KITURAMI Wood PELLET BOILER. User s Manual - KRP-20A

Transcription

1 Pellet KITURAMI Wood PELLET BOILER User s Manual - KRP-20A Make sure to keep the user s manual in the vicinity of the boiler, after reading it. KITURAMI Wood Pellet Boiler The user s manual describes the features of the product and the safety requirements. Please read and make sure you fully understand the user s manual before using the products to ensure an extended lifecycle.

2 Thank you for purchasing a KITURAMI boiler. Please carefully read and make sure you fully understand the user s manual to ensure correct operation and maintenance of the product, and keep the manual safe. If the boiler operates abnormally or you have any questions about its functions, etc., please refer to the manual. Structure and name Cleaning port Controller Hopper lid 03 Structure and name 04 How to operate 12 Precautions for operation 14 How to clean/install 15 How to install 19 Specification for wood pellet boiler 20 Troubleshooting 24 Commissioning Internal circulation pump Heat exchanger Hot water coil Screw set Burner Ash tray drawer Features Fuel tank (hopper) (200 kg) Precautions for Safety The user s manual uses symbols to indicate that caution should be exercised to prevent accidents caused by incorrect operation, or damage to the users and their properties. Please carefully read and make sure you fully understand the symbols and their meanings to ensure correct operation of the product. The precautions are classified into three categories: DANGER, and CAUTION. This symbol indicates hazardous situations where severe injury to or the death of the user may result. DANGER This symbol indicates the possibility of severe injury to the user. This symbol indicates the possibility of minor injury to the user or damage to the product CAUTION High efficiency in Korea -Certified for heating efficiency of 82% under the certification test of the Korea Environmental Industry and Technology Institute (20K) Application of multi-channel mode to prevent flame counter-flow The apparatus incorporates the multi-channel mode to prevent flame counter-flow. The burner fuel feed pipe is made of a special heat-resistant quarter pipe to allow easy monitoring of flames in the burner. Application of a control system and actual load apparatus A blower of high DC voltage is used to reduce the quantity of sludge in the ash tray, thereby extending the cleaning cycle. An actual load apparatus is used for the feed motor and the heater, which triggers the safety shut-off device in the event of overload to prevent damage to the machine. Application of internal circulation pump exclusively for hot water supply The internal circulation pump operates when supplying hot water in order to uniformly distribute heat throughout the heat exchanger. This design enables the effective supply of hot water Accessories: Cleaning tools, user s manual, cleaning brush, water draining tee, and room thermostat

3 Initialization time How to operate Names of components of controller Warning display <8P connector> 1 Internal CP power 2 CH CP power 4 Fuel feed Heater power power Display connector <12P connector> 1 Overheat 7 Water temperature Power distribution 2 Infrared 8 GND (water switch External 3 ROOM(-) temperature, overheat) start contact 4 ROOM(+) 9 GND (infrared) 1 Heater monitoring, 2 GND 5 VOD 10 Empty 3 GND, 4 Fuel supply sending 6 Low level 11 Liquefied overheat Capacity 12 Low level ground setting switch 6 Internal CP COM 7 CH CP COM 8 Fuel feed COM Exhaust power How to operate NO Name Function Remarks Fuel feed Power /restart Setting Fuel feed ON/OFF Blower ON/OFF UP/ DOWN Fuel feed LED Blower LED LED Operation time LED Shutdown time LED Operation/warning LED LED display Used for power supply and restart Used for initializing, starting, shutdown, and fuel time setting Main power ON Main power OFF Main power ON Main power OFF Inoperable Keeping pressing the button for 5 sec converted into manual mode Keeping pressing the button for 5 sec. converted into manual mode (FND OFF in manual mode) Keeping pressing the button for 5 sec. converted into manual mode (FND OFF in manual mode) Used for verifying and setting initialization, start, shutdown fuel time Lighting upon fuel feed ON Lighting upon blower ON Lighting upon verifying and setting initial fuel feed time andautomatic recovery to water temperature indication after 5 sec. Lighting upon verifying and setting fuel feed and operation time Automatic recovery to water temperature indication after 5 sec. Lighting upon verifying and setting fuel feed and operation time Automatic recovery to water temperature indication after 5 sec.. Lighting upon operation or warning Indicating water temp., initialization, operation, shutdown time, safety triggering Fan off upon main power off Fan off after 10 minutes upon room power off Keep pressing the button for 5 sec. when setting. Allowed to turn on/off fuel feed` manually in manual mode Fuel supply kept ON for 3 min. only in manual mode Allowed to turn on/off exhaust fan manually in manual mode Release upon turning the power button on/off Setting initialization, start and shutdown time Setting 17 sec Setting 1 sec Setting 13 Operating temperature of blower, exhaust fan, and circulation pump at individual settings of water temperature (water temperature set at CRT5700PLUS) Water temp. setting (CTR-5700) 45 C (summer) 55 C (fall) 65 C (spring) 75 C (early winter) 85 C (winter) 38 C or lower 48 C or lower 55 C or lower 65 C or lower 75 C or lower Blower 50 C or higher 55 C or higher 65 C or higher 75 C or higher 85 C or higher Flashing upon warming (0.5 sec. ON, 0.5 sec. OFF) Indicating in order of 1 C (0 ~99 C) Circulation pump 39 C or lower 49 C or lower 57 C or lower 67 C or lower 75 C or lower 30 C or higher 35 C or higher 45 C or higher 55 C or higher 65 C or higher Remarks

4 How to operate Names of components of room thermostat(ctr-5700plus) How to operate How to use the function of room thermostat Use the [ ] button to display on the screen. (By each pressing of the function button, > > > lamps are turned on in the listed sequence.) Set the desired temperature with the Up ( )/Down ( ) button. (The boiler starts operating when the desired temperature is higher than the current temperature.) 3 8 Function display Displays operation functions, current temp. and desired temp. Displays reserved operation/shutdown time, season selection and number for failure diagnosis Button for selecting functions of Room Reservation and Outing This button is for selecting the Room, Reservation and Outing functions. Button for selecting bath function This button is for selecting the bath functions. Operation display This is for lighting when the boiler is under operation conditions for each function Up/Down button This button is for changing the settings for each function Season selection (heating water temperature) button This button is for setting the heating water temperature in the boiler Reservation button This button is for changing reserved operation and shutdown time Power button This button is for turning power on/off; it is used when restarting the boiler after correcting a failure of the boiler (Restart allowed up to 3 times in sequence; restart allowed after 5-minute s standby) Press the Season Selection button to set the desired heating water temperature. (At each pressing of the season selector button, the season changes: > > > > ) Press the season selector button and then set up the season, Hint for boiler operation Season Selection function Function for setting heating water temperature for heating of the boiler with Room or Reservation function Season Summer Fall Spring Early winter Winter heating water temperature

5 How to operate How to use Reservation function How to operate How to use Outing function Press the [ ] button until Reservation is displayed on the display. (The operation lamp lights at the predetermined time, and reserved operation starts.) Example: Operate the boiler for 20 minutes, shut down operation of the boiler, and then operate the boiler again for 20 minutes. Press the [ ] button to display Outing. (The Outing function is capable of maintaining the room temperature at the minimal level, and of preventing a rupture of the boiler.) How to change time for reserved start Press the Reserve Set button. When the reserved shutdown (min.) time flashes, press the Up ( )/Down ( ) button to set the desired time (min). When you complete setting in this condition, the reserved shutdown time operates first. Press Reservation Setting button and then set the reservation time Press the Reservation Setting button. When the reserved shutdown (min.) time flashes, press the Up ( )/Down ( ) button to set the desired time (min.). When you complete setting in this condition, the reserved shutdown time operates first. Function of preventing frozen rupture Hint for boiler operation If there is no specified time for arbitrary operation, the boiler operates its function independently of the settings. When you complete setting in this condition, the reserved shutdown time operates first. Utilizing Reservation function Hint for boiler operation The Reservation function enables savings on fuel costs by operating the boiler for a specified number of hours by setting the operation time and the shutdown time of the boiler. (The operation time and the shutdown time will appropriately be adjusted dependent upon the season and the insulation conditions of the houses.) The function for preventing a rupture of the boiler during freezing weather conditions maintains the proper temperature of the boiler body, the floor heater pipes, and the pipes connected to the heating pipe, thus preventing them from rupturing in freezing conditions. When you leave your home in the winter season, you should leave the power cable of the boiler plugged in. When you set the room temperature to 10 to 15 during an absence from home, you can prevent the boiler from rupturing due to extremely low temperatures. The function of preventing a rupture in freezing weather does not operate in any of the cases described below -In the event of a power failure, or when the power cable of the boiler is not plugged in. -In the event of poor insulation of the water feed pipes or exposed pipes.

6 How to operate Use of Bathing Function How to operate Common cautions Use the power outlet exclusive for the boiler, and be cautious for leakage If you wish to use hot water of sufficient volume, press the Bathing button to select the bathing function. If you leave the bathing function on for two and a half hours, the boiler returns to the function previously selected. The pressure of the water feed should be kpa ( kgf/ ). If the water pressure is higher than the proper pressure, install a reduction valve. Danger The operating power is AC 230/50Hz. Operate the boiler only after checking the voltage. Do not touch the power cable or operate the boiler with wet hands to avoid electric shock. Never clean the boiler with water as a leak, shock or failure of the boiler may result. Do not place combustible or inflammable materials in the vicinity of the boiler Install a fire extinguisher in the boiler room. Do not stack wooden materials or place inflammable or combustible materials in the vicinity of the boiler, and keep the area surrounding the boiler clean. Cautions for use of bathing function Hint for boiler operation Pay special attention not to scald yourself when using hot water. MUST DO When you open the tap after selecting the bathing function, hot water may be released. Take particular care to protect children and elderly people from scalding water. When you use hot water for an extended period in the room heating mode, lukewarm water may be supplied. When you turn the power on and off while using the bathing function, the operation will be returned to the previous mode of the bathing function. Never disassemble, repair or modify without approval of the manufacturer Shock or fire may result. Contact the after-sales service center when the boiler needs repairing. Never touch the flue while you operate boiler You may get burnt. Cautions when using the bathing function Take care not to get burnt when using hot water. Do not drink hot water. Hot water may suddenly be released when you open the tap after setting the bathing function. Take particular care to protect children and elderly people from scalding water.`

7 Precautions for operation Precautions for operation Precautions for operation CAUTION Prevent frozen rupture during winter season. If the product is connected to the pipes, and the pipes are fully filled with water, connect the power cable to the outlet. If there is insufficient water in the pipes, then supply water to the pipes in accordance with the water makeup method. Operating the rupture prevention circuit when the pipes are filled with insufficient water may cause the pump to run idle or cause overheating or failure of the pump. Fully insulate the pipes. Take the appropriate actions to prevent a frozen rupture by, for example, winding heating coils around the exposed pipes in the cold area. (It is also desirable to install the pipes adjacent to the heating pipes for insulation.) Do not wrap the water drain valve with an insulator. When you do not use the boiler for an extended period, drain the water from the boiler to prevent a frozen rupture, and disconnect the power cable from the outlet. The exposed pipes should be wrapped with an insulator 25mm thick or more to prevent the pipes from freezing. (50 mm or more in cold areas) If you leave your home for a number of hours, open the hot water tap in the kitchen slightly to allow a small volume of water to flow into the hot water pipe to prevent a frozen rupture of the tap water pipe. The boiler shall be inspected once a year. Request your distributor to conduct periodic inspections of the boiler (i.e., once or twice a year). You can operate the boiler safely only when the boiler has been properly inspected. Request your distributor to conduct periodic inspections of the fire tube, and to clean the burner once or twice every six months. Keep the pellet away from water or moisture Pellets exposed to water or moisture become sawdust powder and thereby lose their fuel property. You pour the powder into the hopper and operate the boiler, the performance of the machine may be seriously affected, including a power reduction and the generation of excessive ash. Use the fuel of class 1 only Use of quality wooden pellets guarantees failure-free operation of the boiler and ensures the extended lifecycle of the boiler. It is recommended to use wooden pellets of class 1 or 2 for boilers manufactured and distributed in Korea. It is essential to use wooden pellets of the quality recommended by the boiler manufacturers. Characteristics Diameter Length Apparent density Ash content Moisture Calorie Unit mm mm kg/ m3 % % kcal/kg (MJ/kg) Use pellet fuel of Φ6 only. Class 1 pellet Class 2 pellet Class 3 pellet Class 4 pellet 10 4,300( 18.0) 6 ~ ,040( 16.9) 6 ~ Never let foreign materials to be introduced into the boiler when you feed the fuel Never allow foreign materials to enter the fuel storage bin when you are feeding fuel into the bin, including gloves, bark, and any part of the gunny bag. The machine may fail or a safety shutdown (Error 03) may result. Remove any foreign material and then restart the machine

8 How to clean/install Cleaning combustion chamber How to install Push down by using steel brush is OK! Open the lid of the cleaning port before cleaning. [How to clean] Stop operation of the boiler, make sure the flame is fully extinguished, and remove the buffle plate from the fire tube. Clean the combustion cham ber with a steel brush to save on fuel costs. [Interval of cleaning] Removal of sludge from the burner and cleaning of the ash tray: 2 3 times a week Use the outlet exclusive for the boiler Otherwise, fire may result. Prevent the flue from contact with combustible materials Otherwise, fire may result. Finish the contact points with an incombustible insulation material when installing the flue to prevent fire. Install the boiler in a boiler room, if any Fig. 1 Cleaning of the dust collector: Once a week Cleaning of the cleaning port of the fire tube: Once a month Caution: Be cautious for preventing burn when you open and close the lid of the cleaning port. Installation Conditions to be checked prior to installation The product shall be installed by authorized engineer pursuant to the methods stipulated in the user s manual. Install a boiler suitable for the purpose of use and the CH area. Install the boiler in a location such that exhaust gas or noise from the boiler does not cause inconvenience to the users or to residents in the vicinity of the boiler s location. Do not install the boiler in a location adjacent to areas frequently accessed by people, such as a staircase or emergency exit. Secure sufficient space for the operation, inspection and repair of the boiler (1 m or more at the front, rear, and left- and right-hand sides of the boiler). The use of water (for CH) containing a large quantity of lime or salinity causes corrosion of the product. Always use tap water if possible. Install the boiler in a boiler room if possible to prevent exhaust gas from being introduced into the living room. Do not install the boiler in a bathroom or a space without a vent. Lack of oxygen causes incomplete combustion. Never install the boiler in an outdoor environment so as to prevent a rupture due to freezing. Drainage of boiler If the capacity of the boiler is deficient for the heating area, the safety valve may open often. Install a nitrogen tank suitable for the capacity. (Overflow) Connect hoses from the safety valve and the air vent to the sewage pipe on the floor to drain water. Keep the floor level by making use of incombustible materials such as cement blocks prior to installing the boiler. Install the boiler at a location 50 mm above the floor. When installing the boiler directly on the floor, the support of the boiler may be corroded, thereby reducing the lifecycle of the boiler. Make sure throughly for keeping pipe warmth of the Boiler. The pipe may be exposed to the risk of a rupture due to freezing. The exposed pipe should be wrapped with an insulator thicker than 25 mm to prevent the pipe from freezing (50mm in a cold area). More than 50mm Incombustible material

9 How to install Installation of flue How to install Standard piping diagram Closed heating circuit Chimney 1m 3m Tap water inlet pipe DHW(domestic hot water) supply pipe Bathtub Drainage device Install the device with inclination of 5 degrees. Install the flue at a position 3 meters above the top of the boiler, and use a T-pipe on the end of the flue to prevent incomplete combustion caused by head wind. Fan coil Central heating pipe Cautions for installation 1morlonger Shorter than1m T-pipe 1morlonger Drainagedevice 1morlonger 3morlonger Drainagedevice Install the flue in such a way that the flue is free from the wind pressure zone, rain or wind. Distance Distance Distance Distance < T h e d i s t a n c e l e n g t h b e t w e e n r a f t e r s a n d c e i l i n g > Warning: Installation of additional flue 1. Clearance greater than 30 cm should be ensured from the flue to prevent contact with combustible materials, and the flue should be finished with ncombustible materials. 2. Sudden heat may be emitted by the flue when supplying sthe fuel. Do not store inflammable or combustible materials in the vicinity of the stove pipe. Install the flue, taking care to ensure sufficient clearance from the flue. If there is a tall building or an obstacle within 1 m of the flue, install the flue 1 meter higher than the roof of the building. Install the flue at a location 3 meters or higher than the top of the boiler The height of the installed flue should be greater than three times the horizontal length.. The use safety valve, be sure to set its pressure at 2.5 kgf/ and internal pressure below 1 kgf/. Supplying water Manual water supplying valve Safety valve (2.5kgf) Supplying central heating Central heating return Nitrogen vessel Air vent Circulation Pump 16 Windpressurezone If the flue is installed in a wind pressure zone, excessive soot resulting from incomplete combustion may result, thus reducing operational efficiency, oafety shutdown may be triggered, causing abnormal operation of the boilerr To prevent this, the flue should be installed in a position outside the wind pressure zone. If the flue is longer than 4 m with two bends, increase the diameter of the flue (Ø150 Ø200, Ø200 Ø250).. If the safety valve operates frequently due to an increase of the pressure inside the pipe, check the nitrogen level inside the nitrogen vessel, and fill the vessel with nitrogen if required. - Install the safety valve, the nitrogen valve, the pressure gauge and the air vent in compliance with the specifications. A supplying water valve with the function of a check valve or a check valve should be installed on the makeup pipe. 17

10 How to install Caution for piping Specification for wood pellet boiler The pipe shall be installed in such a way that the boiler operates at pressure lower than 1 kg/m2 when installing the pipes in closed type(1 bar) (The boiler may be damaged due to abnormal pressure resulted from solid fuel.) Install the Nitrogen vessel at a location 1 m above the top of the boiler. (Install the vessel at a location 1 m above the pipe on the floor when you install the vessel in a cellar.) Warning! The safety valve shall be checked every six months without failure Model Item The supply line of hot water shall be connected to the water tank on the rooftop, not directly to the tap water line. Outlet of hot water Nitrogen vessel Direct connection to tap water line kcal/h 10,000~20,000 Hot water output kcal/h 10,000~20,000 Heat exchanger structure STANDING TYPE 1 PASS Air control mode Forced fan (blower type) 1M or higher Dimensions (W x L x H) 1,256 x 828 x 1,400 Fuel size (W x L x T) Pellet (for Ø6) Mode Circulation pump Ignition Do not use the check valve on the pipe of makeup water and discharge. Nitrogen vessel Check valve The water pressure in the DHW(domestic hot water) supply pipe shall be kept at kg/cm2. Install the reduction valve when using the supply water pump, or making direct connection to the tap water line. Hot water tank (If the water pressure is excessively high, use the reduction valve.) 25 A 15 A Heating pressure Ø150 Hopper capacity 3.5 bar or lower Hourly consumption Heating area Safety functions Operating power Use the expansion Nitrogen vessel pipe larger than 20A. Circulation preventing pipe When connecting the expansion pipe, no pipe shall be bent. 18 Expansion pipe 20A or higher Electric coil heater Inlet and outlet of heating(hot water) Hopper capacity Use the tees on the heating outlet of the heating pipe and the discharge pipe to install the expansion pipe on the separated pipe. (Install the natural circulation preventing pipe when installing at a cellar.) Hot Water & Heating Heating Inlet/Outlet Ash generation Circulation pump KRP-20A Max. CH output The specifications are subject to change for improving performance of the product. The specifications may vary dependent upon installation environment, ambient conditions and climate. Never install the boiler for heating area greater than /h Less than 1% (complete combustion) 66 ~ 99 Overheat shutdown function, low level function, flame extinguishing function, counter-flow flame prevention function, latent heat elevation prevention, duel frozen rupture prevention AC 230V / 50Hz Use the circulation pump with appropriate capacity, and install the discharge valve. Central Heating Return Circulation tank Discharge valve 19

11 Troubleshooting Troubleshooting Trouble: No normal ignition No 01 Failure Troubleshooting 1. Fuel feed screw failure ① Check if the feed motor operates, though, the fuel is not supplied. ② Remove and check the feed motor. ③ Replace the screw. 2. Fuel feed motor failure ① Check whether the controller is supplying power (220 VAC) and the motor is operating. ② Replace the fuel feed motor. 3. Insufficient fuel ① Check whether the fuel in the fuel storage tank is insufficient. ② Fill the tank with fuel to the fuel feed line. 4. Foreign material on screw 5. Photo sensor failure 6. Defective fuel ① Foreign materials are caught on the fuel feed screw, so the screw does not operate. ② Remove any foreign materials (gloves, barks, and parts of the gunny bag). ① Check the photo sensor for any defects (at a voltage lower than 2.5 VDC). ① Remove fuel that has been exposed to moisture and has congealed. Remarks See photo 1 See photo 2 See photo 3 <Photo 1> <Photo 2> <Photo 3> <Photo 4> See photo 4 See photo 5 See photo 6 Trouble: Disconnection of the feed motor and the electric heater No Failure 1. Heater disconnected 2. Fuel feed motor disconnected Troubleshooting Remarks ① Check the wire of the heater for damage. ② Replace the heater. ③ The standard resistance on both ends of the heater is 90~100Ω ① Check the wiring for damage. ② Replace the fuel feed motor. ③ Check the limit sensor to see whether any foreign materials have been caught in it (e.g., gloves, parts of the gunny bag, and bark). See photo 7 <Photo 5> 20 <Photo 6> <Photo 7> 21

12 Troubleshooting Troubleshooting Trouble: Disconnection of temperature sensor and overheat sensor No Failure Troubleshooting Remarks Trouble: Defective transmission/reception No Failure Troubleshooting Remarks Water temp. sensor disconnected 2. Overheat sensor disconnected 1. Blower RPM not detected 2. Low limit, High limit Check the water temperature sensor for correct connection. Check the wiring for damage. Replace the temperature sensor. Check the overheat sensor for correct connection. Check the wiring for damage. Replace the temperature sensor. Check the wiring of the blower for damage. Replace the blower. The RPM of the blower is too low or too high due to foreign materials caught on the blower housing Too high RPM of the blower or the exhaust may be caused by strong wind when the flue is installed in the wind pressure zone Contact the installation shop about changing the location of the flue. Remove condensate from the curved part of the flue, if any. Contact your distributor or the after-sales service center. Disassembled part of burner Trouble: Overheat error 1) Symptom: Detecting water temperature higher than 93 by the water temperature sensor/detecting temperature higher than 92 by the overheat sensor 2) Recovery: Automatic recovery upon water temperature lower than 88 /overheat lower than 87 No Failure Troubleshooting Remarks The circulation pump inoperable 2. The CH valve kept lock to cause rapid elevation of temp erature 3. Controller failure Trouble: Triggering of the overheat sensor (bimetal) due to counter-flow of flame 1) Step 1: Temperature at the water temperature sensor lower than 10 - Released when the circulation pump operates at temperature higher than 12 2) Step 2: Temperature at the water temperature sensor lower than 7 - The circulation pump and the burner start operation. No Failure Troubleshooting Remarks 1. Fuel clogged 2. No Tee installed on the flue causing head wind Check the circulation pump circuit of the coil. The measurement result for a resistance of 0 indicates normal operation; infinite indicates a circuit of the coil. Replace the circulation pump. Check whether the distributor valve is locked; if it is, open the locked valve. The feed motor continues operating even when the fuel feed is in the halting mode. Replace the controller. Clean the flue. Install a Tee on the flue to prevent head wind. Installing detachable pump Installing the boiler in the boiler room Defective transmission/ reception Defective transmission/reception of the room controller and the main controller: Ignition travel turned off If the problem persists for more than ten minutes, Error 08 has occurred, and the power LED blinks. Replace the room controller (automatic recovery). 3. Fire tube clogged Clean the fire tube of the boiler. 4. Poor air-tightness of the fuel feed line Poor air-tightness of the hoses and the pipes used for feeding the fuel to the burner causes overheat ing. Disassemble the band, check the air-tightness, and reassemble the band

13 Commissioning Commissioning HOT-4000N [NO.1] [NO.2] [NO.3] [NO.4] ① Fill the hopper with fuel. ② Turn the power of the auxiliary controller off with the main power kept on, and then press the [ ON/OFF] button for 5 seconds. ③ Check if the LED is lit, and if the fuel feed motor operates normally. ④ After operating the boiler for one to two minutes, make sure that the pellets are fed through the feeding hose. ⑤ After making sure that the pellets are being fed into the burner, press the [Power] button to stop manual fuel feeding. ⑥ Press the [Power] button again to operate the boiler. [No. 5 & 6] 24 25

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15 Memo 30