Ponast KP 10 User guide

Automatic boiler for wood pellets
Instructions for installation and operation
Manufacturer:
PONAST spol. s r.o., Na Potůčkách 163, 757 01 Valašské Meziříčí, CZECH REPUBLIC
tel. [phone] , fax [phone], e-mail: [email protected]
Dear customer,
accept kindly, please, our congratulations on your decision to buy this product and to ensure WARM
FOR YOUR HOME by burning recoverable energy sources - WOOD PELLETS in this case.
You have thus showed your exemplary personal responsibility for healthy environment for your
children as well as for next generations at all.
Believe, please, that our approach to the development of this product was with the same
responsibility and we are looking forward that the product will provide you with good service.
Pay attention, please, to these OPERATING INSTRUCTIONS for correct treatment of this product,
which is a condition of long service life of this product - and thus also your full satisfaction; we would like
to focus your attention mainly on the following chapters:
number 1 – Important notices
number 6 – Putting the product into operation
number 7 – Maintenance and attendance of the boiler during operation
The boiler has been approved for operation in the Czech Republic and in 27 EU countries
by the State Testing Institute, state testing plant number 202.
Tests have been assessed for:
Boiler: Product certificate:
KP 10, KP 10E, KP 20, KP 20E B–30–00273–05
KP 50, KP 50E B–30–00183–06
KP 11, KP 11E, KP 21, KP 21E B-30-00490-05
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Automatic boiler for wood pellets
Instructions for installation and operation
TABLE OF CONTENTS:
1. IMPORTANT NOTICES 4
2. USE OF THE BOILER AND ITS ADVANTAGES 5
3. TECHNICAL DATA OF THE BOILERS KP 11, KP 11E, KP 21, KP 21E 6
4. STRUCTURAL DESCRIPTION OF PRODUCTS 7
4.1 BOILER BODY 7
4.2 CONTROL UNIT OF THE BOILER 10
4.2.1 Connection of connectors of the control unit 11
4.2.2 Block diagram of the control unit 12
4.2.3 Description of the control panel 13
4.2.4 Block diagram of operation of the control unit 14
4.2.5 Manual control 15
4.2.6 Automatic operation 15
4.2.6 Main menu 16
4.3 BURNER FURNACE INCLUDING THE FEEDER 2 19
4.4 CERAMIC PARTS 20
4.5 FEEDER 1 WITH INDEPENDENT DRIVE 20
4.6 JACKETING OF THE BOILER INCLUDING HEAT INSULATION 20
4.7 STANDARD ACCESORIES 20
4.8 OPTIONAL ACCESSORIES 21
4.9 FUEL BIN 22
5. PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION 22
5.1 PLACEMENT OF PRODUCTS IN BOILER ROOMS 22
5.2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL 22
5.3 LEGISLATION IN FORCE 22
5.3.1 Heating system and boiler 23
5.3.2 Venting 23
5.3.3 Fire regulations 23
5.3.4 Electrical 23
5.3.5 Noise control 23
5.4 STORAGE OF FUEL 24
5.5 BOILER ROOM VENTILATION 24
6. PUTTING THE PRODUCTS INTO OPERATION 24
6.1 CONNECTION TO THE SYSTEM 24
6.2 INSTALLATION OF THE CERAMIC CATALYTIC REFLECTOR 25
6.3 INSTALLATION OF THE CERAMIC EXTENSION GRATE 26
6.4 FITTING THE CERAMIC SHIELD 26
6.5 CHECKS BEFORE THE BOILER IS PUT INTO OPERATION 27
6.6 IGNITION 27
6.7 AUTOMATIC OPERATION 29
6.8 SELECTION OF THE REQUIRED HEAT OUTPUT OF THE BOILER 29
6.9 ELECTRIC MODERATE HEATING 29
7. MAINTENANCE AND ATTENDANCE OF THE BOILER DURING OPERATION 30
7.1 ATTENDANCE 30
7.2 MAINTENANCE 31
7.3 ANNUAL AUDIT 32
7.4 OPERATING STATES – BASIC FIGURE 34
8. FAILURE STATES 34
8.1 STOP STATE - DUE TO OVERHEATING 34
8.2 STOP STATE - DUE TO WATER TEMPERATURE DROP 35
8.3 STOP STATE - BLOCKED FEEDER 35
8.4 LACK OF PELLETS IN THE FUEL BIN 36
8.5 ELECTRICITY SUPPLY INTERRUPTION 36
9. DISPOSAL OF PRODUCT AFTER THE END OF ITS SERVICE LIFE 36
9.1 NATURAL PERSON 36
9.2 LEGAL ENTITY 37
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Automatic boiler for wood pellets
Instructions for installation and operation
10. GUARANTEE AND LIABILITY FOR DEFECTS 37
Guarantee conditions 37
Records of performed repairs 38
Picture part 39-46
Directory information -consuption wood pellets for boiler family KP 47
Setting Control Unit from productions 48-49
Technical information - accessories 50-59
LIST OF FIGURES:
Fig.n. 1 Diagram of the product including description of the main parts 8
Fig.n. 2 Control unit of the boiler 9
Fig.n. 3 Connection of connectors of the control unit 10
Fig.n. 4 Block diagram of the control unit 11
Fig.n. 5 Control panel 12
Fig.n. 6 Block diagram of operation of the control unit 13
Fig.n. 7 Tank to heat service water (HUW) 20
Fig.n. 8 Digital indoor thermostat with a weekly programme 20
Fig.n. 9 Recommended draught of the chimney 22
Fig.n. 10 Installation dimensions of boilers 23
Fig.n. 11 Ceramic reflector 24
Fig.n. 12 Parts of the ceramic grate 25
Fig.n. 13 Ceramic shield 25
Fig.n. 14 Recommended wiring diagram of boiler 38
Fig.n. 15 Recommended wiring diagram of boiler 39
Fig.n. 16 Recommended wiring diagram of boiler – cascading wiring 40
Fig.n. 17 Examples of fuel bins, placement of products and requirement on dimensions 41
Fig.n. 18 Wiring - option for supply: 3+PE+N, 50 Hz, 400/230 V, TN-CS 42
Fig.n. 19 Wiring - option for supply 3+PE+N, 50 Hz, 400/230 V, TN-S 43
Fig.n. 20 Schema wiring el. ignition + el. heating 44
Fig.n. 21 Schema wiring electromotive control 4-way valve 44
Fig.n. 22 Wiring room thermostat with weekly programme and independent drive heating HUW 45
Fig.n. 23 Working principle The Boiler in mode modulation 45
Fig.n. 24 Directory information - consuption wood pellets for boiler family KP 46
LIST OF TABLES
Table 1 Thermal and technical parameters of products 6
Table 2 Solid harmful substances in combustion 6
Table 3 Technical parameters of products 6
Table 4 Electrical parameters of products 6
Table 5 Fuel and its parameters 6
Table 6 Setting Control Unit from productions 48-49
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Automatic boiler for wood pellets
Instructions for installation and operation
1 IMPORTANT NOTICES
This product may only be put into operation by an installation organization trained
by the manufacturer. This product may only be operated by adult persons, duly
acquainted with the way the product is controlled and duly acquainted also with these
Instructions. If you adhere to the below mentioned principles, the product will serve you
reliably to your full satisfaction.
1) It is prohibited to intervene in any way in the structure or electrical installation of products.
Having the equipment been disconnected from the electric network, the power supply cord has to
be plugged from the mains outlet!
2) It is prohibited to use inflammable liquids for ignition.
3) No inflammable materials may be stored on the boiler, neither may they be stored within the
distance of 1,500 mm from the boiler (except for operating stock in the metal bin).
4) In order to preserve long-term service life of the boiler body, it is not recommended to operate
the boiler frequently under the temperature of 60°C, if the boiler is not protected with a primary
circuit. The temperature of 60°C should be considered as the minimum temperature.
5) The check how the furnace is filled with fuel is only visual. Any verification with touch is
prohibited as it may result in injury.
6) If any work which generates inflammable vapours takes place in the boiler room (glueing the
floor, etc.), the boiler has to be out of operation and the fire has to be burnt out in the boiler.
7) The door of the boiler has always to be close shut. Should you perform any check, open the
door carefully to prevent from getting jeopardized by gathered products of combustion or to
prevent any sparks flying out from the boiler from being the cause of any accident. Open the
door slowly in order to get the combustion chamber aerated towards the chimney. This
procedure has to be adhered to when the ash is being removed from the ash pan's space.
8) Having the heating season been finished, clean the boiler thoroughly as per the chapter 7 -
Maintenance. Products of combustion stuck to the walls of the exchanger may act corrosively
for the whole period of time when the boiler will be out of operation. If the burner is not cleaned,
this may have effect on faulty combustion. We recommend to hire a specialized company to
perform this work.
9) If you work on or near to the mechanically movable parts (fuel feeder, etc.), ensure safe
disconnection of the equipment from electric voltage. There is a risk of injury.
10) You should always operate the boiler only under parameters and in harmony with
recommendations given in these Instructions for installation and operation.
If the boiler works in the AUTO mode and if there is a failure of current, the boiler will start
operation again with the electric firing programme (if this programme has been installed) after
the delivery of electric current is restored.
11) The manufacturer does not assume any liability for errors and subsequent damage caused by
unskilled operation of the equipment or by infringement of principles given in these Instructions
for installation and operation or by infringement of generally binding standards and regulations or
by using inadequate fuel.
12) If the boiler is moved or otherwise handled with, safety regulations which apply to handling with
heavy loads have to be adhered to.
13) It is prohibited to place heavy loads on jacketed boiler and to step on it. It is recommended to
remove the protective transport after all the building and installation work has been completely
finished.
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Automatic boiler for wood pellets
Instructions for installation and operation
2 USE OF THE BOILER AND ITS ADVANTAGES
The series of automatic hot-water boilers for wood pellets is designed mainly to heat family houses,
small municipal buildings, cottages and small plants or business buildings.
The main advantages of products:
- AUTOMATIC OPERATION ensured by the control unit which cooperates with the indoor thermostat
which ensures COMFORT for the user including maximum saving of fuel.
- Optimized BOILER BODY manufactured from top-quality steel which perfectly transforms the heat
energy generated by fuel combustion and ensures economic operation and long-term operating certainty.
- The resulting efficiency of the product considerably exceeds classic solid fuel boiler in this aspect and
reaches even more than 92 %.
- Modern structure of the control unit which controls the operation of the boiler as such ensures
considerable reduction in manual operation and high operating reliability.
- The structure and software package makes it possible to ensure priority heating of hot service water
without any need for other control elements.
- The burner system used with two independent drives and with a system of ceramic catalytic reflector
ensures perfect SMOKELESS FUEL COMBUSTION, which supports high thermal efficiency of the product
and also excellent ecological parameters with the minimum content of harmful substances in combustion
products (20 – 50x less than in case of classic boilers).
- High SAFETY OF OPERATION given by separated structure of transport routes for fuel and by the
selected transport mode.
- The boiler makes it possible to ensure economical MODERATE HEATING of buildings by a suitably
selected system using electric power.
- Jacket of the product is coated with a heavy-duty COMAXITE COATING which is perfectly resistant to
environment effects and ensures perfect appearance of products on long-term basis.
- The whole design uses modern elements of shape and documents high professionalism of the whole
working team of the manufacturer.
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Automatic boiler for wood pellets
Instructions for installation and operation
3 TECHNICAL DATA OF THE BOILERS
Table number 1: Thermal and technical parameters of products
Parameter Unit KP 10/10E KP 20/20E KP 50/50E KP 11/11E KP 21/21E
Rated output kW 14,9 25 48 17 29
Output range kW 4,5 – 14,9 7,25 - 25 14,5 - 48 5 - 17 8 - 29
Fuel consumption kg x hour-1 ~1,25 - 3,7 ~1,81 - 6,25 ~3,9 - 12,9 ~1,3 - 4,0 ~2,0 - 6,8
Efficiency (rated output) % 86 91,1 92,2
Efficiency (minimum output) % 85,2 90 91
Temperature of combustion products °C 150 – 205 133 - 176 108 - 158
Class of the boiler 3
Table number 2: Solid harmful substances in combustion
Parameter Unit KP 10/10E KP 20/20E KP 50/50E KP 11/11E KP 21/21E
Average mass flow rate
stiff elements pollutions
at rated power g/hour 1,1 1,9 1,3 0,6 1
Average mean value
stiff elements pollutions
in dry air at rated power mg/m322,3 37,2 20,4 21 35
Table number 3: Technical parameters of products
Parameter Unit KP 10/10E KP 20/20E KP 50/50E KP 11/11E KP 21/21E
Weight (complete boiler) kg 210 270 490 255 335
Water content l 55 70 105 55 70
Fume duct diameter mm 130 150 160 130 150
Connections: heating and return water Js G 1 1/2"
Heating surface m21,8 2,1 2,4 1,8 2,1
Dimensions mm 360x1065x1420 497x1065x1420 745x1285x1630 477x 980x1435 614x980x1435
Working overpressure of water bar up to 2,5
Required draught mbar 0,1 – 0,2
Recom.operating temp.of heating water °C 60 – 80
The least temp.of incoming water °C 55
Table number 4: Electrical parameters of products
Parameter Unit KP 10/10E KP 20/20E KP 50/50E KP 11/11E KP 21/21E
Connecting voltage 230 V AC ± 10%, 50 Hz ± 2 Hz
Electric input (2 motors, fan) W 180 210 180 210
Electric protection of the control unit --- IP 65
Electric protection of the boiler's wiring --- IP 20
Guaranteed fuel for the products is represented by wood pellets the parameters of which are given in the
following table.
Table number 5: Fuel and its parameters
Wood pellets diameter 6,0 - 8,5 mm
Caloric value approximately 16-18 Mj / kg
Water content up to 10 %
Ash content up to 1 % ( 0,8 – 1,0% )
Bulk weight 0,6 – 0,64 Kp / dm3
plastic bags á 15 – 25 kg,
giant bags Big Bag á 800 - 1100 kg
Fuel delivery systém
cistern
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Automatic boiler for wood pellets
Instructions for installation and operation
4 STRUCTURAL DESCRIPTION OF PRODUCTS
The structure adheres to the Czech standard ČSN – EN 303.5 / 2000
- i.e. boilers for central heating - part 5 (boilers for central heating with automatic fuel feed of rated
heat output up to 300 kW).
MAIN parts of the boiler are:
4.1 Boiler body
4.2 Control unit of the boiler
4.3 Burner furnace including the feeder 2 with independent drive
4.4 Ceramic parts
4.5 Feeder 1 with independent drive (from fuel bin)
4.6 Jacketing of the boiler including heat insulation
Other delivery:
4.7 Standard accessories
4.8 Optional accessories
4.9 Fuel bin
-
4.1 BOILER BODY
- is made of top-quality steel metal sheets and pipes for boiler in form of a weldment. Its shape is
adapted in such a way so that combustion products are cooled down efficiently at individual levels of
power output, which is, moreover, assisted by a newly developed system of turbulator of combustion
products. The exchanger is shaped in such a way so that the exhaust pipes of combustion products can
be cleaned individually and efficiently.
The boiler body is fitted with the following:
- 1 piece of door which makes it possible to ignite the fuel, to control burning in course of
operation, to install a ceramic catalyst and ceramic extension grate before the operation is started
and to remove the ash pan when the ash is being cleaned.
- exhaust ∅130 – 150 - 160 mm
- output of heating water G 1½´´ (inside thread)
- input of return water G 1½´´ (inside thread)
- rear flanged orifice in order to install the burner system
- removable ash pan in the ash room
- an outlet of ½´´ in order to install an inlet (outlet) valve
- extension piece with inside thread M48 x 2 mm in order to make it possible to install an electrical
heating unit
- turbulators (event. with system of semiautomatic cleaning of the heat exchanger)
- lid of the boiler body
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Automatic boiler for wood pellets
Instructions for installation and operation
Diagram of the products and description of the main parts
Figure number 1 – Diagram of the product including description of the main parts
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2 CONTROL UNIT OF THE BOILER
Figure number 2 - Control unit of the boiler
The control unit of the boiler is used to control the boiler automatically via control elements
(thermometers, sensors, etc.) in required modes.
The control unit makes it also possible to run MANUAL MODE to control the built-in elements, which
is used, apart from other things, to put the boiler into operation.
The control unit is designed as a compact unit. Electric protection (IP 65) enables safe and reliable
operation of the equipment under hard operating and climatic conditions of boiler rooms.
Technical data of the CONTROL UNIT
Dimensions (mm) 195 x 215 x 135
Weight kg 3,5
Supply voltage 230 V AC ±10 %, 50 Hz ±2 Hz
Power input (own power input) max 25 VA
Indication - LCD display unit to communicate with the operator
- three-point seven-segment temperature indicator
- indication LED diodes
Management touch pad keyboard
Control microprocessor
Inputs temperature sensor, indoor thermostat, water heater
3x passive
Outputs 2x outlet contact 6A with current
3x outlet contact 6A
1x fan control
Protection IP 65
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.1 Connection of connectors of the control unit
Figure number 3 - Connection of connectors of the control unit
Interconnection with the ambient is ensured by two connectors – X1and X2.
The connector X1is used to connect the supply voltage and all power elements (motors of feeders,
fan, circulation pump, etc).
The connector X2connects the operating (boiler's) thermometer, emergency thermostat, indoor
thermostat and other low-voltage inputs.
The connector X3forms the null bridge for mutual interconnection of shielding conductors PEN.
Dimensions of the connectors are different and they are provided with mechanical keys against mix-
up. The system also enables easy and quick replacement of the control unit in case of any failure and
prevents from mix-up of wires during possible repairs.
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.2 Block diagram of the control unit
Figure number 4 - Block diagram of the control unit
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.3 Description of the control panel
Figure number 5 – Control panel
1 - The main circuit-breaker - has two positions
off – the handle is in the lower position
on – the handle is in the upper position
The control unit is put into operation by turning the circuit breaker on. The main circuit-breaker protects
the control unit and connected equipment from overload and short circuit
2 - The alphanumeric display unit provides the user with information on the state of the equipment as well
as with information on adjusted values of individual parameters.
3 - The thermometer displays permanently the momentary value of water temperature at the outlet from
the boiler in °C (option in °F is also possible).
4 - The touch pad keyboard is formed by 11 keys with mechanic click. Every key has an indicator light-
emitting diode which is lit up when the corresponding equipment is in operation. Individual keys
control the following devices (activities):
AUTO/MANUAL - selection between AUTOMATIC and MANUALLY operational mode.
FAN - turns the operation of the fan on and off.
PUMP - turns the operation of the pump on and off.
FEEDER 1 - turns the operation of the 1st fuel feeder on and off (in the fuel bin)
FEEDER 2 - turns the operation of the 2nd fuel feeder on and off
⇐⇑⇒⇓- four keys of the cursor's arrows used to control the movement in the
MENU or to adjust required values of the corresponding piece of equipment
(revolutions of fan, activity or downtime of the fuel feeder, duration of
attenuation, etc.).
→ENTER - used to confirm the selected data.
∩ESC - this key is used to return back from the selected MENU to the ground state
5 - The indicating lamp "ALARM" of noticeable red colour is lit up, if the temperature of the water in the
boiler exceeds 95°C.
6 - The indicating lamp " FALL" is lit up when the boiler has entered the attenuation mode.
7 - Operating mode indicator – AUTO/MANUAL – light of yellow LED diode signalizes automatic operation
of the boiler.
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.4 Block diagram of operation of the control unit
Figure number 6 – Block diagram of operation of the control unit
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.5 Manual control
Attention! The mode of Manual control may not be used for permanent operation!
Manual control is only used in the following cases:
- start (ignition) of the boiler
- change of any parameter of an operating mode
The operator may put the control unit into the manual control mode either by:
- depressing the key AUTO/MANUAL
- depressing any of the following keys:FAN, PUMP, FEEDER 1, FEEDER 2
a) Example of manual control of the FAN
− Depressing the key FAN will put into operation the fan to supply combustion air to the
burner. The indicator light-emitting diode of the key is on when the fan is in operation.
(the fan is stopped and the diode extinguished by depressing again).
− The quantity of the air supplied by the fan can be controlled during operation of the fan by
means of the cursor arrows ⇐⇑⇒⇓(cursor arrows) within the range of 30-100%
where:
⇑– increases the quantity of air in steps of + 10 %
⇓– reduces the quantity of air in steps of – 10 %
⇐– reduces the quantity of air in steps of – 1 %
⇒– increases the quantity of air in steps of + 1 %
The manual mode can be left for the automatic mode by depressing the key
AUTO/MANUAL again.
b) Example of manual control of the PUMP.
− The circulation pump is put into operation by depressing the key PUMP, the light-emitting
diode is on. The pump will be stopped by depressing the key again and the light-emitting
diode will get extinguished. The feeder number 1 and the feeder number 2 can be controlled
in the same way as the pump.
− The manual mode can be left for the automatic mode by new depressing the key
AUTO/MANUAL. The main menu can be entered by depressing the key ∩.
4.2.6 Automatic operation
Automatic operation is basic operation mode of the boiler by with the working of the boiler is fully
controlled by the control unit – see chapter 6.7 – 6.8.
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Automatic boiler for wood pellets
Instructions for installation and operation
4.2.7 Main menu
Having the control unit been turned on, the equipment will be put into that operating mode in which it was
before turning off. Thus it may be in the manual and automatic mode.
Both of these modes can be left for the main menu by depressing the key →.
MENU 1 – FAN - will appear on the display unit after a short notification - MAIN MENU. The
following script will appear when the key →is depressed again:
FAN (%) vv VV
Where vv is the existing setting value and VV is the field for a newly required setting value and
is blinking.
Use now the cursor arrows (keys ⇑– ⇓) to adjust such a value (%) as we require within
the range of 30 – 100 % (see the way described in 4.2.5 a), confirm by depressing the key →.
The value VV will stop blinking and is stored for operation in the automatic mode. The values of vv
and VV are now identical.
Depress the key ∩to return back to the MAIN MENU and the selected mode of the fan has
been adjusted.

Note:The new setting value - VV - is only accepted for further use, if it has been
confirmed by the key
→ – i.e. that it is not blinking already.
If the new value has not been confirmed by the key
→ and keeps blinking, it WILL NOT
BE accepted to the MAIN MENU and the original vv value will be still used.
 Note:If we leave the control unit for approximately 20 seconds in idle condition, it will
return back to the MANUAL mode automatically.
MENU 2 – TEMPERATURE of the output water
Menu 2 - temperature - will appear on the display unit after a short notification MAIN MENU
and after adjustment to this menu with the key ⇑. Having the key →been depressed, a part of
the description on the display unit will start blinking.
If we wish to change the temperature level of the output water, we will proceed in a similar
way as in the previous case (however, we will only use the keys ⇑and ⇓).
The temperature of output water is an important parameter to control the activity of the boiler.
If the water temperature increased up to this limit during operation, the boiler will get to
the FALL - attenuation mode (see below).
MENU 3 – feeder ON
It is the feeder 1. The term ON indicates the operation time of the feeder in seconds and thus
also the weight of the fuel is determined which is supplied to the burner in one operation cycle -
which is a very important parameter when you select the power output of boilers.
When you select a new operation time for the feeder, proceed in a similar way as in the MENU
number 2.

Note: Minimum and maximum time is limited by the manufacturer.
MENU 4 – feeder OFF
It is the feeder 1 again. The term OFF indicates the time in seconds for which the feeder
remains idle (does not feed any fuel).

Note: Minimum and maximum time is limited by the manufacturer.
When you select a new idle time for the feeder, proceed in a similar way as in the MENU
number 2.
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Automatic boiler for wood pellets
Instructions for installation and operation
MENU 5 – ADVANCE
It is a time advance in seconds by which the feeder 2 will start running sooner than the feeder
1 starts working.
The range of this parameter is determined within the interval of 0 – 10 sec. This parameter is
selected to be 1 second for common operation with pellets of ∅6 – 8.5 mm.
Start of the feeder 2 before its filling with fuel is very important because this reduces the stress
on the drive and prevents from undesirable grinding of fuel which thus comes to the burner in the
required granulometry which is necessary for perfect combustion.
When a new value of advance is being selected, proceed in a similar way as in the MENU
number 2.
MENU 6 – OVERLAP
It is a time interval for which the feeder 2 works longer than the feeder 1.
This parameter ensures that all fuel transported in a corresponding cycle into the feeder 2 is
always transported to the burner and does not stay in the transport routes. The transport routes are
thus always empty, which has a considerably positive effect on the safety of operation as this
prevents fuel from burning in the transport routes or in the fuel bin.
The scope of this parameter is determined within the interval of 0 – 10 seconds. We select 5
seconds for common operation. When a new value of OVERLAP is being selected, proceed in a
similar way as in the MENU number 2.
MENU 7 – FALL
FALL (attenuation) is a quiet mode of the boiler when the boiler is not burning actively because
the temperature of the output water has reached the value determined in the MENU number 2 or
the temperature in the reference room of the heated building has exceeded the temperature
selected on the indoor thermostat.
The range of the attenuation period is selectable within the interval of 10 – 90 min. The control
unit will do the following at the moment of transition to the attenuation mode:
- light up the indicating lamp FALL
- display the script FALL on the display unit
- stop the fuel feeding cycle
- the fan will be running for 2 minutes after the fuel burns out, the fan will then stop
- the circulation pump will be running until the moment when the output water temperature
drops under the value adjusted in the MENU number 2.
The attenuation mode will be finished, if the output water temperature drops by at least 3°C
under the value adjusted in the MENU number 2 or if the temperature in the reference room drops
under the adjustment level (0.5 to 1°C as per the sensitivity of the room thermostat).
The boiler with el. ignition
In case of fall dismissing, the boiler will immediately resume the automatic operation:
a) If the attenuation time didn´t reach level adjustment in the MENU number 2, the boiler will
resume the automatic operation without the function of el. ignition.
b) If the attenuation time exceeded level adjustment in the MENU number 2, the boiler will resume
the automatic operation with the function of el. ignition.
The boiler without el. ignition
When the attenuation time is reached (for example 45 minutes), the boiler will resume the
automatic operation for 2 minutes and will get again to the quiet mode.
This mode makes it possible to maintain the boiler on standby under minimum fuel
consumption. Only a minimum burning core is maintained in the burner furnace; this core ensures
that the boiler will immediately resume the automatic operation in the same parameters as before
the attenuation, if the attenuation is over.
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Automatic boiler for wood pellets
Instructions for installation and operation
MENU 8 – PROGRAMMES
It makes possible to store 6 completed programmes necessary for the automatic operation of the
boiler in memory of the control unit (1 – 5 heating, 6 heating service water) – see tab. 6.
MENU 9 – EL. HEATING
Applies to modification KPxx/E. See chapter 6.9.
MENU 10 – EL. IGNITION
See chapter 6.6.
MENU 11 – FLUE GAS VENTILATOR
In the construction.
MENU 12 – SETTING
It makes possible 2 levels of access – in Menu user and Menu manufacturer.
Menu user
See figure number 6.
Menu manufacturer
The access in menu is protected by PIN code.
Further functions of the control unit
The control unit enables to control the automatic boiler for wood pellets with high level of comfort and
with a wide variety to adjust the optimum operating mode. See below some other functions of the control
unit:
1) Programmes (heating profiles - Menu 8) make it possible for the user to store 1 - 5
different adjustments of the boiler's operating modes in memory. This may be
advantageously used, for example, for different kinds of fuel or to adjust the required
power output. If a change is required, it is sufficient to read the required adjustment from
memory and to put the boiler in automatic operation.
2) Electric moderate heating (Menu 9). Applies to KP xxE, i.e. if the boiler is equipped with electric
heating coils (in course of production upon the customer's wish or additionally), the user may allow
or inhibit electric moderate heating. If the electric moderate heating is allowed, electric heating coils
will be turned on when the temperature of the heating water drops under 8°C; the electric moderate
heating will be turned off when the temperature of the heating water exceeds 12°C. The circulation
pump is in operation. Electric moderate heating can be used for moderate heating of buildings
which are not occupied permanently or to protect the heating system against freezing in time of
absence.
3) Ignition with electric resistance coil - see chapter 6.5.
4) Adjustment of some parameters of the boiler by user under simultaneous protection with
the PIN code seems to be advantageous, if the boiler is placed in rooms with possible
access of unauthorized persons. This prevents from undesirable interventions in some
functions of the boiler.
5) Control of cascade connection of 1 - 4 boilers. The function is adjusted by the service
engineer in course of putting into operation.
6) Protection of feeders with pulse sensors will stop the operation of the control unit, if the
expected number of pulses does not come to the input of the control unit. Feeders may be
blocked, for example, if improper fuel is used or if a foreign object gets in the transport
routes. Operator is notified of this situation with a script " BLOCKED FEEDER x " on the display unit.
It is protection of motors against damage and also a fire safety element (if only the feeder 2 gets
blocked, this might result in filling the whole transport route with fuel and the fuel might burn
through into the bin).
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Automatic boiler for wood pellets
Instructions for installation and operation
7) Priority heating of hot service water. Excellent properties of this function can fully be
used, if the boiler is connected as per the figure number 15. This function will ensure
heating of hot service water within a minimum time interval. If the boiler sends a request
to heat the hot service water (temperature of water will get reduced and the boiler's
thermostat will switch in), the control unit will:
- stop the circulation pump in the central heating system
- the boiler will start working as per the programme P6 - item 1 (should be adjusted to the
maximum power output)
- the servo actuator will re-route the water from the whole system into the
water heater
- when the temperature of the boiler water is > 60°C, the control unit will turn the boiler's
pump on
- the automatic operation of the boiler will be resumed (original state) after the water has
been heated (the boiler's thermostat will be turned off)
4.3 BURNER FURNACE INCLUDING THE FEEDER 2 WITH INDEPENDENT DRIVE
A diagram of the burner furnace is shown as a part of the figure number 1 and the burner furnace
consists of the following parts:
- The body of the burner as such including the built-in transport route (spiral-chute feeder number 2
including drive), an extension piece to install a flexible hose and an extension piece to install a fan.
- A flexible hose made from non-flammable material.
- Combustion fan.
- Two electric resistance coils for automatic ignition (special equipment).
Body of the burner – is a box-type weldment made from highly alloyed material with the bottom
oblique input of fuel. The fuel is transported by a built-in spiral-chute
feeder 2 driven by an electric
motor with a gearbox.
Assembly of slotted nozzles ensures supply of combustion air in order to reach controlled and
perfect combustion of the supplied fuel during the time when the fuel is in the combustion space of
the burner.
The spent fuel is then shifted through the overflow edge of the combustion space into the ash
pan.
The inside space of the burner's body is connected to the
air fan the revolutions of which may
be widely regulated (see the paragraph on the control unit) in connection with the required power
output of the boiler or with the fuel type used.
The
flexible hose to feeder 2 made from non-flammable material interconnects both feeders
and is thus a part of the transport routes for fuel.
The flexible hose has to be installed so that it:
- does not form considerably rippled folds which block smooth movement of the fuel and
must be built-in under an angle min. 70°(to horizontal plane).
- its fixation on both tube extension pieces has to be tight.
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Automatic boiler for wood pellets
Instructions for installation and operation
4.4 CERAMIC PARTS
- ceramic reflector – is installed on the surface of the burner
- ceramic extension grate – is installed into the boiler body over the burner furnace
- ceramic schield – is installed over the door
- ceramic facing door – is mantled on the door
4.5 FEEDER 1 WITH INDEPENDENT DRIVE (FROM FUEL BIN)
Fuel feeder number 1 consisting of a driven ribbon flight and a tube transport route including the overflow
part.
This feeder is built into the fuel bin under an angle which may not exceed 45°. If the position of the feeder
is more perpendicular, dosing of fuel is not precise.
The feeder has its own drive which is controlled by the control unit.
The feeder is supplied in a standard length equal to 140 cm.
The feeder 1 consists of the following parts:
- body of the feeder with flanges
- spiral – chute feeder 1 with an electric motor with a gearbox
- flexible hose to feeder 2
- pulse sensor of feeders
4.6 JACKETING OF THE BOILER INCLUDING HEAT INSULATION
Jacket of the product is made from sheet steel, is coated with a heavy-duty COMAXITE COATING which is
perfectly resistant to environment effects and ensures perfect appearance of products on long-term basis.
4.7 STANDARD ACCESORIES
- Instructions for installation and operation.
- Letter of guarantee.
- ½´´ inlet valve.
- Cleaning equipment (brush).
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