BioCalora KP Series Operation instructions

Workbook 1
Design - Installation - Service - Maintenance
1
Associated regulations and instructions:
- Workbook 1 - Design - Installation - Service - Maintenance
- Workbook 2 - Controller RKP 12157 - Boiler control
- Workbook 3 - Controller IGNEO - Boiler control
- Workbook 4 - Controller SIGMATEK - Boiler control
- Workbook 5 - Technical parameters
For proper and safe operation of the product is necessary to follow:
- manufacturers instructions
- general principles of the operation and installation of the product
- standards, ordinances and regulations currently in force in the place of use of the product
We would like to focus your attention mainly on the following chapters:
- Important notes
- Putting the product into operation
- Maintenance and attendance of the boiler during operation
The manufacturer reserves the right to innovative changes of product that may not be included in
this manual.
Boilers have been certified for operation in the Czech Republic and the EU countries by Engineering
Test Institute Brno, State testing laboratory n. 202
General information on CAA and smoke control
The Clean Air Act 1993 and Smoke Control Areas
Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a
smoke control area. It is an offence to emit 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 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 it is a requirement that fuels burnt or obtained for
use in smoke control areas have been "authorised" in Regulations and that appliances used to burn solid fuel in
those areas (other than "authorised" fuels) have been exempted by an Order made and signed by the Secretary
of State or Minister in the devolved administrations.
The KPxxx boilers have been recommended as suitable for use in smoke control areas when burning wood pellet.
Further information on the requirements of the Clean Air Act can be found here:
http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision
of smoke control areas and you can contact them for details of Clean Air Act requirements.

Workbook 1
Design - Installation - Service - Maintenance
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CONTENS - PICTURES ....................................................................................................................................3
1. IMPORTANT NOTES..............................................................................................................................4
2. USE OF THE BOILER AND ITS ADVANTAGES..........................................................................................5
3. INSTALLATION INSTRUCTIONS.............................................................................................................5
4. TECHNICAL DATA OF THE BOILERS KP XXX...........................................................................................6
STRUCTURAL DESCRIPTION OF PRODUCTS .................................................................................................6
SCHEME OF THE PRODUCTS, DESCRIPTION OF THE MAIN PARTS.................................................................6
CONTROL UNIT...........................................................................................................................................7
BOILER BODY .............................................................................................................................................7
BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE..................................................8
CERAMIC PARTS .........................................................................................................................................9
FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)................................................................. 11
BOILER SHEATHING INCLUDING HEAT INSULATION ..................................................................................12
CLEANIG SYSTEM......................................................................................................................................13
Ash removal ..........................................................................................................................................13
Heat exchanger cleaning ........................................................................................................................13
External container ..................................................................................................................................14
STANDARD ACCESSORIES .........................................................................................................................15
OPTIONAL ACCESSORIES ..........................................................................................................................15
5. PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION..........................17
PLACEMENT OF PRODUCTS IN BOILER ROOMS ..........................................................................................17
SAFE DISTANCE FROM COMBUSTIBLE MATERIAL .......................................................................................18
CHIMNEY – FLUE GAS ...............................................................................................................................18
Data for calculation of flue gas system ....................................................................................................18
Height 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 THE BOILER INTO OPERATION...................................................... 24
7. BOILER SERVICE AND MAINTANANCE DURING OPERATION ................................................................. 25
SERVICE ...................................................................................................................................................25
Refuelling ..............................................................................................................................................25
Emptying of the external container..........................................................................................................25
MAINTENANCE..........................................................................................................................................26
Flue gases exchanger cleaning................................................................................................................26
Manual cleaning .....................................................................................................................................26
Motorized cleaning .................................................................................................................................26
8. ANNUAL AUDIT ..................................................................................................................................27
9. SAFETY REGULATIONS .......................................................................................................................29
LEGISLATION IN FORCE ............................................................................................................................29
Heating system and boiler ......................................................................................................................29
Venting .................................................................................................................................................29
Fire regulations......................................................................................................................................29
Electrical................................................................................................................................................29
Protection against noise .........................................................................................................................30
10. PRODUCT LIQUIDATION AFTER ITS SERVICE LIFE IS OVER .................................................................30
11. GUARANTEE AND LIABILITY FOR DEFECTS.......................................................................................... 30
GUARANTEE CONDITIONS.........................................................................................................................30
12. APPENDIX 1 - REPORT ON THE PUTTING THE BOILER KP INTO OPERATION ........................................31
13. APPENDIX 2 - SELF-ADHESIVE LABEL - IMPORTANT SAFETY INFORMATION ......................................... 32

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Design - Installation - Service - Maintenance
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CONTENS - PICTURES
Picture No. 1 Description of the main parts................................................................................................6
Picture No. 2 Boiler body – description of the main parts............................................................................7
Picture No. 3 Burner.................................................................................................................................8
Picture No. 4 Ceramic reflector..................................................................................................................9
Picture No. 5 Two parts ceramic reflector ..................................................................................................9
Picture No. 6 Secondary ceramic grate ......................................................................................................9
Picture No. 7 Ceramic plate.....................................................................................................................10
Picture No. 8 Ceramic door jacketing....................................................................................................... 10
Picture No. 9 Feeder F1 ..........................................................................................................................11
Picture 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
Picture No. 20 The arrangement of the flue connection .............................................................................. 20
Picture No. 21 The ceramic catalytic reflector - Istalation ........................................................................... 22
Picture No. 22 Ceramic grate parts placement guide ..................................................................................23
Picture No. 23 Ceramic top placement guide.............................................................................................. 23

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Design - Installation - Service - Maintenance
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1. IMPORTANT NOTES
This product may only be put into operation by an installation organization trained by the manufacturer.
This product may only be operated by adult persons, duly acquainted with the way the product is controlled and
duly acquainted also with these Instructions. If you adhere to the below mentioned principles, the product will
serve you reliably to your full satisfaction.
1) It is prohibited to intervene in any way in the structure or electrical installation of products. Having the
equipment been disconnected from the electric network, the power supply cord has to be plugged from
the mains outlet.
2) It is prohibited to use inflammable liquids for ignition.
3) No inflammable materials may be stored on the boiler; neither may they be stored within the distance of
1,500 mm from the boiler (except for operating metal fuel bin).
4) In order to preserve long-term service life of the boiler body, it is not recommended to operate the boiler
frequently under the temperature of 55°C, if the boiler is not protected with a primary circuit. The
temperature of 55°C should be considered as the minimum temperature.
5) The check how the boiler is filled with fuel is only visual. Any verification with touch is prohibited as it may
result in injury.
6) Never open door of the boiler if there is an ignition process.
7) The door of the boiler has to be always tightly closed. If you´ll perform any check, open the door carefully
to prevent from getting jeopardized by gathered products of combustion or to prevent any sparks flying
out from the boiler from being the cause of any accident. Open the door slowly in order to get the
combustion chamber aerated towards the chimney. This procedure has to be adhered to when the ash is
being removed from the ash pan'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 of
time when the boiler will be out of operation. If the burner is not cleaned, this may have effect on faulty
combustion. We recommend hire a specialized company to perform this work.
10)If you work on or near to the mechanically movable parts (fuel feeder, etc.), ensure safe disconnection of
the equipment from electric voltage. There is a risk of injury.
11)You should always operate the boiler only under parameters and in harmony with recommendations given
in these instructions for installation and operation. If the boiler works in the AUTO mode and if there is a
failure of current, the boiler will start operation again with the electric firing programme (if this
programme has been installed) after the delivery of electric current is restored.
12)The manufacturer does not assume any liability for errors and subsequent damage caused by unskilled
operation of the equipment or by infringement of principles given in these instructions for installation and
operation or by infringement of generally binding standards and regulations or by using inadequate fuel.
13)If the boiler is moved or otherwise handled with, safety regulations which apply to handling with heavy
loads have to be adhered to.
14)It is prohibited to place heavy loads on jacketing boiler and to step on it. It is recommended to remove
the protective foil after all the building and installation work has been completely finished.
15)External ashtray has to be firmly connected to a boiler fitting while in the operation. Cover of this ashtray
has to be tightly closed. There could be a dangerous escape of combustion gases into a boiler room.

Workbook 1
Design - Installation - Service - Maintenance
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2. USE OF THE BOILER AND ITS ADVANTAGES
The series of automatic hot-water boilers for wood pellets is designed mainly to heat family houses, small
municipal buildings, cottages and small plants or business buildings.
The main advantages of products:
1) AUTOMATIC OPERATION ensured by the control unit which cooperates with the indoor thermostat,
thermostat of SW tank for hot water, outside thermometer in the mode of equitherm regulation,
eventually by superior control system, which ensures comfort for the user including maximum saving of
fuel.
2) Automatic ASH REMOVING and heat EXCHANGER CLEANING ensures long time maintenance free and
maximum comfort of heating while keeping high burning efficiency.
3) CONTROL UNIT with modern design – controls operation of the boiler, ensures automatic operation, high
operational reliability and long distance control.
4) PRIORITY HEATING of sanitary water – is secured by the structure and software package of the boiler
without any need for other control elements.
5) MODULATION PERFORMANCE of the boiler allows adjusts production of the heat to an actual need 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 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 less than conventional boilers).
8) SAFETY OF OPERATION ensured by separated structure of fuel transport routes and by the selected
transport mode.
9) DESIGN AND SURFACE – jacketing of the products is coated with a heavy-duty COMAXITE COATING
which is perfectly resistant to environment effects and ensures perfect appearance of products on long-
term basis. Design of whole solution is using modern shape elements.
10)This SUBSIDIED ABLE PRODUCT – is fulfilling all required conditions for obtaining subsidies in many states
of the European Union.
11)LONG DISTANCE CONTROL and monitoring by internet or GSM connection.
3. INSTALLATION INSTRUCTIONS
Only skilled person, trained by the manufacturer or importer of the device is authorized to
commission the boiler.
The boiler may be installed in the environment: Ordinary according to ČSN 332000-1 ed.2
The boiler operates in an area outside the flue gas condensation, and operates at a negative
pressure at the flue outlet.

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Design - Installation - Service - Maintenance
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4. TECHNICAL DATA OF THE BOILERS KP XXX
See Workbook 5 - Technical parameters
STRUCTURAL DESCRIPTION OF PRODUCTS
The structure adheres to the standard EN 303.5 / 2000 i.e. boilers for central heating - part 5 (boilers
for central heating with automatic fuel feed of rated heat output up to 300 kW).
SCHEME OF THE PRODUCTS, DESCRIPTION OF THE MAIN PARTS
Legend:
Picture No. 1 Description of 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 Ceramic shield
22 Ceramic reflector
23 Ceramic grid
24 Ceramic cladding of door
25 Cleaning mechanism
26 Motor with gearbox - cleaning )*
27 Ash removing mechanism )*
28 Motor with gearbox - ash removing)*
)* - according type and design of boiler

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Design - Installation - Service - Maintenance
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CONTROL UNIT
The boiler is fitted with one of the control systems, which are described in detail:
Workbook 2
Controller RKP 12157 - Boiler control
Workbook 3
Controller IGNEO - Boiler control
Workbook 4
Controller SIGMATEK - Boiler control
BOILER BODY
Boiler body is welded together from high-quality steel boiler metal sheets. The shape is designed so the
combustion products are cooled down effectively at any output level, which is aided by a system of combustion
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 1½“ (inside thread)
4 Exhaust pipe – diameter See Workbook 5
5 Backwater input G 1½“(inside thread)
6 Pipe G ½“to install filling valve
7 Rear flanged hole to install the burner system
8 Thermo well for sensor and thermostat
9 Emergency thermostat holder
10 Flanged hole to install ash removing system
11 Inspection door
12 Opening on top for cleaning covered by a lid of the
boiler
´
sbody

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Design - Installation - Service - Maintenance
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BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE
The heating chamber is depicted in picture and is comprises of these parts:
Legend:
1 Burner body with flange
2 Část iron grate with rectifiers )*
3 Fan with transition piece
4 The screw feeder with pin
5 Flexible hoses and mounting clips
6 Seal of ignition flange )*
7 Ignition spiral
8 Motor with gearbox
9 Sealing
10 Rotation sensor with cover
)* if there is only 1 spiral used, it contains only one rectifier.
Picture No. 3 Burner
The burner body – is a hollow weldment made from highly legated material with a bottom transversal fuel inlet.
The fuel is delivered by a built-in
F2 feeder driven by an electric motor with a gearbox.
A set of slit and 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 boiler output or the type of fuel being used.
Impulse revolution sensor
The gearboxes of the F1 and F2 feeders are equipped with impulse sensors, which ensure safe operation of the
boiler.
Connecting hose to the F1 feeder made of inflammable material connect Feeder F1 and Feeder F2. It is part
of the transfer fuel lines. It must meet strict installation rules:
It cannot have significant folds, which would block smooth fuel movement and must be built with inclination of
minimum 50º (in a relation to horizontal plane). Attachment to both adaptors must be tight.

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Design - Installation - Service - Maintenance
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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.
- Ceramic reflector – placed on the top of the burner
- Ceramic secondary grate – placed in the boiler body above the burner 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.
T
yp
e of boile
r
Ceramic secondar
y
g
rid
–
q
uantit
y
KP 08
,
KP 08S 2
(
shortened
)
KP 11
,
KP 11.1
,
KP 12
,
KP 12.1
,
KP 12.1S
,
KP 12S 2
KP 21
,
KP 22
,
KP 22S 3
KP 51
,
KP 51.1
,
KP 52.1
,
KP 52.1S
,
KP 52S
,
KP 61
,
KP 62
,
KP 62S 4
KP 82
,
KP 82S 4
(
transverse
)

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Design - Installation - Service - Maintenance
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Picture No. 7 Ceramic plate
Picture No. 8 Ceramic door jacketing

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Design - Installation - Service - Maintenance
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FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)
F1 feeder delivers fuel from fuel storage to the burning chamber. It comprises of a pipe delivery path with an
overflow part and an end sleeve. The feeder is built into the fuel storage under an angle, which cannot exceed
45º. If the angle was any bigger, fuel could be dispensed inaccurately. The transporter has its own electric drive,
which is controlled by the control unit.
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 ordered fuel bin.
The Fuel bin can be placed further away from the boiler or in the next room – in this case, the length of the
Feeder F1 can be adapted to the proposed solutions and any of the standard Feeders F1 in manufactured range
can be ordered. (also custom production is possible).

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Design - Installation - Service - Maintenance
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BOILER SHEATHING INCLUDING HEAT INSULATION
The product sheathing is manufactured from steel sheet metal. It is painted with durable paint applied with the
powder painting technology (KOMAXIT), which is highly resistant to outside 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 side cladding – Right)*
8 Cover of Heat Exchanger Lid
Picture No. 10 Jacketing KP xxx

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Design - Installation - Service - Maintenance
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CLEANIG SYSTEM
The automatic cleaning system of the boiler significantly affects time of service-free operation of the boiler.
ASH REMOVAL
Ash removal is a complex set of technical and program means, which ensure ash removal from burner heating
chamber to external ash receiver in a regular intervals. The ash is taken out by a spiral conveyor. It is driven by
an electric motor through a toothed chain transmission.
The ash removal system can be mounted on the left or on the right side. Assembly of the particular version is
done in the manufacturing facility based 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 linear movement of
turbulators in the exchanger pipes. It is driven by an electric motor through a lever gearbox.
The heat exchanger cleaning system can be mounted on the left or on the right side. Assembly of the particular
version is done in the manufacturing facility based on an order. A professional service firm can perform a change
(left/right) at the boiler location.
The drive motor is connected with the control unit.

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Design - Installation - Service - Maintenance
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Picture No. 12 Heat exchanger cleaning
EXTERNAL CONTAINER
The external container provides space for long-term ash collection outside the burning chamber. It enables long-
term service-free operation even when using fuel with high ash content. It is attached to the boiler with a detent
lever. During boiler operation 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
1 Container
2 Lid
3 Sealing
4 Opening and locking mechanism
5 Transport wheels
6 Lid securing
7 Handles
8 Withdrawable manipulation handle with
position locking

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Design - Installation - Service - Maintenance
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STANDARD ACCESSORIES
• KP boiler operation and service manual
• Quality and completeness certificate of the product – Warranty Certificate
• Cleaning tools (scraper for manual cleaning of the boiler body)
• Outlet/inlet valve ½ “
• Outside temperature sensor for equithermal regulation *
• Surface temperature sensor – measuring of temperature behind the mixing valve*
• Surface temperature sensor – measuring of temperature of returning water*
* boiler KPxxS
OPTIONAL ACCESSORIES
• Fuel storage (elective size)
• Circulatory pump
• Three-way (four-way) valve with a servomotor
• Flue fan
• Digital room thermostat
• Tank for heating warm water
• Accumulation vessels
• Seasonal large volume fuel storage tanks
• Spiral fuel feeder from seasonal tank – ensures automatic fuel refilling in the daily tank.
• Automatic fuel feeding from the seasonal tank – ensures automatic operations of the spiral feeder from
seasonal 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)
• 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 damage to the boiler and heating system by frost. Heating unit - TJ M 48/2 of power 2,4;
3; 4; 4,5 a 6 kW.

Note: Optional accessories are not included in the boiler price.
FUEL BIN
The tank is supplied as optional accessory.The tank can be refilled up to full volume without limitations. Fuel
refilling of tanks supplied by the boiler manufacturer is safe, because the tank construction ensures safe distance
of the operator from moving parts.
Standard fuel bin sizes:
T
yp
e volume
(
liters
)
dimensions
(
mm
)
de
p
th width hei
g
ht
Fuel bin 100
(
dail
y)
* 100 1000 200 1270
Fuel bin 400 400 1000 500 1270
Fuel bin 700 700 1000 750 1520
Fuel bin 1000 1000 1500 900 1320
Fuel bin 400
(
folded
)
400 1000 500 1270
Fuel bin 700
(
folded
)
700 1000 750 1270
Fuel bin 133
(
for KP08x
)
133 740 350 1170
Fuel bin 165
(
for KP08x
)
165 740 450 1170
* used in combination with auger feeder from silo.

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Design - Installation - Service - Maintenance
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Use of pneumatic fuel transport 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

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Design - Installation - Service - Maintenance
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5. PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF
INSTALLATION
PLACEMENT OF PRODUCTS IN BOILER ROOMS
Minimum distances determine the necessary space to perform the operation and maintenance of equipment.
Placement and design of the boiler room must conform to the general regulations that are bounded on such
areas. During the operating of the equipment, the room temperature range should be between +10 and +40 ° C.
Legend:
A Entrance doors
B Boiler
C Fuel bin
D Combustion air inlet
E Electrical connection
F Boiler front door
G Chimney
H Chimney accessories – draft regulator, cleaning hole
T
yp
e h - kotle
KP 08
,
KP 08S 706
KP 11
,
KP 11.1 1078
K
P 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
Place the device near the chimney. Please observe the following points:
- The distance from the back wall must be at least 600 mm (measured from the rear edge of the casing)
- The distance from the side wall must be at least 200 mm
-Free distance ahead of the boiler must be 700 mm
- required height above the boiler to boiler room ceiling is about 450 mm - 600mm (according to the height
of the boiler) for cleaning.
- gain access to the service area behind the boiler

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Design - Installation - Service - Maintenance
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The boiler must stand on a horizontal floor of non-combustible material that exceeds by at least 10 cm Ground-
plan size of the installed device. Ahead of the cleaning door must be fireproofing floor to a distance of min. 60 cm
in front of the boiler.
SAFE DISTANCE FROM COMBUSTIBLE MATERIAL
Combustibility grade of materials of materials:
Grade A – non- combustible: stone, concrete, bricks, plasters, etc.
Grade B – hardly combustible: inorganic insulation – rotoflex, glass wool, basalt insulation, wood wool slabs, etc.
Grade C1 – low combustible: Formica, versalit, fibreboard, hardwood (beech, oak).
Grade C2 – moderately combustible: soft wood (spruce), chipboard, rubber, floor covering.
Grade C3 – easily combustible: asphalt, tar paper, PVC, paper --- etc.
Minimum safe distance from bulk flammable materials of the type B, C1 and C2 is 200 mm in course of installation
of the boiler (as well as during its operation).
This distance is double - i.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.
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 safe venting.
It is necessary to prevent threats to the safety and health of persons or animals and fire safety must be ensured
in all areas, which the flue gas path passes through.
The flue gas system consists usually of:
- Flue = construction element for connection between the appliance´s flue gas outlet and the flue pipe
- Flue pipe = component of the chimney, to which is connected a flue
- Chimney = structures with one or more vents
Important!
Flue must be designed and built by professional person!
Because of the flue gas temperature, it is recommended that the chimney is constructed as moisture
resistant.
HEIGHT AND DIAMETER OF THE CHIMNEY
The minimum recommended chimney height is 6m.
The diameter of the chimney must be adapted to the output of the boiler, the minimum diameter of
the chimney = 140 mm, possibly 150 x 150 mm.

Workbook 1
Design - Installation - Service - Maintenance
19
The approximate diameter values of the chimney
KP 08, 08S,11, 11.1,12, 12.1, 12S, 12.1S 150 mm
KP 21, 22, 22S 160 mm
KP 51, 51.1, 52, 52.1, 52S, 52.1S, 61, 62,62S 180 – 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 chimney draft