Jaspi Econature40 User manual

07.2011
SOLID FUEL BOILER
INSTALLATION AND OPERATION MANUAL
JÄSPI – HEATING PROFESSIONAL
www.kaukora.fi

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Contents
Contents ...............................................................................................................................................2
Environmental instructions..................................................................................................................3
Packing.............................................................................................................................................3
Removal from Service .....................................................................................................................3
Operating Principle..............................................................................................................................3
Firewood Burning Phases ................................................................................................................3
Technical Data .....................................................................................................................................4
Parts..................................................................................................................................................5
Installation............................................................................................................................................6
Boiler Room.....................................................................................................................................6
Stack.................................................................................................................................................7
Piping Installation............................................................................................................................7
Electric Wiring.................................................................................................................................7
Electrical Diagram ...........................................................................................................................7
Heat Connection Diagram................................................................................................................8
Boiler Operation and Maintenance......................................................................................................8
Fuel...................................................................................................................................................8
Start-up.................................................................................................................................................9
Control Panel....................................................................................................................................9
Firewood burning...........................................................................................................................10
Combustion Air Control.................................................................................................................11
Maintenance...................................................................................................................................12
Cleaning.........................................................................................................................................13
Troubleshooting.................................................................................................................................13
The boiler water temperature does not rise to the desired level.....................................................13
The boiler boils and sputters..........................................................................................................13
The flue gas temperature is too high..............................................................................................13
The flue gas temperature is too low...............................................................................................14
The extractor fan won't work .........................................................................................................14
Installation record ..........................................................................................................................15
Warranty.........................................................................................................................................15
EY Assurance Certificate...................................................................................................................16

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Environmental instructions
Packing Packing is made of 100 % waste materials.
Dispose of packing in accordance with local
waste disposal requirements.
Removal from Service The boiler should be delivered to a waste dis-
posal point for electric and electronic compo-
nents.
Operating Principle
ECONATURE-40 is a solid-fuel water-
heating boiler operating on a rotating combus-
tion principle designed for heating systems in
private houses. The rotating combustion tech-
nique used in ECONATURE-40 is even 30 %
more energy saving than the conservative
upper burning technique.
Firewood Burning Phases
DRYING: Dehumidification of firewood.
PYROLYTIC DECOMPOSITION: Wood starts to
break apart and change to coal and gas. Pyro-
lytic decomposition begins at a temperature
above 100 ºC; when the temperature exceeds
280ºC the resulting reaction causes heat re-
lease. Secondary combustion (the reaction
between pyrolytic gases and oxygen) begins
at a temperature over 600 ºC.
REMAINING COAL BURNING: Remaining coal
burns after pyrolytic gases are removed.
After firewood starts to burn the temperature
must rise quickly since secondary burning
will not be efficient until the combustion tem-
perature is high enough. Efficient and clean
combustion implies full control over the burn-
ing process throughout its phases. The rotat-
ing combustion technique uses secondary
firewood burning efficiently where flue gases
provide additional burning in a separate firing
throat and obtain the hottest and cleanest
flame possible simultaneously reducing ha-
zardous flue gas emissions notably. During
the secondary burning process, the flame
temperature exceeds 1000 ºC making com-
bustion efficient and clean.

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Technical Data
Power: 40 kW
Weight: 450 kg
Volume: 120 l
Max. temperature: 110 ºC
Min. temperature: 0 ºC
Max. pressure: 3.0 bar
Standard pressure: 1.5 bar
Proof-test pressure: 4.0 bar
Power consumption: 0.12 kW
Voltage: 230 V
Frequency: 50 Hz
Body protection: IP 2X
Furnace dimensions: height 600 mm, width
350 mm, and depth 550 mm

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Parts
1. Flue gas extractor fan
2. 90º flue swiveling joint
3. Filling port
4. Maintenance hatch
5. Cleanout
6. Air chamber hatch
7. Electric leads
8. R32 FH (female threaded) outlet to accu-
mulator
9. R32 FH return from accumulator
10. R15 FH drain connection
11. R25 FH expansion connection
12. R15 FH flue gas sensor / analyzer connec-
tion
13. Sensor panel
14. Flame monitor glass
15. Upper primary air adjusting damper
16. Lower primary air adjusting damper
17. Secondary air adjusting damper
18. Mineral wool insulation 75 mm
19. Ceramic fire bar
20. Turbulent components
21. Firing throat
22. Storage furnace
23. Furnace
24. Convection ducting

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Installation
When installing follow the requirements be-
low.
The boiler should be installed upright on a
safe level support/surface. There are four ad-
justable legs supplied with the boiler.
It is recommended to fit the boiler with a flue
gas sensor. Flue gas temperature in the boiler
must be at least 150 °C at normal use. Tem-
perature can be raised by removing the lowest
turbulent plate.
Boiler flue swiveling joint rotates by 90° to
the left, back and right. When rotated to the
right, the joint is turned upside down and fas-
tening and rotation direction of the flue gas
extractor fan motor is changed. Correct rota-
tion direction is marked on the flue swivelling
joint with an arrow.
Boiler Room
Leave free space of at least 1000 m in front of
the filling and maintenance hatches of the
boiler, at least 600 mm over the cleanout
hatch, and 400 mm on one side of the boiler.
Combustion air required for the boiler is sup-
plied from outside and the duct or valve area
should be at least half as large as the stack
area.
An arrow on flue
swiveling joint marks
motor rotation direc-
tion.
To the left,
rotation direction
counter-
clockwise.
To the back,
rotation direction
counter-
clockwise.
To the right,
rotation direction
clockwise, flue
swiveling joint
turned upside
down.
To the back,
rotation direction
clockwise, flue
swiveling joint
turned upside
down.

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Stack
The stack should be round, Ø 150 mm, whole
brick lined.
The minimum required boiler draft is 10 Pa.
The stack should be high enough to prevent
flue gases from polluting environment nearby.
Piping Installation
The boiler is always connected to a 1800-
3000 liter energy accumulator.
We recommend to install three thermometers
into the battery: bottom, middle, and top.
The system should be fitted with shutoff
valves in order to ensure easy filling and emp-
tying of the boiler, accumulator, and heating
system.
The boiler should contain at least one 1.5 bar
safety relief valve with a blowoff capacity of
at least 150 kg/h if the maximum boiler power
is 60 kW. The blowoff capacity can be dis-
tributed among two or three (maximum)
valves if necessary. To confirm functionality,
at least two safety relief valves are recom-
mended to be used at all times, each having
the required blowoff capacity. The blowoff
line of the safety valve should be laid to the
floor drain to ensure that the drain can be no-
ticed and escaping vapor cannot constitute a
hazard for people or property.
The volume of the membrane expansion tank
should be at least 5 % of the entire water
space in the system.
Piping should be installed to ensure that boiler
operation, maintenance, and cleaning are un-
obstructed.
Electric Wiring
The boiler power supply is 230 V / 50 Hz. The wiring should be connected to the termi-
nal block located behind the openable sensor
panel.
Electrical Diagram
Power
10 A
3·1.5 mm
2
Charging
pump
Service
switch
Flue gas thermostat 0-
150 ºC
Lamp
Lamp
Smoke exhauster
thermostat 90 ºC
Limiter
98 ºC
Extractor fan
Pump
thermostat
60-90 ºC

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Heat Connection Diagram
1. Membrane expansion tank
2. 1.5 bar safety relief valve 2 ea.
3. ECONATURE–40 boiler
4. Hot water mixing valve block
5. TERMOVAR DN32 / 72 ºC charging
pack
6. OVALI-1800 energy accumulator
7. JÄSPI tubular electric heater max. 5 ea.
8. Heating loop pump
9. Accumulator thermometer 3 ea.
10. Boiler water filling valve
11. Pump thermostat
Boiler Operation and Maintenance
Fuel
Use dry firewood for burning. Using wet
firewood will absorb energy during evapora-
tion and remove most of it through the stack
as unburnt flue gases, thus uselessly loosing
part of energy and resulting in soot formation
in the stack.
Firewood is considered dry when the moisture
content is 20 %. Such wood is lighter in
weight and smashing logs against each other
produces a clearer sound.
ECONATURE-40 is mainly designed for
birch firewood which has a length of 50 cm, a
diameter of 12 cm, and a weight of 1.5 to 1.9
kg.
Other foliferous and coniferous woods are
also suitable for combustion but coniferous
woods cause more contamination to the
boiler. Different woods burn differently.
Lighter woods with a smaller wood diameter
will burn better.
C
C
H

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Start-up
Check that:
•The flue is open and there is no installa-
tion or other waste at its base.
•The boiler and the heating system are
filled with water and circulation is work-
ing.
•Piping connections are tight.
•The system is under pressure.
•The safety relief valve is working, i.e.
water runs from the drain line during
valve testing.
Use a small amount of firewood for the first
burning to avoid bar splitting by boiling water
that could soak in the ceramic fire bar.
If the system is filled for the first time the air
dissolved in water will penetrate into the sys-
tem but will be removed from the boiler water
when the temperature exceeds 90 ºC. When
used for the first time, the system should be
deaerated.
Control Panel
1. Pressure gauge. Measures pressure in the
boiler.
2. Thermometer. Measures water tempera-
ture in the boiler.
3. Pump thermostat 60-90 ºC. Activates
the charging pump when the boiler water
achieves the setpoint. The setpoint should
be at least 85 ºC under normal operating
conditions.
4. Smoke exhauster thermostat 90 ºC. De-
activates the smoke exhauster if the boiler
water achieves the setpoint of 90 ºC.
5. Flue gas thermostat 0-150 ºC. Deacti-
vates the smoke exhauster when the flue
gas temperature drops to the setpoint.
6. Power switch. The power switch of the
smoke exhauster and the charging pump.
7. Pump thermostat indicator lamp. On
when the pump is on.
8. Flue gas thermostat indicator lamp. On
when the smoke exhauster is on.
9. Temperature limiter. Deactivates the
smoke exhauster and the charging pump if
the boiler water temperature exceeds
98 ºC. The limiter will not actuate unless
the instrumentation is improperly used or
until it fails. Acknowledgement is pro-
vided by opening the protective cap and
pressing the limiter. Note that the boiler
water should cool down before acknowl-
edgement.

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Firewood burning
•Position the power switch (6) to ON.
•Put about eight 50 cm long pieces of
wood evenly onto the fire bar, altogether
weighing about 6 kg, and insert paper or
birch bark in between to ensure ignition.
•Fire the wood and start the smoke ex-
hauster by rotating the thermostat to posi-
tion 0. The filling hatch is kept slightly
open during ignition.
•Wait 15-20 minutes to allow about a 10
cm layer of live coals to form on the bar.
•Charge blocks (about 18-20 birch logs
altogether weighing about 32 kg) evenly
and closely, bark upward, onto the bar so
that the blocks touch the rear wall of the
furnace.
•Set the smoke exhauster thermostat to the
setpoint which is about 90 ºC. The set-
point is correct if the smoke exhauster
stops when there is a small amount of
coals left in the boiler.
•Put new blocks onto the remaining coals.
One firewood charge will burn about 2.5
hours producing about 100 kW heat, i.e. a
1800 liter energy accumulator will be heated
to approximately 50 ºC.
If the boiler has not been used for a long
while, use a small amount of firewood for the
first burning to avoid bar splitting by boiling
water that could soak in the ceramic fire bar.
Charge the firewood on the fire bar so that
it does not block the firing hole located in
the middle of the bar.