Kovarson PREDATOR Series User manual

KOVARSON s.r.o.
Lhota u Vsetína 4
755 01, Vsetín
tel. ČR: [phone]
tel. SR: [phone]
email: info kovarson.cz
Manual for combi boiler
PREDATOR

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Dear customer,
Thank you for purchasing pyrolytic boiler MAKAK and the trust you have put in
KOVAR ON s.r.o.
The boiler you have purchased has been comprehensively tested by our development
department and. We believe that you will be satisfied with our product. To avoid any
problems, we advise you to read carefully the installation manual of the boiler, before you
start using it.
If you have any questions, please do not hesitate to contact our service engineers who will
help you with your inquiries and always resolve your issue quickly.
Comfortable heating by
KOVAR ON s.r.o.

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Content
1) Boiler application and benefits ................................................................................... - 4 -
2) Boiler description ..................................................... Chyba! Záložka není definována.
2.1 Boiler construction ............................................... Chyba! Záložka není definována.
2.2 Function parts of boiler ................................................................................................ 6
2.3 Boiler accesories ................................................... Chyba! Záložka není definována.
3) Technical parameters ................................................ Chyba! Záložka není definována.
4) Recommended fuel ................................................... Chyba! Záložka není definována.
5) Boiler installation ..................................................... Chyba! Záložka není definována.
5.1 Rules and regulations ................................................................................................. 11
5.2 Placement options ................................................. Chyba! Záložka není definována.
5.3 Connecting the boiler to the chimney and outlet of combustion products ....... Chyba!
Záložka není definována.
5.4 Air supply to the boiler ......................................... Chyba! Záložka není definována.
5.5 Connecting the boiler to the heating system .............................................................. 14
5.6 The cooling loop connection ................................ Chyba! Záložka není definována.
5.7 Connection to the mains ....................................... Chyba! Záložka není definována.
5.8 Boiler parts installation ......................................... Chyba! Záložka není definována.
5.8.1 Installation of the boiler casing and thermostatic valve ........................................... 16
5.8.2 Exhaust fan connection ............................................................................................. 16
5.8.3 Universal burner connection ..................................................................................... 17
5.8.4 Fan and screw feeder installation ............................................................................. 17
5.8.5 Installation of the tank .............................................................................................. 17
5.8.6 Control unit FOX installation .................................................................................... 18
6 Boiler operation by user ................................................................................................ 18
6.8 Verification activities before usage of the boiler .. Chyba! Záložka není definována.
6.9 Firing ......................................................................................................................... 19
6.10 toking .................................................................. Chyba! Záložka není definována.
6.11 Combustion control ................................................................................................... 21
6.12 Power settings and regulation .................................................................................... 22
6.13 Ash removal .......................................................... Chyba! Záložka není definována.
6.14 Boiler cleaning ........................................................................................................... 23
6.15 Maintance and inspection of the boiler ...................................................................... 23
7 Control unit FOX .......................................................................................................... 24
7.8 Control unit FOX description .................................................................................... 24
7.9 Operation of the controller ................................... Chyba! Záložka není definována.
7.10 Temperature sensors installation .......................... Chyba! Záložka není definována.
7.11 Technical data ....................................................... Chyba! Záložka není definována.
7.12 A wiring diagram of the controller ............................................................................ 26
7.13 Commissioning .......................................................................................................... 26
8 Important alerts ............................................................................................................. 27
9 Disposal of the product after its service life .................................................................. 27
10 Warranty and liability for defects .................................................................................. 28
11 Warranty does not cover ............................................................................................... 28
11 Trouble shooting ........................................................................................................... 28
12 Recommended connection of the boiler ........................................................................ 30

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EC DECLARATION OF CONFORMITY .............................................................................. 31
1) Boiler application and benefits
Czech boiler PREDATOR is designed for economical and ecological heating of family
houses, business premises and medium – sized objects, including the ability to heat the water.
2) Boiler description
2.1 Boiler construction
The boiler is based on the principle of two-stage combustion at a high temperature
during a process is a wood gasification followed by combustion flue gases with an exhaust fan
which exhausts gases from the boiler. Universal burner is placed under the boiler for brown
coal combustion.
Boiler PREDATOR is welded boiler plate of high quality. The upper internal part of
the boiler consists of a fuel hopper, which is at the bottom equipped with a heatproof pipe
fitting having an elongated hole for the passage of gases. In the space below the fitting is a
burn-out area and below this ares is placed universal burner, below burner is an ashtray. At
the rear of the vertical flue gas heat exchanger which is in the upper part of the collecting
channel through which cold gases coming into the chimney.
Most strongly stressed part of the boiler by a high temperature, corrosive gases, acids
and condensates is the upper chamber, which is equipped with stainless steel inserts, which
protects the combustion chamber of the boiler and increases the durability of the boiler.
The inner part of the boiler is made of sheet metal with a thickness of 6mm, flue gas
heat exchanger at the back of the boiler is constructed by 5-exchanger tubes with inner
diameter of 6mm. The boiler has double casing, the inner part is made of 6 mm high quality
steel and any areas which might be in contact with the flame are reinforced by 8mm plate.
The outer part of the boiler is made from metal sheet 4mm.
In front of the boiler are upper stoking door, middle cleaning (ignition) door, bottom
cleaning (ignition) door and bottom door for the ash.
On the back of top boiler cover is a removable casing under which you will find
cleaning access for flue gas chamber. On the side of the boiler is located a handle for cleaning
turbulators.
The feeder shaft extends into the burner, where it is fastened on the far side. The screw
feeder extends to the combustion chamber and pushes against a counter screw, which forces
the fuel upwads.
The upper part of the burner is made of two cast iron rings.
The burner is fed air by a fan placed on the flange of the burner under the fuel hopper.
The fan can be regulated electronically.
The screw feeder is placed next to the covered fuel hopper. Boilers can be ordered in
two variations:
• Right fed – The fuel hopper is on the right side of the boiler.
• Left fed – The fuel hopper is on the left side of the boiler.
There is wax plug inside the burner, which is the emergency extinguisher.

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The boiler body, base and doors are insulated with non-toxic mineral insulation to
minimize heat transmission losses to the surroundings.
The body is insulated with mineral wool 40 mm thick and shielded by metal plating.
Pic. No. 1 Main boiler dimensions

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Pic. No. 2 Main parts of the boiler
1) Control unit display
2) Control unit
3) Handle for cleaning
4) Upper casing
5) ide Casing
6) toking door
7) Cleaning door
8) Middle door - burner
9) Exhaust fan
10) Flue outlet
11) Back casing
12) Heating water inlet
13) Drain valve
14) Top cover – heat exchanger
15) Heating water outlet
16) Cooling loop, waste connection
17) Primary air intake
18) econdary air intake
19) Hopper
20) Ash door
21) Fan
22) Cleaning tank lid
23) Gearbox
24) Engine
25) Tank lid
26) crew feeder tube
2.2 Function parts of boiler
Filling chamber – here is the primary combustion (gasification) process and it also serves as
the fuel hopper.
Refractory concrete fitted with nozzle intake of secondary air to the nozzle.
Post - combustion area there is a secondary combustion process and area which serves for
the collection of ash.
Main tube exchanger transmitting the heat from the flue gases to heated water.
Fan blows the air which is required for the combustion process, divided into:
a) Primary air intake to the filling chamber supports the primary combustion.
b) Secondary air intake into the nozzle is mixed with the woodgas.
Antismoke flap system using a flap which draws smoke when you open the filling door.

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Universal burner – combustion of the brown coal supported by a fan.
Fan – supports combustion of fuel in the universal burner.
Fan flap – must close this valve during manual heating to avoid sucking air through the
burner.
Hopper – reservoir volume 350 liters.
Vermiculite plates – during the manual heating it is neccesary to place this plates above the
burner.
Boiler regulation regulates the amount of air using the fan speed control, regulates the
efficiency of the boiler on the basis of the output temperatures. Controls pump and mixing
valve + it can also monitoring the storage tank.
Heatexchanger turbulators additional device, which is located in the rear exchanger tubes.
Turbulators increasing efficiency and simplify cleaning of the boiler.
Cooling loop The loop should be permanently connected to a water order and to the waste.
This system is monitoring a temperature using a bimetallic sensor to prevent overheating of
the boiler. In case that the boiler is overheated system is able to cool him quickly.
2.3 Boiler accesories
The boiler is delivered with the following accessories:
teel brush 1pc
craper 1pc
Exhaust fan 1pc
Flange 2pc
Boiler manual 1pc
Manual FOX 1pc
Filling valve 1pc
Fan VPA06 1pc
3) Technical parameters
Chart, No. 1 – Dimensions and technical parameters of the boiler
Boiler Type
PREDATOR
20
PREDATOR
25
PREDATOR
30
PREDATOR
35
PREDATOR
40
Wood efficiency % 84,9 86,2 8 ,5 88,8 90,25
Coal efficiency –
nominal power % 86,23 8 ,16 88,1 89,96
Coal efficiency –
Minimal power % 68,4 68,4 68,4 68,4
Weight kg 50
Water volume l 140
Flue diameter mm 156
Combustion chamber depth mm 550
Combustion chamber
volume dm
3
135
Coal hopper volume dm
3
350
Boiler dimensions mm See Figure 1
Size of hopper loading
window mm 440x300
Size of coal hopper loading
window mm 3 0x335
EN 303-5 boiler class -
wood - 4 5 5 5 5
EN 303-5 boiler class –
brown coal - 4 4 4 4

8
Chart. No.2 Thermal technical parameters of the boiler when burning wood and coal
Boiler Type
PREDATOR
20
PREDATOR
25
PREDATOR
30
PREDATOR
35
PREDATOR
40
Nominal power - wood kW 20 25 30 35 40
Nominal power - coal kW 20 25 30 35 36
Minimum power - coal kW 6,5 8 10 12 12
Fuel consumption at rated
power - coal kg.h
-1
4, 38 5,2395 5, 41 6, 6, 44
Fuel consumption at
minimal power - coal kg.h
-1
1,658 1,658 1,658 1,658 1,658
Fuel consumption - wood kg.h
-
1
5,694 6, 2 , 46 9, 8 9, 98
Burning time at nominal
power - wood h 2,1 2,1 2,2 2,2 2,3
Burning time at nominal
power - coal h >6 >6 >6 >6 >6
Flue gas temperature -
wood °C 3,1 8 ,3 101,5 115,8 130
Flue gas temperature – coal,
Nominal power °C 118,1 124,4 130, 140 140,3
Flue gas temperature – coal,
Minimal power °C 60,4 60,4 60,4 60,4 60,4
Flue gases mass flow –
wood, Nominal power kg.s
-1
0,016 0,019 0,022 0,025 0,028
Flue gases mass flow –
coal, Nominal power kg.s
-1
0,016 0,01 0,018 0,020 0,020
Flue gases mass flow –
coal, Minimal power kg.s
-1
0,006 0,006 0,006 0,006 0,006
Maximum operating
excess water pressure bar 2
Tested operating excess
water pressure tolerance bar 2
Recommended operating
tem. of heating water °C 50-85
Hydraulic boiler loss mbar
Recommended operating
temp. of heating water °C 0 - 90
Minimum temperature of
returning water °C 55
Noise level dB < 60
Chimney draft during the
exhaust fan running at a
rated power
Pa 20
Boiler connections - water
heating, return water DN G 2"
Returning water DN G 2"
Filling, Draining DN G 1"
Cooling loop DN G 1/2"
Supply voltage V 230
Electric load W 60
International protection - IP20

9
The values need adjustment depending on quality and type of fuel. Therefore, it is necessary
to make corrections during adjustment of feeding cycle, fan speed or exhaust fan speed,
possibly setting primary and secondary air. For example, if during the automatic combustion
occurs the unburned fuel in the ashtray it is necessary to either increase or decrease the fan
speed or fuel feeding cycle. In the event that the fuel drops into the burner below the
recommended limit, it is necessary to reduce the fan speed or increase fuel level.
4) Recommended fuel
Ruční provoz - zplyňování:
It is recommended to burn wood in maximum lengths according to the parameters of the
boiler. It is neccesary to burn the wood with a maximal dampness up to 20%. When damp
wood is burned it releases the water that condenses on the walls of a body and chimney. This
combustion reduces the durability and performance of the boiler due to the formation of
aggressive substances.
The vertical axis shows the calorific value of wood kWh/kg and the horizontal axis shows
percentually the water content in wood. Moreover the comparison between coniferous and
deciduous trees.
Pic. No. 3 Calorific value of wood material in dependence on the water content
Automatic operation:
Warranty fuel parameters – fuel with which the tests are carried out in T U:
• Water volume
• Volatile matter volume
• Temperature of ash deformation caused by melting
• Low caking

10
Chart. No. 2 Záruční palivo v automatickém provozu
Fuel Fuel Type Operation Granularity [mm] Calorific Value [MJ.kg
-
1
]
Brown coal
Nut 2 Automatic 10.25 18,2
Chart. No.4 Warranty fuel – brown coal (automatic operation)
Fuel Granularity
[mm]
Calorific
Value
[MJ.kg-1]
Ash
content
[%]
ater
content
[%]
Sulfur
content
[%]
Specific
sulphur
content
[g/MJ]
Tar
content
in dry
matter
[%]
Tar content
in
combustible
[%]
Graded brown
coal from down
Bílina (coal
elaboration
Ledvice) - nut 2
10,25 18,2 9,8 Max.20 0,76 0,44 15,1 15,71
5) Boiler installation
When handling and storing of the product you must be careful to avoid any breaches of
boiler.
The boiler has to be installed by heating specialists with a valid license for the installation
and maintenance of such equipment. The installation project must be undertaken according to
valid regulations.
Before the installation, check the completeness and integrity of the boiler package, if they
are correct with the data according to the product label.
Before commissioning a boiler, it meets the requirements of C N. (e.g. chimney revision,
approval of the boiler by chimney office, heating system project, heating test, etc.)
The main condition for boiler installation is the involvement of the mixing valve in the
boiler circuit and wiring of the cooling loop. If there will be no cooling loop connected, it is
necessary to ensure heat dissipation during a blackout which will block the pump and the
mixing valve actuator.
Before the heating season it is necessary to check the water pressure and bleed the heating
system.
The manufacturer is not responsible for demages of the boiler caused by errorneous
installation!

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5.1 Rules and regulations
The solid fuel boiler has to be installed by heating specialists with a valid license for
the installation and maintenance of such equipment. The installation project must be
undertaken according to valid.
The heating system must be filled with water which meets Č N 07 7401 requirements
and, in particular, its mineral content must not exceed the maximum parameters.
Recommended values
Hardness mmol/l 1
Ca2+ mmol/l 0,3
Total Fe & Mn concetration mg/l (0,3)*
CAUTION!!! The manufacturer does not recommend the use of antifreeze.
a) About the heating system
Č N 06 0310 Heating systems in buildings - Design and installation
Č N 06 0830 Heating systems in buildings – afety equipment
Č N 07 7401 Water and steam for thermal energy equipment with
working pressure up to 8 MPa.
Č N EN 303-5 CH boilers – Part 5: CH boilers for solid fuel with manual
or automatic delivery, nominal heat output of up to 300 kW
– Terminology, requirements, testing and marking.
b) About the chimney
Č N 73 4201 Designing chimneys and flues.
c) Due to fire regulations
Č N 06 1008 Fire safety for heating equipment.
Č N 73 0802 Fire safety in building – nonproductive – objects.
Č N 73 0823 Technical fire properties of materials. Flammability rank of
building materials.
d) To the mains
Č N 33 0165 Electrical regulations. Marking of wires with colours or
numbers. The implementing regulations.
Č N 33 1500 Electro-technical regulations. Testing of electrical devices.
Č N 33 2000-3 Electro-technical regulations. Electrical devices. Part 3:
Declaration of the basic characteristics.
Č N 33 2000-4-41 Electrical devices: Part 4: afety ection 41: Protection
against electric shock.
Č N 33 2000-5-51 Electro-technical regulations. Construction of electrical
devices.
Č N 33 2130 Electro-technical regulations. Indoor electrical wiring.
Č N 33 2180 Electro-technical regulations. Connection of electrical
devices and appliances.

12
Č N 34 0350 Electro-technical regulations. Regulations for mobile
connections and cable placement.
Č N EN 60 079-10 Electro-technical regulations. Regulations for electrical
equipment in potentially explosive areas with flammable
gases and vapours.
Č N EN 60 079-14 ed.2 Electrical apparatus for explosive gas atmospheres - Part
14: Electrical installations in hazardous areas (other than
mines).
Č N EN 60 252-1 AC motor capacitors - Part 1: General - Performance,
testing and rating - afety requirements - Guide for
nstallation and operation.
Č N EN 60 335-1 ed.2 Electric appliances for household and similar purposes -
afety - Part 1: General requirements.
Č N EN 60 335-2-102 Electric appliances for household and similar purposes
afety - Part 2-102: pecific requirements for appliances
burning gas, oil and solid fuel and containing electrical
connections.
Č N EN 60 445 ed. 3 Basic and safety principles for man-machine interface,
marking and identification.
Č N EN 60 446 Basic and safety principles for man-machine systems –
Identification of conductors by colours or numbers.
Č N EN 61000 – 6 – 3 EMC – Part 6 – 3: Generic standards - Emission - for
residential, commercial and light industry.
Č N EN 61000 -3 – 2 EMC - Part 3 – 2: Limits – Limits for harmonic current
emissions (equiptment input current up to and including 16).
Č N EN 61000 – 3 –3 EMC – Part 3 – Bounds – ection 3: Limitation of voltage
luctuations and flicker in low-voltage supply systems for
devices with nominal current <16A.
e) About the DHW heating system
Č N 06 0320 Heating systems inside buildings – DHW set-up –
Design and planning.
Č N 06 0830 Heating systems inside buildings – afety equipment.
Č N 73 6660 Indoor water systems
5.2 Placement options
The boiler can be installed and operated in a simple environment AA5/AB5 according
to C N 33 2000-3. The boiler is equipped with a portable power cable and plug. The
boiler must be in compliance with EN 60 335-1 ed. 2 Article 7.12.4, positioned so that
the plug is accessible.
The installation and use of the boiler must comply with all Č N 06 1008 requirements.

13
Location of the boiler in conformance to fire regulations:
1. Positioning on a floor made of non-combustible material:
• The boiler has to be set on a non-combustible insulating mat exceeding the dimensions of
the boiler by 20 mm on all sides.
• If the boiler is located in the basement, it is recommended to placed the boiler on a base at
least 50 mm high. The boiler must be established at horizontally level; any unevenness in
the subsctructure is eliminated using the screws under the fuel hopper.
2. afe distance from combustible materials:
• When installing and operating the boiler, keep a safety distance of 200 mm from
combustible materials
• For easily flammable materials that burn quickly and by themselves even after removal of
the ignition source (such as paper, cardboard, asphalt and tar paper, wood and fibreboard,
plastics, floor coverings) the safe distance is doubled to 400 mm
• The safety distance must be doubled to 400 mm also when the reaction to fire is not proven
Boiler positioning with regard to the necessary handling space:
• In the front of the boiler must be left minimally 1000 mm space for handling.
• The minimum distance between the rear of the boiler and the wall is 400 mm.
• The minimum distance from the side wall of the boiler is 400 mm.
• Above the boiler minimally 450 mm.
Boiler positioning with respect to the mains:
• The boiler must be positioned so that the plug in the socket (230 V/50 Hz) is always
accessible
Location of fuel:
• For proper combustion, it is necessary to use dry fuel. Manufacturer recommended fuel
stored in cellars or at least sheltered.
• It is impossible to store fuel for the boiler or next to the boiler at a distance of less than
400 mm.
• The manufacturer recommends to keep the distance between the boiler and fuel minimaly
1000 mm or store the fuel in a different room than the installed boiler.
Connecting to the heating system must be made by a heating specialist with a valid
license.

14
Pic. No. 4 Location of the boiler
5.3 Connecting the boiler to the chimney and outlet of combustion products
The flue must lead to a chimney flue with a minimal possible lenght. The flue must
rise towards the vent, in no case shall fall. The flue must be mechanically strong, tight passes
and the accessible for cleaning. The inner diameter of the flue shall not be greater than the
diameter of the flue and it is forbidden to narrows the flue toward the chimney. The use of
large quantities of knees is not recommended.
Methods of implementation flues are given in Č N 06 1008.
The chimney must be designed so that the chimney flue develop a sufficient draft
(referred to the technical parameters of the boiler) and led the flue gases into the atmosphere.
The manufacturer recommends the chimney inset.
If the chimney draft is big or small it is necessary to install the draft regulator.
5.4 Air supply to the boiler
In the room where the boiler is installed, it must be ensured continuous supply of air
for combustion and ventilation. If it is not provided, it is necessary to ensure air vent from the
outside according to the standards.
5.5 Connecting the boiler to the heating system
The boiler is connected to heating system with 2" mouthpiece. For the filling and
draining of the boiler there is located an inlet (drain) valve beneath the return water. Filling
and draining should be performed using a hose. The heating system must be filled with water
that meets the requirements of Č N 07 7401.
The boiler must be connected to the circuit so the temperature of the return water was
above 55°C. This can be achieved by mechanical or controlled mixing valve, which is

15
controlled by the control unit. If the minimum temperature of the return water is not reached,
manufacturer can not guarantee the required service life of the boiler.
Boiler construction allows the connection of the boiler with a maximum pressure
according to the technical parameters of the boiler.
Connection the cooling loop as it is described in chapter 5.6
5.6 The cooling loop connection
Connection of the cooling loop (unless otherwise stated) is performed according to
pic. n.5. First 1/2" outlet serves for the water main connection and the other one 1/2" outlet
serves for joining runoff into drains.
In case the boiler is overheated (temperature above 95°C) the thermostatic valve will
automatically open. This valve is installed on cold water supply pipe. When the overheating
alarm turns on, the fan will stop and boiler remains in stable heat mode. Bimetallic sensor
which senses temperature is placed in the boiler sump. After the end of the cooling proces, is
the boiler temperature lower by 15°C then water flow will stop automatically.
This protection system only works reliably provided a constant supply of pressurized
water from the water main. Due to a mechanical protection which serves mainly for situations
as a power failure. It is necessary to be careful while connecting it to a water system!
Connect the cooling loop is the only condition for safe operation of the boiler.
Connections must be performed only by authorized personnel.
Pic. No. 5 Cooling loop

16
5.7 Connection to the mains
The power supply 230 V / 50 Hz with boiler attached by a cord and plug. The plugging
must comply with C N. The plug must always be in reach. Unauthorized intervention in the
electrical installation of the boiler will cause damage and can also cause fatal injuries.
5.8 Boiler parts installation
Situated the boiler on the substructure (pad) into a hori ontal position.
5.8.1 Installation of the boiler casing and thermostatic valve
The boiler is always supplied with the casing and it is also neccesary to install the
bimetalic thermostatic valve on the left side of boiler:
1. Remove the upper casing – upward movement.
2. Remove the back casing.
3. Remove the screws on the top of the casing and remove the side casing.
4. crew the bimetalic element to mouthpiece on the left side of boiler., Pic. No. 5
5. Unhinge the side casing.
6. Install the side, upper and back casing to its original state.
ATTENTION: If you do not install the supplied thermostatic valve, the boiler during
pressurization squirt water.
5.8.2 Exhaust fan connection
Apply sealant to outlet of the flue pipe and place the exhaust fan. The flue pipe outlet
must be placed upwards! After settling, tighten the screws on the exhaust fan and use sealant
thoroughly to avoid air intake.
Connect capacitor according to wiring diagram capacitor.
NCT4C, NCJ4C
Pic. No. 6 – Wiring diagram of the capacitor

17
5.8.3 Universal burner installation
1. Remove the cast iron collar from the burner body
2. Seal the flange burner head
3. Put the universal burner into the base without the collar and tighten the bolts.
4. Use stove sealant on the collar and puti t back (Pic. No. 8)
5. Connect the burner feeder and shorten the leg as required. It must correspond to the red
mark
Pic. No. 8 Sealing the top cast-iron collar and flange
5.8.4 Fan and screw feeder installation:
1. Put the fan in place and bolt it on.
2. Connect the screw feeder and make sure it correspond to red mark.
Pic. No. 9 Fand and feeder installation
5.8.5 Tank installation:
1. When assembling the fuel feeder to the base and to the fuel hopper, first, ensure that
everything is in horizontal level and then tighten the bolts.
2. Apply sealant to the fuel screw feeder where is the contact with the surfuces of the fuel
hopper. Put he fuel hopper in place and tighten the screws.
3. Follow the instructions of the burner manual, which is part of the package.

18
Pic. No. 10 Installing the hopper on screw feeder.
5.8.6 Control unit FOX installation:
1. Place the control unit from the left or right side of the boiler.
2. Connect the temperature sensors according to manual.
• Put the CH sensor into the reservoirs in the boiler’s water output connection.
• The DHW sensor is placed into the boiler reservoir or taped directly onto he pipe
(the sensor is set to OFF in the factory settings, the sensor is only used when the
boiler is in use).
• The temperature regulation sensor (an emergency thermostat) i sput into a separate
reservoir in the boiler’s water output pipe, as close to the boiler as possible.
• The hopper temperature sensor is put into a pipe placed on the screw feeder, behind
the fan.
• The rest of the sensors is possible to connect according the FOX manual.
3. Connect the control unit, feeder, fan, pump according to the manual.
4. Continue to follow the instructions on the control unit FOX manual.
6 Boiler operation by user
The boiler must be operated according to the manufacturer's instructions to avoid any
problem caused by the user, so it is highly recommended to read instructions manual for the
boiler and control unit FOX.
This appliance can not be used by younger children than 8 years old and persons with
reduced physical, sensory or mental disorders or by users without sufficient experience. They
are able to operate the boiler only if they are under the supervision or receiving the
instructions from the specialist and they understand the dangers that they come into contact.
Children should not play with the appliance. Cleaning and maintenance of the boiler can not
be perform by the kids.
Once in every 14 days period is needed to check the water pressure in the heating system.
If the pressure is low it is necessary to replenish the water. If the boiler in the winter period is
not operated, it is recommended to drain the water from the system due to freezing. The

19
discharged of the water is not recommended only when it is necessary and for the shortest
period of time. At the end of the heating season, it is necessary to thoroughly clean the boiler
and check the boiler for any damages that might be caused by the operation.
It is recommended to clean the impeller and an air chamber of the exhaust fan twice in a
year.
Při ručním režimu musí být nad hořákem umístěny šamotové desky. Při automatickém
režimu se desky musí vytáhnout.
6.8 Verification activities before usage of the boiler
Before the commissioning of the boiler it must be checked:
a) naplnění otopného systému vodou
The mineral content (hardness) of the water used inthe boiler must comply with Č N
07 7401 standards and it is essential that, if the mineral content is not in compliance, the water
must be softened – this is covered in ection 05.01.
Heating systems with open expansion tanks allow direct contact between the water and air in
the environment. During the heating season the expanding water in the tank absorbs oxygen,
which hastens the effects of corrosion while allowing significant water evaporation. If more
water is added, it must be treated according to Č N 07 7401 standards.
The heating system must be thoroughly rinsed out in order to eliminate all impurities.
During the heating period a constant volume of water in the heating system must be
maintained. When adding water to heating system, It must be ensured that no air is drawn into
the system. Water from the boiler and heating system must never be discharged or removed
except in cases of emergency such as repairs etc. Draining the water and replenishing it
increases the risk of corrosion and scaling. If it becomes necessary to add water to the
heating system, do soonly when the boiler is cold to avoid cracking.
b) A tight heating system
c) Connecting the flue The flue must be approved by a chimney inspector
d) Connection to the mains
You must connect the flexible cord with a plug into a standard socket 230 V/50
Hz/10A.
6.9 Firing
Please note that making fire is strictly forbidden to use flammable substances.
− Check the settings in the boiler control, operating control FOX.
− Check the amount of water in the heating system by looking at the gauge.
− Open the shut-off valves between the boiler and the heating system.
− Check the operation of pumps (mechanical spinning)
− Clean the boiler (if it is not the first firing). The ash door must be permanently closed
during the fire making and operation.

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− During the manual mode there has to be vermikulit plates above the burner. Automatic
mode is working without these plates.
Manual mode - gasification:
− Check the vermikult plates above the burner.
− Primary air slider control set to the open position.
− At the bottom of the filling chamber make fire using the small chips, sawdust or shavings.
− Put a few pieces of small wood in to the filling chamber, close the filling door.
− Ignite the wood throught the middle door.
− tart the control unit, using the fan we will support combustion in the chamber, which
create a hot layer in order to fill up the filling chamber with the wood.
− If we follow the correct procedure we should be able to stoke a wood to the chamber in
about 10 – 15 minutes.
− table combustion indicates that we can set the boiler to the desired performance and
reduce the amount of primary and secondary air.
Automatic mode:
− Pull out the plates above the burner.
− Clean the burner and ash pan (not for the first firing). The ash door must be shut at all
times when the boiler being fired up adn when i tis in operation.
− Fill the fuel hopper with the appropriate amount of fuel. After filling the fuel hopper, close
it tightly to prevent possible air intake into the burner through the feeder.
− witch the unit on in manual mode and start feeding the feeder using the “+ button”. The
fuel must be fed into the burner to approximately 1 cm below the edge. The feeder will
feed the burner for approximately 7 minutes. If the motor gets too hot, the thermo-fuse will
cause the feeder to stop. After cooling, the motor begins feeding again.
− The fuel should be ignited with liquid or solid fire starters, or with wood chips.
− Ignite and let it burn.
− Allow to burn for about 3 minutes, then gradually start the fan by pressing the “-button” In
the beginning, start the fan and then stop it. If the fan blows too hard in manual feeding
mode, the maximum fan speed needs to be set in the service menu.
− When firing up, keep the fuel level about 2 cm below the edge of the cast iron grate.
− When the space inside burner has completely heated up, the boiler can be switched to
automatic mode by pressing the ↑ button.
Checking the shape of the flame at automatic operation
The shape of the flame gives us information about the correct settings for the nominal
rating. It is reccomended to check the shape of the flame everytime you change the fuel.
When checking the shape of the flame, make sure that the boiler is set at nominal power.
Brown coal nut 2: