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Automatic boiler for wood pellets

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

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

Содержание KP 12-ES

Страница 1: ...Automatic boiler KP 12S KP 22S KP 62S KP 12 ES KP 22 ES KP 62 ES Service and operation manual www tetan ua ...

Страница 2: ... 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 ...

Страница 3: ... 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 ...

Страница 4: ...ner 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 Pic...

Страница 5: ...e 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 ...

Страница 6: ...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 w...

Страница 7: ...otstick 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 sys...

Страница 8: ...of products Parameter Unit KP 12S KP 12 ES KP 22S KP 22 ES KP 62S KP 62 ES Weight kg 310 370 590 Water content litres 55 70 160 Fume duct diameter Mm 130 150 160 Connections heating and return water Js G 1 1 2 Heating surface m2 1 8 2 1 3 2 Dimensions w d without ashtray mm 477x 980 614x980 845x1360 Dimensions h mm 1435 1435 1720 Working overpressure of water bar in to 2 5 Hydraul loss ΔT 10 K mba...

Страница 9: ... 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 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 in...

Страница 10: ... way so that the exhaust pipes of combustion products can be cleaned individually and efficiently Picture No 2 Boiler body Steel weldment with heat exchanger Inspection door Exhaust pipe 130 150 or 160 mm Heating water output water G 1 inside thread Backwater input water G 1 inside thread Rear flanged hole to install the burner system Pipe G to install filling valve Pipe with inside thread M48x2 m...

Страница 11: ...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 HC...

Страница 12: ...s 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 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 s...

Страница 13: ...Automatic boiler for wood pellets 12 Picture No 4 HZS 532 1 HZS533 HZS533 HZS535 Picture No 5 Other modules ...

Страница 14: ...A Loads connected over fuse F7 10 AT X8 Ignition maximum 2300 W maximum 10 A Loads connected over fuse F8 10 AT X5 heat exchange cleaner maximum 690 W maximum 3 A X6 grate open maximum 690 W maximum 3 A X7 grate closed maximum 690 W maximum 3 A The power supply not switched over STB L Loads connected over fuse F9 10 AT X10 boiler circuit return flow pump maximum 2300 W maximum 10 A HZS532 1 Intern...

Страница 15: ... 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 c...

Страница 16: ...ontrast 600 Brightness Typically 350 cd m Angle CR 10 Left right below 75 above 60 Environmental conditions Storage temperature 10 85 C Operating temperature 0 50 C Humidity 10 90 uncondensed EMV stability EN 61000 6 2 noise immunity EN 61000 6 4 noise emission Vibration tolerance EN 600068 2 6 2 9 Hz Amplitude 3 5 mm 9 200 Hz 1 g 10 m s Shock resistance EN 60068 2 27 15 g 150 m s Délka 11 ms 18 r...

Страница 17: ...ntrolled full burning of delivered fuel during its stay in the burner chamber The burned out fuel is subsequently pushed over the edge of the chamber into the ash receiver The inner space of the burner body is connected to an air fan whose revolutions can be regulated within a large range depending on the required boiler output or the type of fuel being used See MENU 11 9 Fans chapter 9 4 9 Impuls...

Страница 18: ...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...

Страница 19: ...ansporter 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 ...

Страница 20: ...s 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...

Страница 21: ...Automatic boiler for wood pellets 20 Picture No 15 Jacketing KP 22S KP 22 ES ...

Страница 22: ...Automatic boiler for wood pellets 21 Picture No 16 Jacketing KP 62S KP 62 ES ...

Страница 23: ...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 ...

Страница 24: ...ver 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 conta...

Страница 25: ...al 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 inta...

Страница 26: ...Automatic boiler for wood pellets 25 Note during operation the cover must be closed Picture No 20 Standard fuel bin sizes Chyba Picture No 21 Assembly guide ...

Страница 27: ... 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...

Страница 28: ...nnections 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 lea...

Страница 29: ...ndard 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 ...

Страница 30: ... 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...

Страница 31: ...bustion 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 i...

Страница 32: ...amic 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 a...

Страница 33: ...ture 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 Picture No 28 Ceramic shield ...

Страница 34: ...nge 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 6 7 CHECKING TASKS BEFORE BOILER FIRST OPERATION The ...

Страница 35: ...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 as...

Страница 36: ...om 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 clea...

Страница 37: ...rd 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...

Страница 38: ...rals 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 b...

Страница 39: ...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 ...

Страница 40: ...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 Button Information and Service menu Button Heating circuit setting Button Move to second screen Button SELECTION OF OPERATING MODE Actual st...

Страница 41: ... 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 ...

Страница 42: ...d pellets 41 9 3 MAIN MENU 9 3 1 Setting menu 9 3 1 1Info menu Button Back on the previous screen Button Alarm list Software version No dated Software version visualisation No dated Operating hours Button Move to second screen ...

Страница 43: ...Automatic boiler for wood pellets 42 9 3 1 2Menu users settings ...

Страница 44: ...l 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 ...

Страница 45: ...Automatic boiler for wood pellets 44 Cleaning an ash removeing Skin Time window setting ...

Страница 46: ... pellets 45 IP Adress 9 3 1 3Menu 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 ...

Страница 47: ...or turn on Feeders 1 Feeder F2 2 Feeder F1 The rotation is signalized by two small red windows blinking When fuel is falling down from Feeder F1 into Feeder F2 immediately stop Feeders Overfilling of fuel is dangerous Other functionality are used for diagnosing of functionality Button Password Showed Please insert your password After touch on the box for password Insert password and enter In the e...

Страница 48: ...Automatic boiler for wood pellets 47 Actual values Configuration ...

Страница 49: ...ality 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 Next page ...

Страница 50: ...9 Next page Temperatures 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 ...

Страница 51: ...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 ...

Страница 52: ... 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 ...

Страница 53: ...ellets 52 Modulation Feeders Note if it is set 0 then there is no control of the motor PID regulation recommended Parameters for regulations Time count impulses Allowed errors On time feeder F2 before F1 Off time feeder F2 of F2 ...

Страница 54: ...Automatic boiler for wood pellets 53 Cleaning Ash removing USB Time window setting ...

Страница 55: ...Automatic boiler for wood pellets 54 Load from USB Save on USB ...

Страница 56: ...Automatic boiler for wood pellets 55 9 3 2 Menu heating circuits Button for open window for addition heating circuits Button for confirmation ...

Страница 57: ...atic boiler for wood pellets 56 After confirmation 9 3 2 1 Tank Demand for heating Time window setting Button for settings menu Button for manual functionality Visualisation of pump status Green On Grey Off ...

Страница 58: ...Automatic boiler for wood pellets 57 Funkcion for setings of parameters Funkcion for manual control of pump ...

Страница 59: ...er for wood pellets 58 9 3 2 2Sanitary water Demand for heating Blue heating Red not heating Time window setting Button for settings menu Button for manual functionality Visualisation of pump status Green On Grey Off ...

Страница 60: ...Automatic boiler for wood pellets 59 ...

Страница 61: ...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 ...

Страница 62: ...Automatic boiler for wood pellets 61 ...

Страница 63: ...Automatic boiler for wood pellets 62 i ...

Страница 64: ...rator intervention service which must evaluate why this situation occurred 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 strain...

Страница 65: ...tion 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 Possible causes Elimination Performed by defective emergency thermostat replace emergency thermostat ...

Страница 66: ...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 wr...

Страница 67: ...n the motor or its electrical supply check the motor and its connection service defective gearbox replace the gearbox service Commissioning After removing the cause of blocking by operator or authorized service center boiler can go to the automatic operation by pressing START Comment The work associated with cleaning the routes entrust professional service Important At any manipulation of the traf...

Страница 68: ...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...

Страница 69: ...ell 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 ...

Страница 70: ...69 Picture No 31 Principle of the modulation ...

Страница 71: ...70 Picture No 32 Dim Req for the placement of KPx2 in boiler room exam of using collecting troughs ...

Страница 72: ...71 Picture No 33 Directory information consuption wood pellets for boiler family KP ...

Страница 73: ...72 Picture No 34 Circuit diagram control unit ...

Страница 74: ...73 Picture No 35 Circuit diagram modul HZS 533 ...

Страница 75: ...74 Picture No 36 Circuit diagram HZS 533 HZS 535 ...

Страница 76: ...tatus 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 80 80 80 producer Minimum exhaust temperature Minimum...

Страница 77: ...or prolong of stabilization of fire Min 2 2 3 producer Aplication time during burn on Aplication time during burn on additional fuel for burn on Min 0 0 0 producer Start program after ignition Start program after ignition 3 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 45 45 15 producer Time fire ...

Страница 78: ... Exhaust fan settings 0 0 0 producer Program No 5 70 of nominal boiler power Feeder 1 on Time for feeding of fuel feerder 1 Sec 5 9 7 producer Feeder 1 off Breaktime of feeder 1 Sec 38 40 29 producer Primary fan Primary fan settings 42 40 38 producer Exhaust fan Exhaust fan settings 0 0 0 producer Program No 6 80 of nominal boiler power Feeder 1 on Time for feeding of fuel feerder 1 Sec 5 9 8 prod...

Страница 79: ...regulation Min 1 1 1 service Start actual boilertemp In program Start actual boilertemp In program C service Proporcional constant Proporcional constant 1 1 1 service Integrative constant Integrative constant service Derivative constant Derivative constant 1 1 1 service Start program after ignition Start program after ignition 3 3 3 service 3 3 6 Feeders Menu Feeders parameters settings Time for c...

Страница 80: ...feeding cycles information Ash sweeping Number of cycles Number of cycles 250 250 150 producer Removal time Removal time min 3 3 3 producer Run only in STANDBY Run only in STANDBY Button OFF OFF OFF producer 3 3 8 USB Menu USB 3 3 8 1 Load from USB Load from USB service Load program settings from flash Load program settings from flash Load parameters from flash Load parameters from flash service L...

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