KIPI ROT-POWER 10-50 kW Service Manual Download

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Service Manual

Unit: Pellet burner

Type: ROT-POWER

Models:

4-16 kW,

5-20 kW,

6-26 kW,

8-36 kW,

10-50 kW.

BTI GUMKOWSKI Sp. z o.o. Sp.k.

ul. Obornicka 71, 62-002Suchy Las

Tel. +48 606-936-692, +48 61-811-70-37

[email protected]

update:

20-04-2016

Summary of Contents for ROT-POWER 10-50 kW

Page 1: ...nual Unit Pellet burner Type ROT POWER Models 4 16 kW 5 20 kW 6 26 kW 8 36 kW 10 50 kW BTI GUMKOWSKI Sp z o o Sp k ul Obornicka 71 62 002Suchy Las Tel 48 606 936 692 48 61 811 70 37 biuro kipi pl update 20 04 2016 ...

Page 2: ...the operational mode 16 8 List of common problems 18 9 Maintenance adjustment and servicing the burner 19 10 Operational Safety 31 11 Burner Liquidation after its Service Life is Over 32 12 Electric diagram 32 13 Burner models Overall and Mounting Dimensions 36 14 Burner s technical data 41 Declaration of Conformity 42 15 Burner Installation Protocol 43 16 Warranty 45 Warranty Card 46 ...

Page 3: ...llection and selection of ash The burner is an ecological device as it uses fuel from renewable sources It also fea tures a small demand for electricity The burner is equipped with a controller which is responsible for an optimal dosing of fuel in accordance with the parameters set by the user and variable speed power control This controller operates with a room thermostat which helps to maintain ...

Page 4: ...ion parameters in par ticular with a different calorific value ash level and moisture the power of the burner may be different usually smaller 3 Construction and Operation of the Burner No Description 1 Rotary combustion chamber 2 Aeration chamber rotary 3 Thermal insulation option 4 Bearing of the aeration chamber and the combustion chamber 5 Blower chamber 6 Connection elbow for pellet feeding 7...

Page 5: ...5 Fig 1 Block diagram of the burner ...

Page 6: ...ntral heating boiler or other boiler adapted to work with the burner Burner is fully automatic and adjustable Fuel is automatically drawn from the tray depending on the demand for thermal power In the event of exceeding set limits burner goes into standby mode The transition from standby mode to operating mode is also automatic the burner goes into ignition mode and then again in the continuous mo...

Page 7: ...perature sensors of the central heating boiler The first sensor is used for continuous measuring the boiler temperature when the set temperature is exceeded boiler cooling temperature the controller will attempt to lower the temperature of the boiler by dis charging the excessive heat to the hot water container and by activating mixer servo motors When the temperature drops by 10 O C the controlle...

Page 8: ...r operational length 1 85 m with an extension option 4 Flexible hose meltable length 0 75 m for connecting the burner with the auger feeder 5 Elbow connection 6 Emergency mechanical sensor for boiler temperature with wiring type STB 7 Central heating boiler temperature sensor with wiring 8 DHW temperature sensor with wiring 9 Optional thermal insulation of the outer pipe aeration pipe ...

Page 9: ...9 Fig 2 Components of the set ...

Page 10: ...rner must connected to the pellet tray which may be purchased from the manu facturer of the burner or you may use another tray made of non combustible material which enables you to connect to the auger feeder ø60 pipe observe the installation instructions in sec 11 14 Pay particular attention to the bottom of the feeder where the feed screw auger is present it must be fully covered by the fuel and...

Page 11: ...1 Place the pellet tray next to the boiler insert the fuel feed conveyor and hang by the handle beside the auger drive 12 Ground all metal parts connected to the igniter and carry out effectiveness measure ment of grounding and zeroing 13 Put the elbow connection on the burner and connect the elbow with the fuel feeder us ing a flexible hose Flexible pipe length can be adjusted by sliding it forwa...

Page 12: ...4 16 kW 5 20 kW 6 26 kW 8 36 kW 10 50 kW Fig 4 Layout of mounting holes in burner 4 16 kW 5 20 kW 6 26 kW 8 36 kW including the insulating jacket and the mounting plate insulation cord insulation plate hinge insulation cord insulation plate hinge ...

Page 13: ...ting jacket and the mounting plate Power burner kW øSM mm øM mm A mm B mm OMS mm OMW mm OMF mm 4 16 114 9 50 70 185 40 225 5 20 120 9 50 70 185 40 225 6 26 135 9 50 70 205 45 245 8 36 146 9 45 65 205 45 245 10 50 175 9 45 65 230 50 270 insulation cord insulation plate hinge ...

Page 14: ...14 partition Required size of the furnace chamber Fig 6 Top view of the furnace chamber Fig 7 Side view of the furnace chamber hinge ...

Page 15: ...per 1 kW of power not less than 300 cm2 equal to at least the mid section of the supply cable not less than 200 cm2 Position of the central heating boiler in the boiler room shall be in accordance with the guidelines specified in the boiler manufacturer s instructions Leave at least 30 cm of free space around the burner More space will facilitate maintenance and cleaning the burner and removal of ...

Page 16: ...alues or short ed default setting 4 Press MENU button to set the operational parameters of the burner and boiler All settings and operating parameters are described in the accompanying user manual of the controller 5 Press the knob of the controller and select YES the controller will be activated 7 Operation of the burner in the operational mode After completing the steps specified in sec 6 the bu...

Page 17: ...ed to dose fuel needed to fire up the furnace Af ter the fuel is dosed the igniter is activated to ignite the supplied fuel Firing time may vary as it depends on the fuel type It usually takes 1 3 min The display shows message FIRING When the supplied dose of the fuel lights up i e the value of the parameter measured by the photodetector reaches the pre set value the firing mode ends and the burne...

Page 18: ...hamber 2 Alarm Feeder maxi mum temperature exceeded Excessive temperature rise on the burner housing which results by flame backfiring from the com bustion chamber default 90O C The controller automatically enters the furnace quenching mode The alarm may be delet ed only by the user Insufficient chimney draft Verify the value of the chimney draft and take necessary action in order to increase it S...

Page 19: ...e burner The fan is damaged Contact the customer service of the Manufacturer 8 Too much slag in the furnace Incorrect fuel type Use fuel recommended by the manufacturer The rotating drive of the combustion chamber is damaged Contact the customer service of the Manufacturer Any maintenance work requiring changes in the burner or auger feeder must be carried out after disconnecting the burner from t...

Page 20: ...hat secure the burner housing 2 pcs 4 Remove the burner housing 9 5 Unscrew the fixing screws 7 4 pcs 6 Carefully remove the plate with drives and fan 8 7 When removing the plate 8 remove also igniter 12 from its slot 8 Put aside the removed assembly in a safe place paying particular attention to the igniter 9 Locate and remove screw 5 and when its setting prevents loosening manually rotate the ou...

Page 21: ...tch the undercut in the shaft of the drive motor you may rotate the drive shaft by turning the tube 1 in Z direction The temperature sensor 13 should match the slot in the tee connector of the fuel supply Tighten screws 7 20 Replace the housing 9 21 Tighten screws 6 22 Close the boiler door 23 Connect cables disconnected in par 1 24 The burner is ready for operation ...

Page 22: ...22 Fig 8 Cleaning the tubular blower chamber view 1 ...

Page 23: ...23 Fig 9 Cleaning the tubular blower chamber view 2 ...

Page 24: ...ure the burner housing 2 pcs 2 Remove the burner housing 2 3 Use an Allen key size 5 4 to turn the screw 3 Counter clockwise rotation to decrease the airflow while clockwise rotation increases it Rotation from the minimum to the ma ximum airflow is 900 4 After finishing the adjustment replace the burner housing 2 and tighten the screws 1 Fig 10 Adjusting the blow intensity into the combustion cham...

Page 25: ... in a few places on the circumfer ence applying the lubricant between the bearing raceway and the bearing cage For lubri cation use grease e g Towot LT 43 11 Place the shaft 14 in the bore with the sleeve 15 of the burner front plate The latch 12 should be between the teeth of the wheel 13 as shown in the figure 12 Place the shaft 15 in the opening of the platen with bearings set the gearing as sh...

Page 26: ...emperature sensor should match the slot in the tee connector of the fuel supply 16 Tighten screws 3 17 Replace the housing 2 18 Tighten screws 1 19 Connect cables disconnected in par 1 20 The burner is ready for operation ...

Page 27: ...27 Fig 11 Lubricating the bearings of the combustion chamber view 1 ...

Page 28: ...28 Fig 12 Lubricating the bearings of the combustion chamber view 2 ...

Page 29: ...oving the plate 4 remove also igniter 6 from its slot 9 7 Remove only the igniter from the tube 8 Depending on the type connect cables 8 to the new igniter or connect firmly the cables of the igniter to terminals Z2 brown wire Z4 blue wire 9 Place the igniter inside the tube in a manner enabling it to slide out of the tube if neces sary bend lamellas locking the igniter inside the tube 10 Place th...

Page 30: ...30 Fig 13 Igniter Replacement ...

Page 31: ...e burner any spills can damage the burner as well as increase the risk of electric shock 7 The burner and tray are equipped with rotating parts do not insert hands fingers or other objects into during their operation 8 It is not allowed to interfere with the burner automation systems and other electrical devices installed in it 9 The burner is a device generating heat some of the elements of the b...

Page 32: ...ronmental protection 12 Electric diagram 12 1 Electric diagram of the controller Fig 14 Wiring diagram of the controller where Connection marking Function sub assembly T1 temperature sensor of CT4 boiler T2 DHW temperature sensor CT4 T3 feeder temperature sensor OS flame optical sensor AL RB voltage output for alarm signalling or reserve boiler control RELAY relay ...

Page 33: ...nal modules B module B adds the support of two additional mixer circuits and operation of the thermal buffer MX 03 additional module provides the control of additional two mixers and a circula tion pump λ Lambda probe module L N PE mains 230V FU mains fuse STB safety temperature limiter input FO air blower for the burner FG main feeder FH burner feeder I igniter PB boiler buffer pump PHD hot water...

Page 34: ...34 12 2 Electric diagram of the burner Fig 15 Wiring diagram of the burner where ...

Page 35: ...R4 Rotation of the combustion chamber S2 S4 Fuel supply to the combustion chamber W2 W4 Fan F2 F4 Photodiode C2 C4 Temperature sensor of the burner housing Z2 Z4 Igniter P2 P4 External fuel feeder PE Earthing N Neutral conductor Protective strip PE Connect all yellow green conductors cables ...

Page 36: ...36 13 Burner models Overall and Mounting Dimensions 13 1 ROT POWER 4 16 kW Fig 16 View of burner 4 16 kW Fig 17 View of Burner 4 16 kW including the insulating jacket and the mounting plate ...

Page 37: ...37 13 2 ROT POWER 5 20 kW Fig 18 View of burner 5 20 kW Fig 19 View of Burner 5 20 kW including the insulating jacket and the mounting plate ...

Page 38: ...38 13 3 ROT POWER 6 26 kW Fig 20 View of burner 6 26 kW Fig 21 View of burner 6 26 kW including the insulating jacket and the mounting plate ...

Page 39: ...39 13 4 ROT POWER 8 36 kW Fig 22 View of burner 8 36 kW Fig 23 View of burner 8 36 kW including the insulating jacket and the mounting plate ...

Page 40: ...40 13 5 ROT POWER 10 50kW Fig 24 View of burner 10 50 kW Fig 25 View of burner 10 50 kW including the insulating jacket and the mounting plate ...

Page 41: ...r Models 8 36 kW 10 50 kW 15 Power 8 36 kW 10 50 kW 16 Power supply 230 VAC 50 Hz 6 A 17 Average power consumption 30 W 45 W 18 Igniter s power 150 W 19 Combustion efficiency 99 20 Boiler efficiency 96 21 Power Adjustment YES power modulation correctly the burner 22 Operation of the central heat ing pump YES 23 Operation of the DHW YES 24 Burner control by room ther mostat YES 25 Burner control wi...

Page 42: ...le with 2006 42 WE 2006 95 WE 2004 108 WE and complies with the following harmonized standards PN EN 953 A1 2009 PN EN ISO 13732 1 2009 PN EN 60127 1 2008 A1 2012 PN EN 60445 2011E PN EN 60519 1 2011E PN EN 60730 2 5 2006 A2 2010E PN EN 60730 1 2012E PN EN ISO 12100 2012 PN EN 61000 6 3 2008 PN EN 60730 2 9 2011 PN EN 15270 2008 The person authorized to compile the technical file is Szymon Bajerle...

Page 43: ...del Serial Number Power Year of production Installation Date Boiler Year of production Boiler power Data on the burner settings at the time of installation Ventilation revolutions for 100 power Ventilation revolutions for 50 power Ventilation revolutions for 30 power Amount of fuel for 100 power Amount of fuel for 50 power Amount of fuel for 30 power Hearth brightness for the flame failure ...

Page 44: ...the gas analysis Exhaust temp MIN power Exhaust temp MAX power CO2 emissions at MIN power CO2 emissions at MAX power Chimney Draft Excess air ratio l Efficiency I have read this Service Manual understand its content I accept the conditions of the warranty I have been trained to operate the burner Date Customer s signature ...

Page 45: ...dates 7 Completed installation protocol should be sent to the manufacturer within 14 days from the date of installation of the burner in paper or electronic form 8 The first run of the burner and setting the operating parameters is the one carried out by an authorized service technician 9 Warranty will not apply in the case of installation operation or use of the burner conducted not in accordance...

Page 46: ...gnature and stamp Fills the point of sale Maturity guarantee subject to perform annual inspections by Warranty Terms and Conditions p 1 date the point of sale s signature and stamp Service fills Protocol burner maintenance and repair Date maintenance repair Specification the point of sale s signature and stamp ...

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