Ponast KP 10, Instructions For Installation And Operation Manual

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Page 2: ...uct 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 ...

Page 3: ... 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 T...

Page 4: ... 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 Wirin...

Page 5: ...s 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 c...

Page 6: ...e 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 prod...

Page 7: ...1E 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 m2 1 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...

Page 8: ...iciently 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 cours...

Page 9: ...ic 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 8 ...

Page 10: ...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 se...

Page 11: ... elements motors of feeders fan circulation pump etc The connector X2 connects the operating boiler s thermometer emergency thermostat indoor thermostat and other low voltage inputs The connector X3 forms 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...

Page 12: ...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 11 ...

Page 13: ...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...

Page 14: ...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 13 ...

Page 15: ...ng 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...

Page 16: ...nit 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 t...

Page 17: ... 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 ru...

Page 18: ...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 f...

Page 19: ... 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 t...

Page 20: ...sition 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 JACKETI...

Page 21: ... 4 4 5 and 6 kW Circulation pump Digital indoor thermostat Tank to heat service water 100 l 125 l 160 l 200 l Tank with two heating coils to heat service water 200l 250l figure number 7 Storage tanks 500 l 750 l 1000 l Fuel bin Optional accessories are not included in the price of the boiler NTRR 200 NTR 100 Figure number 7 Tank to heat service water Figure number 8 Digital indoor thermostat with ...

Page 22: ...r including the bin can be placed on If the boiler is installed outside a sub basement boiler room concrete floor it has to stand on a floor made from non flammable material and has to overlap the top view dimension of the equipment being installed by at least 10 cm The necessary height over the boiler to the ceiling of the boiler room is approximately 450 mm cleaning 5 2 SAFE DISTANCE FROM COMBUS...

Page 23: ...ation of chimneys and fume ducts as well as connection of fuel appliances are governed by the following standard ČSN 73 42 10 Recommended draught of chimney has to be within the range specified by the manufacturer see figure number 9 in connection with the installed power output of the boiler Figure number 9 Recommended draught of the chimney Chimney systems resistant to humidity in which condensa...

Page 24: ...ents They may be filled without any limits up to their total volume Large volume bins have to meet corresponding fire and safety regulations The supplier is obliged to work out working regulations and instructions for operation and maintenance of large volume bins 5 5 BOILER ROOM VENTILATION Permanent ventilation of the boiler within approximately 75 m3 x hour 1 of fresh air has to be ensured if a...

Page 25: ...nts which might jeopardize failure free operation of pumps have to be thoroughly rinsed before the system is finally filled with water 6 2 INSTALLATION OF THE CERAMIC CATALYTIC REFLECTOR The ceramic catalytic reflector is manufactured from highly heat resistant material 1500 C It has two functions directs the flow of combustion products through the boiler body assists very efficiently to burn out ...

Page 26: ...oducts through the exchanger b This grate is installed into the boiler in such a way that individual parts the left part the right part are passed through the middle open part of settling bars and shifted tightly to the wall of the furnace KP 10 KP 11 As regards KP 20 KP 21 we continue in such a way that we will install the middle part of the grate which has the shape of the letter X KP 50 has the...

Page 27: ...d FEEDER 2 3 Now perform the ignition as such which can be done in several ways a Use classic way of paper and wood chips which will be gradually placed on pellets in the furnace and set on fire b Use the solid firelighter PEPO or ecological firelighter made from excelsior type Jőtul which will be set on fire and placed on the pellets in the furnace c Also a hot air gun may be used to ignite the s...

Page 28: ...e has been selected when electrical ignition is allowed the following option may be chosen from the menu 10 El ignition with the cursor arrows after the key ENTER has been depressed START This mode is used when the boiler is put into operation for the first time Note If the boiler is equipped for electrical ignition and the electrical ignition is allowed by the programme the state FALL and the tim...

Page 29: ...electric moderate heating is a substitute operating mode frost blanket measure which makes it possible for the user to apply moderate heating to the whole heating system for example if the user is absent for a long time if there is any failure on the boiler or in case of lack of fuel If the boiler is equipped with electric heating coils the programme of the control unit will ensure that if the hea...

Page 30: ... totally modern and WOOD PELLETS with clearly guaranteed quality values are exclusively used as fuel the maintenance attendance of the product is very simply during operation 7 1 ATTENDANCE 1 The level of fuel in the bin has always to be kept to be at least 10 cm over the functional transport part of the ribbon flight Irregular dosing may take place in case of further variation reduction of the fu...

Page 31: ...vidual parts of the ceramic extension grate clean the walls of the boiler including draughts of combustion products clean the surface of the burner Assumed interval 1x a month or after spent fuel cca 1000 kg Note Proceed in reverse order in installation of the removed parts Be careful to place individual parts correctly which is necessary in relation to correct operation of the equipment Therefore...

Page 32: ...e pulling forward remove all parts of the ceramic extension grate first pull out the middle parts KP 20 KP 21 KP 50 and then both lateral parts KP 10 KP 11 Lift the parts always perpendicularly up then turn them 90 along the longitudinal axis and lower down through the opening in the placement bars which is approximately in the centre of the boiler Now remove all sediments of ash from all ceramic ...

Page 33: ...ion grate can be precisely placed on them back 6 Back installation of all parts should be done in reverse order Ensure mainly the following in course of this activity Electric resistance coils have to be placed in such a way so that their heating parts are at least 5 mm from the wall of the burner Maximum tightness has to be ensured between the flange of spirals and the wall of the burner The flan...

Page 34: ...ion on conditions FALL STOP TEMP report on exceeding of emergency temperature the red indicating lamp ALARM lights fault message another proceed in according to par 8 1 STOP STATE the operation of the boiler is stopped by reason that the temperature rise hasn t been reached fault message another proceed in according to par 8 2 BLOCKED FEEDER 1 report on blocked feeder 1 fault message another proce...

Page 35: ...TEMPERATURE DROP If the boiler does not reach the expected temperature of 30 C within 10 minutes after ignition the control unit will assess this situation as abnormal and operation of the boiler will be stopped Reasons may be low quality fuel lack of fuel impassable transport routes etc This situation is indicated by the following script on the display unit STOP STATE Useless idle operation of th...

Page 36: ...ler every electricity supply interruption triggers the electric ignition routine and thus further automatic operation is started boiler WITHOUT electric ignition automatic operation mode State of fuel burning in the boiler has to be checked after electricity supply interruption Manual ignition has to be performed see chapter 6 6 if the fire has been extinguished 9 DISPOSAL OF PRODUCT AFTER THE END...

Page 37: ...llation of the boiler and putting it into operation only by an authorized servicing organization which has the manufacturer s accreditation and the user is also obliged to send the letter of guarantee number 1 to the manufacturer s address immediately after the product has been put into operation 2 The boiler has to be operated only within these Instructions for operation and only prescribed fuel ...

Page 38: ...ctions for installation and operation RECORDS OF PERFORMED REPAIRS guarantee and after guarantee repairs Attachment to the letter of guarantee for user Date Intervention performed Stamp and signature of contractual service User s signature 37 ...

Page 39: ...Automatic boiler for wood pellets Instructions for installation and operation Figure number 14 Recommended wiring diagram of boiler 38 ...

Page 40: ...Automatic boiler for wood pellets Instructions for installation and operation Figure number 15 Recommended wiring diagram of boiler 39 ...

Page 41: ...Automatic boiler for wood pellets Instructions for installation and operation Figure number 16 Recommended wiring diagram of boiler cascading wiring 40 ...

Page 42: ...Automatic boiler for wood pellets Instructions for installation and operation Figure number 17 Examples of fuel bins placement of products and requirement on dimensions 41 ...

Page 43: ...Automatic boiler for wood pellets Instructions for installation and operation Figure number 18 Wiring option for supply 3 PE N 50 Hz 400 230 V TN C S 42 ...

Page 44: ...Automatic boiler for wood pellets Instructions for installation and operation 43 Figure number 19 Wiring option for supply 3 NPE 50 Hz 400 230 V TN S ...

Page 45: ...Automatic boiler for wood pellets Instructions for installation and operation 44 Figure number 20 Schema wiring el ignition el heating Figure number 21 Schema wiring electromotive control 4 way valve ...

Page 46: ... wood pellets Instructions for installation and operation 45 Figure number 22 Wiring room thermostat with weekly programme and independent drive heating HUW Figure number 23 Working principle The Boiler in mode modulation ...

Page 47: ...Automatic boiler for wood pellets Instructions for installation and operation 46 Figure number 24 Directory information consuption wood pellets for boiler family KP ...

Page 48: ...me 45 min Programs kW Feeder 1 ON Feeder 1 OFF Advance Feeder2 Run in Feeder2 Fan Fall time Temperature P 1 7 5 5 90 1 5 30 45 80 P 2 13 5 5 45 1 5 45 45 80 P 3 20 0 5 29 1 5 53 45 80 P 4 22 5 5 25 1 5 64 45 80 P 5 25 0 5 22 1 5 75 45 80 P 6 22 5 5 25 1 5 64 45 80 9 El Heating No 10 El Ignition No 1 Fan 75 2 Temperature 80 C 3 Feeder 1 ON 10 s 4 Feeder 1 OFF 20 s 5 Advance Feeder 2 1 s 6 Run in Fe...

Page 49: ...l Heating No 10 El Ignition No 1 Fan 47 2 Temperature 80 C 3 Feeder 1 ON 9 s 4 Feeder 1 OFF 22 s 5 Advance Feeder 2 1 s 6 Run in Feeder 2 3 s 7 Fall time 45 min Programs kW Feeder 1 ON Feeder 1 OFF Advance Feeder2 Run in Feeder2 Fan Fall time Temperature P 1 5 1 9 85 1 3 30 45 80 P 2 9 4 9 43 1 3 36 45 80 P 3 13 6 9 27 1 3 43 45 80 P 4 15 3 9 22 1 3 47 45 80 P 5 17 0 9 20 1 3 51 45 80 P 6 15 3 9 2...

Page 50: ...ets burnt out the control unit will evaluate this fact shortly and the boiler gets stopped The combustion chamber and the burner thus do not get filled with unburnt fuel Electric equipment of the boiler has been expanded with Connector CANON 25 located on the subpanel on the rear side of the boiler see the figure number Ti001 1 Interconnection of the boiler with the control unit see the figure num...

Page 51: ...mbustion products is higher than the adjusted t value the boiler resumes its operation If the temperature value is lower than the t value the boiler will get to the state STOP ignite fail Boiler without automatic ignition The t value is always evaluated after the boiler gets to the mode of AUTO AUTOx or BOILER from the STANDBY mode at the pre programmed moment in time No evaluation takes place und...

Page 52: ...ines are put out of operation turned off Note Changes in adjustment of values are accepted by the control unit after the RESET of the equipment the control unit has to be truned off and on Software change in circuitry from the serial number 291 2006 on Use in case of products family KPxx equipped with combustion products thermometer Figure number Ti001 3 ...

Page 53: ...transport route is increased by installation of thermostat placed in the burner where the fuel enters the burner It is a provision exceeding the requirements of the standard ČSN EN 303 5 and increases safety The following has been added to the electric equipment of the boiler Burner thermostat Interconnection of both emergency thermostats in series connection see figure number 4 page 11 Indicator ...

Page 54: ...and feeder 2 may not contain any fuel The burner and mainly its air nozzles should be checked whether they are clean The secondary ceramic grate should be checked whether it is clean The boiler and routes of its combustion products should be checked whether they are clean The chimney should be checked whether it is clean as well as its draught If the parts have been cleaned and they are in order t...

Page 55: ...and the flange of the gear box has to be limited with a corresponding washer in order to prevent from any deformation of the disc when the screw is tightened Two distance columns OK 10x20 shall be screwed on the face of the gear box on which the cover of the sensor with electronics will be fastened by means if 2 screws M 6x10 with washers 6 2 The sensor is equipped with a non detachable cable with...

Page 56: ...bution box mounted on the front side of the daily weekly fuel bin with an independent electric power supply and electric connection to the drive of the feeding screw P 0 Figure number Ti004 1 Description of operation The automatic system controls replenishment of daily weekly fuel bin from the seasonal fuel storage room depending on the time adjustment and emptying of the daily weekly fuel bin It ...

Page 57: ... Figure number Ti005 1 The microwave aerial is equipped with a magnet for easy fastening Description of operation The software package of the control unit is enlarged with the programme routines to receive and emit short text messages A set of defined commands which ensure simple control of the boiler STATUS this command will be responded by the control unit with information on the momentary opera...

Page 58: ...trol unit SW modification In the menu 12 Setup 12 1 User PIN 1 the following menu has been added 12 1 5 GSM modem Enabled the selected command will be confirmed by the key ENTER the control unit will confirm acceptance of the command by short blink and by the following notification Enabled and resumes the work with the adjusted telephone numbers processes incoming text messages and send informatio...

Page 59: ...llowing command ESC 3 the following menu is added 12 1 7 Mobile number 2 everything as in the menu 12 1 6 Mobile number 1 apples to the function adjustment and control the only limitation is that no failure messages are sent to this number 4 the following menu is added 12 1 8 Credit number if a SIM card with credit charging is used this menu may be used to enter a number where a corresponding oper...