Galmet Galaxia kwe-12 User manual

Service and installation manual

C.H. boiler Galaxia KWE kW

With a tank (hopper):

PC RK

Left Right

Straight feeder - xed retort

Straight feeder - rotary retort

Slanted feeder - xed retort

Slanted feeder - rotary retort

Controller:

eLider

Catalogue No. ...............................

Production date ............................

Please read the instructions carefully before beginning the installation and use of the product.

www.galmet.euMade in Poland Original Instruction

1. General information......................................................................................................................................................................................................3

1.1. Application.........................................................................................................................................................................................................3

1.2. Fuel....................................................................................................................................................................................................................3

1.3. Technical-operational parameters of the Galaxia KWE boiler .............................................................................................................................4

1.4. Dimensions of the Galaxia KWE boiler................................................................................................................................................................5

2. Technical specication ..................................................................................................................................................................................................6

2.1. Galaxia KWE boiler construction.........................................................................................................................................................................6

2.1.1. Boiler water body...............................................................................................................................................................................................7

2.1.2. Doors..................................................................................................................................................................................................................7

2.1.3. Insulation panels................................................................................................................................................................................................7

2.2. Feeder................................................................................................................................................................................................................7

2.2.1. Feeding unit.......................................................................................................................................................................................................7

2.2.2. Burner unit.........................................................................................................................................................................................................7

2.3. Boiler equipment ...............................................................................................................................................................................................8

3. Controller......................................................................................................................................................................................................................8

3.1. eLider.................................................................................................................................................................................................................8

4 Assembly ......................................................................................................................................................................................................................9

4.1 Boiler transport..................................................................................................................................................................................................9

4.2 Boiler setting....................................................................................................................................................................................................10

4.3 Boiler connection diagram to central heating system ......................................................................................................................................10

4.4 Connecting of boiler to chimney and installation.............................................................................................................................................12

5. Operation and service .................................................................................................................................................................................................12

5.1. Lighting up ......................................................................................................................................................................................................12

5.2. Air adjustment .................................................................................................................................................................................................12

5.3. Resupplying of fuel ..........................................................................................................................................................................................13

5.4. Stopping boiler operation ................................................................................................................................................................................13

5.5. Boiler cleaning.................................................................................................................................................................................................14

5.6. Overload safety breaker ...................................................................................................................................................................................14

6. Conditions of safe operation........................................................................................................................................................................................15

7. System of protections..................................................................................................................................................................................................16

7.1. Safety temperature breakers (STB)...................................................................................................................................................................12

7.2. Boiler temperature sensor................................................................................................................................................................................12

7.3. Feeder temperature sensor ..............................................................................................................................................................................13

7.4. Fuel bin cover opening sensor..........................................................................................................................................................................12

8. Troubleshooting..........................................................................................................................................................................................................17

9. Declaration of Conformity ...........................................................................................................................................................................................18

10. Examination certicate ...............................................................................................................................................................................................19

11. Certicate....................................................................................................................................................................................................................20

Table of Contents

1. General information

The Instruction manual is destined to acquaint the user with operation of the solid fuel red boiler. Prior to commencing installation and operation of the

boiler each user should acquaint oneself precisely with the operation instruction manual of the boiler, feeder and controller. The instruction comprises

recommendations concerning boiler installation and its operation. Incompliance of the user with regulations and recommendations included in this

instruction manual released the boiler manufacturer from all his obligations and guarantees.The boiler should be operated by an adult person only.

Full satisfaction from the boiler performance can be accomplished only using the proper fuel.

1.1. Application

Galaxia KWE type steel heating boilers with a screw conveyer feeder are designed for water central heating systems of detached family houses. The top

temperature of water in the boilers does not exceed 85°C. The boilers belong to the low temperature water boilers operating in open type installations and

do not require registration at the regional Oce of Technical Inspection. The boilers are designed for operation in gravitational central heating installations or

with open system enforced circulation, having protections compliant with the requirements of PN-91/B-02413 standard. The boilers may operate in closed

installations provided devices used for relief of excessive heat are installed (relief-cooling valve of DBV type or a cooling coil).

An indicative table of the boiler selection for a building (building heat demand 40÷60W/m3 without domestic hot water demand).

Boiler output [kW] Room height [m] Room surface area [m2] Room cubature [m3]

12 2,5 80 ÷ 120 200 ÷ 300

17 2,5 113 ÷ 170 282 ÷ 425

22 2,5 146 ÷ 220 365 ÷ 550

30 2,5 200 ÷ 300 500 ÷ 750

40 2,5 266 ÷ 400 665 ÷ 1000

Table 1 - Estimated selection of the boiler heat output for the building

Presented values of room heated area for the boiler output are approximated ones.The boiler should be selected individually for the building by a designer

or installer on the basis of the energy certicate.

1.2. Fuel

Boiler operation depends, to a large extent on fuel quality. In order this operation was trouble-free the fuel should comply with the below requirements:

Specication Unit Value

Diameter mm 8 ÷ 20

Density kg/m3≥ 600

Caloric value MJ/kg 28 335

Humidity % 4,4

Ash content % 7,87

Sulfur content % 0,4

Ash melting temperature °C ≥ 1200

Fuel class - a1 (according to the EN 303-5 norm)

Table 2 - Fuel parameters: SILESIAN eco-pea coal

It is allowed to apply substitutive fuels in the Galaxia KWE boilers (e.g. brown coal). While burning substitutive fuels one should consider changing of the

boiler heat output approximately proportional to the caloric value. Combustion of substitutive fuels may result in shortening of the boiler life span.

CAUTION! Coal must be dry! Maximum fuel moisture 4.4%.

1. General information

1.3. Technical-operational parameters of the Galaxia KWE boiler

Parameters Unit Galaxia KWE

Rated output kW 12,0 17,0 22,0

Output range kW 4,0 ÷ 12,0 5,0 ÷ 17,0 6,6 ÷22,0

Boiler class acc. to EN 303-5:2012 standard - 5

Boiler heating surface area m2- - 3,24

Fuel - SILESIAN eco-pea coal granulation 8 ÷20

Fuel class - a1 (according to the EN 303-5 norm)

Fuel bin capacity l 150 240

Real fuel stream (at maximal capacity) kg/h - - 3,022

Combustion stability for the rated output h - - 60

Thermal eectiveness % - - 94

Required chimney draught mBar - - 0,20

Minimal chimney height m 6

Minimal chimney cut section area mm Ø 160

Flue gas temperature for the rated output °C - - 71

Flue gas temperature for the minimal output °C - - 61

Flue gas mass stream for the rated output kg/s - - 0,0083

Flue gas mass stream for the minimal output kg/s - - 0,0035

Flow resistance mbar - - 147

Operation temperature range °C 55÷85

Maximal temperature on supply °C 85

Minimal temperature of return °C 55

Permissible operation pressure bar 2,2

Boiler water capacity l - - 90

Boiler mass including the burner, feeder and bin kg - - 533

Outer diameter of ue mm Ø 160

Supply/return tube diameter ” 6/4

Discharge tube diameter ” ½

Boiler height mm - - 1660

Boiler width mm - 1165

Boiler depth mm - 1320

Flue distance to the oor mm - - 1397

Maximum power consumption W 354

Stand-by power consumption W 4

Electric connection/protection - 230V~/50 Hz, 6,3A/250V~

Protection degree IP 40

Noise emission (EN ISO 12100:2010) dB < 66

Operation with a blowing fan - tak

1. General information

1.4. Dimensions of the Galaxia KWE boiler

Drawing 1 - Dimensions of the Galaxia KWE boiler

DIMENSION A B C *D E* F G H *I J K POS

2 3 7 9 10

Galaxia KWE-12 - - - - - - - - - - - - - - - -

Galaxia KWE-17 - - - - - - - - - - - - - - - -

Galaxia KWE-22 778 487 1317 1196 163 755 1164 1620 360 ø160 600 4 2 4 1 2

Galaxia KWE-30 - - - - - - - - - - - - - - - -

Galaxia KWE-40 - - - - - - - - - - - - - - - -

*in boilers with slanted feeder, a 30 mm should be added because of the legs below the boiler.

2.1. Galaxia KWE boiler construction

3942

38 46

36 35 4

20 48

23 19

5047 8

25 28

21 22

Drawing 2 - Galaxia KWE boiler construction

1. Combustion chamber

2. Ceramic water tubes

3. Swirlers

4. Bottom

5. Horizontal water tube

6. Water tube swirlers

7. Combustion tubes

8. Combustion tube swirlers

9. Vertical water tube

10. Vertical water tube swirlers

11. Cleaning door

12. Chamber door

13. Burner door

14. Door insert

15. Door knob

16. Door guard

17. Door frame sealing

18. Burner door insulation

19. Water tube duct cover

20. Upper cleaning hole

21. Bottom cleaning hole

22. Ash drawer

23. Flue

24. Flue insert

25. Feeding tube

26. Return tube

27. Feeder flange

28. Insulation

29. Guards

30. Deflector

31. Fire box ring

32. Fire box pan

33. Retort band

34. Burner guard

35. Burner cleaning hole

36. Screw conveyer

37. Collector

38. Overload safety breaker

39. Feeder tube

40. Feeder stokehole

41. Bin cleaning hole

42. Reducer

43. Motor

44. Bin

45. Bin damper

46. Blower

47. Boiler controller

48. Boiler temperature sensor

49. Feeder temperature sensor

50. STB

51. Damper opening sensor

52. Thermomanometer

2. Technical specication

2.1.1. Boiler water body

The exchanger in boilers is made from certied boiler steel plate grade P 265 GH thickness 6 mm. The boiler shell is made from 4 mm steel plate.

The boiler is constructed as a 4-draugth exchanger:

- vertical combustion chamber

- horizontal combustion tube exchanger

- vertical water tube exchanger

In the combustion chamber (1) there are ue gas reheating elements, a deector (30) and ceramic shells (2) with swirlers (3) placed between them. Over

the chamber there is a vertical water tube (5) and horizontally mounted combustion tubes (7), inside of which there are swirlers (8) placed. The vertical

exchanger comprises a vertical water tube (9) located in a duct ended on top with a cleaning hole (20) and in the back ended with a hole, in which the ue

(23) is mounted with a dust collector (24) tted inside of it. In the boiler bottom (4) there is a drawer (22) comprising two parts: in the front one the ash from

the chamber is accumulated while in the back part the dust from the back water tube duct is collected. Tightness of the duct is provided by the cleaning hole

cover (21) with a seal mounted between the two parts of the drawer.

2.1.2. Doors

The boiler is provided with 3 steel doors with knobs (15), featuring adjustable pressure on seals (17). The doors have an insulation board (14) protecting

the doors against overheating. The cleaning door (11) is used for cleaning water tube ducts and upper surface of the combustion tube. The chamber door

(12) is used to position the system of swirlers and cleaning the combustion chamber surface. The burned door (13) is used for lighting up the burner,

removing of ash and dust produced in the combustion process accumulated in the ash pan drawer. They have an insulation board protecting the doors

against overheating and an additional insulating plate (18) placed under the door guard (16).

2.1.3. Insulation panels

The insulation panels (29) are xed on the surface of the water body. The are made from powder coated steel plate with high corrosion resistance. From

inside they are lined with mineral wool (28). Their job is to limit boiler heat loss to the environment apart from the aesthetic purpose.

2.2. Feeder

The feeder comprises a feeding unit, which is outside of the boiler and a burner set located inside of the boiler, which is xed to the boiler ange (27).

2.2.1. Feeding unit

The feeding unit is constructed of a feeder tube (39) ended with two anges and a stokehole (40) with a rectangular ange, to which a fuel bin (44) is

mounted through a seal. The fuel bin is constructed from bent and welded steel plates and a bin cover (45) closed with two locking devices. Tightness of

the connection is assured by a rubber seal located on the damper circumference. The stokehole of the feeder features holes closed with covers (41), used

for emergency emptying of the fuel bin. There is a screw (36) mounted in the feeder tube (39) driven by a gear motor comprising an electric motor (43),

coupling and two-stage reduction (42). An overload safety breaker (38) is mounted in the beginning of the screw shaft, whose task is to protect the motor

in case of blocking of the screw.

2.2.2. Burner unit

The retort burner is constructed of a burner ring (31), burner box pane (32) and bend (33). The above elements are made from cast iron and placed in a

steel air chamber (34), which is xed with a rectangular ange by bolts through a seal to the boiler body. From the bottom the air chamber is covered with

the burner cleaning hole (35) with the seal and xed with M8 thumb nut. The burner unit comprises also a cast iron deector (30) suspended over the

combustion box whose task is reheating of carbon oxide and spreading the ame so as the hot ue gas blew against the combustion chamber walls. The

fuel is fed by the screw (36) from the bin (44), feeder tube (39), bend (33) to the burner ring (31) where it is burned. Air to the burner ring nozzles in the

combustion box is supplied by a low noise fan (46).Tightness between the steel body of the air chamber (34) and the bottom of the combustion box bottom

(32) is obtained by placing a water and high temperature 1200oC resistant sealing. M10 that are located on the air chamber circumference (34) are used to

center the combustion box pan towards the bend (the chamber and loosing tightness in respect to the combustion box pan).

2. Technical specication

In the feeder with a rotary retort the screw shaft (36) passes through the retort bend (33) and conveys driving force on the rotary combustion box using a

carrier (37) positioned outside the bend on the screw end. The retort rotary movement causes even combustion of the fuel from each side of the combustion

box.

The feeder tube in the diagonal feeder is placed at an angle.The fuel fed by the screw located in the tube reaches the retort via the open angle bend.Thanks

to this solution smaller force is required to push the fuel into the combustion box, which allows for burning the eco-pea coal with dierent fraction sizes and

results in less frequent breaking of the overload breaker.

We kindly request you to acquaint yourselves with the detailed instruction manual of the feeder!

2.3. Boiler equipment

The boiler equipment comprises:

- a set of documents (guarantee cards, instruction manuals),

- a cleaning set

- an ash drawer,

- a weather sensor

- a set of sensors and wires,

- an analogue thermometer,

- 4 pcs of feet (concerning only the boilers with a diagonal feeder installed).

3. Controller

The boiler is provided with a microchip eLider controller (47) providing full control of safe and economical boiler operation and adjustment of the combustion

process. Thanks to the PID algorithm it can smoothly modulate the boiler output depending on heat reception.

It receives signals from:

- central heating boiler body temperature sensor (48)

- household hot water tank temperature sensor

- external temperature sensor

- valve sensor

- return sensor

- feeder tube overheating sensor (49)

- boiler overheating sensor (50)

- bin damper opening sensor (51)

- fan

The controller operates:

- boiler output (by changing of feeding time and feeder interval)

- fan blowing force

- central heating pump operation

- household hot water pump operation

- household hot water circulation pump operation

- operation of a mixing valve actuator

Optional additional equipment that the controller co-works with:

- room panel

- internet module

- mixing valve module

Prior to starting up the boiler the controller should be congured for the particular boiler output and for the external equipment it is supposed to co-work

with. The kind of fuel has to be input with its caloric value (see page 8 in the controller instruction manual for details).

Detailed information:

- safety (page 28 of the controller instruction manual); - settings (page 12 of the controller instruction manual); - alarms (page 29 of the controller

instruction manual).

2. Technical specication / 4. Controller

In the operation mode the controller automatically adjusts the boiler output depending on its load, trying to maintain the boiler as close to the set

temperature as possible. In summer, when the boiler is used for heating the household hot water only, the controller can enter the supporting mode. In this

mode the boiler operates acc. to the default supporting and cannot change them. Correct selection of these parameters is the on the user’s side because they

depend on many factors such as: boiler output, household hot water tank capacity, volume of water consumed, chimney draught, fuel quality. In the extreme

cases incorrect settings of supporting parameters may be the cause of excessive temperature increase or boiler switching o.

In order to learn about the possibilities oered by the eLider boiler controller from Elster we kindly request you to acquaint yourselves with

its detailed instruction manual.

4. Assembly

4.1. Boiler transport

The boiler with burner, feeder and fuel bin is supplied on a pallet.The boiler should be removed from the pallet acc. to the below drawing.

1. Unscrew bolts connecting the boiler with the pallet.

2. Remove the upper guard.

3. Hook on the lifting lug.

4. Lift the boiler and remove the pallet.

5. Position the boiler on the oor.

2 Zdejmij osśonń górnć

3 Zaczep hak za ucho

5 Ustaw kocioś na posadzce

Drawing 3 - Removing of boiler from transport pallet.

The boiler is supplied on the pallet in assembled condition. In order to reduce the boiler mass during transport to the boiler room it is allowed to remove the

bin and detach the feeder from the boiler. For this purpose you should:

- remove the plug from the bin opening sensor (51),

- unscrew M10 bolts connecting the bin (44) with the stokehole (40,

- remove the plugs of the blower (46) and motor (43),

- remove the feeder sensor (49),

- unscrew 4 M10 bolts from the round ange and remove the feeder tube from the boiler,

- unscrew the blower.

We kindly ask you not to unscrew the Allen’s screws xing the position of the feeder bend!

After installing the boiler in the boiler room check aligning of setting of feeder elements. If the boiler was stored in conditions of high humidity do not start

the boiler controller until it is completely dry.

3. Controller / 4. Assembly

4.2. Boiler setting

The boiler does not require a foundation however, the oor should be hard and level. In order to provide easy and safe operation of the boiler it should be

removed from the particular walls of the boiler room acc. to the below drawing.

Drawing 4 - Positioning of boiler in boiler room (dim. in mm)

This way of positioning of the boiler will allow for access to the particular

boiler parts, which is necessary for its correct exploitation and maintenance.

Minimal space of 600 mm must be provided over the boiler.

150800

1000

- Boiler installation should be executed in compliance with PN 87-87/B024411 standard. The room, in which the boiler is going to be located should have

two ventilation holes (gravitational ventilation) with dimensions 140x140 mm, of which one should be 150 mm over the oor level while the second one

should be under the The entrance door to the boiler room should open outside and it must be made from ame resistant material

- The room should be dry with a oor drain, installed water main and electric main with a protective wire.

- Provide lighting for the boiler front.

- The boiler should be placed away from ammable elements, fuel should be behind a partition.

4.3. Boiler connection diagram to central heating system

Installing of the controlled mixing valve (e.g. 4-way) will provide the user with heating comfort and protect the boiler against low temperature corrosion.

Prior to starting up of the boiler check if the central heating installation is lled up with water and the controller is connected to the socket with earthing

protection. Check the direction of fan and feeder revolutions.

The block diagram of boiler connection to the open type central heating installation with enforced circulation changing the layout of radiators provided with