELECTRICAL PARTS 24 CHECK PROCEDURES BEFORE PUTTING TH...

Page 4: ...e No 10 Jacketing KP xxx 12 Picture No 11 Ash removal system 13 Picture No 12 Heat exchanger cleaning 14 Picture No 13 External container 14 Picture No 14 Standard fuel bin 700l 16 Picture No 15 Assembly guide 16 Picture No 16 Placement of the product in boiler rooms 17 Picture No 17 Chimney draft 19 Picture No 18 Regulator limiter of chimney draft 19 Picture No 19 Generator of chimney draft 20 Pi...

Page 5: ...an s space 8 If any work which generates inflammable vapours takes place in the boiler room glueing the floor etc the boiler has to be out of operation and the fire has to be burnt out in the boiler 9 Having the heating season been finished clean the boiler thoroughly as per the chapter Maintenance Products of combustion stuck to the walls of the exchanger may act corrosively for the whole period ...

Page 6: ...g 6 Heating in EQUITHERM regulation mode lowers the cost of the heating 7 The burner system used with two independent feeders and with a system of ceramic catalytic reflector and grate ensures perfect SMOKELESS FUEL COMBUSTION which supports high thermal efficiency of the product and also excellent ecological parameters with the minimum content of harmful substances in combustion products 20 50x l...

Page 7: ...f the main parts 1 Boiler 2 Ash pan 3 Boiler door cover 4 Boiler door 5 Insulation 6 Heat Exchanger 7 Heating water output 8 Return water input 9 Smoke flue 10 Control unit terminal 11 Control unit 12 Burner 13 Auger feeder F2 14 Motor with gearbox of F2 15 Auger feeder F1 16 Motor with gearbox of F1 17 Connecting hose 18 Fan inlet of combustion air 19 Ignition spirals 20 Flue gas thermometer 21 C...

Page 8: ...ustion products turbulators Shape of the exchanger itself is designed so it is possible to clean the flue gas installation effectively within the prescribed time intervals Legend Picture No 2 Boiler body description of the main parts 1 Steel weldment with heat exchanger 2 Lid of the boiler body 3 Heating water output water G 1 inside thread 4 Exhaust pipe diameter See Workbook 5 5 Backwater input ...

Page 9: ... round jets in the burning grill ensures inflow of air in order to facilitate controlled full burning of delivered fuel during its stay in the burner chamber The burned out fuel is subsequently pushed over the edge of the chamber into the ash receiver The inner space of the burner body is connected to an air fan whose revolutions can be regulated within a large range depending on the required boil...

Page 10: ...heating chamber Ceramic plate placed above the door Ceramic door jacketing mounted on the door Picture No 4 Ceramic reflector Picture No 5 Two parts ceramic reflector Picture No 6 Secondary ceramic grate Ceramic secondary grid is composed of identical parts in quantity according to the type of boiler Type of boiler Ceramic secondary grid quantity KP 08 KP 08S 2 shortened KP 11 KP 11 1 KP 12 KP 12 ...

Page 11: ...Workbook 1 Design Installation Service Maintenance 10 Picture No 7 Ceramic plate Picture No 8 Ceramic door jacketing ...

Page 12: ...Feeder F1 and F2 gearboxes are equipped with impulse sensors which ensure safe operation of the boiler The F1 Feeder set contains of Legend 1 Feeder tube with inlet and outlet opening 2 Auger 3 Auger bracket with pin 4 Motor with gearbox 5 Rotation sensor with cover Picture No 9 Feeder F1 Selection of Feeder F1 The boiler is supplied with feeder corresponding to the type of boiler and size of orde...

Page 13: ...de 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 Legend 1 Door cladding 2 Door with the control terminal 3 Cover of Heat Exchanger insulation 4 Cover of the combustion chamber s door 5 Parts of the rear cladding 6 Parts of the side cladding Left 7 Parts of the si...

Page 14: ...ed 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 Picture No 11 Ash removal system 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 linea...

Page 15: ...eration 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 Legend Picture No 13 External container ...

Page 16: ...ther three loops circulatory pump GSM modem for remote control and monitoring of boiler operation Module for boiler connection to Ethernet communication network Internet Surface temperature sensor Compact hydraulic modules REGPON On special request it is possibly to supply with Electric heating unit used for tempering of the building as a substitute program Heating units serve as safeguard against...

Page 17: ... is recommended for Fuel bins over 400L and the boiler power up to 50 kW Atypical tank finish can be delivered based on special order after consultation with the manufacturer Note during operation the cover must be closed Picture No 14 Standard fuel bin 700l Picture No 15 Assembly guide ...

Page 18: ... kotle KP 08 KP 08S 706 KP 11 KP 11 1 1078 KP 12 KP 12 1 KP 12 1S KP 12S 1066 KP 21 1100 KP 22 KP 22S 1146 KP 51 KP 51 1 1102 KP 52 KP 52 1 KP 52 1S KP 52S 1078 KP 61 KP 62 KP 62S 1198 KP 82 KP 82S 1348 Picture No 16 Placement of the product in boiler rooms Important Boiler room chimney heating and electrical installation must meet the applicable standards and legal transcripts Installation site P...

Page 19: ...tion to the electrical network it is necessary to ensure that the wall socket where the boiler is connected is always accessible CHIMNEY FLUE GAS DATA FOR CALCULATION OF FLUE GAS SYSTEM Data are listed in Workbook 5 Technical parameters Flue gas system must be designed and constructed so that under all operating conditions of connected fuel devices and locally normal weather conditions can ensure ...

Page 20: ... 200 mm KP 82 82S 200 250 mm CHIMNEY DRAFT FLUE GAS PATH The height of the chimney its diameter construction solutions and the flue solution affect the draft on the flue gas outlet At higher chimneys the maximum permissible draft will be usually exceeded Picture No 17 Chimney draft Use of the regulator limiter for reduction of excessive draft is appropriate Picture No 18 Regulator limiter of chimn...

Page 21: ... as the injector draft generator Picture No 19 Generator of chimney draft Chimney protectors and extension It must be made of non combustible material and must not narrow down cross section of the chimney reduce chimney draft and prevent chimney cleaning SMOKE FLUE Chimney connection is made through the flue between the boiler flue throat and chimney The flue must be directed through shortest and ...

Page 22: ...f products Workbook 5 Technical data Recommended connection of the boiler to the heating system Workbook 5 Technical data Important For boilers with an output exceeding 45 kW is necessary to parallely connect both outputs of heating water Filling of water is done in a standard way it is necessary to respect the following principles water for the heating system must be clean free from any impuritie...

Page 23: ... 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 21 The ceramic catalytic reflector Istalation 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 i...

Page 24: ...ll the way up to ceiling of a burning chamber the front side of the ceramic has to lift up in to a horizontal level and then place the ceramic part downwards in to s grooves Grooves of the ceramic grate are in front and back side of a burning chamber Steps Picture No 22 Ceramic grate parts placement guide INSTALLATION OF CERAMIC SHIELD Insert the ceramic shield flatways across the boiler space and...

Page 25: ...urve CHECK PROCEDURES BEFORE PUTTING THE BOILER INTO OPERATION Authorized service technician who puts the boiler into operation is required before starting to perform tasks described below A report about hte results of this check must me made by filling in the form Report on the putting the boiler KP into operation Control sheet Check the amount of water in the heating system and adequate water pr...

Page 26: ...manually 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 Before emptying the ash pan turn off the boiler Estimated interval guaranteed fuel 1 x month ash pan inside the boiler 1 in 6 months external ash bin up to 20 kW 1 in 2 months external ash bin over 20 kW Note The ash c...

Page 27: ...ler is showing signs of poor combustion smoke when opening the door or increasing temperature of the flue gas check the efficiency of heat exchanger cleaning if necessary change the interval of cleaning If necessary the operator can perform heat exchanger cleaning by switching on the drive of the cleaning in diagnostic functions for service BURNER CLEANING When carrying out inspection tasks it is ...

Page 28: ...hboard 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 s...

Page 29: ...y scraper from a burning chamber in to a auger Back installation of all parts Should be done reverse order Ensure mainly the following in course of this activity Electric resistance coils Maximum tightness has to be ensured between the flange of spirals and the wall of the burner The flange of the burner has to be put precisely so that the packing cord of the flange fits tightly on the protruding ...

Page 30: ...Scotland Building Scotland Act 2003 and the Building Procedure Scotland Regulations 2004 Installed system is able to meet the installation requirements of Building Regulations in England The product may only be installed by an organization trained by the manufacturer with authorization Electric parts may only be connected by an authorized person on professional competence in electrical engineering...

Page 31: ...s 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 φ6 8 5 mm free from any admixtures and foreign object Alternative fuel must be a...

Page 32: ...Workbook 1 Design Installation Service Maintenance 31 12 APPENDIX 1 REPORT ON THE PUTTING THE BOILER KP INTO OPERATION ...

Page 33: ...Workbook 1 Design Installation Service Maintenance 32 13 APPENDIX 2 SELF ADHESIVE LABEL IMPORTANT SAFETY INFORMATION ...

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