KIPI 24 kW User manual

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Manual
Name: KIPI air heater
Models:
24 kW,
30 kW,
50 kW,
70 kW,
100 kW,
150 kW,
200 kW,
250 kW
BTI GUMKOWSKI Sp. z o.o. Sp.k.
ul. Obornicka 71, 62-002 Suchy Las
[phone]
[email protected]
update 15-01- 2021

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Symbols:
Warning. Indicates that the user must read with an operating manual where you
can find important information such as cautions and warnings that cannot be
included for various reasons on the medical device.
Moving parts symbol. The moving parts symbol indicates areas of the analyzer
where moving parts may cause physical injury. Do not operate the analyzer with
open covers.
Warning under voltage.
Hot surfaces, do not touch.
Follow the instructions for use. Indicates the need for the user to read the
instruction manual.

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Table of Contents
1. General information ...................................................... Błąd! Nie zdefiniowano zakładki.
2. Description and purpose of the device .......................... Błąd! Nie zdefiniowano zakładki.
3. Fuel specification .......................................................... Błąd! Nie zdefiniowano zakładki.
4. Construction of the heater ............................................. Błąd! Nie zdefiniowano zakładki.
5. Components .................................................................. Błąd! Nie zdefiniowano zakładki.
6. Safety systems used in the heater ...................................................................................... 10
7. Transport ........................................................................................................................... 14
8. Assembly ........................................................................................................................... 15
8.1. The sequence of assembly works .......................... Błąd! Nie zdefiniowano zakładki.
9. Installation ..................................................................... Błąd! Nie zdefiniowano zakładki.
9.1. Connecting the heater to the electrical system .......................................................... 21
9.2. Connecting the heater to the chimney installation . Błąd! Nie zdefiniowano zakładki.
9.3. Verification of the ventilation system ................... Błąd! Nie zdefiniowano zakładki.
10. Running ..................................................................... Błąd! Nie zdefiniowano zakładki.
10.1. Preparing the device for the first start ................ Błąd! Nie zdefiniowano zakładki.
10.2. The first start of the burner. ................................................................................... 25
10.2.1. The sequence of works related to the first start-up ........ Błąd! Nie zdefiniowano
zakładki.
11. Exploitation ............................................................... Błąd! Nie zdefiniowano zakładki.
11.1. Safe operation conditions ................................... Błąd! Nie zdefiniowano zakładki.
11.2. Heater maintenance ............................................... Błąd! Nie zdefiniowano zakładki.
11.3. Wytyczne ogólne ............................................... Błąd! Nie zdefiniowano zakładki.
11.4. General guidelines ............................................. Błąd! Nie zdefiniowano zakładki.
11.5. Cleaning the combustion chamber ..................... Błąd! Nie zdefiniowano zakładki.
11.6. Cleaning the hatch .............................................. Błąd! Nie zdefiniowano zakładki.
11.7. Cleaning the ash pan .......................................... Błąd! Nie zdefiniowano zakładki.
12. Technical data ........................................................... Błąd! Nie zdefiniowano zakładki.
12.1. Models of heaters, overall dimensions ............... Błąd! Nie zdefiniowano zakładki.
12.2. Device identification .......................................... Błąd! Nie zdefiniowano zakładki.
12.3. Electrical diagram of the ecoTOUCH 920P regulator ....... Błąd! Nie zdefiniowano
zakładki.
12.4. Technical parameters of heaters ......................... Błąd! Nie zdefiniowano zakładki.
13. EC declaration of conformity ........................................................................................ 42
14. List of common faults ............................................... Błąd! Nie zdefiniowano zakładki.
15. Spare parts list ........................................................... Błąd! Nie zdefiniowano zakładki.
16. Terms of warranty ..................................................... Błąd! Nie zdefiniowano zakładki.
17. Attachments: .................................................................................................................. 53
17.1. Warranty - first run - a copy to be sent along with the GDPR consent clause ...... 53
17.2. Warranty - first start of the heater ...................... Błąd! Nie zdefiniowano zakładki.
17.3. Warranty - annual inspection ............................. Błąd! Nie zdefiniowano zakładki.
17.4. Warranty - two-year inspection.......................... Błąd! Nie zdefiniowano zakładki.
17.5. Repairs ............................................................... Błąd! Nie zdefiniowano zakładki.

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1. General information
This manual for the KIPI air heater, which is automatically fueled with solid fuel, pellet,
constitutes the Technical and Operation Documentation. Document is an integral part of the
device 1 . Detailed analysis of the instructions will allow the user to learn about the structure of
the device, installation and operation tips. Respecting the manufacturer's instructions in the
manual will ensure correct and safe operation of the heater.
Connection and first running of the heater, as well as possible installation of the
burner
must be performed by an authorized and qualified service center
The manufacturer is not responsible for any damage caused as a result
defective installation, inconsistent with these instructions.
Works related to the installation and use of the heater should begin with:
- checking the heater's housing in case of damage caused by transport,
- verification of the content of the delivery, both in terms of the presence of all
components and their compliance (comparison with nameplates),
- getting acquainted with the operating instructions for the heater, burner and regulator.
The KIPI air heater may only be used for its intended purpose.Any other use will be considered
improper by the manufacturer and dangerous. The heater is an integral part of the ROTARY
KIPI burner and the regulatorecoMax 920 TOUCH. The heater and its components are under
warranty. Specific warranty conditions are given by the manufacturer in this manual, with
warranty card included.
The manufacturer is not liable for damages resulting from the selection of
others
components than those included in the heater kit - in particular another burner,
feeder or regulator.
The manufacturer allows the use of a different type of container than the suggested one

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KIPI tank, but minimum feeder capacity is maintained (indicated in the burner operating man-
ual).The heater operating manual provides general information about the burner and regulator.
Detailed information on these components has been attached.
In the event of a breakdown or incorrect operation of the device, turn it off
immediately and disconnect the electrical supply. Any attempts to repair it yourself
will break manufacturer's warranty conditions. Any repairs on the heater and its components
should be performed by the manufacturer's authorized service, using original spare parts.
1. Description and purpose of the device
The KIPI air heater is a heat generator powered automatically with solid fuel, pellets. The
device has been designed for internal use to heat the air. The principle of operation is based on
use forced air circulation, which is provided by a centrifugal blower fan. The air stream passing
through the heater absorbs heat energy through circulations near the heat source. As a result,
the air leaves the heater at elevated temperature (ryc. 1.) .
The heat is generated as a consequence of burning pellets in the combustion chamber. By
means of a centrifugal blowing fan mounted in the lower part device, air is blown into the
device. Air is taken in directly from the room with the heater 3 . The heater uses only fresh air,
or a mixture of fresh air and air returning from heated rooms.
The heat energy of exhaust fumes is transferred to the injected air through the process natural
and forced convection. Air and fumes are separated in airtight channels, as a result there is no
pollution of the heated air. After losing heat energy, exhaust fumes are removed through a duct
connected to the chimney system. The diameter of the chimney is important, which must be
large enough to provide effective exhaust gas removal. Ash, created as a result of burning, is
discharged to the ash pan drawer from where it can be removed easily (see cleaning the ash
pan). Heat is transferred through adjustable air outlet duct (located in the upper part of the
heater), distributing air directly to the sides or to other rooms through supply ducts equipped
with dampers.
After reaching the required air temperature in the room, the heater when heating one room:
 using a thermostat - it will turn off,
 not using the thermostat - it will continue to work,
when heating several rooms:

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 using a thermostat in each of them - it will turn off,
 when using a thermostat in several rooms - dampers
installed on distribution ducts to these rooms will remain closed, at the same time the heater
will continue to heat rooms without thermostats,
 without using the thermostat, in any of the rooms - it will continue the work.
Ryc. 1. Diagram of air flow through the heater (hot – read, blue – cold air)

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1. Fuel specification
The burner, which is an integral part of the air heater, is designed to burn wood biomass in
the form of pellets. Recommended for best performance the use of certified pellets meeting the
following quality requirements (Table 1).
Fraction
granules
Diameter [mm]
6±1,8±1
Length [mm]
3,15 ÷ 40
Dust content [%]
≤ 1
Bulk density [kg / m3]
≥ 600
Moisture [%]
≤ 10
Calorific value [MJ / kg]
16,5÷19
Ash [%]
≤ 0,7
Tab. 1. Quality requirements of pellets intended to power the heater.
In case of changing the fuel batch it is necessary to perform the "feeder test".
This action is important for the optimal operation of the heater. When refilling the fuel
in the tank, particular attention should be paid to undesirable elements in the form of mechanical
impurities, e.g. rock fragments. Any solid contamination, regardless of its size, may damage
the heater, including the pellet feeder, burner or ash removal system, thus leading to the failure
of the entire device..
The manufacturer is not responsible for any resulting damagefrom
failure to follow the above recommendations.
2. Construction of the heater
The KIPI air heater consists of the following components
(see Table 2, Fig. 2).
name of the element marking
Counterflow exchanger Combustion chamber
A1

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Flame tubes of the 2nd line A2
Reversing chamber
A3
Flame tubes 3 pass
A4
Exhaust outlet chamber
A5
Flue
A6
Ash removal system Ash removal spiral
B1
Gear motor
B2
Ash removal pipe
B3
Cleaning Rear cleanout cover
C1
Door
C2
Ash container
C3
Ash pan cover
C4
Insulation Heater thermal insulation
D
Accessories Torch
E1
Blower fan
E2
Air outlet elbow
E3
920ecoMAX driver panel
E4
920ecoMAX driver module
E5
Burner thermal insulation
E6
Mounting flange
E7
Tab. 2. KIPI air heater components.

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Dig. 2. Construction of the KIPI air heater.
3. Component parts
The heater is supplied as a complete air heater kit (see Figure 3).
The set consists of::
E7
E6

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1. heater body, with a built-in exchanger, automatic ash removal mechanism, radial blower
fan, as well as removable elements such as:
1.1. air outlet duct,
1.2. removable ash pan
2. ROTARY KIPI burner, along with: zewnętrznym podajnikiem paliwa,
2.1. connection elbow,
2.2. 2.2. flexible spiro pipe,
2.3. 2.3. mounting flange,
2.4. 2.4. the 920 Touch regulator
cubature fuel container adjusted to the heater
Dig. 3. Components of the KIPI air heater kit.
1.1
1
1.2
2
2.1
2.4
2.5
3
2.2
2.3

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3 Safety systems used in the heater
The KIPI air heater is equipped with a number of components that contribute to the safety
system of the entire device. The safety system consists of components of the burner, controller
and the heater body, which include a photocell, a burner temperature sensor, a flexible pipe in
the pellet feeding system, an exhaust gas temperature sensor, a screw preventing the heater door
from opening, a digital exchanger temperature sensor, a mechanical temperature sensor.
I. Photodetector
A photodetector, otherwise known as an optical flame sensor, is a burner protection element,
designed to prevent, among others, overheating of the burner and the device in which it is
mounted. The photocell is responsible for lighting the burner in the absence of flame detection.
Firing up is a 2-minute cycle consisting in supplying the burner with a moderate amount of fuel
and switching on the igniter. If the ignition still fails, the cycle is repeated 3 times. In a situation
where the ignition does not take place, the regulator will announce an error, in which the further
operation of the burner is impossible.
II. Burner temperature sensor
The second element protecting the burner is the temperature sensor in the blower chamber.
This sensor is responsible for stopping the fuel movement from the container to the combustion
chamber. The break will take place when the fuel inside the screw feeder ignites, at the same
time the burner will switch from operating mode to blanking. The output temperature for sensor
activation is 90˚C. Sensor switching on a permanent alarm is triggered (the alarm can only be
removed by the user).
III. Flexible pipe in the pellet feeding system
In addition to the sensors, the burner safety system uses a structural one safety component.
The fuel feeding system consists of two screw feeders, the so-called external and internal
(stoker) connected by a section of flexible pipe made of a material with limited thermal re-
sistance. In the event of a flashback from the burner to the feeding system, it prevents ignition
of the fuel in the main container..

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IV. Mechanical temperature sensor
The sensor, also known as the STB thermal protection, is mounted on the sensor tightly in
the heated air outlet duct. If the air temperature exceeds 92.5 ˚C, the sensor will knock out a
special button installed in the housing of the device and turn off the heaters. The construction
of the sensor allows it to work even in the absence of mains power or in case of damage to the
regulator. The STB protection is classified as mechanical protection because restarting the
heater can only take place after pressing the sensor button that has been knocked out.
V. Outlet temperature sensor
Another element of the safety system of the regulator that operates the heater is the outlet
temperature sensor. The sensor should be tightly installed near the hot air outlet. A wide range
of temperature detection allows the user to accurately monitor the temperature of the outgoing
air
VI. Mechanical protection of the heater door
The heater body is equipped with a structural safety element, which is a screw preventing
the opening of the heater door on which it is mounted there is a burner (see figure 4). It is
physically impossible to open the door without first unscrewing the screw, to prevent unneces-
sary openings. The screw should only be disassembled for cleaning internal components de-
vices..

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Dig. 4. Location of the mechanical protection of the door.
VII. Digital exchanger temperature sensor
Sensor mounted on the surface of the heater to protect the device against overheating. After
the exchanger has reached the limit temperature of 400 ˚C on the controller will activate a mes-
sage in the form of an alarm. When the alarm is on, the device immediately switches from the
operating mode to the extinguishing mode, and it is stopped fuel feeding - switching off the
external feeder, extinguishing the burner, shifting the fan speed to higher efficiency and opening
all air dampers. The alarm is maintained until the exchanger temperature drops by the hysteresis
of 15 ˚C relative to the alarm activation temperature. The heater is restarted automatically after
the alarm stops.
The KIPI air heater is a heating device which, despite the use of numerous safety systems
and guidelines for safe use, there is a potential risk of burns or fire. It is recommended that users
follow basic safety precautions before taking any action and exercised extreme caution.

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2. Transport
The KIPI air heater can be transported as a compact set or without burner and hopper. The
heater must be transported in a vertical position, and it is recommended that the entire outline
of the heater is within the pallet.
During transport, it is necessary to properly secure the device against shifting and tilting
both on the surface of the pallet and on the vehicle platform (Fig. 5). It is recommended that
to protect the heater during transport, as well as loading and unloading, protects the device
against mechanical damage and unfavorable environmental conditions. Lifting and lowering
the heater body should be carried out with the use of transport handles and slings, using
mechanical lifts or cranes (see Fig. 6).).

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Dig. 5. Instructions for securing the heater body during transport.
Dig. 6. Instructions for lifting and lowering the heater body.
Upon receipt of the device, check the delivery for possible damage and its completeness.
Objections must be immediately reported to the supplier or the shipping company responsible
for insuring the goods. In the event of damage to the device during transport, please contact the
manufacturer to remove the defects, it is not excluded that the device must be returned to the
manufacturer.
The manufacturer is not liable for damage caused during transport.
3. Mounting
Installation of the device at its destination should be in accordance with the manufacturer's
recommendations. During installation, it is recommended to observe the following
recommendations:

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-The location of the device should allow free access to the heater from all sides. Compliance
with the minimum mounting distances is essential to carry out all kinds of works related to
operation and service or maintenance of the device. The minimum installation distances are
shown in Table 3.
o
rientat
ion relative to the device
designation in Fig.
7.
minimum mounting distance
from the side wall on which
the
tank is placed A
30 cm
from the side wall where there is
no tank B
50
-
70 cm
from the service side
C
100
-
120 cm
from the rear wall
D
100 cm
from the ceiling
E
30 cm, the height of the room should
not be less than 2.3 m
Tab. 3. Minimum mounting distances
Dig. 3. Minimum mounting distances.

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- The surface on which the heater is to be placed should be made made of non-flammable
materials with strength proportional to the weight of the device. The heater should be carefully
leveled after placing it in its final location.
- When planning the location of the device, provide space for electricity supply cables and flue
gas discharge channels.
- In order to ensure high comfort of use and efficiency of the device, it is recommended to take
into account any obstacles in the assembly work in the room, such as pillars, and that the air
flow is not directed directly at people..
3.1. The sequence of assembly works
Work related to the installation of the heater should be carried out in the following order:
1. Unpacking the device and checking if it is complete and not damaged in transport,
2. Placing and leveling the device at its destination,
3. Installing the burner. Work related to the possible assembly of the burner is limited
to fix the burner with screws to the door of the heater (fig. 8).
The burner should have a spacer plate installed and should include thermal insulation in
the set. After installing the burner, connect the round multi-pin plug connecting the controller
with the burner. Detailed information and technical data are specified in the burner instruction
manual enclosed with the heater..

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Dig. 8. Instructions for mounting the burner to the heater.
Installation of the hopper. In order to achieve high comfort of use of the heater, it is worth
analyzing the location of the fuel tank. The side on which the container is located may be of
great importance during the subsequent refueling and the operation of the heater itself. Tray
supplied it comes in cardboard packages, the number of which depends on the capacity of the
tank. The tank should be assembled according to instructions (see figure 9). Detailed installation
instructions for the pellet hopper are delivered with the device.

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Dig. 9. Instructions for assembling the pellet tank.
1 Assembly of the feeder. The external feeder is usually delivered in parts, its assembly
consists in connecting the gearmotor with the spiral that is placed in the delivery pipe
connected with the so-called truncated pipe. The feeder should form a single unit,
consistent with that presented in Fig. 10. Further work is related to inserting the feeder
into the hole in the side wall of the feeder (as shown in Fig. 10.). Of great importance
for the correct operation of the feeding system is the correct settings of the feeder in
relation to the tray. After positioning the external tray in the pellet container, it remains
to connect the feeder with the burner using the flexible spiral pipe included in the set
and connect the fuel feeder supply cable into the corresponding socket in the burner..

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1. Dig. 10. Instructions for connecting the pellet feeder to the burner.
Adjusting the seal of the automatic ash removal system. Correct tightness of the ash removal
system will ensure its efficient and proper operation. The adjustment consists in tightening /
unscrewing the screw located at the outlet of the ash removal system to the ash pan (see Fig.