Kalvis Kalvis-2-30U Manual

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Stick product
barcode here
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CENTRAL HEATING
SOLID FUEL BOILER
KALVIS - 2 - 30 U
KALVIS - 2 - 40 U
TECHNICAL CERTIFICATE, INSTALLATION AND
MAINTENANCE MANUAL
ĮST 144948958.13.2011
LST EN 303
-
5
ГОСТ 20548-87 ГОСТ 20548-93
Example

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© 1996-2011. UAB „Kalvis“. Copyright ©
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KALVIS - 2-30U, -2-40U 2012.02.06
F-02/IN- F-02/IN-
04
To
______________________
Application for Warrant Service
After having familiarized with boiler “Kalvis__________” certificate (product No._______ ) and,
in accordance with
the requirements set forth therein
, having connected the boiler to heating system and chimney, I have the following
claims
:
1.
Thinking that this happened due to defects of the boiler, I ask you to send your representatives for checking the
installed boiler, finding and elimination of
the defects found.
If the mentioned boiler faults occurred due to incorrect connection of operation of the boiler, I oblige myself to
indemnify the arrival costs of your representatives
(__________) and time spend during the trip and in situ (_________
per employer including driver
).
My address
tel.
Name Surname
Example

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NOTES ON WARRANT AND NON-WARRANT REPAIRS PERFORMED
Company: Address:
Experts: Telephone:
Failure, works carried out:
Repairs date: Expert’s signature:
Company: Address:
Expert: Telephone:
Failure, works carried out:
Repairs date: Expert’s signature:
Company: Address:
Expert: Telephone:
Failure, works carried out:
Repairs date: Expert’s signature:
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KALVIS - 2-30U, -2-40U 2012.02.06
CONTENTS
Dear Buyer ...............................................................................................4
1. Recommendations ................................................................................5
2. Purpose.................................................................................................6
3. Main technical specifications...............................................................6
4. Construction description ......................................................................7
5. Transportation and storage...................................................................8
6. Boiler installation.................................................................................9
6.1. Fire prevention requirements ..........................................................10
6.2. Requirements for chimney ..............................................................10
6.3. Connection to heating system .........................................................12
6.4. Burning chamber assembly .............................................................17
6.5. Draught regulator insertion .............................................................17
6.6. Connection of boiler cooling system...............................................17
6.7. Requirements for electric part installation ......................................19
6.8. Exhauster connection of the boiler..................................................19
7. Boiler maintenance.............................................................................20
7.1. System preparation for heating .......................................................20
7.2. Firing the boiler...............................................................................20
7.3. Draught regulator adjustment..........................................................22
7.4. Exhauster control of the boiler........................................................22
7.5. Boiler extinguishing ........................................................................22
7.6. Cleaning the boiler ..........................................................................23
7.7. Risk analysis and elimination ways.................................................23
8. Boiler disposal....................................................................................24
9. Safety requirements............................................................................24
10. Wearing parts in boiler use...............................................................25
11. Fuel types and properties..................................................................25
12. Set.....................................................................................................26
13. Acceptance certificate ......................................................................26
14. Product warrant and guarantee service conditions...........................27
Sales mark .............................................................................................28
Boiler installation report........................................................................29
Marks on warrant and non-warrant repairs performed ........................31
Application for guarantee service ..........................................................32
Example

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DEAR BUYER
We are very pleased that you have purchased our
manufactured central heating boiler. This versatile product is
designed for space heating. For combustion you can use a variety of
solid lump well dried fuel. If desired, the boiler is easy to adapt for
stoking in mechanized way, with pellets. The boiler is manufactured
using modern materials and technologies.
We believe that if you carefully read this guide, properly install
and operate the boiler, it will cause no troubles in handling, and serve
you reliably, safely for a long time.
We wish you a warm and comfortable life!
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KALVIS - 2-30U, -2-40U 2012.02.06
REPORT ON BOILER INSTALLATION
Boiler was installed by:
Company:
Address: City:
Telephone, fax, e-mail:
Data:
Chimney: Flue pipe:
Dimensions: Diameter:
Height: Length:
Chimney draught: Number of elbows:
Last revision date: Outgoing smoke temperature:
Brief description of boiler connection:
Fuel used for testing:
Type: During boiler testing functions of all boiler,
Size: regulation and safety elements were checked
Moisture:
Person responsible for installation (and testing) :
Date: Customer’s signature:
Example

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SALES MARK
Boiler was sold by:
Company:
Sales date:
Address:
Telephone:
In the case of failure please call:
Company:
Address:
Telephone:
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KALVIS - 2-30U, -2-40U 2012.02.06
1. Recommendations
In order the boiler served long and without troubles and you did
not loose the right for guarantee service, please observe the following
main rules:
1. Boiler installation, adjustment, operator training can be performed
by a firm, attested for such jobs and having qualified specialists or
by representative authorized by manufacturer. Installation note
has to be done in this certificate, installation report.
2. Boiler has to be installed in accordance with recommended or
other diagrams, with 4-way mixing valve or thermostatic 3-way
valve in order, to ensure temperature that the water returning to
the boiler was of no lower than 60ºC.
Attention: If you fail to meet this requirement, corrosion will occur
due to condensate which will significantly reduce service life of the
body and ceramic tiles.
3. Optimum operation of the boiler is achieved at close to nominal
power.
4. If boiler power is too high and it has to be operated at lower than
nominal power, we recommend to install the boiler with
accumulation capacity.
5. Use fuel no damper than 25%. In the case of higher fuel
dampness, boiler power drops, fuel consumption rises.
Note. This operation manual is compiled following the requirements
provided for in LST EN 12171 Building Heating Systems. Operation,
Maintenance and Use Document Preparation Procedures. Heating
Systems Needing no Trained Operator.
Example

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2. Purpose
Solid fuel water heating boiler Kalvis 2-30U, Kalvis 2-40U (hereinafter referred
to as boiler) is designed for heating of various premises where central heating
system is installed with natural or forced circulation and closed or open expansion
system. The boiler operates most efficiently under nominal taken thermal power, if
operating with lower power, accumulation capacity is recommended to use.
3. Main Technical Specifications
Boiler model Kalvis-2-30U Kalvis-2-40U
Nominal power (Q
N
), kW * 30 40
Minimum power (Q
min
), kW * 8 15
Heated area, m
2
,
when building partition thermal resistance is ~ 2,5 m
2
·K/W 220 ... 380 300 ... 480
Fuel consumed *
firewood ****
Size of firewood L x Ø, up to, cm 35 x 15 45 x 15
Position of firewood in hearth across or along across
Loading hole sizes, mm: from top 288 x 492 288 x 592
from bottom 230 x 292 230 x 292
Hearth volume, dm
3
(l) 160 200
Fuel * combustion time (Q
N
), hrs. 4 ... 5
Approx q-ty of consumed firewood per season, Q
N
/ Q
min
, m³ * 18 ... 28 25 ... 35
Efficiency rate during operation at nominal power, no less than, % 82
Boiler class under LST EN 303-5 2
Boiler water capacity, l 102 116
Min volume of accumulation capacity, l * 800 960
Water pressure in boiler no more than, MPa (kgf/cm
2
) 0,15 (1,5)
Max permissible water temperature, ºC 95
Min return water temperature during operation, ºC 57
Hydraulic resistance, mbar 8 8,3
Operation environment temperature, ºC 3 ... 60
Temperature regulator adjustment range, ºC 65 ... 90
Parameters of cold water used for excess
heat dissipation: ** (***)
pressure, bar
≥
2,0 **
temperature, ºC
≤
15 **
Min chimney draught, Pa 26 35
Adjustable exhauster node type ***
DM-01
Adjustable cooling coil type *** AAG9
Exhausted flue temperature, up to (Q
N
/ Q
min
):, ºC 200 / 90 200 / 90
Exhausted gas volume at Q
N
, kg/s (m
3
/val) 0,025 (113) 0,035 (158)
Exhausted gas volume at Q
min
, kg/s (m
3
/val) 0,013 (59) 0,016 (72)
Connection flange sizes:
to exhauster (K),
mm
to system (M), G
for output (N), G
Ø178
G2-B
G½-B
Sizes, no more than
(Overall / at transportation on pallet)
height, mm
width, mm
length, mm
1540 / 1700
715 / 800
1260 / 1300
1540 / 1700
815 / 900
1260 / 1300
Mass, no more than (net/gross), kg 364 / 385 473 / 494
* Firing with 18-20 % damp birch firewood.
It is not recommended to fire with firewood damper than 30%.
** For boilers with emergency cooling system installed.
*** Available for installation having purchased separately.
**** As spare fuel, coal, lump wood waste, chip or peat briquettes can be used.
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KALVIS - 2-30U, -2-40U 2012.02.06
14. Product warranty and guarantee service conditions
Manufacturer guarantees that product is in line with technical
documentation requirements.
•If you correctly install and operate the boiler in accordance with these
instructions, the following guarantee service period will be applied
calculated from the purchase date:
- for boiler case - 24 months.
- for completing parts - 12 months.
- for wearing parts - 6 months.
•Please take care for the installation works performing person or firm
filled the installation report.
•Manufacturer obliges to eliminate failures occurring due to its fault
during the mentioned period for free.
•Manufacturer takes no obligation for boiler operation and related
consequences, grants no warrant if the boiler is inadequately selected,
poorly installed (see chapter 6) or operated (see chapter 7) and this is
found out during the visit at user. In this case user shall pay for
technicians’ arrival and repairs!
•No rarely than once a year perform revision of the boiler and its control
elements with the help of adequately qualify specialists.
•Keep purchase receipt or invoice throughout the warrant period.
•For warrant repairs apply to this service providing company, specified by
seller.
•In the case of boiler failure, apply to the specified service, upon its
arrival fill the application form shown on the last page.
•We ask user to take care for after warrant repairs service employee made
relevant record in this certificate “Notes about warrant and non-warrant
repairs” and filled warrant repairs report
I familiarized with warrant repairs conditions. I am informed that in the
case boiler is installed and operated without observing the requirements
given in this manual otherwise I loose the right for warrant repairs.
Buyer:
(name, surname, signature)
Example

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12. Set
1. Boiler "Kalvis-2-___U" - 1 pc.
2. Draught regulator (screwed into boiler) - 1 pc.
3. Scrapper - 1 pc.
4. Ash removal scoop - 1 pc.
5. Poker - 1 pc.
6. Ash pick - 1 pc.
6. Technical certificate of boiler - 1 pc.
7. Wooden pallet for transportation - 1 pc.
Electric heating block, cooling coil with temperature valve and exhauster
node are not included into the boiler set.
13. Acceptance certificate.
Solid fuel heating boiler "Kalvis-2-___U" plant No._____________ meets
drawings, ĮST144948958.13.2011, LST EN 303-5, ГОСТ 20548-87 and
ГОСТ 20548-93 standard requirements and is fit for use.
Boiler was tested with 0,4 MPa pressure.
Manufacturing date ___________________________
Supervisor ___________________________
Manufacturer UAB “Kalvis”
Pramonės 15, LT-78137 Šiauliai, Lithuania
Telephone: [phone], 540558, 540565
E-mail: prek[email protected]
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KALVIS - 2-30U, -2-40U 2012.02.06
4. Construction description
Note: Since boiler construction is under constant improvement, non-essential
deviations from this manual are possible.
Fig. 1.
1. Boiler body. 2. Upper loading cover. 3. Electric heating element installation place **. 4.
Cooling coil installation place **. 5. Service cover. 6. Firing valve. 7. Upper decorative cover. 8. Hot
water branch. 9. Flue pipe. 10. Exhauster control panel installation place **. 11. Exhauster
installation place**. 12. Turbulizers. 13. Secondary combustion chamber. 14. Secondary air holes
with valves. 15. Decorative thermal insulation shields. 16. Return water branch. 17. Outlet branch.
18. Catalyser combustion chamber tiles. 19. Ash drawer. 20. Firegrate lifting gear. 21. Sooth
removal cover. 22. Movable firegrate. 23. Hearth door. 24. Primary air supply valves. 25. Cast iron
door. 26. Hearth. 27. Front decorative door. 28. Draught regulator. 29. Fuel loading door. 30.
Thermal pressure gauge***. 31. Grounding screw. 32. Boiler lifting screw for transportation. 33.
Thermal pressure gauge sensor socket. 34. Emergency thermostat sensor socket.
* Overall sizes specified for „Kalvis-2-30U (Kalvis-2-40U)“
** Available for installation having purchased separately.
*** Thermal pressure gauge installed on the boiler (0-120ºC, 0-4 bar) is of indication-type and
does not replace obligatory heating system devices.
View from above
(with taken upper cover 7)
Example

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Boiler body (1) (see fig. 1), welded from steel sheets has water spaces where
water is heated. Body’s internal part walls are 6 mm thick, external part 3 mm
thick. Body is covered with decorative shields with heat insulation (15). Front part
is closed with decorative door (27).
In the front part of the boiler there is thermal pressure gauge (30); fuel loading
chamber door (29); draught regulator (28) controlling primary air supply valves
(24); hearth door (23), behind it there is cast iron door (25); sooth removal cover
(21).
Inside the body there is firing valve installed (6), opening the way for flue to
get directly to the chimney, used during boiler firing or additionally loading fuel.
Air necessary for combustion, is supplied through firegrate (22) and secondary air
holes (14). From the bottom there is fuel loading chamber cover (2) and, under the
closable decorative shield (7) there is service cover (5) for cleaning of inner
surfaces of the boiler.
In the sides of the boiler there are secondary air regulation valves (14).
In the rear part of the boiler there is water discharge branch (17), returning
cooled (16) and discharged hot (8) water branches, flue pipe (9).
In the rear wall below flue pipe (9), closed with cover, there is the place to
fasten separately purchase exhauster node DM-01 (11).
In the side wall of the boiler, under decorative coating, there is branch welded
(4) used for installation of boiler cooling coil.
In the boiler’s heat exchanger there are turbulizers suspended (12) which
improve heat take-away. If chimney draught is insufficient, turbulizers are
recommended to remove.
In the lower part of secondary combustion chamber (13) there are heat-proof
concrete bricks (18) installed, which maintain high temperature in the chamber,
assure full combustion of flue gas, which results in reduced volumes of harmful
pollutants emission into atmosphere.
Into the boiler, having unscrewed heating element socket cover (4), it is
possible to install separately purchased 3x1,5…3x2 kW electric heating elements
(with 2" thread) with temperature regulation and emergency thermostats or
without them.
It is prohibited to change boiler construction without permission.
5. Transportation and storage
Boilers are stored and transported fastened onto wooden pallet and twisted
with polythene film, of nothing else is agreed in the supply agreement
(see fig.2a.).
Boilers are allowed to transport exclusively in vertical position with any kind
of covered transport. If weather is dry, open transport is allowed. Extra measures
have to be taken to protect boilers from falling down, scratching against each
other. During loading/unloading/transportation it is prohibited to beat, turn, throw
the boilers.
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KALVIS - 2-30U, -2-40U 2012.02.06
The following is necessary:
•Periodically (twice a year) check if grounding is working properly;
•Before cleaning the boiler disconnect it from electric power network.
10. Wearing parts in boiler use
Sealing parts from glass fibre; cast iron firegrate (21) (see fig. 1) and doors
(24); heat-proof concrete parts (18) (see fig. 1 and 5) can become worn, burn
out, disintegrate while in use.
These parts are available for purchase at boiler manufacturer or its agents.
Note. It is advisable to use only manufacturer’s original spare parts.
11. Fuel types and properties
Combustion heat of absolutely dry wood actually doesn’t depend on wood
spice and is equal about 4500 kcal/kg. So, as to assess different wood species,
one should take into consideration their comparative weight. Weight per cubic
metre of various firewood species is as follows:
- oak firewood - 500 kg;
- birch firewood - 450 kg;
- fir firewood - 330 kg;
- aspen firewood - 330 kg.
The damper is firewood the less is its caloric content. Wet firewood
caloricity reduction, compared with dry firewood (dampness ~20 %) is as
follows:
- 30 % moisture - 10 ÷15 %;
- 50 % moisture - 35 ÷40 %.
Just cut tree contains 35 ÷60 % water. Tree cut in the beginning of winter
contains least quantity of water. Hardwood contains less water.
Wood has to be cut and split to make firewood. Firewood, after one year
spent in garret is of 20 ÷25 % moisture.
After two years it is 13 ÷17 %, and this means that after drying less fuel is
needed than combustion with damp firewood.
Equal weight of firewood and peat give similar heat quantity.
1 kg of coal gives 2 ÷3 times more heat than 1 kg of firewood, due to this
reason, coal change into hearth should not exceed 10 kg.
Volume of air needed to combust 1 kg of firewood is 4 ÷5 m
3
, for coal - 10
m
3
.
The poorer quality is fuel, the more ash it generates.
Combustion of 1 kg average caloricity coal gives about 6500 kcal
(7,56 kWh).
Example

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Fault Reasons What to do
Boiler does not
reach nominal
power
Bad, damp fuel.
Poor draught.
Use drier fuel, opening firing valve.
Check chimney draught.
Boiler weeps
Bad fuel.
Too low return water
temperature (>57°C !).
Poor draught.
Check boiler primary air valve
adjustment with draught regulator.
Use dry fuel.
Adjust mixing valve and circulation
pump switch on time according to
temperature (if thermostatic power switch
is installed).
Boiler generates
overpressure
Boiler overheats.
Safety valve fails.
Expansion vessel fails in
closed system.
Close air supply, watch water temperature
in the boiler.
Check and, if needed, replace safety
valve.
Check expansion vessel.
8. Boiler disposal
Dispose the boiler after expiration of its service life or if it is uninstalled
due to other reasons. Boiler is constructed from various materials, so:
•Bring electric appliances, if present, to electric appliances recycling
organization;
•Metal parts go to metal scrap;
•Remaining materials go to landfill or waste storage sites.
Note. Disposal actions shall be in line with laws and rules of user’s country.
9. Safety requirements
The following is prohibited:
•To operate boiler without having filled heating system with water. Water in
the heating system has to be protected from freezing;
•To connect boiler into closed system without safety valve, which prevents
the system from exceeding pressure by more than 0,15 MPa (1,5 kgf/cm
2
);
•To close supply or return water line valves when boiler is in operation;
•To dry fuel or other easily combustible materials near or on the boiler;
•To fire the boiler with the help of easily combustible fluids (petrol,
kerosene etc.);
•To operate boiler with open doors or covers;
•To pour non-extinguished coal and ash near living or auxiliary buildings;
•To entrust boiler maintenance to minors or non-trained persons;
•To operate boiler without grounding the case;
•To touch electric installation of the boiler.
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KALVIS - 2-30U, -2-40U 2012.02.06
Boilers are stored in dry premises, without presence of chemically active
substance gases.
Note. After unpacking the boiler, use its wooden pallet as fuel for the boiler,
dispose polythene film to waste disposal company.
Fig.2a. Boiler packing for transportation.
6. Boiler installation
Boiler shall be installed in the premises meeting requirements of
BPST Nr.64/2005-02-18; STR 2.01.01(2):1999; STR 2.01.01(6):1999 and
STR 2.09.02:2005 as well as according to the solid fuel heater installation in
buildings rules ST 8860237.02:1998, or according to relevant requirements of the
installation country.
We recommend to install smoke exhaust hood above the boiler. Boiler is to be
installed upright or leant forward by no more than 1°.
Premises have to have ventilation, assured fresh air inflow.
Boiler is not allowed to install in living rooms or corridors.
Fig. 2b. Recommended distances to non-combustible partitions
Example

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If installing this boiler outside Lithuania, it is necessary to observe all local
rules based upon European and national standards.
Before connecting boiler to heating system and chimney, take into
consideration the fact that during operation it will have to be cleaned, adjusted etc.
For boiler maintenance as well for fire prevention necessary minimum
distances to walls and ceiling are given in fig. 2.
Note. Boilers are manufactured in the right positioning option, but user, for own
convenience, can reinstall direction of opening the front decorative door (27)
and firing valve handle (6) into the opposite side of the boiler. Place of
installation of electric heating elements (3), cooling coil (4) and exhauster
control panel is provided on the both sides of the boiler.
6.1. Fire prevention requirements:
•Put boiler onto non-combustible base;
•If boiler is connected to chimney through metal pipes, they have to be made of
no thinner than 1,5 mm metal sheet and coated with heat insulation material.
Attention! If chimney draught is too strong, using chips, slivers, hards or other
powdery materials as fuel, during its loading or after fuel burns out and its
remains are shaken, sparks can flow out of the chimney.
If for roof or building constructions easily-combustible materials are used,
or other similar design buildings, building materials, fuel etc. are located
closer than 20 m away from the chimney, use of fuel of mentioned kinds ir
strictly prohibited!
6.2. Requirements for chimney
Options for chimney construction and boiler connection to chimney are shown
in fig. 3.
Requirements:
•Chimney draught has to be no less than it is specified in the main technical
specification table (see page 3);
•Chimney hole has to be no less than 120 x 250 mm in cross-section;
•Boiler needs separate chimney hole. Nothing else can be connected into the
same hole;
•If chimney is connected with extra elbow, it has to have no less diameter that
the cross-section of smoke escaping from boiler hole, with bending radii no less
than 100 mm;
•Pipe between boiler flue pipe and chimney has to be no longer than 1,5 m and
has to go up towards chimney, providing the possibility for its cleaning;
•Gaps at butting and entrance into chimney places have to be excellently sealed;
It is necessary to know that:
•Smoke, after getting into chimney from boiler flue pipe, continues cooling,
steam contained in the smoke condense by settling on chimney walls, especially
in unheated loft and external part of the chimney;
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KALVIS - 2-30U, -2-40U 2012.02.06
7.6. Boiler cleaning
Ash, accumulated under the firegrate may prevent air supply to the
combustion chamber. So, no rarely than every second firing (every second
day), remove ash from the ash box and scoop remaining ash from ashtray.
In order to assure efficient boiler operation, it is necessary to periodically
clean sooth from internal surfaces of the boiler. Intervals between cleanings
depend on fuel quality (especially moisture), burning intensity, chimney
draught and other circumstances. It is recommended to clean boiler heat
exchanger and combustion chamber when sooth layer is up to 3 mm thick, but
no rarely than 2 - 3 times per month. For cleaning take of service cover (5) and
thoroughly, with the help of scraper and brush, clean internal surfaces of the
boiler.
Remove ash and sooth after having unscrewed bottom cleaning cover (21).
In order to remove hardened scale, it is recommended to use chemical
cleaners (Swedish „Fauch 300“ or similar).
It is recommended to clean chimney no rarely than every year and
necessarily before start of the heating season.
Attention! We recommend to remove exhauster before cleaning the boiler in
order it was easier to clean the flue pipe and to clean exhauster’s impeller.
Note. During first firing of the boiler of after a long period of non-firing,
chimney can block smoke. In this situation, when firing the boiler, open
chimney or boiler chimney connection cleaning door and through it
carefully insert lit crumpled paper. Close door after paper burns out.
Draught should improve.
7.7. Risk analysis and its elimination methods
Safety valve and expansion vessel serve as protection from overpressure in
the boiler.
Don’t overheat (boil) water in the boiler.
Water overheating may be caused by: too intense combustion, water level
drop or circulation absence in the system.
Fault Reasons What to do
Boiler overheats
Too intense combustion.
Electric power loss (for
systems with forced
circulation).
Close air supply, observe water
temperature in the boiler.
After temperate drops, return to normal
combustion mode.
Electric power
loss
Call qualified specialist.
In winter, when there is no electric power
for a longer time and frost risk, discharge
water from the system.
Example

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chemically aggressive acids, under effect of which boiler service life can be
reduced significantly. In order to ensure whether the boiler is tight, burn it
intensely for 1-2 hrs, then observe for growing condensate volume. If
condensate does not grow in volume, boiler is tight.
In order to ensure whether the boiler is tight, burn it intensely for several
hours, then stop burning and observe for growing condensate volume. If
condensate does not grow in volume, boiler is tight.
Attention! If boiler is operated incorrectly, fuel is unsuitable, low chimney
draught, valves installed in the boiler can get stuck, so during the heating
season move the valves: open and close several times all the valves
installed in the boiler.
7.3. Draught regulator adjustment
Attention! Draught regulator (28) (see fig. 1) is supplied screwed into the
boiler but unsealed, it has to be sealed (see par. 6.5).
After boiler reaches desirable temperature (70÷90°C), comparing with the
readings of thermal pressure gauge (30) installed in the boiler, set regulator at
similar temperature.
Note. Regulator’s dial misalignment with readings of thermal pressure gauge
is possible.
Reduce chain so that primary air supply valves (23) were closed or the gap
was no more than 2 mm. Set desired temperature by turning regulator knob to
relevant position. If exhauster (11) is used, set its temperature in the same way
as for draught regulator (28).
7.4. Chimney exhauster control
More about exhauster DM-01 control read in „Exhauster control manual “.
7.5. Boiler extinguishing
During usual operation, boiler is self-extinguishing when fuel charge
completely burns out. If boiler has to be extinguished in the forced way,
firstly, remove fuel from hearth. Throw burning fuel into a vessel with water –
this will reduce smoke in the premises. During forced extinguishing, open
roods or windows to assure good ventilation of the premises.
Attention! It is prohibited to pour water onto burning fuel in the hearth.
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KALVIS - 2-30U, -2-40U 2012.02.06
Fig.3.
•Acids of the condensate and heat-cold erosion can disintegrate chimney in a
couple of years;
•Uncontrolled sooth in the chimney in some time can get on fire and, if
chimney is in bad order or roofing is easily combustible, cause fire.
We recommend:
•To install stainless steel insert in the chimney. Orderly installed insert protects
chimney from condensate effect and improves draught;
•Insert has not to reduce chimney hole cross-section significantly;
•Parts of the insert have to be sealed together (not by soldering);
Example

- 12 -
•Install condensate collector in the bottom;
•To fill the gap of chimney between insert and chimney walls, at least in the
external part of the chimney with non-combustible heat insulation material. Seal
the gap on the top right with plaster and trim with tin with inclination from the
hole towards chimney edge;
•Winterize chimney in cold loft with non-combustible heat insulation material;
•If inside of the chimney gets on fire, close air supply to the boiler and call
firemen;
•In the chimney joint, in the comfortable place, make holes for periodic (once a
month) sooth cleaning;
•It is recommended to have chimney examined by qualified chimney
maintenance specialist once a year.
6.3. Connection to heating system
Requirements for connection:
•Boiler has to be connected to heating system in accordance with the project
prepared by thermal technique specialists or the works can be performed
independently by highly qualified plumber-welder, well experienced and
familiarized with boiler design and this manual;
•If in the system pipes there are installed valves, disconnecting the boiler
from heating system, they must be fully open. In order to avoid mishap due
to negligence, after opening of the valves it is advisable to remove their
handles;
•Heating system can be of open or closed type. In this case instead of
pressure expansion vessel expansion reservoir can be correctly installed;
•In order to avoid condensate formation, which may reduce service life of
the boiler significantly, install in the heating system 4-way or 3-way
automatic mixing valves, (see recommended diagrams fig. 4a - 4d), in order
to maintain no less than 60°C return water temperature;
•It is necessary to install into the system safety valve, which does not permit
exceeding 0,15 MPa (1,5 kgf/cm
2
) working pressure in the heating system.
Check valve operation every time when firing the boiler, by turning valve
handle;
•Boiler can be connected into heating system (with expansion reservoir
which is also safety valve backuping device protecting from overpressure),
with working pressure no more than 0,15 MPa (1,5 kgf/cm
2
);
•It is recommended to have boiler examined by qualified boiler maintenance
specialist once a year;
•Water discharge pipe is used to discharge water from the system and boiler
in the case there is system frosting risk.
Recommended boiler connection diagram options Fig. 4a – 4d
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KALVIS - 2-30U, -2-40U 2012.02.06
To fill boiler with fuel:
-Open firing valve (6);
-Open door (22) and verify that ash does not block firegrate holes (21) for
air could enter hearth (27). If needed, move bottom fuel layer with poker;
-Close the door (22);
-Turn draught regulator handle1) to close primary air supply valves in the
door (23);
-Open fuel loading door (29), after 15...20 seconds (for opening time: keep
opened observing for there is no more smoke in the chamber) fully open
the door and load hearth with fuel;
-close tightly the fuel loading door and valves;
-with the means of draught regulator (28) open primary air valves (24).
We recommend to refill fuel only when the last charge has fully burned
out; refilling on non-fully burned out charge is possible only in the case
of necessity when there is no other option.
Combustion process control without measuring devices is done by
monitoring colour of the smoke going out of the chimney. If combustion
process is good, smoke is thin, grey. If smoke is thick and dark, fuel is not
fully burn, secondary air is insufficient. In such case open secondary air valves
more. secondary air volume is established depending on fuel type and fuel
moisture. Combustion quality is checked when water temperature is ≥80ºC.
It is advisable for secondary air adjustment to call a specialist with gas
analyser; this is expedient if you have large volume of good quality
homogenous fuel..
When fuel burns, ash remains, it covers firegrate; combustion intensity and
boiler efficiency drops. Due to this reason fuel has to be poked. Burning coal
is poked with poker through gaps if inner door or by moving firegrate with the
help of pedal. Large volume of generated ash prevents primary air from
entering, so ash has to be removed timely.
Avoid opening fuel loading door during intense combustion (2 and 29).
Boiler combustion needs much air, so enough volume of air has to enter
into the premises where boiler is installed.
Recommended consumed fuel moisture is no more than 15-22 %.
Note. When boiler is started to operate, during firing, on internal boiler walls,
when there is no sooth layer yet, when firewood burns, water condensate
forms, which can look like the boiler is not tight and leaks water. Water
steam condensate disappears when water temperature in the boiler raises
up to 70-80°C with the help of 4-way distributor. It is recommended to
maintain water temperature in the boiler as high as possible. If return
water temperature is less than 60°C, water steam condenses on internal
surfaces of the boiler, which combine with combustion products and form
Example

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7. Boiler operation
Boiler can be operated by adult persons well familiarized with boiler
construction and this technical certificate.
Attention! When boiler is fired with damp fuel (firewood or chips), formed
condensate combines with combustible gases resulting in acids, which
reduce service life of the boiler significantly. Besides that, this is
inefficient, because given efficiency rate cannot be reached, so much more
firewood is consumed.
It is prohibited to fire the boiler with fine wood waste, because
explosion risk or sparking from chimney is possible.
7.1. System preparation for heating
Before firing the boiler, it is necessary to verify that heating system is filled
with thermal water and de-aerated; it is recommended to fill with de-salted,
soft or at least rain water. If prepared soft water is used in the system, boiler
case will serve longer. It is also necessary to verify that the valves
disconnecting boiler from the system are open.
7.2. Boiler firing (see fig.1)
When firing the boiler for the first time, also for long period of non-
operation (after summer season), it is necessary to heat up the heat-proof
concrete parts for the moisture contained inside, turning into steam, did not
disintegrate such parts. Put into the hearth, onto firegrate (21) small quantity
of fine firewood and, after opening firing valve (6) fire them. Fuel volume
must be such that it burned within 20 - 30 min. Repeat the process after 2
hours. Repeat this cycle 3 times.
Before firing the boiler, open firing valve (6), through door (22 and 24) put
on firegrate (21) fine-cut dry firewood or slivers and fire. Secondary air hole
valves (14) have to be closed. Valves are regulated when temperature in the
boiler reaches 60°C.
After the fuel combusts, firing charge burns out, fill loading chamber with
fuel (how to fill: see below), close firing valve (6).
Fine chopped firewood burns more efficiently and raise boiler power.
Load firewood into loading chamber loose, for while burning they could
fall down to the bottom of the chamber.
If coal is to be used, take 5 - 10 kg firewood and top with 10 cm coal. Coal
is to be poured layer by layer in a number of times, depending on fuel quality
and desirable heat volume.
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Example

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KALVIS - 2-30U, -2-40U 2012.02.06
heating system circulation pumps) it is necessary to have extra water supply to
the cooling system.
Attention ! Emergency cooling coil cannot be used for hot water
preparation.
Note. For the boilers, operated in open expansion system, it is not necessary
to install the device for heat surplus dissipation in the boiler, because heat
surplus is dissipated in the form of steam through open expansion vessel.
Recommended connection diagrams are given in fig. 4b, 4c.
6.7. Requirements for boiler electric part connection
If electric heating elements are installed for the boiler:
•Use only certified heating elements;
•It is recommended to install electric heating elements into the boiler in the
case when the boiler is connected to heating system under diagram shown in
fig. 4a;
•Electric part connection works on the boiler can be performed by the
person having electrician’s qualification and permission – licence for
execution of installation works;
•Installation works have to be carried out in accordance with the prepared
project, (taking into consideration existing general input power).
Recommended electric heating elements connection diagram see fig. 7.
6.8. Connection of boiler’s exhauster
More about connection of exhauster DM-01 to the boiler read in Exhauster
Control Manual.
Pos. Description Q-ty
F1-F3 Automatic
switch 3 16A
E
Heating element
(fastening thread
G2B L=400)
1 3x1,5 kW
3x2 kW
fig.7.
Recommended electric heating elements connection diagram
Example

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disturbed in the heating system, in order not to exceed the max boiler water
temperature.
For boiler protection from overheating, it is possible to install in its case
the safety cooling coil. When boiler heats over 95°C, temperature valve opens
and cold water flowing from water supply through the coil cools the boiler.
The cooling water is then directed to sewage through pipes no thinner than
those installed on exit from the coil (water has to flow freely to sewage).
Recommended cooling system connection is shown in the principal
diagrams of the boilerhouse fig. 4a, 4d.
Cover tightening scheme. Screw nuts gradually, in specified sequence
Fig.6.
a) cooling water discharge branch (G ¾)*
b) temperature sensor screwing socket (G ½)
c) cooling water supply branch (G ¾)*
* a and c connections can be inter-changed
During cooling coil installation:
•After unscrewing the screws, take cover from
trimming shield (or brake perforation away);
•After unscrewing nuts, take the blind away;
•Replace sealing ring;
•Insert and screw in cooling coil (according to
directions in the figure).
Temperature valve is connected to the cooling coil (see recommended
boiler house connection layouts). Temperature valve has to be connected with
no less than ¾ inch pipes, temperature sensor of the valve is inserted into
socket „b“ (see fig.6). Temperature valve used shall have the following
parameters :
Min water temperature 10 ºC;
Opening temperature 97 ± 2º;
Max water temperature 110 ºC;
Max water debit 6,5 m³/h;
Max water pressure 10 bar.
If electric power supply is interrupted in the house with local water supply
system (water is supplied by hydrophore) boiler overheat can occur (stopped
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Example

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KALVIS - 2-30U, -2-40U 2012.02.06
If boiler operates at the power less than the nominal power specified in the
technical specifications, efficiency of the boiler reduces, environmental
indices become worse. Therefore it is recommended to use boiler connection
diagrams with accumulation capacities (see fig. 4c, 4d). Minimum volume of
accumulation capacity is calculated according to the formula given at fig. 4d.
6.4. Burning chamber assembly
Boilers are supplied fully assembled, but after completion of all boiler
installation works it is necessary to check whether heat-proof concrete bricks
are put in correctly (18) (see. fig.1) in the burning chamber (13). If bricks are
out of their original positions, return them back to correct places. If the bricks
are supplied separately or if you want to replace the worn bricks, do this in the
following sequence:
Through front door (22 and 24) into secondary combustion chamber (13)
insert the side and the central bricks (D) (see fig.5). Place rear bricks (C) and
bottom bricks (B) into the spaces. Lastly, put frontal bricks (A) onto the side
and the central brick edges (recess down, towards inside of combustion
chamber).
Fig. 5
Firestone brick combustion chamber construction.
6.5. Inserting the draught regulator
Attention! Draught adjuster (28) (see fig.1) is supplied screwed into the
boiler but not sealed.
Draught regulator (hereinafter referred to as regulator) is screwed in, for
sealing using oakum or sealing tape. Connect the chain with primary air
supply valves (24) (see also chapter 7.3).
6.6. Connection of cooling system for boiler
According to the requirements of LST EN 303-5 standard par. 4.1.5.11.3,
for boiler operation it is necessary to install the devices used for
dissemination of heat excess, is for some reasons normal heat take-away is
Example