Kabola ECOLINE KB Series User manual

User manual KB-ECOLINE series English
Ecoline series
CH
Calorifier
Combi

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
2
Preface
This user-manual is written to enable the safe operation of the central heating boilers with integrated tap
water supply ore boiler function. 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]
Web: www.kabola.nl
E-mail [email protected]
Vianen 2022
© 2022 Kabola Heating Systems
Copying of (parts of) this manual, is only allowed with written consent of Kabola Heating Systems.

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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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 and domestic hot water 8
4.1.3 Flue gas outlet 10
4.1.4 Electrical connection 12
4.1.5 Filling the central heating system 14
4.1.6 Mounting the oil filter and oil burner. 15
4.2 Starting your system 15
5 Operating the boiler 15
5.1 Explanation of the dashboard 16
5.1.1 Electric element maximum power use 18
5.2 Operating the tap water on/off button and function 19
6 Cleaning and maintenance 20
6.1 Points for attention 20
6.2 Cleaning and maintenance 20
7 End of life of the boiler 20
Appendix A Technical specifications 21
Appendix B Troubleshooting 22
Appendix C Boiler parts 22
Appendix D EG-declaration 27
Appendix E CE declaration 28
Appendix F Guarantee conditions 30

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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1 Introduction
1.1 General
Congratulations with your purchase of this Kabola boiler. This user-manual covers all kind of boilers in
the KB-series. The KB- 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 Kabola KB-Series are designed to generate heat for the heating of water and for a central heating
system. The boilers can also be used for the generation of domestic hot water generated by a compact
brazed heat exchanger. 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 KB- 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 version. For fuel, diesel oil B7 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.

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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2 Safety
In this chapter we emphasis 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 emphasis 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 from 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.

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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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;
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;
➢Store the boiler standing up;
➢Store the boiler on a firm horizontal base.
Figure 1

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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No.1 Dashboard and burner plug.
230 Vac 360 Watt
No.2 Feeding Electric element 3000Watt
230 Vac 16 Ah. Landline or generator
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 (figure 1)
➢Keep a minimum distance of 250 mm behind the boiler for the flue-gas outlet
➢Use an earthed plug socket for connecting the 230 Volt AC versions to the power supply.
➢For a 230 Volt version, ensure a grounded wall socket to connect the boiler. The normal thin plug
feeds the burner and the dashboard (360Watt).
➢The second thick plug feeds the 230Volt electric element and must be secured at 16Ah and should
only get its power directly from the generator or shore power. This is to ensure that the batteries of
the means of transport cannot be taxed too heavily.
Hint: As a rule of thumb for the ventilation openings, take 2,5 times the diameter
of the flue gas outlet.

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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4.1.2 Connection to the KB 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.
Installation KB - CH:
Connect the piping to the boiler as follows (see figure 2 –2.2):
1. Install the feed of the boiler on nr 1
2. Install the return of the boiler on nr 2
3. Install the fill and pressure gauge on nr 4
Hint: Because the water pressure in the domestic water system is not always
stabile, we recommend to use thermostatic controlled water cranes.
It is possible to use the boiler when the domestic water side is not connected
KB-20 / 40 / 45 / 50 / 75
4
2
1

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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Installation KB boiler with Calorifier control:
Figure 2.3
1. Install the feed of the calorifier on nr 1 / B
2. Install the return of the boiler and calorifier on nr 2
3. Install the feed of the boiler on 3 / A
4. Install the fill and pressure gauge on nr 4
5. The numbers A and B you will find on the housing of the three-way valve
Note: There must always be a thermostat mounted on the calorifier to
communicate with the KB series (available at your Kabola supplier with number: 9-i025)
2
4
1
3
B
A

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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Installation KB –Combi:
Figure 2.4
1. Install the feed of the boiler on nr 1
2. Install the return of the boiler on nr 2
3. Install the fill and pressure gauge on nr 4 (see figure 2.3)
4. Install the output (hot water) of the combi on nr 5
5. Install the input (cold water) of the combi on nr 6
4.1.3 Flue gas outlet
GENERAL
The flue gas outlet is an essential part of your heating installation.
Flue system shall be made of 316 stainless steel in designation T250-P1-D.
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 150-200°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 exhaust 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 condensation water always can flow back to the drain of the
boiler, avoid water bags!! The boiler has got a high efficiency, and the burner will
start even when there is no heat demand, this is done to avoid that there is a lot
of condensation in the boiler. Condensation will short the life time of the boiler
1
2
5
6

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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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, without curves is 10
meters. At more than 10 meters in length, always contact Kabola for advice.
➢Don’t use more than 4 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 4 elbows 90°.
➢The maximum allowed length is 10 meters. At more than
10 meters in length, always contact Kabola for advice.
➢Every elbow of 90° is equivalent to 1 meter straight pipe.
➢Use outside double walled chimney pipe
Hint: To reduce the noise from flames, it
is wise to install a silencer in the
exhaust.
Figure 4.a
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.
Figure 3
Figure 4
Always install a drain with tap directly on the boiler
See Figure 4.a

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4.1.4 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.
To connect the room thermostat for KB-Standard:
➢Remove the cover of the thermostat
➢Connect the two thermostat wires to point 2and 3(figure 6.2)
➢Remove the cover from the connector that is located on the left backside of the dashboard
(green arrow).
➢Remove the bridge from T1 and T2 and connect the 2-core cable ( 2x0.75mm2) of the room
thermostat to T1 and T2, as indicated on the sticker in the connector A.
A
Figure 6.2
Figure 5
23

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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To connect the room thermostat for KB Combi –Calorifier:
➢Before you connect the room thermostat with Hot Water Switch, use a 4-core insulated wire
0,75 mm2.
➢Remove the cover of connection A(figure 5) which you can find at the backside of the Kabola
dashboard.
➢Connect the 4 wires of the room thermostat at T1 and T2 and S3 and B4 in connection Aat
the backside of the dashboard as shown on the sticker inside the connector.
➢Connect the T1 and T2 wires inside the room thermostat (Fig. 6.1) to 2and 3
➢The thermostat itself doesn’t have a hot water switch. You can use a connect and disconnect
switch to use this fuel saving function.
➢Connect the hot water on / off function (S3 & B4) on a connect and disconnect switch.
When the wires are not connected, the hot water function in on.
Be aware that the 3-way valve only opens to the central heating system when the temperature
in the boiler is above the 50 Celsius degrees, this is to avoid that there is condensation in the
boiler.
Figure 12
Figure 6
Figure 6.1
23
Figure 6.1
A

Instruction manual Kabola KB- Hybrid -Series version 1, 2022
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Figure 7
4.1.5 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
➢Adjust the temperature of the room thermostat higher than the ambient temperature (for
example, 5 degrees higher);
➢Set the on / off switch (button lights);
➢Put the circulation pump on automatic venting position. This will take 10 minutes.
➢Check the entire system for air and check the working pressure (Top up if necessary.)
-Press the green button 9
times for settings
-3 times stand on ^p-c
-3 times stand on ^p-v
-3 times fixed speed 1, 2, 3,
(RPM)
User manual para SC/U (self-control)

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4.1.6 Mounting the oil filter and oil burner.
The KB-series will be standard supplied with a self-bleeding oil filter, what is SI approved, this oil filter
should always be hung at least 20cm above the burner, if this filter is not above the level from the oil
pump it will not work correctly!
The oil burner is already mounted on the boiler, the flexible oil hoses, what are fitted on the burner,
needs to be connected to the oil filter, those two flexible oil tubes, an inlet, and a return line. Place
these lines on the filter. On the filter are arrows!
Use the oil line from the fuel oil pipe stainless steel with an inner diameter of 6-8 mm.
For further instructions from the oil burner, refer to the instructions of the burner.
4.2 Starting your system
After the room thermostat is connected, the following steps:
1. Insert the two plugs into the grounded socket for 230 volt version.
- Number 1 normal power (360Watt)
- Number 2 power feed for the electric element (3000Watt). Direct to generator or shore
power!
2. Switch the boiler on, at the on / off switch on the control panel. The lamp in the switch indicate
that the system is on.
3. Set the room thermostat. (see manual of the room thermostat)
4. Open the valve on the fuel tank;
5. Open the valve on the oil filter;
6. Disconnect the power from the motor to the oil burner (only Kabola engineer)
7. Use the startup cable, and connect with this cable the power to the motor from the oil pump
8. Assemble the pump pressure gauge at plug P from the oil pump
9. Check if the system is bled and check the right oil pressure
10. Start the burner;
11. After ± 2 minutes, the burner will start
12. Check all oil connections for leaks;
13. If the burner does not start, the fault light is on;
14. Wait about 3 minutes;
15. Reset the burner and go to 5.4 (repeat if necessary).
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 for the boiler is very simple.
The required temperature is set with the room thermostat, which controls the boiler. The boiler
thermostat controls the 3-way valve on 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.

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5.1 Explanation of the dashboard
KB-series Boiler
The hybrid function means: The boiler operates on diesel as well on the electronic element.
This is how it runs:
•0°C - 50°C = Diesel burner as well the electronic element on max. power
•50°C - 60°C = Diesel burner off and the element on max. power
•60°C - 70°C = Diesel burner off and the element on 2/3 power
•70°C - 80°C = Diesel burner off and the element on 1/3 power
Note: The 80°C can be changed by the installer.
The red colour is showing the active mode: in this example the Hybrid mode
Explanation of the operating panel
Numbers
Explanation
Phot
0
Rest position (boiler is on stand-by)
Circulation pump stopped
1
Room thermostat demands heat.
Circulation pump operating above 40°C
3
Circulation pump further running time.
Circulation pump operates for ± 3 minutes
Current boiler temperature
Function boiler
0
1
3

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KB-series Combi-Calorifier
Dashboard front of the KB Hybrid series.
The red colour is showing the active mode: in this example Standby & Hybrid mode.
Standby: only activated on the Calorifier & Combi boilers.
The boiler remains at 80°C, to provide hot water very fast.
Explanation of the operating panel
0
Rest (boiler is stand-by)
Circulationpump not active
1
Room thermostat is demanding
Circulation pump active above 40°C
2
Hot water is being tapped or external boiler requires heat.
Circulation pump active
Oil burner starts for maximum capacity
3
Pump timer active
Circulation pump running ± 3 minutes
4
Boiler is heating to keep domestic water on temperature.
Hot water stand-by
The number (78.6) in the middle of the display shows the current
boiler water temperature
Switching between Hybrid, Diesel, Power always through Stop!
Current boiler temperature
Function of the boiler
0
1
2
3
4
78.6

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5.1.1 Electric element maximum power use
This function will only work when direct power in on the element plug
The Hybrid system has got the possibility to bring down the maximum use of electricity.
The element can work on 3000Watt, 2000Watt or 1000Watt. Here is how to set that:
Be aware of the power consumption from landlines!
3000Watt=16Ah 2000Watt = 11 Ah 1000Watt= 6Ah
Push “setting”
Push the green 1.3 button to
switch from 3 => 2 => 1
1= 1000Watt
2= 2000Watt
3= 3000Watt
You see this. When ready push “diff”.
Now you see this screen. Push “main”.
Electric element is set and you are
back at the base screen.
When changing the 50 behind hybrid to 60, the burner
will stop at 60°C instead of 50°C. The fuel
consumption will rise of course.

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5.2 Operating the tap water on/off button
The hot water function can be switch on and
off also on the display from the boiler.
On this display it’s called “standby”.
First push the button “stop”. Now you can
push the functions you want.
- Push “standby” (colour is red now)
- Push the mode you want. This
mode will change in colour from
green to red.

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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 with the door from the boiler;
1.2. Remove the insulation.
1.3. Clean the inside of the boiler, using a stiff brush;
Attention: Don’t use any aggressive solvents like thinner or gasoline.
1.4. Clean the boiler with a vacuum cleaner;
1.5. Replace the isolation;
1.6. Replace the door with 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 of them separately.
•Process any excess oil in an environmentally friendly way.
•Transport the boiler according to the instructions in chapter 3
•Recycle this manual.