Kalvis 6 MPP User manual

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Barcode
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CENTRAL HEATING BOILER
ON SOLID FUEL
KALVIS - 6 MPP
WITH PellX BURNER
USER‘S MANUAL
LST EN 303-5 ГОСТ 9817-95
ĮST 144948958.13:2004

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F-02/IN-04
To _________________________________
Guarantee servicing request
Having acquainted with fireplace‘s “Kalvis________” user‘s manual (Products No.________ ) and having installed it as
required I have following claims:
1.
I consider it a manufacturing error and I ask you to send your representatives to inspect the fireplace, determine the defects
and remove them.
If the aforementioned defects are due to wrong installation and operation of the fireplace I shall cover the arrival costs of
your representatives (_______) and the time spent for travel and on site at _____/hour for each representative including the driver.
My address Phone number.
Name Surname Signature
Notice: Request should be sent by a registered mail to the address specified in this passport, in case of emergency call
specified phone number.
KALVIS – 6MPP 2009.05.18

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Boiler sold
by:
Company
Sales date:
Address
Phone
Boiler
installed by:
Company
Address
Phone
Foreman
(name, last name, signature)
In case of a
breakdown
contact
Company
Address
Phone
Manufacturer
UAB “Šiauliųtauro kalvis”
Pramonės 15,
LT-78137 Šiauliai, Lithuania
Phone: [phone]
E-mail: [e-mail]
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KALVIS – 6MPP 2009.05.18
ATTENTION !
Get acquainted with this technical certificate before installing the boiler. It
shall help you to mount and operate the boiler as efficiently as possible.
1. Basic engineering data
Central heating boiler with pellet burner „Kalvis-6MPP“ (hereinafter
referred to as the boiler) is used for heating various premises with installed
central heating system with enforced water circulation.
Boiler combusts 6-8 mm diameter saw dust pellets, or may be used as
a solid fuel (coal, fire-wood) fired boiler, when burner is removed and
protection is mounted.
Main technicla data Table 1
Name of parameter Parameter value
Fuel fired
Saw dust pellets
(max diameter ∅
6-8 mm)
Fire wood, waste
wood, coal, saw
dust and peat
briquettes, coal
Heated area, up to m2200
Fuel load, dm3470 50
Max wood length, mm 380
Combustion duration*: - wood fired, h.
- coal fired, h. 130 3 6
Fuel consumptio per heating season, pellets /wood m³ 7 - 8 20 - 25
Nominal output, kW 20 - 25
Efficiency, no less than: - firing wood, %
- firing coal, % 80 72 78
Water pressure in the boiler, no greater than, MPa
(kgf/cm²) 0,15 (1,5)
Water volume in the boiler, l 86
Water temperature control range, °C 55 – 90 70-90
Minimum recommended water temperature in the boiler
during operation, °C 65
Recommended water tmeperature during operation, ºC 70-90
Minimum chimney draught, Pa 15 25
Smoke outlet dimensions, mm Ø198
Loading dimensions, mm 270 x 400
Voltage, V 230
Electric capacity (motor + fan), W 90 + 57
Electric protection grade IP 40
Loading hole diemnsions: H×B, mm 270 x 400
Overall dimensions, not greater than:
height x dempth x lenght, mm 1390 x 950 x 2260
Mass, not gretaer than, kg 365
* Combustion duration depends on fuel type and quality, humidity, external conditions
and other factors.
Firing wood with moisture content of over 30% is not recommended.

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KALVIS – 6MPP 2009.05.18
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10.Certificate of acceptance
Boiler “Kalvis-6MPP” factory No.__________ conforms to requirements of
LST EN 303-5, and ĮST 144948958.13:2004 and is fit for comissioning.
Boiler was tested at 0,4 MPa pressure.
Hydraulic test date _____________________
Date of manufacture ___________________________
Q/A manager ___________________________
11.Complement
1. Boiler “ Kalvis-6MPP ” 1 pcs.
2. Draught adjuster C20/25 1 pcs.
3. Grinder 1 pcs.
4. Scoop 1 pcs.
5. Poker 1 pcs.
6. Boiler user‘s manual 1 pcs.
7. Burner PellX 20kW with fuel pipe 1 pcs.
8. Tank 1 pcs.
9. Burner hole cover 1 pcs.
10. Burner PellX 20kW user‘s manual 1 pcs.
12.Warranty
12.1. Manufacturer guarantees, that products conforms to reequirements
of technical documents and ĮST 144948958.13:2004.
12.2. Manufacturer applies the following warranty terms from the date
of sale:
•Boiler frame – 24 mėn.
•Complement – 12 mėn.
•Consumables (para 7) – 6 mėn.
Manufacturer is obliged to remove all the malfunctions appearing due to
manufacturer‘s fault during this period, unless user has violated
transportation, storage, connection or operation and servicing requirements.
I am acquainted with rules of installation and servicing and guarantee policy:
1 fig.
1.Draugth adjuster. 2.Thermomanometer. 3.Fuel load. 4.Door. 5.Door. 6.Air
damper. 7.Ash tray. 8.Fire grate. 9.Cleaning holes. 10.Water drain pipe. 11.Return
water pipe. 12.Internal partition. 13.Dispenser. 14.Hot water pipe. 15.Service
cover. 16.Isnulation shields. 17.Catalyst plate. 18.Fuel loading cover.
19.Secondary air valve. 20.Draught damper. 21.Burner mounting hole. 22.Boiler.
23.Burner door. 24.Burner. 25.Fuel pipe. 26.Tank. 27.Hose. 28.Burner hole cover. Purchaser:
(name, last name, signature)

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User may purchase consumables from manufacturer of the boiler.
Use only manufacturer‘s spare parts
8. Fuel types and properties
Combustion heat of absolutely dry wood does not depend on the kind of
wood and equals 4510 kcal/kg. So in order to compare different kinds of
wood we need to assume their relative weight. 1m3weighs:
- oak wood - 500 kg;
- birch wood - 450 kg;
- fir wood - 330 kg;
- asp wood - 330 kg.
The higher wood humidity – the less calorie value. Decrease in calorie
value of humid wood in comparison to 20% humidity wood:
- 30 % humidity - 10 ÷15 %;
- 50 % humidity - 35 ÷40 %.
Fresh cut tree has about 35 ÷60 % water. Wood cut in the beginning of
winter or hard wood has least water.
Peat and wood calorie value is similar.
1 kg of coal gives 2 ÷3 times more heat than 1 kg of wood.
Combustion of 1 kg of wood requires 4 ÷5 m3 of air, coal – around 10
m3.
The more ash is left – the worse fuel is.
Energy radiation from combusting 1 dm3 of wood of 20 % humidity:
Wood type Kcal Kwh Comparison to oak %
Oak, maple 2520 2,93 100 %
Ash 2460 2,86 98 %
Birch 2270 2,64 90 %
Alder 1900 2,21 75 %
Pine 1850 2,15 73 %
Asp 1810 2,10 72 %
Polar 1680 1,95 67 %
Fir 1610 1,87 64 %
Average coal caloric value 6500 kcal/kg (7,56 kWh/kg).
9. Operating burner.
Boiler uses PellX pellet burner. Operating burner is described in pellet
burner PellX user‘s manual.
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KALVIS – 6MPP 2009.05.18
2. Design description
Boiler design is constantly improved. There may be minor deviations
from this manual.
Boiler frame is welded from steel sheets and has water cavities where
water is heated (see 1 fig.). Internal walls are 6 mm thick, external – 4mm.
Bopiler exterior is covered with insulation shields (p.16). In the front of the
boiler there is a draught adjuster (p.1), that controls air damper (p.6);
thermomanometer (p.2), doors (p.4), with servicing doors (p.5) behind them
and an ash tray (p.7). Fuel loading chamber is closed with a cover (p.18),
with installed secondary air valve (p.19).
In the chamber there is a catalyst plate (p.17) and fire grate (p.8). For
servicing of internal boiler surfaces, under the top insulation shield (p.16)
there is a cover (p.15). Catalyst plate (p.17) should be removed when firing
coal.
On the sides of the boiler there are covers (p.9) used to remove the ash.
On the back side of the boiler there are drain water (p.10), return water
(p.11) and hot water (p.14) piepes with G2-B thread; smoke outlet with
smoke damper (p.20).
Burner (p.24) is moutned on boiler‘s burner door (p.23). Burner has a
separate manual. Fuel pipe (p.25) supplies granulated fuel from the tank
(p.26. Burner and fuel pipe are connected by a hose (p.27). Burner hole
cover (p.28).is mounted when firing wood.
It is prohibited to alter the design of the boiler.
3. Transportation and storage.
Transport boilers only in vertical position by all types of covered
transport. Transporting by not covered transport is possible only when the
weather is dry. Use additional protection means to protect boilers against
fall downing and scratching. Striking, turning over or throwing boilers
during loading, unloading or transportation time is strictly prohibited.
The boilers are to be stored in the dry rooms, where there is no
vapour of chemicaly active materials.
4. Boiler mounting
Boiler shouild be mounted in premises, complying with the requirements
of RSN-159-95 ir RPST-01-97 and according to the rules of installation of
solid fuel boilers in premises ST 8860273.02:1998.
Boiler should be mounted vertically, or with forward inclination not
exceeding 1o.Exhaust cover should be moutned above the boiler.

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KALVIS – 6MPP 2009.05.18
When boiler is mounted outside the territory of Lithuania, mountign and
installation should proceed according to relevant national regulations.
Error Reason Solution
Boiler overheats
Too intense combustion.
Power outage (for systems
with enforced circulation)
Close air supply. Monitor boiler
temperature.
When temperature drops return to
regular combusiton mode.
Power outage
Call serviceman.
In case of a risk of system freezing,
during prolonged power outage, drain
water from the boiler
Boiler does not reach
nominal output
Humid fuel.
Insufficient draught.
Use dry fuel.
Check chimney draught, clean the
chimney.
Boiler „weeps“
Bad fuel.
Too low return water
tmeperature
(>57°C !).
Use dry fuel.
Adjust mixing valve.
Too high pressure Boiler overheats. Protection
valve malfunctions.
Close air supply, monitor water
temperature.
Check and replace protection valve.
4.1 Fire precautions:
*Boiler should be placed on an incombustible material;
*If boiler is connected to the chimney by metal pipes, pipes should not be
thinner than 1,5mm and they have to be covered by thermal insulation
Attention !
When chimney’s draught is too great and sawdust is used for fuel sparks
may fly out through the chimney.
It is prohibited to use sawdust for fuel, if the distance between chimney
and flammable roof or other flammable structures is less than 20 m.
4.2. Requirements for chimney:
Chimney design and boiler connections into it are shown on the fig 3a,
3b and and 3c.
6. Safety precautions
3a fig.
Boiler to chimney connection.
* not less than 60
° A - incorrect B – correct
3b fig.
Chimney insert installation
Prohibited:
•Disassemble boiler or electric installation;
•Connect boiler to the system without protection valve, that keeps
pressure in the system below 0,15MPa (1,5 kgf/cm2);
•Close hot or return water valves when boiler is operated;
•Store dry fuels or other combustible materials close to or on top of the
boiler;
•Store fuel closer than 500 mm to boiler;
•Ignition fuel with combustible liquids (petroleum, kerosene etc.);
•Operate boiler with doors and covers open;
•Open burner while boiler is operated;
•Allow children to be by the working boiler without adult supervision;
•Operate boiler without having it grounded;
•Rapidly open loading doors during combustion (open a little, wait, then
slowly open wide);
•Operate boiler with tank cover opened or non hermetic pellet supply
hose;
•Clean or service boiler when electric power is on.
7. Consumables
Fire grate and cast iron door may burn up, especially if user combusts
coal, serivicing door and servicing cover fiber gasket may wear out.

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KALVIS – 6MPP 2009.05.18
Boiler premises have to be well ventilated.
Recommenmded fuel humidity not greater than15-20 %.
Notice. At the start of operation, until there is no soot layer on the
internal boiler surfaces, during combustion a water condensate may form,
giving the impression that boiler is not tight. Water vapour condensate will
disappear when water temperature in the boiler reaches 70-80°C. It is
recommended to keep water temperature in the boiler as high as possible.
When water temperature is below 55°C condensate will form intensely and
may cause acorrosion. In order to avoid low temperature corrosion, it is
recommneded to have an accumulation tank installed into a heating system,
in order to fire boiler at maximum output..
3c fig.
Requirements:
•Chimney draught has to be no smaller than 22 Pa;
5.4.Mounting and adjusting the draught adjuster •Chimney hole‘s cross section should be not less than 120 x 270 mm;
Draught adjusters manufactured by Swedish ESBE C20/25 with
protection from boiler overheating or without it are used. Adjuster is turned
into a socket, scotch tape is used for sealing, Attach chain to air supply
damper.
When boiler heats up to 70°C, adjust adjusters handle to position "4" and
shorten the chain so that, air supply damper is closed. Turning adjuster to
the correspondent position sets desired temperature. Position "6"
corresponds to 90°C. Temperature increment between positions is 10°C.
•Boiler needs a separate hole for the chimney connection. No other
connections through that hole are allowed
•If chimney is connected with additional elbow, it‘s cross section has to
be not less than that of the boiler smoke pipe, and bending radii not less
than 100mm;
•Pipe from the smoke pipe to chimney has to be not longer than 1,5 m
and lean upwards toward chimney;
•Joints have to be well sealed;
•Chimney hole has to be well cleaned.
Necessary to know that:
5.5.Boiler cleaning (1 fig.)
To ensure optimum boiler performance slag has to be removed from the
burner and ash has to be cleaned from the internal boiler’s surfaces and ash
tray..
Intervals between boiler cleaning depend on fuel type and quality
(especially humidity), combustion intensity, chimney draught, etc. It is
recommneded to clean internal surfaces when soot layer on heat
exchangiong surfaces is no greater than 3mm. Remove service covers (p.4),
dampers (p.3; p.10) and carefully clean boiler surfaces.
Use special chemicals for hard residue cleaning.
Clean chimney at least once a year before heating season.
•Smoke continues to cool in the chimney, vapor condenses on the
chimney walls, especially in the unheated loft and on the outside of the
building;
•Condensate acids and erosion may destroy the chimney in few years;
•Uncleaned soot in the chimney may self-combust and become the cause
of fire.
Recommended:
•Mount an insert into the chimney. Well mounted insert protects chimney
from condensate influence;
5.6.Troubleshooting •Insert should not significantly decrease the cross section of the chimney;
•Insert parts should be well joined together (no soldering);
Boiler is protected against excessive pressure by protection valve and
expansion tank mounted in the system.
•Condensate collector and drainage should be arranged in the bottom;
•An incombustible material should insulate the cavity between the insert
and chimney. Top slit should be hermetically sealed;
•In the unheated loft an incombustible material should insulate chimney.

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4.3. Connection to heating system
Recommended connection method is shown in the 4a-4d fig
•Boiler may be connected to the heating system according to the project
prepared by heating equipment specialists or works may be performed
by a well qualified plumbing welder who is well acquainted with this
manual and boiler design
•Boiler should be connected by hot and return water pipes not smaller
than 1.5” in diameter
•Boiler may be connected to the heating system with the expansion tank,
where operating pressure does not exceed 0,15 MPa (1,5 kgf/cm2);
•If system pipes have valves, that disconnect boiler from the system,
mounted, they have to be fully opened. To avoid break down due to
inadvertence, valve handles should be removed.
•It is necessary to mount the protection valve that keeps the operating
pressure in the system not greater than 0,15 MPa (1,5 kgf/cm2).
•In order to avoid forming of condesate, which can significantly shorten
the lifespan of boiler, it is necessary to install a four way mixing valve,
or thermostatic valve in the system (see recommended connections),
which will maintain return water temperature above 55°C;
•It is recommended that boiler is inspected at leats once a year by a
competent plumbing engineer;
•Water draing pipe is used to let the water out of the system whem there
is a risk of freezing.
When boiler operates at smaller than nominal output, it‘s efficiency and
environmental performance drops. It is recommended to use connections
with accumulation tanks (see. 4c, 4d fig.). Minimum volume of
accumulation tank is quoted accotrding to the formula provided in 4d fig.
Mounting of burner and fuel tank with fuel pipe is described in
PellX 20kW user‘s manual.
5. Operation
Adults that are well acquainted with the design and users manual may
operate and service the boiler.
Attention! When firing humid fuel or saw dus, condensate and
combustion products may form agressive acids that may shorten the
lifespan of the boiler significantly.
It is prohibited to fire boiler with fine waste wood, due to explosion risk.
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KALVIS – 6MPP 2009.05.18
5.1. System preparation for heating
Fill system with softened or desalinated water and let the air out. Check
if valves disconnecting boiler from the heating system are fully opened and
remove their handles.
5.2. Firing pellets
Boiler firing with pellets is described in Pellet burner PellX 20kW user‘s
manual.
5.3. Firing boiler with solid fuel (1 fig.)
Open damper (p.20), load some wood through door (p.5) on the fire
grate and ignite it. If coal will be fired, take 5 - 10 kg of wood and add a
layer (about 10 cm) of coal. Secondary air valve (p.19) has to be closed.
When fuel is well ignited, loading chamber may be filled with fuel
(wood, coal). Finer wood increases boiler output. Chminey draught is
adjusted with damper (p.20).
Wood should be loaded freely, so that it is able to slide down during
combustion.
Coal is added in layers, depending on desired heat output and quality.
Catalsyt plate should be removed when firing coal.
Adding fuel:
-Open door (p.4) and check is ash is not blocking fire grate air gaps.
Shake the bottom fuel layer, close door in 15...20 seconds;
-Remove draught adjusters (p.1) chain from the door damper (p.6), so
that the damper is closed tight;
-Carefully open fuel cover (p.18), in 5...10 seconds open cover fully
and add fuel;
-Close fuel cover;
-Attach adjuster‘s chain to the damper.
Secondary air valve (p.19) is opened when temperature in the boiler
rises to 60°C. Valve‘s position is adjusted depending on the fuel type and
combustion intensity.
Check the smoek color out of chimney. Smoke should be thin of a light
grey color. If smoke is thick and black it means incomplete combustion, not
enough secondary air. Open secondary air valve.
As a part of combustion process ash is formed, it blocks the openings in
fire grate, boiler capacity and combuistion intensity drops. Move the fuel
and ash by pressing the pedal of the fire grate mover. Excess of ash in an
ashtray blocks primary air supply, that is why ash needs removal.
Unless there is a necessity it is not recommended to open fuel loading
doors during combustion.

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KALVIS – 6MPP 2009.05.18

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KALVIS – 6MPP 2009.05.18