Kovarson TIGER User manual

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KOVARSON s.r.o.
Lhota u Vsetína 4
755 01, Vsetín
tel. ČR: [phone]
tel. SR: [phone]
email: info kovarson.cz
Installation and operation manual automatic
boiler
TIGER

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Dear customer,
Thank you for purchasing an automatic solid fuel TIGER boiler and the trust you ha e
put in KOVARSON s.r.o.
Please read this manual before putting your new boiler into operation to a oid
unnecessary complications resulting from handling issues. Section 7 – Operating the
Boiler by the User, Section 8 – Important Instructions, Section 9 – Maintenance and
the Operation Manual for the LIDER Control Unit are particularly important.
To ensure a long and trouble-free boiler life, please follow the manufacturer’s
instructions as well as those of the authorized installation company that sets up your
boiler.

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Content:
1. Boiler uses and benefits ..................................................................................... - 4 -
2. Boiler technical specifications ............................................................................. - 4 -
3. Recommended fuel............................................................................................. - 6 -
4. Description .......................................................................................................... - 7 -
4.1 Boiler construction ......................................................................................... - 7 -
4.2 Control, regulation and safety elements ...................................................... - 10 -
5. Location and installation ................................................................................... - 11 -
5.1 Regulations and Requirements ................................................................... - 11 -
6. Boiler installation .............................................................................................. - 15 -
6.2 Installation procedure .................................................................................. - 16 -
7.1 Electrical Wiring .......................................................................................... - 20 -
7.2 Pre-fire-up check list ................................................................................... - 21 -
7.3 Control unit parameters setting ................................................................... - 22 -
7.4 Putting the boiler into operation - Firing up ................................................. - 23 -
7.5 superior regulation – room thermostat ............................................................ - 25 -
8. Important instructions ....................................................................................... - 26 -
9. Maintenance ..................................................................................................... - 27 -
10. Disposal of the product after a period of his life .............................................. - 28 -
11. Guarantee and liability for defects .................................................................. - 28 -
12. Trouble shooting ............................................................................................. - 29 -
EC DECLARATION OF CONFORMITY ............................................................... - 30 -

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1. Boiler uses and benefits
The TIGER boiler is designed to heat households, commercial buildings and other
medium-sized structures economically and ecologically using an automatically
controlled feeder for solid fuels and with minimal ser icing. It can also be used as a
boiler for domestic hot water (DHW).
Boiler benefits:
− high efficiency
− cast iron body manufactured by a well-known Czech producer
− high exchanger durability
− uni ersal burner - burns brown coal or wood pellets
− simple boiler controls
− unattended operation, boiler maintenance takes 10 minutes e ery 3 days
− electronically controlled fan speed managed by the control unit
− low power consumption
− in warm seasons, it can be used to heat DHW only
− controlled by a room thermostat
− option to order the boiler with the large hopper on the right or left
2. Boiler technical specifications
Tab.1 Dimensions and technical parameters of the boiler
Boiler model
TIGER
20
TIGER
25
TIGER
30
TIGER
35
TIGER
40
TIGER
48
TIGER
55
Number of sections pcs 4 5 6 7 8 9 10
Weight kg 384 438 547 594 634 713 778
Water volume l 33.3 35 44.7 50.4 56.1 61.8 67.5
Flue diameter mm 160 160 160 160 180 180 180
Combustion chamber
volume dm
3
37.5 51 64.5 78 91.5 105 118.5
Combustion chamber
depth mm 295 405 515 625 735 845 955
Hopper capacity dm
3
290 290 290 290 290 290 290
Boiler dimensions mm see Figure
Size of hopper loading
window mm 370x335
370x335 370x335
370x335
370x335
370x335
370x335
EN 303-5 boiler class - 3 3 3 3 3 3 3
Maximum operating
excess water pressure
tolerance
bar 3
Tested operating excess
water pressure tolerance bar 6
Recommended operating
temperature of heating
water
°C 60 - 85
Minimum temperature of
returning water °C 60
Hydraulic pressure loss in
the boiler at ΔT= 20/ 0K mbar
0.55÷1.82
0.76÷2.635 0.97÷3.45
1.15÷4.23
1.29÷5.08
1.5÷5.9 1.74÷6.71
Noise level dB 67
Flue draw when the
emissions fan is running
and system is at nominal
output
Pa 4 4 4 4 7 9 22

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Boiler connections - water
heating Js G 2"
- returning
water Js G 2"
Supply voltage V 230
Electric load
(fan + motor) W 70 70 70 70 70 2 0 2 0
International protection
rating - IP20 IP20 IP20 IP20 IP20 IP20 IP20
Tab.2 Thermal technical parameters of the boiler (brown coal combustion)
Boiler model
TIGER
20
TIGER
25
TIGER
30
TIGER
35
TIGER
40
TIGER
48
TIGER
55
Number of sections pcs 4 5 6 7 8 9 10
Nominal output kW 20 25 30 35 40 50 55
Minimum output kW 6 7.5 9 0.5 2 5 6.5
Consumption of fuel at
nominal output kg.h
-1
4.2 4.9 5.5 6.8 8. 9.4 0.7
Consumption of fuel at
minimum output kg.h
-1
,2 ,4 ,7 2,0 2,3 2,7 3,0
Burning time at nominal
output h > 6 > 6 > 6 > 6 > 6 > 6 > 6
Efficiency % 79.9 79.5 79.2 78.8 78.5 78.3 78.
temperature of emissions
at nominal output °C 82 72 66 57 63 69 75
temperature of emissions
at reduced output °C 97 0 05 09 06 03 00
Volume of emissions
output at nominal level kg.s
-1
0.0 8 0.020 0.022 0.024 0.03 0.038 0.045
Volume of emissions
output at reduced level kg.s
-1
0.008 0.0 0 0.0 2 0.0 3 0.0 7 0.020 0.024
Thermal technical parameters of the boiler (wood pellets combustion)
Boiler model
TIGER
20
TIGER
25
TIGER
30
TIGER
35
TIGER
40
TIGER
48
TIGER
55
Number of sections pcs 4 5 6 7 8 9 10
Nominal output kW 20 25 30 35 40 50 55
Minimum output kW 6 7.5 9 0.5 2 5 6.5
Consumption of fuel at
nominal output kg.h
-1
5.0 6. 7.3 8.4 0.2 2. 4.0
Consumption of fuel at
minimum output kg.h
-1
.5 .8 2.2 2.6 3.0 3.4 3.8
Burning time at nominal
output h > 6 > 6 > 6 > 6 > 6 > 6 > 6
Efficiency % 83.4 83.0 82.6 82.2 82.2 82. 82.
temperature of emissions
at nominal output °C 57 55 52 50 50 50 50
temperature of emissions
at reduced output °C 96 97 99 02 98 94 9
Volume of emissions
output at nominal level kg.s
-1
0.0 4 0.0 7 0.02 0.024 0.030 0.036 0.04
Volume of emissions
output at reduced level kg.s
-1
0.008 0.0 0 0.0 2 0.0 3 0.0 4 0.0 5 0.0 6
These alues ary depending on the quality and type of fuel. Therefore, it is necessary
to make corrections when adjusting the feeding cycle and fan speed. If, for example,

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there is unburned fuel in the ash pan, the fan speed or feeding cycle needs to be
adjusted. Or, con ersely, if the burning fuel in mo es toward the feeder, the fan speed
should be reduced or more fuel added!
3. Recommended fuel
Warranty fuel parameters– fuel with which the tests were carried out in the National
Testing Facility:
• Moisture content
• The content of olatile matter
• Ash fusion temperature
• Low sintering capacity
• Low expansion capacity
Tab.3 Fuel tested
Fuel Fuel type Operation
Granularity
[mm]
Heating value
[MJ.kg
-1
]
Bro n coal
nut 2 Automatic 10.25 16,5 - 19,5
B
iomass
Wood pellets Automatic Ø6-8 15 - 19
Tab.4 Fuel tested - brown coal (automatic operation)
fuel Diameter
[mm]
Heating
alue
[MJ.kg-1]
the ash
content
[%]
moisture
content
[%]
sulfur
content
[%]
specific
sulfur
content
[g/MJ]
Tar
content
in dry
matter
[%]
Tar content
in
combustible
elements
[%]
Sorted brown
coal from the
Bílina Mine
(Úpra na uhlí
Led ice) - nut 2
0.25 7.6 9.8 maximum
20 0.77 0.44 5. 5.7
Wood pellets must satisfy at least one of the following specifications or standards:
• Specification number 14-2000 MŽP ČR
• DIN 517 31
• ÖNORM M 7135
Prescribed diameter of pellets 6 – 8 mm
Moisture content in a fuel maximum 12%
Ash content maximum 1.5%
CAUTION! Poor quality pellets may negati ely affect output and boiler emission
parameters.

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4. Description
4.1 Boiler construction
The boiler construction meets ČSN EN 303-5 : 2000 requirements:
- boiler for CH - Part 5: boiler for DHW using solid fuel with manual or automatic
feeding, at a nominal heat output of up to 300 kW -
Terminology, requirements, testing and marking.
The core of the boiler is the cast-iron body. The body is composed of front, rear and
middle sections. The main function of the boiler body is to transfer thermal energy from
the exhaust gas to heat water. The upper cleaning door and the middle door are
located on the front section. The smoke extension that funnels emissions to the flue is
located on the back section.
The cast iron body is set on the base. The base is made from a 5mm-sheet of steel.
The ash pan door is on the front of the base.
The burner is placed into the side wall of the base. 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
upwards. The upper part of the burner is made from two cast-iron rings.
Two ceramic plates are positioned inside the boiler body in front of the cleaning door
to impro e combustion.
The burner’s ash pan is placed at the bottom of the base.
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 co ered fuel hopper. Boilers can be ordered in
two ariations:
• right fed – The fuel hopper is on the right side of the boiler body from the front
perspecti e
• left fed – The fuel hopper is on the left side of the boiler body from the front
perspecti e
There is wax plug inside the burner, which is the emergency extinguisher.
The boiler body, base and doors are insulated with non-toxic mineral insulation to
minimize heat transmission losses to the surroundings.

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Figure1 Main boiler dimensions (right fed)
A B C D E F G H
dimension
4-7čl
1530
1445 1245 600 500 147
mm
8-10čl
1630
1545 1295 600 500 147
I J K L M N O P
dimension
4-7čl
620 1225 1400 1350 1710 158 2" 2"
mm
8-10čl 720 1325 1500 1450 1810 178 2" 2"
Boiler
TIGER
20
TIGER
25
TIGER
30
TIGER
35
TIGER
40
TIGER
48
TIGER
55
Number of
sections
4 5 6 7 8 9 10
C 493 603 713 823 933 1043 1153
D 640 750 860 970 1080 1190 1300

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1. LIDER control unit
2. boiler cover
3. flue damper
4. fuel hopper cover
5. top cleanin door
6. fuel hopper
7. middle door
8. base
9. lower door
10. fan
11. fuel hopper cleanin plate
12. feeder motor
13. fuel feeder
14. output of heatin water
16. input for heatin water
18. boiler body

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4.2 Control, regulation and safety elements
The LIDER electronic control unit manages and controls the system - see separate
manual.
Safety elements:
• An emergency heating system thermostat safeguards against overheating. It is set
at 0° C by the manufacturer, above which temperature the fan shuts down for a
certain time while the feeder works in cycles to smother the fire.
• A fuel tank temperature sensor safeguards the system against fuel back-burn. The
factory setting is at 70°C, but the user may reset the temperature according to
his/her needs. If the temperature is higher than the setting, the feeder motor is
started up according to the time set in the control unit to smother the fire. This
function is only available if the boiler is connected to a power source.
• There is an overheating safeguard for the motor. The normal operating temperature
is anything below 80°C.
• Fire extinguishing equipment is included as an element of the safety system in case
of back-burn. The system is triggered if the wax plug is melted – this happens if the
temperature in the feeder exceeds 0°C. Water will be released from the plastic
tank.
4.3 Boiler accessories
Standard accessories:
• Boiler operation and installation manual
• Control unit manual
• 2 ceramic top tiles ( 2 tiles)
• Ash pan
• Ash brush
• Poker
• emergency fire extinguisher with wax plug
• 2 flanges (upper and lower)
• 2 ¾” plugs
• fill/drain valve
• 2 shear fuses
• 2 reservoirs for sensors

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5. Location and installation
5.1 Regulations and Requirements
The solid fuel boiler is only 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.
The heating system must be filled with water that meets ČSN 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 concentration mg/l (0,3)*
CA TION!!! The manufacturer does not recommend the use of antifreeze.
a) About the heating system
ČSN 06 0310 Heating systems in buildings - Design and installation
ČSN 06 0830 Heating systems in buildings – Safety equipment
ČSN 07 7401 Water and steam for thermal energy equipment with
working pressure up to 8 MPa.
ČSN 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
ČSN 73 4201 Designing chimneys and flues.
c) Due to fire regulations
ČSN 06 1008 Fire safety for heating equipment.
ČSN EN 13 501-1+A1 Fire hazard classification: Buildings and construction
Buildings - Part 1: Classified from results of reaction to fire
d) The power supply
ČSN 33 0165 Electrical regulations. Marking of wires with colours or
numbers. The implementing regulations.
ČSN 33 1500 Electro-technical regulations. Testing of electrical devices.
ČSN 33 2000-3 Electro-technical regulations. Electrical devices. Part 3:
Declaration of the basic characteristics.
ČSN 33 2000-4-41 Electrical devices: Part 4: Safety Section 41: Protection
against electric shock.
ČSN 33 2000-5-51 ed. 2 Electro-technical regulations. Construction of electrical
devices.
ČSN 33 2130 Electro-technical regulations. Indoor electrical wiring.
ČSN 33 2180 Electro-technical regulations. Connection of electrical
devices and appliances.

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ČSN 34 0350 Electro-technical regulations. Regulations for mobile
connections and cable placement.
ČSN EN 60 07 -10 Electro-technical regulations. Regulations for electrical
equipment in potentially explosive areas with flammable
gases and vapours.
ČSN EN 60 07 -14 ed.2 Electrical apparatus for explosive gas atmospheres - Part
14: Electrical installations in hazardous areas (other than
mines).
ČSN EN 60 252-1 AC motor capacitors - Part 1: General - Performance,
testing and rating - Safety requirements - Guide for
installation and operation.
ČSN EN 60 335-1 ed.2 Electric appliances for household and similar purposes -
Safety - Part 1: General requirements.
ČSN EN 60 335-2-102 Electric appliances for household and similar purposes
Safety - Part 2-102: Specific requirements for appliances
burning gas, oil and solid fuel and containing electrical
connections.
ČSN EN 60 445 ed. 3 Basic and safety principles for man-machine interface,
marking and identification.
ČSN EN 60 446 Basic and safety principles for man-machine systems –
Identification of conductors by colours or numbers.
ČSN EN 61000 – 6 –3 EMC Part 6-3: Generic standards - Emission - for residential,
commercial and light industry.
ČSN EN 61000 -3 – 2 EMC - Part 3-2: Limits - Limits for harmonic current emissions
(equipment input current up to and including 16).
ČSN EN 61000 – 3 –3 EMC – Part 3 - Limits - Section 3: Limitation of voltage
fluctuations and flicker in low-voltage supply systems for
devices with nominal current <16A.
e) About the DHW heating system
ČSN 06 0320 Heating systems inside buildings – DHW set-up –
Design and planning.
ČSN 06 0830 Heating systems inside buildings – Safety equipment.
ČSN 73 6660 Indoor water systems
5.2 placement options
The boiler can be installed and operated in a simple environment AA5/AB5 according
to CSN 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 ČSN 06 1008
requirements.

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Location of the boiler in conformance to fire regulations:
1. Positioning on a floor made of non-combustible material:
• The boiler is 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 that it be placed it on a
base at least 50 mm high. The boiler must stand horizontally level; any unevenness
in the substructure is eliminated using the screws under the fuel hopper.
2. Safe distance from combustible materials:
• when installing and operating the boiler a safe distance of 200 mm is to be
maintained from combustible materials
• For highly flammable materials that can ignite quickly and sustain combustion after
the source of ignition has been extinguished (e.g. paper, paperboard, cardboard,
asphalt and tarpaper, wood and fibreboard, plastics, floor coverings), the safe
distance is doubled to 400 mm.
• When in doubt about the combustibility of materials the clearance should be doubled
(i.e. 400mm).
Operating clearance:
• Roughly 1000 mm should be allowed for front clearance.
• The rear of the boiler must clear the wall by 400mm
• 1000 mm should be allowed for clearance on the hopper side in case the feeder
screw needs to be removed.
• There should be at least 450 mm of clearance space above the boiler.
Electrical outlet and boiler placement:
• The boiler must be positioned so that the electrical outlet (230 V/50 Hz) is always
accessible.
Location of fuel
• Dry fuel must be used for proper combustion. The manufacturer recommends that
fuel be stored a cellar or under shelter
• Do not store fuel less than 400 mm from the boiler.
• The recommended minimum distance between the boiler and fuel is 1000 mm or
storage in separate room

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There must be a continuous supply of air for combustion and ventilation in the boiler
room.
Tab.6 – Air consumption
Boiler model
TIGER
20
TIGER
25
TIGER
30
TIGER
35
TIGER
40
TIGER
48
TIGER
55
Number of sections 4 5 6 7 8 9 10
Air consumption [m3.h-1] 45 60 75 0 105 120 135
All heating pipes must be installed by authorized personnel.
CAUTION: When connecting the boiler to the heating system the fill / drain valve must
be placed as close as possible to the boiler.
Figure2 Placement of the boiler

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6. Boiler installation
6.1 Packaging and accessories
The boiler is delivered disassembled on 2 pallets. Accessories are shipped inside
boiler body. Open the cleaning door to remove them. The base for the burner, the
universal burner, the control unit, the fan, the fuel hopper and complete metal plating
with mineral fibre insulation are delivered on the second pallet.
Standard boiler delivery:
− 1 boiler on a palette in the particular number of sections
− The boiler casing with mineral fibre insulation
− 1 ash pan
− Cleaning tools (scraper, brush with handle, poker, 2 wall plugs, 2 threaded hooks)
− 1 thermo-manometer
− 1 1/2” fill/drain valve
− 1 6/4” end plug
− 2 seals (φ 60 x 48 x 2)
− 1 rod with handle to manipulate the damper
− 1 damper label
− Assembly hardware for the boiler body shell (4 spring clips, 4 connection pins, 16
8x13 ST4 bolts)
− Two 2" heating and returning water flanges (for sizes 4-7); one hot water flange
(for sizes 8-10); and one “Y” pipe for returning water with flange
− 2 seals φ 0 x 60 x 3
− adjustment wrench
− technical and sales documentation
− LIDER control unit with temperature sensors and connectors
− fan with relevant output
− universal burner with relevant output
− One telescoping leg
− Assembly hardware for the burner and the base (four M12x30 bolts, four M12
nuts)
− stove sealant (1 tube)
− plastic ties for binding control unit cables
− 2 ceramic upper tiles
− One ½”- end plug
− 4 turbulators
− base covering
− fuel hopper
− boiler base
− assembly hardware for fan (four M6x30 bolts, four M6 nuts)
− assembly hardware for fuel hopper (six M8x30 bolts, six M8 nuts)
− rubber fan mat
− rubber fuel hopper mat

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− two HEYCO grommets
− extinguishing system (one plastic tank, 3/8” 1 m hose, hose connector, 12mm
compression fittings, two wax plugs)
− extinguishing system bracket
− assembly hardware for extinguishing system (two M6x10 flush-head screws, two
M6 nuts)
− four tensioners (Ø8 mm)
− two ¾” plugs
− two thermo-reservoirs
6.2 Installation procedure
6.2.1 Installation of the boiler body and base
1. Position the boiler body with the retaining wall at the base pad in a horizontal
position.
2. Fill the space between the base and the boiler with sealant.
3. Connect the boiler’s smoke outlet to the flue pipe in the chimney with a 160mm flue
pipe.
4. Plug the 1 ½” threaded holes in the front section of the boiler with plugs. Seal each
plug with an O-ring.
5. Plug the ½” threaded holes in the front section of the boiler with plugs. Seal each
plug with an O-ring.
6. Open the cleaning door and insert upper fire bri
Obr. č. 6 Sealing base
6.2.2 Mounting the casing
Boiler casing
1. Remove the casing components from box.
2. Fit the sheet metal components with the appropriate fasteners (see Figure 6 - 10
bolts - ST 4.8 x 13).
3. Assemble the boiler casing (see Figure 6)
4. Assemble the left and right casing components on the anchoring bolts and then
add the front part of the casing. Bolt the rear part to the sides. On the side parts
put the front seat with the inscription. Insert the thermo-manometer and capillary
tubes into the upper part of the shell, leading to the recovery valve up the isolation

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upper part of the shell. Care must be taken so that the capillary tubes do not touch
the boiler body.
Figure 6 Boiler body casing
Base casing:
1. Remove the casing from the carton.
2. After screwing the burner head on, hook the side burner base casing onto the boiler
casing. Add the rear of the casing and tighten the screws.

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6.2.3 Burner Installation
1. Screwed the cast iron burner head onto the base.
2. Remove the cast iron collar from the cast iron head
3. Seal the flange burner head
4. Put the universal burner into the base without the collar and tighten the bolts
5. Use stove sealant on the collar and put it back (Figure 8)
6. Join the burner screw and shorten the leg as required. It must correspond to the
red mark.
Figure 8 Sealing the top cast-iron collar and flange
6.2.4 Fan installation
1. Put the fan in place and bolt it on.
Figure Fan installation

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6.2.5 Fuel hopper installation
1. When assembling the fuel feeder to the base and to the fuel hopper, first ensure
that everything is level and then final tighten the bolts.
2. Apply sealant to the fuel screw feeder where the contact surfaces of fuel hopper
are to be placed. Put the fuel hopper in place and tighten the screws
Figure 10 Fuel hopper installation
6.2.6 Installation of control unit and temperature sensors
1. Place the control unit on the boiler.
2. Engage temperature sensors:
• Put the CH sensors into the reservoirs in the boiler’s water output connection
• The DHW sensor is placed into the boiler reservoir or taped directly onto the
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) is put 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
3. Connect the feeder, fan and pumps according to the control unit instructions.
6.2.7 Installation of emergency fire safety equipment
1. Remove the silver-coloured plug from the burner.
2. Screw in the copper hose connector
3. Put one end of the hose onto the hose connector and tighten the hose clamp.
4. Cut the hose to the desired length.

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5. Fasten the other end of the hose to the tank’s tap nozzle and tighten the hose
clamp.
6. Install the water tank in the bracket at the back side of the hopper.
7. Operating the boiler by the user
Only authorized heating specialists are to put the boiler into service.
Figure12 Boiler connection dimensions
Boiler A B C
4 - 7 section 620 1225 1400
8 – 10 section 720 1325 1500
7.1 Electrical Wiring
It is not necessary to interfere with the electrical wiring in any way when putting the
boiler into operation. All the connectors are connected to the rear of the control unit;
these connectors allow for quick and easy connection to, or disconnection from, the
control unit.
Shorten or extend sensor cables abiding by the following recommendations:
• Do not cut the sensor cables to a length shorter than 0.5m
• We do not recommend extending the sensor cable more than 10m
• CMSM - H 2 x 0.5 mm cable is recommended for extensions
• Take care in extending cables. When shortening or extending a cable ensure
there is a good connection.