Kabola HRE300 User manual

User manual
Kabola HRE serie
Kabola Heating Systems BV
Placotiweg 1E
4131 NL Vianen (Utr.)
Nederland

User manual HRE-serie version 6, November 2013
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Preface
This user-manual is written to enable the safe operation of the HRE-series central heating boilers. The
user must read this manual before installation of the boiler and must follow the instructions within this
manual.
Therefore, this manual must be kept with the boiler.
In chapter 2, the safety instructions are detailed, which have to be complied with, when installing and
using the boiler. In other chapters you will find safety instructions, that can be identified in the following
way.
Hint: This gives the user suggestions and advises to facilitate the execution of
certain tasks.
Attention: Additional information is supplied to the user, and possible problems are indicated.
Warning: Watch out for possible (life-threatening) injuries.
For any remarks, wishes or omissions you can contact Kabola Heating Systems. We also welcome
any remarks to improve this manual. We wish you a lot of pleasure from your purchase.
Kabola Heating Systems
Placotiweg 1E
NL 4131 NL Vianen
The Netherlands
Phone [phone]
Fax [phone]
Web: www.kabola.nl
E-mail [email protected]
Vianen, November 2013
© 2013 Kabola Heating Systems
Copying of (parts of) this manual, is only allowed with written consent of Kabola Heating Systems.

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Table of contents
Preface 2
Table of contents 3
1 Introduction 4
1.1 General 4
1.2 Range of application 4
1.3 Product description 4
1.4 Technical specifications 4
2 Safety 5
2.1 General safety 5
2.2 Safety instructions 5
3 Transport and storage 6
3.1 Transport 6
3.2 Storage 6
4 Installing and preparing for first use 7
4.1 Installation 7
4.1.1 Fitting the boiler 7
4.1.2 Connection to the central heating system 8
4.1.3 Flue gas outlet 8
4.1.5 Electrical connection 10
4.1.6 Filling the central heating system 11
4.1.7 Mounting the oil burner 12
4.1.8 Mounting the oil filter and oil burner. 12
4.2 Starting your system 13
5 Operating the boiler 13
5.1 Explanation of the dashboard 14
6 Cleaning and maintenance 15
6.1 Points for attention 15
6.2 Cleaning and maintenance 15
7 End of life of the boiler 15
Appendix A Technical specifications 16
Appendix B Electrical diagram 230 V 17
Appendix C Troubleshooting 18
Appendix D Boiler parts 19
Appendix E Burner parts. 20
Appendix F EG-declaration 22
Appendix G CE certification 23

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1 Introduction
1.1 General
Congatulations with your purchase of this Kabola boiler. This user-manual covers the HRE-series. The
HRE-boilers cover a wide range of boilers with a broad range of applications. By purchasing this boiler,
you have acquired a product, which is of high quality through the application of the latest European
standards and directives.
1.2 Range of application
The HRE-boilers with are designed to generate heat for the heating of water for a central heating
system.
The dimensions of the rooms to be heated, have to be taken into consideration. These boilers are not
designed for direct heating of the rooms in which they are installed.
1.3 Product description
The boilers of the HRE-series heats the boiler water by means of a pressure jet burner which is
installed at the front of the boiler. The boilers are available in 230 VAC. For fuel, diesel oil has to be
used.
1.4 Technical specifications
The most important technical specifications are listed on the plate at the back of the boiler. More
technical details are listed in Appendix A.

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2 Safety
In this chapter we emphasizes the safety-related points for operating the boiler.
2.1 General safety
Warning: Although Kabola Heating Systems designs and produces its products
according to the current safety standards, it is possible that dangers may
present themselves, which could lead to injuries or damage to the boiler, if
the safety instructions in this manual are not complied with.
The user must:
Have read and understood the chapter "safety";
Avoid any actions which may lead to dangers to his health or others;
Avoid any actions which may lead to damage to the boiler;
Ensure that the boiler is only used when the boiler is in sound technical condition;
Ensure that the safety regulations are observed whilst operating the boiler.
Attention: No alterations to the boilers may be done, without the explicit written consent
of Kabola Heating Systems!
2.2 Safety instructions
In this chapter we emphasizes the safety-related points for operating the boiler.
MEASURES FOR A SAFE INSTALLATION
Don't store any flammable and/or gaseous products in the room where the boiler is installed to
avoid explosions and fires.
Install the boiler in a non-humid environment on a firm horizontal base.
Ensure that there is sufficient ventilation in the room where the boiler is installed (See also § 4.1.1).
Make sure, before you start connecting the boiler, that the system is disconnected from the power
supply.
Only use multi-stranded wire for electrical connections.
MEASURES FOR A SAFE OPERATION
Never change the settings of the burner.
Don't use any aggressive solvents which may affect the boiler (like petrol or turpentine).
Insulate the chimney, when it can be touched by body parts.
Make sure that the boiler and burner are checked annually by a skilled expert.
Make sure that before you start any work on the boiler that the system is disconnected form the
power supply.
Make sure that any surplus oil is collected in case of oil spillage.
We advise you to have any maintenance or repairs carried out by skilled experts.

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3 Transport and storage
3.1 Transport
Take following precautions before transporting the boiler:
Drain the water from the boiler;
Uncouple the fuel system;
Remove the burner (see § 4.1.5, replacing the burner).
While transporting the boiler take following precautions:
Don't damage the boiler, use a blanket to cover the boiler;
Transport the boiler standing up.
3.2 Storage
Take the following precautions when the boiler is stored for a longer period of time:
Store the boiler and accompanying parts in a dry place;
Dismount the burner (see § 4.1.7.)
Store the boiler standing up;
Store the boiler on a firm horizontal base.

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Figure 1
4 Installing and preparing for first use
In this chapter you will find directions and hints for a correct placement and fitting of the boiler and
accompanying parts.
Warning: Do not store any flammable or
gaseous substances in the room
where the boiler installed. This is to
ensure that no explosions or fires
can occur.
4.1 Installation
4.1.1 Fitting the boiler
Install the boiler in a dry place.
Install the boiler on a firm horizontal base.
Make sure there is sufficient supply of fresh air in the room
where the boiler is installed (see hint below).
To avoid movement secure the base of the boiler by using
the holes with M5 threat in the feet from the boiler.
Keep a minimum distance of 250 mm behind the boiler for
the flue-gas outlet (see figure 1).
Use an earthed plug socket for connecting the 230 Volt AC
versions to the power supply.
Hint: As a rule of thumb for the ventilation openings, take 2,5 times the diameter of
the flue gas outlet.

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4.1.2 Connection to the central heating system
PIPING
Take note of the following points, when installing the piping:
Install the piping in such a way, that the boiler (cover and dashboard) remains accessible;
Provide enough bleeding points in places where air may collect, especially near the boiler.
Attention: Install a bleeding point near the
boiler, especially when the piping
does not go up.
Connect the piping to the boiler as follows (see figure 2):
1. Install the feed from the CH at point 1;
2. Install the return of the CH at point 2
Hint: Install a shunt with pressure equalizer, when thermostatic radiator valves are
applied.
4.1.3 Flue gas outlet
GENERAL
The flue gas outlet is an essential part of your heating installation. An incorrect flue gas outlet reduces
the lifespan of your boiler considerably and has a negative impact on the efficiency. Remember when
installing the flue, that even the best boiler won't work properly unless the flue is properly installed.
Warning: Because the flue gas temperature lies between 180-240°C, it is advisable to
insulate the flue with heat-resistant material on those parts where contact
with human body parts is possible.
For a correct flue gas outlet the following points need to be observed:
Use the proper diameter, use a diameter equal to the diameter of the flue gas outlet on the boiler
(see also technical specification).
Use double-walled chimney pipe outside to prevent a rapid cooling of the dlue gasses, which may
result in condensation in the chimney.
Hint: When using an existing chimney of a larger diameter than the diameter on
the boiler, you can install flexible piping of the correct diameter insides
the existing chimney.
Warning It is necessary that condense water always can flow back to the drain
or the boiler, avoid water bags!!
Figure 2

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Figure 3
Figure 4
The flue can be installed in several different ways. You must carefully consider under which
circumstances the boiler will be used. For sea going boats and sail boats we advise the installation of a
vertical flue where the heel angles of the boat may be larger. The following installation examples are
most common.
HORIZONTAL FLUE GAS OUTLET
It is possible to fit a horizontal flue gas outlet to the boiler. The following points need to be observed:
Make sure that the outlet is positioned at a sufficient
height above the waterline. If this is not possible use a
swan neck bend in the pipe as in figure 3.
Use the correct hull fittings for installing the flue through
a hull side
The maximum allowed length is 5 meters.
Don’t use more than 3 elbows of 90°.
Every elbow of 90° is equivalent to 1 meter straight pipe
VERTICAL FLUE GAS OUTLET
This way if installation is preferable for seagoing boats and sailing boats, because these boats
encounter large angles of heel through waves and under sail. For this kind of flue gas outlet, the
following points are important:
Install a proper storm cowl on top of the chimney (this
must stop rain from entering) (figure 4).
Install deck fittings for installing the flue through a deck.
Install a water trap, to drain possible water caused by
condensation
Keep the chimney as vertical as possible.
Don't use more than 3 elbows 90°.
The maximum allowed length is 7 meters.
Every elbow of 90° counts as 1 meter.
Use outside double walled chimney pipe
Hint: To reduce the noise from flames,
it is wise to install a silencer in the
flue.
Your Kabola supplier can provide you with all components
which may be required for installation such as:
Cowls;
Flexible piping;
Single and double walled chimney pipes;
Hull and deck fittings;
Silencers;
Water traps;
Insulation.

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4.1.5 Electrical connection
Warning: Disconnect the power supply from
the boiler before you start the
installation. The quality of 230 VAC
power supply to the boiler should
be as good as the power supply
from a land line.
Connecting the room thermostat (Figure 5a & 6)
For connecting the room thermostat you must use a wire with 2 cores 0.75 mm 2isolated hose. The
room thermostat you need to connect at the following way:
Remove the lid from the connector A (figure 5a), what
is mounted at the back of the dashboard;
Connect the wires from the room thermostat as
pointed at the sticker in the connector;
Connecting the circulation pump (figure 5 & 5a and
appendix C)
1. Remove the lid from connector A and connect the
wires from the circulation pump as pointed at the
sticker in the connector;
2. Don’t forget the earthing;
3. Close the lid from the connector.
Figure 6
Figure 5
Figure 5a

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Figure 7
Figure 8
4.1.6 Filling the central heating system
The pressure in the system should:
Never be lower than 0,5 bar cold;
Never be higher than 2,5 bar hot.
Follow the procedure below for filling the CH-system (see
figure 7):
Switch off the boiler;
Remove nob 4
Screw the adaptor 3 at the thread,
Connect the filling tube at 3 and open 5 by turning it;
Fill the system slowly with water, until the pressure
indicator indicates a pressure of 2 bar;
Close the valve (2);
Bleed the CH-system;
If necessary, fill with water again up to 2 bar of pressure;
Switch on the boiler and let the pump run for about 5 minutes;
Switch off the boiler;
Check the water pressure, if it is too low, repeat steps 5 through 10;
Remove the hose.
Hint: The CH-system can be filled with cooling fluid, suited for CH-systems (pH-
value 8.5)
Bleeding the circulation pump
See instruction manual
Attention: When locking pump couplings are
supplied with the boiler, the adjusting
grooves must point towards the
pump.

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Figure 10
4.1.7 Mounting the oil burner
Follow the instruction below for mounting the oil burner:
Passionate the insulation (2) and the burner clamp (3)
that they are in one line with the mounting holes in the
door.
Assemble the burner clamp with the 4 M8 bolts. The
arrow at the burner clamp must point to the top.
Hint: Smear some sealant in the crack in
the flange to seal
Slide the burner trough the burner clamp and push it
as far as possible.
Fasten the screw from the burner clamp what is
clamping the burner.
Attention: Take care that the flame tube is not
damaged during installation. Repairs
to the flame tube are very expensive
and don't fall under warranty.
4.1.8 Mounting the oil filter and oil burner.
To connect the filter to the burner follow the procedure below
(see also figure 9):
Remove the burner cover from the oil burner (1);
Connect the oil pump (2) to the oil filter (3), using the
included fuel hoses. Make sure that the flow
directions on the pump comply with those on the filter;
Connect the fuel line from the tank to the filter (5A).
The fuel line must have an outer diameter of 8 mm
and must be made from copper or steel. The fuel line
has to be connected directly to the oil tank. Correct
functioning of the burner can not be guaranteed when a fuel manifold or T connection is
installed;
Connect the plug (4) from the boiler to the burner.
Hint: When the oil tank is situated below
the boiler or when the oil supply line
comes from below the boiler, it is
advisable to use a self bleeding oil
filter. The articlenumber 4-D133
(figure 11) standard the 4-D131
(figure 12) is supplied with the set.
This prevents unnecessary
malfunctioning of the burner. In the
manual of the burner you will find an
overview with the allowed
dimensions of the oil supply line.
Figure 9
Figure 11

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4.2 Starting your system
When everything is connected follow the procedure below:
1. Connect the boiler to the power supply. The 230 VAC will
need to be connected for the 230 VAC Switch the boiler
on with the on/off switch on the dashboard. The lamp in
the switch will indicate that the system is active.
2. Set the required boiler temperature between 65 and 90°C
using the boiler thermostat.
3. Set the room thermostat so that it is switched on (see
manual of the room thermostat)
4. Starting of the oil burner (see figure 10):
4.1. Open the valve in fuel line (5);
4.2. Install the bleed hose (3C) on the bleed opening of
the oil filter;
4.3. Open the valve on the oil filter (5A);
4.4. Start the oil burner;
4.5. The burner switches on, this will take approximately
1,5 minutes because of the oil pre-heating element;
4.6. Open the bleed valve on the oil filter (3B);
4.7. Check if oil is coming out of the hose(3C);
4.8. Check all oil connections for leaks;
4.8.1.If the burner does not start, the control light will
light;
4.8.2.Close the bleed valve (3B) on the oil filter;
4.8.3.Wait approximately 3 minutes;
4.8.4.Reset the burner by pushing button and return to 5.4 (repeat if necessary).
4.9. Close the bleed valve(3B) when only oil and no bubbles come out of the hose;
Attention: The oil burner is tested by the manufacturer, not adjusted. The adjustment of
the burner has to be done by an experienced installer, because this
requires expert knowledge. To be eligible for warranty, the boiler has to be
adjusted by an approved installer. Contact your Kabola supplier to make an
appointment.
Never adjust the burner using your own initiative.
5 Operating the boiler
When the boiler has been started and adjusted according to 4.2, operation fo the boiler is very simple.
The required temperature is set with the room thermostat, which controls the boiler. The calorifier
thermostat controls the boiler. The operation of the room thermostat is explained in the manual of the
room thermostat.
If problems arise with the operation of the boiler, you will find a list of possible problems and solutions
in Appendix C.
Figure 12

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5.1 Explanation of the dashboard
Explanation from the number in the figure 13:
A. Fuse holder with a glass fuse 10A 230V,
B. On/ off switch,
C. Analogue display for boiler temperature ,
D. Adjust nob for boiler temperature,
E. Reset nob maximal thermostaat.
Figure 13
< A
< B
E
< D
< C

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6 Cleaning and maintenance
6.1 Points for attention
Spare parts must be ordered through your Kabola supplier. For warranty purposes only original spare
parts must be used. When ordering spare parts, state the type of boiler and its serial number. Your
Kabola supplier will then be able to supply the correct parts. In Appendix B, the main spare parts are
listed.
6.2 Cleaning and maintenance
Warning: Maintenance and repairs should only take place when the boiler is switched
off, this is because the boiler may start unexpectedly. Take the plug form the
wall socket for the 230 VAC versions.
Warning: Maintenance and repairs may only be performed by personnel, who have
read and understood the information in this manual, preferably an expert
installer or a service engineer from Kabola Heating Systems.
Every year
1. Clean the boiler
1.1. Remove the burner (see § 4.1.5);
1.2. Remove the burner from the boiler;
1.3. Open the door of the boiler,
1.4. Remove the insulation.
1.5. Clean the inside of the boiler, using a stiff brush; Attention: Don’t use any aggressive
solvents like thinner or gasoline.
1.6. Clean the boiler with a vacuum cleaner;
1.7. Replace the door, if necessary use a new isolation;
1.8. Replace the burner;
2. Clean the chimney;
3. Change the oil filter element;
4. Clean the burner (see manual of the burner)
Attention: The old oil filter element has to be processed as chemical waste.
7 End of life of the boiler
When the boiler is scrapped, take note of the points listed below:
Process the oil filter and the oil hose as chemical waste;
Separate the metal from the plastic parts and dispose off them separately.
Process any excess oil in an environmentally friendly way.
Transport the boiler according to the instructions in chapter 3
Recycle this manual.

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Appendix A Technical specifications
Boiler dimensions
Letter
HRE300
HRE400
HRE500
A
380
460
505
B
330
330
330
C
354
370
370
D
61
75
185
E
298
298
306
F
360
392
467
G
242
242
242
H
344
344
344
I
140
140
140
J
75
75
75
Technical specifications
HRE300
HRE400
HRE500
Flue gas Ø
mm
60
80
80
C.H. connection
mm
22
22
22
Max. capacity
kW
8-10
10-14
20
Service pressure
Bar
2
2
2
Working pressure
Bar
3
3
3
Weight
Kg
60
70
81
Exhaust gas temp. Max.
ºC
230
230
230
Efficiency
%
90
90
90
Max. length horizontal max.
mtr.
5
5
5
Power consumption 230V
Power consumption 230V starting load
Operating load 230V
W
740
740
740
W
230
230
230
Fuel
Diesel
Diesel
Diesel

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Appendix B Electrical diagram 230 V

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Appendix C Troubleshooting
Listed below you will find a list with possible problems, their reasons and solutions. When you
encounter problems not listed, you should contact your dealer. Never try to solve problems on your
own.
Problem
Possible reason
Possible solution
Burner will not start
Oil supply interrupted
Bleed the oil filter
Change contaminated filter element
Fill the oil tank
Power supply interrupted
Check the fuses
Check the power supply
Check the maximal thermostat
Burner stops
Reset burner (once)
Flame protection dirty (photo cell)
Clean glass of flame protection
Flame protection defect
(photo cell)
Replace flame protection
Burner starts pulsing
Flue gas flow interrupted
Clear chimney opening
Boiler dirty
Clean boiler
Oil supply interrupted
See above
Nozzle defective
Replace nozzle
Burner shows error
Reset burner (once)
Low voltage
Check voltage level
Oil supply interrupted
See above
Boiler does not react to thermostat
Boiler thermostat incorrectly
adjusted
Adjust boiler thermostat
Battery of room thermostat flat
Replace battery
Water is not circulating
Pump couplings are closed
Open pump couplings
Pump not connected to electricity
supply
Connect pump

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Appendix D Boiler parts
Pos
Discription
Article number
1
Dashboard HRE-serie 230V
9-I138
2
Insulation Rockwoll 25 mm
3
Conversion coupling 1" int. x 22mm
17-R161
4
Locking pump coupling 1”
9-I023
5
Circulation pump 230V Kabola h=130 mm
9-i129
6
Conversion coupling 1" int. x 22mm
9-I023
7
Pipe nipple 1" x 40 mm
18-S481
8
Knee 221 1"
18-S482
9
Reducing ring 1 x 1/2" ext. x int.
18-S297
10
Pipe niple 1/2" x 120 mm
18-S483
11
Fill,drain pressure relief valve wivakom
9-I015
12
Stainless steel eficiency tube HRE300-400
14-N219
12
Stainless steel eficiency tube HRE500
14-N225
13
Insulation door 294 x 294 x 20 mm HRE300
9-I081
13
Insulation door 300 x 300 x 20 mm HRE400
9-I082
13
Insulation door 355 x 300 x 20 mm HRE500
9-I096
14
Door gasket cord HRE-serie 15 mm per m.
9-I083
15
Insulation door 276 x 276 x 15 mm HRE300
9-I084
15
Insulation door 282 x 282 x 15 mm HRE400
9-I085
15
Insulation door 282 x 338 x 15 mm HRE500
9-I097
16
Door HRE300
9-I086
16
Door HRE400
9-I087
16
Door HRE500
9-I120
17
Door mounting knob HR-series
9-I089
18
Isolation burner Kabola SLV100B
35-007
19
Burner fixing flange Kabola SLV100B
35-035
20
Mounting clamp HRE-series
9-I088
21
Kabola SLV100B burner HRE300 230V
2-B023
21
Kabola SLV100B burner HRE400 230V
2-B024
21
Kabola SLV100B burner HRE500 230V
2-B025

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Appendix E Burner parts.