Roca P-10 User manual

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P-10
Multifuel Boiler
Installation, Assembly
and Working Instructions
for the INSTALLER
GB
Combustibles fluidos
For fluid-fuel firing Combustibles sólidos For solid-fuel firing
Caldera policombustible
Instrucciones de Instalación,
Montaje y Funcionamiento
para el INSTALADOR
E
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42 – Interruptor del circulador / Pump On/off switch
43 – Interruptor del quemador / Burner On/off switch
44 – Termostato de regulación / Control thermostat
45 – Termostato de seguridad / Limit termostat
46 – Termohidrómetro / Combined temp./altitude gauge
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53 - Recogedor / Shovel
54 - Rastrillo / Scraper
55 - Atizador / Slice bar
56 - Cepillo rectangular, con mango / Flue brush with handle
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Nota: Si se coloca termostato ambiente, deshacer el puente existente entre los bornes 5 y 6.
Note: Where an ambient thermostat has been installed, remove the jumper across terminals 5 and 6.
Esquema de conexionado / Wiring diagram
Esquema eléctrico de principio
Schematic Wiring Diagram
Interruptor circulador
Pump On/off switch
Circulador
Pump
Termostato ambiente
Ambient thermostat
Interruptor puerta quemador
Burner door microswitch
Interruptor quemador
Burner On/off switch
Termostato regulación
Control thermostat
Termostato seguridad
Limit thermostat
Quemador
Burner
Interruptor circulador
Pump On/off switch
Interruptor quemador
Burner On/off switch
Termostato regulación
Control thermostat
Termostato seguridad
Limit thermostat
Circulador
Pump
Termostato ambiente
Ambient thermostat
Interruptor pta. quemador
Burner door microswitch
Quemador
Burner
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Main features
Constructed basically from cast-iron, which constitutes a guarantee of indefinite continuous use.
It permits fitting the ashpit door and the burner door, with burner assembly at the same time and therefore it is not necessary to
change accessories for adapting the boiler for using different fuels.
The cast-iron sections, joined together by means of push nipples, make up a completely sealed combustion chamber and
flueways, for making full use of the combustion heat and energy consumed.
Combustion chamber with fixed water-cooled grates adapted for burning all types of fuel, with no need of firebrick protection.
It has an ash-pan for quick and clean removal of ashes and cinders.
The boiler body and all the doors are thermally insulated to prevent heat loss and improve efficiency.
Automatic damper regulator, control panel and burner safety microswitch for use according to the chosen fuel.
Dimensions and Technical Features
GB
ORIFICIOS: a = ida 2”
Flow 2”
b = retorno 2”
Return 2”
c = desagüe 1/2”
Drain 1/2”
d = aparatos de regulación y control 1/2”
Comb. gauge & damper regulator 1/2
For solid-fuel firing For fluid-fuel firing
(3) (1) (2) (4)
Boiler
Type Nº. of Sections Water content Flueway Pressure
Drop
Depth
AHeat Output Net Efficiency Fuel Load Volume Ashpit Volume Approx. Weight Anti- runaway
Equipment
Heat Output Net
Efficiency Approx. Weight
Litres mm.w.g. mm kcal/h kW % dm3dm3kg kcal/h kW % kg
P-10-3 3 13 0,10 309 7.000 8,1 75 12 5,3 118 AE0 10.000 11,6 82 125
P-10-4 4 17 0,15 414 10.000 11,6 75 19 7,6 147 AE1 14.000 16,3 82 154
P-10-5 5 21 0,20 519 13.000 15,1 75 26 10,0 176 AE1 18.000 20,9 82 183
(1) Output obtained with coal
- Granulometry 20 ÷ 60 mm
- Calorific value (net) 7,000 kcal/h
(2) Corresponds to the volume occupied by the fuel from the grates to the bottom of the firedoor.
(3) With excess air e ≈25%
(4) Optional
Chimney sizing
To guarantee the necessary negative pressure at the base of the chimney, the diameter should be 17.5cm and the minimum
height 5 m. When fitting approved chimneys, please observe the makers’ directions.
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Delivery
1 - TheP-10 boilerforsolidfuelsis deliveredintwopackages:
Pack 1 - Fullyassembledboiler body,paintedwithananti-
rust primer, protected with wooden packing for
transport.
The ash-pan beneath the grates.
The automatic damper regulator, in its packing,
and the shovel inside the combustion chamber.
Pack 2 - The casing unit in a cardboard pack which
contains:
The casing, comprising:
- Top cover
- Right-hand panel
- Left-hand panel
- Back cover
- Firedoor case
- Ashpit door case
Boiler cleaning tools:
- Flue brush
- Brush handle
- Scraper
- Slice bar
Insulating blanket for the boiler.
A plastic bag containing:
Theprotectivecoverforthedamperregulator,the
screws for fixing it, as well as the screws and
washers for fixing the casing.
2 - The P-10 boiler for fluid fuels comes in three packages.
The contents of two of them are similar to those for the
solid-fuelversion,and the other contains the conversion kit
CLS-7 for fluid-fuel firing and comprises:
Pack 3 - Burner door with fitted casing.
- Control panel with burner door microswitch.
- Plastic bag with accessories and nuts & bolts.
Assembly
Checking the material
First we suggest checking the number of packages, that their
contents conforms to those indicated in “Delivery” and that no
incident in transport or lying on site has altered their
composition.
With respect to the boiler, proceed to:
1 - Remove the packing.
2 - Open the ashpit door (1) by means of the handle (2).
3 - Lower the front section grille (3) hinged on the built-in
section brackets (4) and leave it upside down.
4 - Take outthematerialcontainedinthecombustionchamber
and replace the grille (3) in its original position. Close the
door (1).
5 - Open the firedoor (5) using the handle (6) and check the
flues to make sure that no foreign body has entered them.
It so, it should be removed. Close the door (5).
Location
6 - Check that the P-10 boiler is properly levelled on the base
chosen for its use.
Damper Regulator
7-Remove the plastic cap that protects the threads ofthe1¼”
x ¾” tapping (7) in the front section and fit the body with
handle of the automatic damper regulator (8)* according
to the instructions that come with this accessory.
* This operation can be omitted in boilers intended for continuous use of
fluid fuels and the bushing in the tapping (7) substituted by a 1¼” plug.
Nevertheless, from the aesthetic point of view it is suggested that this
piece be fitted.
In any case, it is preferable not to fit the hexagonal rod and chain
permanently until after assembling the casing.
Controls
8 - Ifitis decidedtofita combined temperature/altitudegauge
in boilers intended for continuous use of solid fuels*, the
metal plug must be removed from the top tapping (9) in
thefrontsectionandthepocketshouldbescrewedinto it.
Thecombinedtemp./altitude gauge shall be installedafter
fitting the casing.
If an altitude gauge and a thermometer are being fitted
separately, the former will have to be screwed into the
sametapping(9)inthefrontsection,afterfittingthecasing.
* Operation 8 should be omitted in boilers intended for continuous use
of fluid fuels.
Insulating blanket
9 - Cover the body of the boiler with the insulating blanket
(10) passing it between the body and the four tie-rods
(11) to ensure its immobility.
Connecting to the installation
10 - Remove the plastic caps that protect the threads of the
upper (12) and lower (13) tappings in the back section
and make connections to the flow and return circuits
respectively.
11 - Remove the plug from the tapping(14) inthebacksection
and fit a drain cock.
Safety devices
12 - Fit the specific safety devices for sealed system or open
vented installations (safety valve, sealed or open
expansion vessel).
Inanycasethediametersofthesafety pipes shall comply
with current regulations.
Connecting to the flue duct system
13 - Connect the boiler to the flue duct system through the
smoke hood (15).
14 - Carefully pack round the base of the chimney with putty
and check the sealing of the smoke hood to ensure that
no air can leak in.
Fittingcomplementaryequipmentforusingfluidfuels
Inordertousefluid fuels it is necessary to equip the boiler with
the required components which are:
- Burner door with fitted casing.
- Control panel and microswitch.
15 - Open the ashpit door (1) and lower the front section grille
(3). This action prevents damage to the blast tube (17)
which, on closing the burner door (16) with the burner
fitted, might strike the grille if this were still in its original
position.
16 - Adding the burner door(16) totheboiler does not make it
necessary for the ashpit door (1) to be removed. It is
sufficient to leave the latter open and hang the former
from the hinges (18) after fitting them to the left of the
front section using the four bolts which, together with the
twofixingpins, are supplied in a plastic bag with thedoor.
17 - Fit the microswitch (20)(aswitchnecessary for preventing
accidentalfunctioning oftheburnerwhenusing solidfuels),
with its bracket (21) on the lower right part of the rear
surface of the front section, using the two M4 x 25* bolts
in such a way that the operating lever can be pushed by
the M5 x 55* bolt (22) which will have been fixed in the
hole for this purpose in the burner door, with an M5* nut.
* Supplied in a plastic bag.
18 - Fix the burner to the door (16) with the flange adapted for
“Roca” burners, in accordance with the instructions that
come with it. Close the burner door and immobilize it by
tightening the locking screw (23) with a suitable tool.
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Safety against opening the firedoor
It is impossible to open the firedoor (5) accidentally once the
burner door (16) is immobilized since the flange (24) makes it
impracticable. The firedoor can be opened only after
deliberately loosening bolt (23) and opening the burner door.
Controls
19 - Insert the triple* pocket in the tapping (9) and the pocket
for the control panel altitude gauge in the tapping (25) in
thefrontsection after removing the metal plugs from both
of them.
* Supplied in a plastic bag inside the control panel packing.
Control panel
The control panel that forms part of the complementary
equipment for using fluid fuels has to be installed on the top
casing cover, and so will be fitted after assembling the casing.
Watertight test
20 - Fill the installation with water and check that there are no
leaks in any part of the hydraulic circuit.
Fitting the casing
According to whether the boiler is intended for continuous use
ofsolidor fluid fuels,itisadvisable to opentherequirednumber
ofpre-punchedholesin the top cover, taking intoconsideration
the apparatuses or control panel that are going to be fitted. In
the latter case, the three knock-outs should be cleared.
21 - Place the top cover (27) on the boiler, introducing the rear
endsofthe twotie-rodsinthe holes providedinthecasing.
22 - Situate the right (28) and left* (29) side casing panels in
their respective sides of the boiler. The left panel has an
opening (30) where the cable entry carrying the cable
connecting the burner and the control panel in fluid-fired
boilers should be fitted.
* When the boiler incorporates a burner door, the slots (31) on the front
edge which coincide with the hinges should be left free.
23 - The lower front brackets (32) should be fixed between
the two nuts screwed on the ends of the tie-rods*, while
the rear ones (33) fit on the ends of the tie-rods.
* Where a burner door has been fitted to the boiler, this should be
opened to allow easy manipulation of the nuts.
24 - Insert the side edges of thetopcover(27)intothe locating
lugs (34) on the upper edges of the side casing panels.
Fasten the two sides to the top cover using the four self-
tapping screws provided – two in the front part (26) and
two in the rear (57).
25 - Hang the back cover (35) introducing the four locating
lugs into their respective slots (36) punched on the rear
edge of the side casing panels.
26 - Fit the casing panels (37) and (38) to the firedoor and
ashpit door respectively, using the screws and washers
provided.
27 - Fit* the hexagonal rod (39) and the chain (40) of the
damperregulator asindicatedinthe instructionsthatcome
with it.
28 - Open the firedoor and fit* the plate (41) for protecting the
damper regulator in the front part of the top casing cover,
using the two M4 screws supplied. Close the firedoor.
* Thisoperationwillnotbenecessaryinboilersintendedfor continuous
use of fluid fuels if a damper regulator has not been fitted.
29 - In boilers designed for solid fuel firing, screw the altitude
orcombinedtemp./altitudegauge,-whichever control unit
is chosen-, in the pocket provided for this purpose in the
front section. (See operation 8 in “Assembly”).
Fitting the control panel
The control panel that is supplied with the complementary
equipment for using fluid fuels incorporates the relative parts,
as well as the terminal strip and the burner door microswitch.
30 - Fit the two fixing brackets for the control panel to the top
casing cover, using the screws provided.
Electrical connections
31 - Before fitting the control panel, make the electrical
connections in accordance with the following diagram.
The burner cable incorporates a multiple connection plug and
acableentry. Thelatter should be fitted in theexistingopening
(30) in the left-hand side casing panel.
Likewise with the cable that supplies the pump, its cable entry
should be fitted in the exiting opening (58) in the rear part of
the left-hand side casing panel.
The mains power cable is passed through cable entry (47).
If an ambient thermostat is installed, then its cable will pass
through (59).
Thedifferent cablesfromthe controlpanelwill comeoutthrough
the same knock-out in the top casing cover.
32 - The bulbs for the control thermostat (48), limitthermostat
(49) and the thermometer (50) are inserted* in the triple
pocket which is in turn introduced in the tapping provided
forthispurposeinthefrontsection. Fastenthecapillaries
with the clip in the pocket.
Screw*the altitudegaugesensor(51)inits pocket,located
inthechosen tappinginthefront section. (See“Assembly”
operations).
* Through the knock-outs in the top casing cover which have not been
used for passing electrical cables.
33 - Secure the control panel (52) using the bracket fitted to
the top casing cover and the M6 screws provided.
Operation
Schematic Wiring Diagram
(See Diagram)
Operations prior to the first lighting
1 - Check that the installation is full of water and place the
fixed pointer on the altitude or combined temp./altitude
gauge in the position corresponding to the static head of
theinstallation.
2 - Check the pump for correct operation.
3 - Bleed the air from the system and radiators.
4 - In installationswitha sealed expansion vessel, top up with
water (if necessary) until the mobile pointer on the altitude
orcombinedtemp./altitude gauge isslightlyabovethe fixed
one. Whereanopenexpansionvesselhasbeeninstalled,
refill until the mobile pointer levels with the fixed one.
First lighting with solid fuels
5 - Check that the smokehood damper is open. (Handle in
position “A”).
6 - Open the ashpit door, lower the front section grille and put
a sufficient amount of straw or paper, kindling or coal so
as to aid lighting up.
While doing this, keep the firedoor and its observation
window closed. The latter will be kept open only when
using fuel with an excessive content of volatile material
requiring a secondary supply of air for burning.
7 - Switch on the system circulating pump.
8 - Following the initial combustion, put the grille back in its
original position and close the ashpit door.
9 - Open the firedoor and stoke with the chosen fuel, loading
it so as not to smother the fire, to an appropriate level.
Closethefiredoorandcheck that there are no leaks of flue
gases.
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10 - Set the automatic damper regulator according to the
instructions that come with it.
11 - Bleed all the radiators and ensure that they reach the
required operating temperature in accordance with that
selected on the damper regulator.
First lighting with fluid fuels
5 - Connect the fuel supply line to the burner.
6 - Check that the smokehood damper is open. (Handle in
position “A”).
7 - Turn ON the main switch for the power supply to reach
the control panel.
8 - Turn ON the switch (42) to start up the system pump.
9 - Turn ON the switch (43) to start up the burner and check
its running against the instructions that come with it.
10 - Set the control thermostat (44) to 80 ºC approximately.
Check that both the control and limit thermostats operate
correctly.
Whereanambient thermostat has been installed, setitto
the required comfort temperature.
11 - Bleed all the radiators and ensure that they reach the
required operating temperature in accordance with that
selected on the control thermostat.
12 - Check that there are no leaks of flue gases.
13 - Check the burner safety devices.
Maintenance
To aid operating and cleaning the boiler, a set of tools is
supplied,comprising:
53 - Shovel
54 - Scraper
55 - Slice bar
56 - Flue brush with handle
The shovel (53) is used in stoking the boiler, for putting solid
fuel in the combustion chamber, as well as for collecting and
removing cinders from the ash-pan.
The scraper (54) permits drawing ashes and slag which might
havefallenontothebase of the boiler, from the back to a more
accessible place for collecting and removing.
The slice bar (55) eases cleaning of the grate bars in such a
way that the cinders which have remained on the surface can
fall onto the ash-pan. It can also be used –if necessary– for
poking the solid fuels.
Thefluebrush (56) isusedforcleaning the fluesandtheinterior
walls of the boiler.
Important recommendations
- If the installation is located in a frost-risk area, some anti-
freeze solution should be added to the water in proportion to
the minimum outside temperature of the place.
- The characteristics of the water in the installation should
preferably be:
pH : 7.5 ÷ 8.5
Hardness: 8 ÷ 12 French degrees*
* One French degree is equivalent to 1 gram of calcium carbonate in 100
litres of water.
- If it were essential to add water to the system, always wait
until the boiler has cooled down completely.
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