PER-EKO type KSW & KSW PLUS Instruction Manual

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2 TABLE OF CONTENTS INTRODUCTION GENERAL INFORMATION Application Fuel Dimensions & technical parameters BOILER TECHNICAL SPECIFICATION Water main body Doors Upper washout door Loading door Grate & ash pan door Flue Insulation panels BOILER EQUIPMENT 7 4. BOILER INSTALLATION MANUAL Boiler set up Boiler connection to the chimney Supplementation of the boiler with central heating water Information on terms and conditions enclosed in the PN-91/B norm BOILER OPERATION MANUAL Water filling Ignition of the boiler Boiler type KSW. 9 Boiler type KSW PLUS Burning fuels in the boiler Boiler malfunctioning Maintenance instruction Transportation instruction Final remarks WARRANTY TERMS & CONDITIONS. 12

3 INTRODUCTION Dear purchaser and user of the boiler type KSW & KSW PLUS the following start-up and technical documentation comprises all the information necessary to operate and maintain our boiler type KSW & KSW PLUS. 1. GENERAL INFORMATION The purpose of the following instruction manual is to familiarize the user with the operation of the solid fuel boiler. Before installing and using the boiler, every user ought to get acquainted with the instruction manual. The manual comprises recommendations and clues concerning handling and appropriate use of the boiler. Violation of the terms, conditions and clues enclosed in the following documentation frees the boiler manufacturer from any obligations and warranties. As a standard feature, KSW PLUS boilers have an inbuilt electronic temperature controller with a fan. Before the boiler is installed, one ought to get acquainted with the instruction manual and make sure that the boiler did not get damaged during transport and that the equipment is complete. 1.1 Application Steel central heating boiler KSW & KSW PLUS is meant for providing water-based heating for family houses, garages, utility rooms, etc. The highest water temperature in the boiler cannot exceed 95 C. The boilers belong to a group of low-temperature boilers and are not subject to registration in the District Office of Technical Supervision. The boilers are meant to operate in central heating water systems with gravitational or forced circulation in an open thermal cycle, both having all the safety features in accordance with the requirements of the PN- 91/B norms, which relate to the security of water - supported heating of an open thermal cycle. Boiler s technical specification: Boiler type Nominal power [kw] Utility room height [m] Size of heated surface* [m 2 ] Cubic capacity of heated surface [m 3 ] KSW 5 5 2, KSW 9 9 2, KSW , KSW , KSW , KSW , KSW , KSW , KSW , KSW , * depending on the insulation of a building; 1. 2 Fuel The basic fuel used with the KSW & KSW PLUS boilers is coal of the following granulation: mm or mm, with a fuel value of about 25 MJ/kg. The substitute fuel is a mixture of coke (type OI or OII) and coal type 32.1, range nut coal class II 24/12, according to norm PN-82/C and a proportion of both fuels 1:1 or 2:1. The substitute fuel can also be a mixture of nut coal (70%) and dust coal (30%). It is not recommended to burn entirely with dust coal with boilers KSW and KSW PLUS. Other fuels not mentioned in the Instruction Manual (i.e. briquettes from hard coal or brown coal, 3

4 wood, etc.), can also be used with KSW and KSW PLUS boilers. However, burning wood negatively affects the lifespan of the boiler as well as its efficiency. Continuous use of wood as the main fuel leads to soot accumulation and water condensation in the boiler and the chimney system, which results in symptoms similar to a leak. Attention: Sustaining the temperature of the heated medium below 57 C leads to the condensation of fumes in the convection pipes of the boiler and results in lower efficiency and soot accumulation in the boiler. Additionally, long-term boiler activity in the above conditions leads to a quicker pit and surface corrosion. 1.3 Dimensions & technical parameters Boilers dimensions and technical parameters: Parameter Unit Boiler type KSW 5 KSW 9 KSW 12 KSW 16 KSW 18 KSW 24 KSW 30 KSW 35* KSW 40* KSW 50* Height [mm] Dimensions WIdth [mm] Depth+flue [mm] Nom.inal power [kw] Efficiency [%] ~80 Power regulation range [%] ± 2 Hopper capacity [dcm 3 ] , Boiler water capcity [dcm 3 ] Heat exchanger material Steel P265GH [PN-EN 10028]; thickness 5 mm Max. working pressure [MPa] 0,15 Required min. chimney draught** [Pa] Water temperature min./max. [ C] 57/95 Voltage/Power*** [V/W] 230/85 Boiler weight (excl. water) [kg] Water supply pipe diameter [cal] G11/2 * features only in PLUS version; **PN-EN 12809, PN-EN 303-5:2002; ***applicable to version PLUS; 2. BOILER TECHNICAL SPECIFICATION 2.1 Water main body Boilers type KSW & KSW PLUS are made of steel sheet used for pressure devices and are meant for work in increased temperature P265GH. The sheet is 5mm thick from the inside and 4mm thick from the outside. The metal sheet parts of the main body are welded and the flat sides are additionally strengthened with conjoining steel bars. The convection channels from smoke tubes are situated in such a way that the cleaning is conducted via the upper washout door. The construction of the boiler allows effective heat reception thanks to the application of fumes recurrence. 2.2 Doors The boiler has the upper door, the loading door and the common door for the embers chamber and the furnace (welded, made of steel or cast iron), each equipped with an incandescent plate Upper washout door The upper washout door is used for cleaning the upper and the lower smoke tubes chamber once the fumes swirl inserts are removed. 4

5 2.2.2 Loading door The loading door is used to fill the hearth chamber with coal and to clean the heatable surfaces of the boiler. The door is equipped with a recurring air throttle* and an upper incandescent plate which protects the door against excessive overheating. * Applicable only to boiler type KSW Grate and ash pan door The grate and the ash pan chambers have got one door equipped with a flap which controls the air inflow. 2.3 Flue The boiler has a welded flue which is responsible for transferring the fumes from the boiler to the environment. The flue also has a smoke throttle responsible for controlling chimney draught. 2.4 Insulation panels Located on the surface of the water main body, the insulation panels limit the boiler s heat loss to the environment. The panels are made of esthetic tinplate metal caskets covered with a highly corrosion-resistant powder paint. The inside of the caskets is laid with mineral wool (type of insulation material).

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7 3. BOILER EQUIPMENT The boiler is equipped with tools used for cleaning and operating the boiler, as well as devices responsible for controlling and regulating the burning process and ensuring safe and economical boiler activity. Boiler temperature controller is a standard feature of the KSW PLUS type. The controller s instruction manual is enclosed separately. The boiler s equipment includes: bimetallic thermometer C, release tap G1/2, brush, hook, ash shovel and ash remover. 4. BOILER INSTALLATION MANUAL The boiler is delivered in the assembled state. Before setting up and installing the boiler with the central heating system and the chimney flue, it is strongly advised to get acquainted with the instruction manual; check if all the devices are in working order and that the boiler is fully equipped with maintenance and cleaning tools. 4.1 Boiler set up The boiler does not require foundation. It is allowed to lay the boiler on an underpinning not lower than 50mm. The distance between the boiler and the opposite wall ought to be at least 0,5m greater than the boiler length but not smaller than 2m. The distance between the back of the boiler from the boiler room wall ought to be at least equal to the length of the connector. The distance between the side of the boiler and the wall of the boiler room should not be smaller than 1m. The utility room in which the boiler is to be situated ought to have 2 air holes: ventilation duct with a diameter not smaller than 50% of the chimney diameter surface, efferent duct with a diameter not smaller than 140x140mm, with an inlet hole under the ceiling of the boiler room. 4.2 Boiler connection to the chimney The flue is to be attached to the chimney via the connector (this product can be purchased from the manufacturer) made from 3mm thick metal sheet, which is to be fixed on the outlet of the flue, mounted in the chimney and sealed. It is allowed to narrow the diameter of the connector towards the direction of the chimney duct. Under no circumstances should the diameter be extended. The connector ought to rise up slightly from 5 20 C. An appropriate height and chimney diameter (in accordance with the PN-89/B norm) plays a significant role in appropriate boiler activity. Before fixing the boiler to the chimney, it is advised to check whether the chimney diameter is appropriate and that the chimney is free from other heating objects connected to the system. The technical condition of the chimney being connected to the boiler is to be evaluated by the chimney sweep. In order to avoid the reverse draught effect in the chimney duct, the chimney height ought to be built above the ridge and not lower than 1,5m. ATTENTION: Boilers type KSW are to be used together with chimney insert made of corrosion-resistant steel, making sure that the required diameter of the chimney duct is maintained.

8 Diagram depicting boiler installation with a cross valve and a central heating tank. 4.3 Supplementation of the boiler with central heating water Water supplementation can be performed from the water supply system via the release tap in the boiler by means of elastic hosepipe which is to be detached from the boiler once the installation is filled with water and the release tap is closed. Boilers type KSW PLUS are adapted to operate together with the circulation pump Information on terms and conditions enclosed in the PN-91/B norm The boiler ought to be connected with the installation by means of appropriate connectors. The heated water coming from the heating system cannot be used for other purposes than heating only and the working pressure cannot be higher than the acceptable pressure for the application with installation elements and devices. The inner diameter of the safety pipe ought to be at least 25mm. The inner diameter of the expansion pipe ought to be at least 25mm. The safety pipe and the expansion pipes (with the exception of vertical sections) ought to be run without bends, with a decrease of at least 1% towards the boiler; changes in directions of pipes ought to be carried out using arcs with the axis radius of at least 2d, where d stands for the external pipe diameter. The inner diameter of the overflow pipe should not be smaller than the inner diameter of the safety and the expansion pipe. The inner diameter of the venting and the signaling pipe ought to be at least 15mm. 5. BOILER OPERATION MANUAL 5.1 Water filling Before lighting the boiler up, the system and the boiler are to be filled with water, according to the instructions given by the executor of the system. The hardness of water should not exceed 20 n. Check whether the expansion vessel (located in the highest point in the system) has water inside it. This inspection is to be carried out during a period of few seconds, in order to ensure that the water flows down the vessel.

9 5.2 Ignition of the boiler Ignition in a cold boiler should only take place after ensuring that an appropriate amount of water is in the system and that the water has not frozen. Before the ignition, make sure that both the boiler and the whole system are in good working order. It is forbidden to use flammable substances for the ignition. The ignition ought to take place gradually using wood and a small layer of coal afterwards. For boilers type KSW The throttle located in the lower door and the flue throttle ought to be open. The lever of the movable grate ought to be situated in the outermost position towards the back of the boiler. Once the fuel has been on fire, the hearth chamber can be loaded up to the bottom edge of the loading chamber of the upper door. Afterwards, the flue throttle and the lower door throttle are to be set according to the required boiler temperature. The recurring air throttle is to be shut during the ignition stage. The degree to which the throttle is to be opened depends on the type of fuel. The worse the fuel, the bigger the opening of the recurring air throttle. For boiler type KSW PLUS Check the fitting of both the fan and the controller to the boiler s main body as well as their electrical connection. Connect the controller s cord plug to the electricity socket with the voltage of 230V. Electronic controller parameters Parameter Base value - coal Optimal value Set temperature above 60 C Blow time 5 seconds Blow break minutes Constant work range 2 C Blower power 2 Once the boiler has been loaded with fuel and after the initial ignition (by pressing the START button) has started, the system goes into the lighting mode. This will activate the fan which will increase its operation gradually, until finally reaching its preset working parameters (these parameters are to be set according to the controller s instruction manual). After reaching the temperature of 30±2 C the controller automatically activates the circulation pump. In order to deactivate the controller a STOP button has to be pressed. 5.3 Burning fuels in the boiler The fuel is to be loaded periodically until the whole chamber has been filled up. Fuel supply in the boiler lasts around 4-8 hours (depending on the quality of the fuel used) when operating with the rated power. When operating with lower heating power, this period is to be increased accordingly. The burning process in the KSW boiler can be regulated manually by changing the location of the throttle in the lower door by means of a regulated screw, or automatically, by means of an automatic draught regulator. Opening the furnace door throttle causes an increase in the heat efficiency of the boiler. When using the draught regulator, the regulating screw of the throttle is to be unscrewed in the way that allows the throttle itself to close the opening. Weak light in the furnace coming from the embers shows that the furnace grate has been overfilled with ash, which results in the decrease of the temperature in the boiler. Deashing of the grate while the boiler is operating is carried out by repeatedly shifting the lever of the mechanical grate to the back and towards the boiler, leaving the lever in the outermost back position. The burning process in the KSW PLUS boiler is performed by the temperature controller. The fan is to be turned off before supplementing the KSW PLUS boiler with fuel. While using the boiler with the temperature lower than 60 C, the steam coming from the fumes condenses on

10 the sides of the boiler. During a long-term use this can result in corrosion which decreases the lifespan of the boiler. Therefore, it is recommended to use the boiler above the temperature of 60 C. This can be achieved by: Choosing the boiler according to the required size of utility rooms. Using tee or cross valves between water outlet and inlet in the boiler. When starting the boiler for the first time or when starting the boiler from cold, a boiler sweating effect may occur, making it look like the boiler is leaking. In this case, the boiler is to be ignited intensely to the temperature of around 80 C, in order to dry out the boiler and the convection channels. A similar procedure is to be applied once a week in cases when the boiler persistently operates in lower temperatures. 5.4 Boiler malfunctioning Typical problems and solutions Problem Cause Solution insufficient chimney draught remove every leakiness in the chimney, the flue and the boiler door insufficient chimney height raise the chimney at least 1,5 m above the ridge Smoking on the outside adjust the flue throttle, decrease excessively small chimney diameter the airflow force very low atmospheric pressure apply a draught intensifying chimney fan pollution of the chimney ducts clean the ducts using a low calorific fuel change the fuel to a highly calorific one lack of air inflow to the boiler room allow the air inflow through a window or a ventilation duct Low heat efficiency of the boiler set the parameters once again controller or fan breakdown according to the instruction manual or change to a new one pollution of the fume ducts in the smoke tube chamber clean the ducts, adjust the throttle using wood as the main fuel use the fuel according to the instruction manual maintaining low temperature use the boiler in temperatures in the boiler of at least 57 C Leak to be assessed by the manufacturer Per-Eko service team repair Humidity and excessive soot inside the boiler (symptoms similar to a leak) 5.5 Maintenance instruction Regular and meticulous cleaning of the boiler is essential for its appropriate functioning. When the deposit layer is too thick, the boiler looses its heat reception capabilities which results in lower efficiency and may lead to a breakdown. The boiler is to be cleaned at least once a week. The ash is to be thoroughly removed from the hearth chamber and the furnace. Once the upper and the lower inspection cover in the rear part of the boiler has been opened, both the smoke tubes and the fume ducts are to be cleaned and the soot is to be removed from the fume ducts. Periodical servicing is to be carried out once a year, when the boiler is in the stoppage mode. In order to perform the service and determine possible repairs, the boiler is to be thoroughly cleaned from all the remains which had been left in the burning process.

11 More serious repairs resulting from a faulty usage, ensuing breakdowns or mechanical breakdowns, ought to be carried out immediately after having been certified. 5.6 Transportation instruction The KSW boilers are delivered in a fully assembled state. The furnace lever is fixed in a transportation-adapted position. For the transportation purposes, the boiler is placed on a wooden pallet and secured with plastic wrap. 5.7 Final remarks The fundamental feature of the central heating boilers type KSW & KSW PLUS is their construction, which guarantees high efficiency with comparatively low fuel consumption. The boilers are always accompanied with a warranty card which is to be demanded each time the boiler is purchased. With regards to service repairs, the first step is to contact the manufacturer stating the boiler factory number and type and the boiler production year.

12 WARRANTY TERMS AND CONDITIONS A warranty card without date, factory stamps and signatures is considered invalid. In case of losing the warranty card, a duplicate warranty card will not be issued. The warranty given for the boiler s good working order is provided for a period of 24 months from the moment the boiler has been purchased; the warranty is approved by the company and the reselling unit stamp and signature of the seller. The warranty period for welded connections is: 10 years from the production date for the KSW boilers and 5 years from the production date for the KSW PLUS boilers. The warranty given for welded connections is not tantamount to warranty for tightness of the whole boiler. The warranty is therefore applicable strictly to the leakiness of welded connections. The warranty is subject to extension from the date of declaring the repair to the day of informing the client that the repair has been accomplished. That period is stated in the repair card and in the warranty card. The factory is obliged to perform the repair during a period of no longer than 21 days from the date the client reported the breakdown. The boiler is subject to exchange once it has been declared by the factory that the boiler cannot be repaired. The warranty card is the only document that allows the client to have the boiler repaired free of charge. Quality complaints are to be declared in the nearest selling outlet or directly to the company, using the address provided in the warranty card. The warranty does not apply to: draught regulator, boiler connector, rope insulating the boiler door and tools used for maintenance and cleaning. The warranty for the electronic controller is provided by its manufacturer and enclosed together with other documentation. The warranty is not applicable in the cases of: Using safety measures which are incompatible with the PN-91/B norm. Connecting the boiler to a thermal closed cycle. Starting the boiler with an insufficient amount of water inside it. Breakdowns which resulted from overheating the boiler. Repairs during the warranty period which had been carried out by either unqualified or unauthorized persons. Breakdowns resulting from not following the instruction manual appropriately. If the customer complaint turns out to be unjustified, the costs of service arrival will be covered by the person responsible for declaring the breakdown. The warranty will be acknowledged on condition that a cross valve is used in the system and that the temperature in the boiler is at least 57 C.

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