Topling TKP 20 User manual

TOPLING
USER GUIDE
Hot Water Boiler TKP Type

User Guide TKP
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CONTENTS
Page
1. NOTES ON THIS USER GUIDE 3
1.1. Introduction notes 3
1.2. Structure of the User Guide 4
1.3. Glossary 5
2. SAFETY TIPS 6
2.1. Proper Use 6
2.2. Always present risks 7
2.3. Used warning and safety signs 8
2.4. Duty - be informed 9
3. DESCRIPTION AND PURPOSE OF BOILER 10
3.1. Introduction 10
3.2. Technical data 11
3.3. Installation of boiler TKP type 13
3.4. Declaration of conformity 22
4. BOILER MAINTENANCE 23
4.1. Frequency of cleaning and maintenance 23
5. POSSIBLE PROBLEMS IN FUNCTIONING 26
6. FIRST COMMISSIONING 27
6.1. Requirements for successful commissioning 27
7. DISPOSAL AFTER END OF LIFE 28
7.1. Dismantling of boiler 28
7.2. Disposal of boiler 28
8. WARRANTY 29
8.1. Warranty period 29
8.2. Warranty Terms & Conditions 29
8.3. The Warranty does not apply to 29

User Guide TKP
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1.NOTESONTHISUSERGUIDE
1.1Introductory
notes
EASY AND SAFE USE
READ USERGUIDE
TECHNICALCHANGES
COPYRIGHT
This User Guide contains significant information for
appropriate and safe use of hot water boiler type TKP. If
you follow these Instructions, you can avoid risky
situations, reduce maintenance costs, avoid failures,
provide reliability and prolong boiler life.
This User guide must be read and applied by anyone
using the boiler type TKP.
We keep developing and enhancing our boilers. All
information regarding this Guide that are related to the
boiler type TKP are correct at the moment of printing.
Before the use, all details mentioned herein concerning
standards and legislation must be checked and
compared to standards and legislation applied in the
location where the boiler is to be installed.
We reserve the right to make changes on the boilers that
would differ in technical data and drawings herein.
Written approval of Topling d.o.o. to copy, store in
electronic form, transfer information in electronic
format, photography, translation of this manual in
whole or in part is required.

TKP User Guide
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User Guide TKP
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1.2 Structure of User guide
This User Guide consist of
Chapter
You can find the following herein.....
1. Notes on User Guide
... how to use the instructions.
2. Safety tips
...all related with safety use, what you should keep in mind
when using a boiler.
3. Description and purpose
of boiler
... structure and all about characteristics of boiler, technical
data, how to connect the boiler on central heating installation
4. Maintenance
... how to clean the boiler, the frequency of maintenance and
cleaning
5. Possible problems in
operating
...which problems can be experienced during boiler use
6. First boiler
commissioning
... requirements for successful commissioning
7. Disposal of boiler after
its life ends
... what should be taken into account when dismantling and
preparing of the boiler for disposal.
8. Warranty
... warranty terms and conditions
Table 1. Structure of the User guide

User Guide TKP
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1.3 Glossary
Term
Explanation
TKP
The boiler intended for solid fuel combustion
Flue vent
The part of the boiler where flue gas comes out and enters the
chimney pipe
Draft regulator
Is used to regulate the amount of air which enters the boiler
through the flap on the lower door.
Flue gas pipe
Takes out flue gas from flue pipe to chimney
Boiler firebox
The place where solid fuel burns in the boiler
Solid fuel
Firewood, charcoal, wood briquettes
Safety valve
It is used for pressure relief in boiler water space when it is
exceeded
Table2.Explanationofterms

User Guide TKP
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2 SAFETY NOTES
2.1Properuse
MAINPRINCIPLES MAINPRINCIPLESOF SYSTEM CONSTRUCTION
The boiler is made in accordance with the known principles of
safe use. Improper use may cause harm, injury or even death
to those who do not comply with safety guidelines as well as to
third parties, which may result in damage to the boiler, and
damage to other resources in the immediate environment.
Specialized person who made the boiler installation and
commissioning should demonstrate you how to use it.
Use boiler only when it is completely in order. Use it the right
way and for the purpose for which it is intended, always taking
care of your own safety and the safety of others and the safety
of property. Constantly comply with this manual.
Any defect which may impair safety must be immediately
removed.
USEOFBOILER RELIABLEANDUNRELIABLEUSE
The boiler is designed to burn solid fuel (firewood, charcoal,
wood briquettes).
Use of any other fuel is not allowed. The manufacturer is not
liable for any damages resulting from improper use. In case of
improper use the responsibility is borne by the one who used
boiler improperly.

User Guide TKP
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2.2 Alwayspresentrisks
Despite of all precautions, the below given risks should be always considered:
Attention!
High temperature surfaces.
Contact with such surfaces may cause burns.
Waitfor the boiler to coolto touch these uninsulatedsurfaces.
Warning!
Dangerofchokingcarbonmonoxide.
Whenboilerisused,carbonmonoxidecanbeemittedthroughopeningsinthe
boiler.
Donotleaveboilerdooropenmorethanrequired.
.

User Guide TKP
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2.3 Used warning and safety signs
The following warning and safety signs are used in this User
Guide:
Danger!
Danger from electrical current.
Work on devices marked with this symbol is only
allowed for the qualified persons.
Warning
Work in areas that are marked with this symbol could
result in serious injury or create serious damage.
Attention
High temperature surfaces.
Work in areas marked with this symbol can lead to
burns.
Attention
Danger from fire.
Work in areas marked with this symbol can lead to fire.
Attention
Dangeroffreezing.
Work in areas marked with this symbol can lead to
freezing.
Notes on proper disposal.
Additional information for the operator.

User Guide TKP
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2.4Duty-beinformed
READING
USERGUIDE Anyone who intends to use the boiler is required to read and understand
this manual, and special attention must be paid to the Chapter 2, Safety
instructions. This especially refers to those who only occasionally use the
boiler, for example, only when cleaning or other tasks related to the
maintenance of the boiler.
This manual must be constantly ''at hand'' where the boiler is installed.
Particular attention should be paid to the standards applicable
to the place where the boiler is installed.

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3. DESCRIPTION AND PURPOSE OF
BOILER
3.1. Introduction
Boiler types TKP have modern construction and design, and is made of quality certified
materials.
Boiler testing was done according to EN 303-5 and meets all requirements for connection to the
central heating system.
Hot water boiler is designed for heating of small residential units, family houses, shops and
small manufacturing units
It uses sold fuel. It is designed to operate in the temperature regime of 90/70.
The firebox and convective part of the boiler are made of high-quality boiler metal sheet using
welding technology. The boiler is well insulated with hard pressed mineral wool in quality sheet
boiler casing.
The installation and commissioning are simple and connectors are standard.
Boiler is attested by the Faculty of Mechanical Engineering in Banja Luka. Nominal power of
furnace is achieved with lignite "Stanari" which is of small thermal power, about 11 00 kJ/kg.
The boilers manufactured in the compliance with EC Directives : The Pressure Equipment
Directive
97/23/EC and
And applied harmonized standards, especially: EN 303-5:1999;
Other mentioned standards and technical specifications:
EN 287-1: 2004, EN 288-3:1992, EN ISO 7000 :2004;
EN 10204:2004;

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3.2. Technical data
Identification table for boilers
Identification of the boiler can be done with identification table on boiler flue vent>
Figure 1.Identification table of the boiler type TKP
Boiler technical data

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Figure 2. Boiler TKP
TYPE
Power
rating
s
[kW]
DIMENSIONS
[mm]
CONNECTIONS
[col]
Draft
[Pa]
Mass
of the
boiler
[kg]
Water
Volume
inside
boiler
[l]
A
B
C
D
E
H
R1
R2
R3
TKP 20
20
465
705
1142
160
190
810
5/4
1/2
3/4
21
235
80
TKP 25
25
465
730
1250
160
190
950
5/4
1/2
3/4
22
258
85
TKP 30
30
495
775
1320
180
190
1030
5/4
1/2
3/4
23
305
109
TKP 35
35
550
785
1355
180
190
1040
5/4
1/2
3/4
25
336
135
TKP 40
40
590
760
1390
180
190
1050
5/4
1/2
3/4
26
362
140
TKP 50
50
710
785
1430
180
190
1090
5/4
1/2
3/4
28
380
150
TKP 65
65
748
890
1375
200
190
1040
6/4
1/2
3/4
30
480
200
TKP 80
80
765
990
1375
200
190
1040
6/4
1/2
3/4
35
595
220
Table 3. Characteristic dimension of boilers TKP type
TIP
TKP
20
TKP
25
TKP
30
TKP
35
TKP
40
TKP
50
TKP
65
TKP
80
Maximum power
[kW]
20
25
30
35
40
50
65
80
Heat output range
[kW]
10-20
12-25
15-30
17-35
20-40
25-50
30-65
40-80
Maximum operating
pressure [bar]
3
3
3
3
3
3
3
3
Maximum operating
temperature [°C]
90
90
90
90
90
90
90
90
Operating
temperature
interval [°C]
70-90
70-90
70-90
70-90
70-90
70-90
70-90
70-90
Class of the boiler
according to EN
303-5
3
3
3
3
3
3
3
3
Necessary draft
[Pa]
21
22
23
25
26
28
30
35
Temperature of flue
gases [°C]
-Maximum
250
250
250
250
250
250
250
250
Table 4. Technical data
Fuel
The boiler is intended for solid fuel combustion (firewood, wooden briquettes, wood waste,
lignite, coke, coal. Its design allows to feed large pieces of wood.

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During the testing, power ratings of the boiler is achieved with "Stanari" lignite, whose thermal
power is about 11 000 kJ/kg.
3.3. Installation of the TKP type boilers
Assembly of the outer casing of the boiler TKP type
In order to prevent damage of metal casing which could occur during the transport and storage
of the TKP type boilers, final assembly of the boiler casing on the boiler body is done on the
location of the installation. The assembly of casing must be done in the compliance with the
scheme of assembly show in Figure 3.
Legend :
1. Cover of the casing
2. Right side of the casing
3. Left side of the casing
4. The back side of the casing
5. Front upper side of the casing
6. Front lower side of the casing
7. Protection of measuring and safety instruments

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8. Upper door isolation
9. Lower door isolation
Figure 3. Scheme of the assembly of boiler casing
Order of assembly of the metal casing on the boiler body:
1. Assembly of the back side of the boiler casing (Figure 3, position 4) ,
2. Assembly of the sides (Figure 3, position 3and 4) ,
3. Assembly of the front lower side (Figure 3, position 6)
4. Assembly of the front upper side (Figure 3, position 5)
5. Assembly of the cover of the casing (Figure 3, position 1)
6. Assembly of the protection of measuring and safety elements (Figure 3, position 7)
7. Assembly of the upper and lower door insulation (Figure 3, position 6)
Handling the boilers can be done only by adults who have read and understood the technical
user guide. Incorrect handling of the boiler may result in injury, failure of boilers and
installations, as well as serious consequences for humans.
The boiler must be installed on a flat, stable surface. Water supply system connections,
connection or possible drainage, and connection to electrical network (220V, 50 Hz) must be
provided in the boiler room.
Also, the boiler should be installed on a non-combustible surface and the safety distances of
200 mm away from flammable materials must be complied with. This applies to boilers and flue
gas pipes located near flammable things and materials, flammability class B, C1 and C2.
Safe distance of 440 mm must be respected if the boiler is located along the material
flammability class C3.
The boiler room must be physically separated from other rooms (especially the rooms where
people live and sleep).
Safe distance must be complied with when setting the installation elements near to the boiler.
Boiler failures which occurred because of improper and
negligent handling of the boiler are not covered with the
Warranty.
Natural ventilation must be provided in the boiler room, which
is necessary for the proper operation of the boiler ( See table
5).

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Q (kW)
15
25
30
35
40
50
65
80
A0(cm2)
775
1000
1096
1184
1265
1415
1613
1789
aoxb0(cm)
28x28
32x32
34x34
35x35
36x36
38x38
41x41
43x43
A1(cm2)
258
334
365
395
422
472
538
597
a1xb1(cm)
16x16
19x19
20x20
20x20
21x21
22x22
24x24
25x25
A0= 200 , Q (kW) - air inlet opening
A0(cm) –minimum effective area of the inlet opening for ventilation and combustion
A1= 1/3 .A0- drain opening
Openings should be protected with outside fixed louver in order to prevent entry of
rainfalls
Table 5. Dimensions of inlet and drain openings for natural ventilation of boiler room
Dimensions of the chimneys for boiler type TKP
The chimney must be sized according to the diagram in Figure No. 4.for good and safe
operation. The Figure 5 shows proper installation of the chimney regarding the roof
construction.

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Figure 4 Selection of chimney section when using solid fuel - firewood (Schiedel)
Boiler power ratings in [kW]
Firewood boilers with
necessary draft and
temperature of flue gas on
the boiler exit tw<2500C
Light size of chimney in cm
Necessary pressure drop in the boiler [N/m2]
Useful height of the chimney in [m]

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Figure 5 Proper installation of the chimney
When connecting boiler with the chimney, flue gas pipe must be installed rising and horizontally.
All connections must be good fixed.
The boiler must be installed by a qualified person in the compliance
with applicable regulations. Topling Compay cannot accept the
responsibility for the damage cased by improper installation.

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Connecting the boiler on central heating installation
In the following part of this technical user guide it is show recommended connection of the boiler
type TKP on central heating installation,
Legend:
1- boiler
2- flue vent
3- draft regulator
4- radiator lock shield
valve
5- radiator valve
6- radiator
7- circulating pump
8- block valve
9- safety valve
10-closed expansion
container
11-the vent
12-manometer
13-thermometer
14-tap for filling and
emptying
15-thermo valve
16-drainage of waste
water
17-thermal protection of
boiler
Figure 6. Connecting the boiler on central heating installation

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Figure 7. Connecting the boiler type on central heating installation with opened expansion
container