Highland heat Kompakt User manual

Solid fuel boiler
Kompakt
User manual
Maintenance and installation
JSC Aukstaitijos katilai
Linų str. 85, Ukmerge, Lithuania www.highland-heat.com [phone] | [email protected]

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Safety provisions
1. Introduction
1.1. General information
1.2. Standards and regulations
2. Technical parameters
3. Construction
3.1. Boiler components
3.2. Boiler
3.3. Boiler set
4. Boiler installation
4.1. General information
4.2. Boiler location and position
4.3. Connecting the boiler to the chimney
4.4. Connecting the boiler to the central heating system
4.5. Recommended connection diagrams
4.6. Changing the door direction
4.7. Adjustment of the air supply valve
5. Using the boiler
5.1. General information and sefety
5.2. Boiler fuel
5.3. Ignition
5.4. Boiler operation
5.5. Maintenance
6. Warranty conditions
7. Efciency and emissions
8. Disposal of the boiler
Table of content

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Safety provisions
During the use of the boiler, its individual parts: chimney, door,
individual points of the body - can heat up and cause burns if
touched.
Do not allow children to touch or use the boiler without adult
supervision.
The boiler can be operated by a capable adult who has
carefully familiarized himself with this instruction.
Only a qualied specialist can install the boiler and connect it
to the heating and electrical systems.
If you suspect that the boiler has malfunctioned, please
contact the organization that installed the boiler or
the manufacturer’s representative. Do not under any
circumstances use a malfunctioning boiler.
Improperly connected and used boiler can cause injury or
death.

1.1 General information
The boiler heat exchanger is characterized by exceptional
durability and low requirements for chimney draft. Maintenance
is simple - the control elements consist of a draft valve and
a draft regulator, which controls the air supply to the boiler.
The enlarged loading opening makes it possible to load larger
rewood. Kompakt - small but powerful boilers suitable for
burning wetter fuel.
Before connecting the boiler to the heating system, read this
manual carefully and check that all boiler components and
equipment are working properly.
Boilers are designed for heating private residential houses,
commercial and auxiliary premises. The boilers belong to the
so-called low-temperature boilers category, i.e. the average
temperature of the heat carrier cannot exceed 90 °C, and the
maximum operating pressure - 1.5 bar.
The manufacturer reserves the right to make minor changes
that do not signicantly affect the quality of the combustion
process and the operation of the boiler.
1.2 Standards and regulations
The boiler must be installed and operated in compliance with
the legal requirements of the country to which it is supplied. It
must be installed in accordance with the requirements of the
maintenance and installation instructions.
Otherwise, the manufacturer assumes no responsibility and
does not guarantee repair for any defects.
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1. Introduction

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2. Technical parameters
Models and power output 12 kW 16 kW 20 kW
Heated area
Combustion chamber load
Combustion chamber depth
Combustion chamber opening size
Heat exchanger area
Number of horizontal heat exchangers
Volume of water in the boiler
Weight
Hydraulic connections size
Chimney inner-outer diameter
Lowest operating temperature
Highest operating temperature
Heating efciency
Highest operating pressure
Required draft in the chimney
120
72
400
29x23
1,5
2
42
150
G 11/4
160
90
500
29x23
1,8
2
50
170
G 11/4
200
105
500
29x23
2,3
3
59
200
G 11/2
iki m2
l/dm3
mm
cm
m2
vnt
l
kg
coliai
150/160 mm
60º C
90º C
83%
1,5 bar
>15 Pa

1. Chimney
2. Heat exchanger
3. Combustion chamber
4. Cast iron grates
5. Return branch pipe
6. Adjustable legs
7. Supply branch pipe
8. Thermometer
9. Cleaning door
10. Ignition valve
11. Door handle
12. Fuel loading door
13. Service door
14. Air supply valve
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3. Construction
3.1 Boiler components

3.2 Boiler
The boiler heat exchanger consists of three main zones. Two
(three 20 kW) horizontal heat exchangers (2) are located in
the area of the upper door. The cleaning door (9) is used when
it is necessary to clean the surface of the heat exchanger.
There is a solid fuel combustion chamber in the area of the
fuel loading door (12). Through this door, the fuel is loaded into
the combustion chamber. Service doors (13), an ash box is
installed in the area for ash removal. The boiler is equipped with
a thermometer (8) and it is possible to install a draft regulator.
The internal heat exchanger body of the boiler is made of bent
and welded heat-resistant steel sheets, and the nish is made
of powder-coated sheets. Under the boiler nish is an insulating
layer of glass wool, which protects against heat loss through
the boiler’s outer walls. The double doors are sealed with heat-
insulating material and painted with heat-resistant paint.
Gases generated during combustion are removed through
the chimney pipe (1) installed in the upper part of the boiler.
The boiler works on the principle of direct combustion, so it is
possible to burn wetter fuel.
3.3 Boiler set
1. Ashtray
2. Instruction
3. Thermometer
4. Transition sleeve
5. Legs
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3. Construction

4.1 General information
Kompakt boilers are delivered ready for operation. Before
connecting the boiler to the heating system, read this manual
carefully and check that all boiler components and equipment
are working properly. Kompakt boilers are delivered to the
buyer fully assembled, but the thermometer and chain
mounting plate are not installed in order to avoid damage
during transportation. They come packed in an ash box.
4.2 Boiler location and position
The boiler must stand on a hard, smooth and non-ammable
dry surface. It is forbidden to place the boiler near ammable
materials. The safe minimum distance (from ammable
materials) for Kompakt boilers is 100 cm.
Provide good access to the boiler for service personnel.
Also ensure good access from all sides of the boiler so that
nothing interferes with loading fuel and cleaning the boiler, it is
convenient to access the ash collector, liner, connections and
chimney.
The boiler room must be equipped with adequate air supply
and smoke extraction ventilation. Minimal active ventilation
channel’s cross-sectional dimensions are specied for the
country’s regulatory acts in which it is operated.
To prevent a decrease in draft and uncontrolled smoke
emission, do not install mechanical smoke removal equipment
(smoke extractors) in the boiler room.
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4. Boiler installation

4.3 Connecting the boiler to the chimney
The chimney must be installed to meet the requirements of the
country where it is installed. The recommended chimney draft
is 15-20 Pa. The minimum chimney liner recommended by the
boiler manufacturer dimensions are:
• diameter of round insert – 150 mm;
• dimensions of the square insert - 140x140 mm.
The boiler ue pipe must be connected to the ue itself with
a rigid steel connection of suitable cross-section, shape and
thickness. The connection of the solid fuel boiler to the chimney
must be properly insulated to prevent burns
4.4 Connecting the boiler to the central heating system
Delegate the work of connecting the boiler to properly qualied
specialists.
In order to extend the service life of the boiler and to ensure
adequate comfort of use, it is necessary to follow such an
installation scheme that ensures the maintenance of the
working temperature of the boiler not below 60°C. With the help
of a specialist, make sure that the condition of the boiler, the
tightness of the plumbing connections and the ue and the
components are working properly. In a closed heating system,
there must be a thermal expansion compensation vessel of
suitable capacity (at least 10% of the total liquid volume in
the system). The use of safety valves or valves that limit the
ow in a closed heating system is prohibited. Recommended
connection schemes are presented in subsection 4.5.
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4. Boiler installation

4.5 Recommended connection diagrams
With four-way valve
With 4-way valve for older (gravity) systems:
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4. Boiler installation
1. Small perimeter pump
2. Big perimeterpump
3. Boiler pump
4. Four-way valve
5. Reverse valve
6. Boiler
1. Small perimeter pump
2. Boiler pump
3. Four-way valve
4. Reverse valve
5. Boiler

1. Screw DIN 912 M10x16
2. Screw DIN 912 M10x12
3. Eccentric M10
4.6 Changing the door direction
4. Door handle
5. Spring washer
6. Screw DIN 912 M8x14
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4. Boiler installation
The direction of the upper and middle doors is changed by
turning the door together with the hinge (hinges) away from the
boiler body and screwing it on the opposite side of the boiler.
The door handle is unscrewed, turned over and screwed back.
The direction of the lower door is changed by turning the door
away from the hinge. The hinge is unscrewed from the boiler
body and screwed on the opposite side of the boiler. The door
is screwed to the hinge, and the door handle is unscrewed from
the door and screwed to the opposite side of the door. The
draft regulator is xed at the top of the boiler depending on the
direction of door opening. The chain mounting plate is mounted
on the hinge side.

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4. Boiler installation
The draft regulator automatically operates the air valve in
front of the lower door by chain. During combustion, when the
temperature rises, the damper is closed, and when it falls, it
is opened. Check the operation of the shutter - it must move
freely. On the inner side of the lower door, a valve limiting the
maximum power is installed, which is locked in the desired
position depending on the desired power, and more accurate
air supply settings are made with the help of the draft regulator.
4.7 Adjustment of the air supply valve

5.1 General information and sefety
Use the boiler safely and follow the basic safety and boiler
operation rules.
• Check the operation of the safety valve (max. 1.5 bar) and
open the shut-off valves between the heating boiler and the
heating system.
• Check the water pressure in the system.
• The heating system must be lled with water and bled.
• Do not use ammable liquids such as gasoline, paint thinners
etc. when starting solid fuel.
• Do not burn plastic, rubber and other air-polluting waste.
• The smoke extraction system must be reliably connected and
tight.
• Unmaintained chimney, insufcient draft can cause Carbon
monoxide poisoning.
• Carry out maintenance work on the boiler only after it has
cooled down.
5.2 Boiler fuel
Wood. The boiler will reach the power specied in the technical
parameter table if you burn wood with a moisture content
of no more than 20%. However, the Kompakt design allows
for the burning of wetter wood as well. The burning duration
depends on the amount of fuel charged, its quality, outdoor
and indoor temperature, the building’s thermal resistance, the
working capacity of the boiler and the quality of compliance
with the recommendations of the user manual (connection and
adjustment of the boiler, heating water ow and temperature
maintenance).
Coal. Black coal mixture: medium and ne coal (50/50%).
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5. Using the boiler

5.3 Ignition
1) Check the water pressure and tightness of the boiler and
system.
2) Check the draft and the condition of the smoke channels.
3) Clean the boiler ash grates, smoke channels and internal
side walls of the boiler.
4) Put fuel through the middle door.
5) Fully open the foundation shutter and close the middle door.
6) Fueling is done through the bottom door. After lighting the
fuel the door must be closed.
7) After the fuel ignites, the ignition valve is closed.
8) If the boiler works too intensively, the power can be reduced
with the power limiting valve (See 4.7.).
8) The recommended working temperature of the boiler is 80-
85 ºC.
9) If the working temperature of the boiler is exceeded, it must
be adjusted with the help of the traction regulator circuit.
If a specialist installs the boiler for the rst time, he must
familiarize the user with the instructions for using the boiler.
Grates must be placed correctly (“VVVVV”). When stacked in
reverse, wood fractions and ash fall, clogging the gaps. In this
case, the boiler loses its traction and power, the grates fold.
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5. Using the boiler

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5. Using the boiler
5.4 Boiler operation
1) Depending on the heat demand and burning intensity,
refuel periodically.
2) When leaving the boiler to operate during the night, the air
supply valve can be set - thereby reducing the boiler power. But
after reducing the air supply too much, it starts to accumulate
soot on the walls of the boiler and the efciency of the boiler
decreases.
3) The boiler door must be closed during operation.
5.5 Maintenance
Ashtray.
Clean the ashtray as needed, depending on the type of fuel
used. A full ashtray prevents the proper combustion of fuel -
improper air distribution occurs, so the fuel burns unevenly
along the entire length of the boiler.
Cleaning.
It is recommended that all combustion waste and slag be
cleaned before each new ignition. The heat exchanger is easily
cleaned through the upper door. The combustion chamber is
cleaned through the middle door. Cleaning of cast iron grates
and ashtray is done by pulling out the components through the
bottom door.
Recommendations.
• The tar layer formed inside the boiler can be reduced by
burning aspen or black alder wood at maximum temperature.
• Periodically inspect the boiler and heating system.

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6. Warranty conditions
When selling the boiler, the seller must familiarize the buyer with
the terms of the warranty.
1. The manufacturer provides:
• 4-year warranty for the tightness of the boiler heat exchanger.
• 2-year warranty for the included parts.
2. The boiler installation scheme must ensure a return water
temperature of at least 60˚C.
3. Boiler connection must be performed only by a qualied
specialist.
4. During the warranty period, the manufacturer undertakes
to carry out free of charge elimination of malfunctions, if they
occurred due to the fault of the manufacturer.
5. The warranty does not apply to:
• Failure to submit purchase documents.
• Violation of installation, operating instructions or warranty
conditions requirements.
• In case of mechanical damage to the boiler.
• After determining that the boiler has been repaired by an
outsider.
• In case of natural disasters.
6. Defects detected during the warranty period will be
eliminated within 21 working days from the date of the
complaint.
7. Costs related to service calls and repairs, if it is determined
that the warranty conditions have been violated, are covered
by the buyer.

Kompakt
Ecodesign 2015/1189
Kompakt 16
Manual ignition - the boiler should be used with a hot water tank of at least x* liters
Condensing boiler [no] Solid fuel cogeneration boiler [no] Combined boiler [no]
Fuel Most suitable
fuel Other suitable
fuel
ηs[x%]: Sezoninis patalpų šildymo išmetamųjų teršalų
kiekis
SP GOC CM NOx
[x]mg/m³
Log wood, humidity ≤ 25 % Yes No 77±3 50±10 20±5 589±10% 273±5%
Characteristics when burning only the most suitable fuel
Useful heat release Heat utility
Parameter Symbol Value Unit Parameter Symbol Value Unit
At nominal heat
output Pn13,0 kW At nominal heat output
ηn80,2 %
At [30%/50%]
rated heat
uotput, if
applicable
PpNon appli-
cable. kW At [30%/50%]
rated heat
output, if
applicable
ηpNon
applica-
ble.
%
List of equivalent models Kompakt 12, Kompakt 20
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7. Efciency and emissions
SP – solid particles, GOC – Gaseous organic compounds, CM – carbon monoxide
NOx - nitrogen oxides, ηs - Seasonal energy consumption efciency for space heating
(Efciency factor - 3%)
ηn - Seasonal energy consumption efciency for space heating at maximum power
ηp - Seasonal energy consumption efciency for space heating at 30% capacity
X - Chamber volume = 45 × Pr × (1 – 2.7/Pr) or 300 liters, whichever is greater, Pr is expressed in kilowatts
(kW)
Y - Chamber volume = 20 × Pr, Pr is expressed in kilowatts (kW)
8. Disposal of the boiler
The boiler must be disposed of in accordance with the requirements of the
country where it is disposed of.

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Notes

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Notes

20 www.highland-heat.com
[phone] | [email protected]