KALVIS - 3 - 50 DS
Contents
1. 1 Burner is connected to the boiler frame Burner is manufactured together with the fuel tank Digital programmable controller Omron ZEN is used to control and optimize combustion Main technical data Table 1 Name of parameter Parameter value Fuel load m 0 9 Maximum wood chips length mm 50 Pellets calorific value 5 kWh kg 3 6 12 Ruel consumpaon KE BE Chips calorific value 3 3 KWh kg 54 18 Output adjustment range kW 15 50 Nominal output kW 50 Efficiency no less than 87 Boiler water temperature adjustment range C 60 90 Minimal recommended water temperature in the boiler C 60 Minimal draught in the boiler smoke outlet Pa 25 Voltage V 400 AC Electric output motor fan kW 0 67 Electric protection grade IP 55 Overall dimensions of boiler with burner not greater than height x depth x length mm 1950 x 1300 x 3350 Weight Not greater than kg 955 Fuel humidity 30 2 Design description Design of the boiler in under constant improvement so minor inconsistencies may be present in this manual Constituent parts boiler Kalvis 3 50eK eD with the hole for burner attachment in the left or right side burner fuel tank with an auger drive control panel Boiler see fig 1 Boiler 1 is specifically designed to work with the burner Extensive information is provided in Boiler Kalvis 3 50 user s manual Burner2. 4 capillary thermostats in the control panel fig 2 ST1 operation thermostat adjusts the hot water flowing out of the boiler It s sensor is mounted on top of the boiler frame ST2 combustion control thermostat monitors if combustion takes place It s capillary sensor is fixed to a top part of the burner fig 1 p 8 ST3 emergency thermostat s sensor mounted near operation thermostat s ST1 sensor ST4 fire protection thermostat To be set to 75 C temperature If fuel ignites in the fuel channel pushes the ignited fuel into the boiler It s capillary is mounted near the capillary of the automated fire extinguishing system s 4 4 Control panel connection Control panel connection works have to be performed with the power turned off and abiding to the relevant safety regulations Works may only be performed by qualified personnel Panel s principal electric diagram is provided in fig 4 5 Control of the equipment Control process is performed by an Omron ZEN controller that adjusts the quantity of fuel supplied and maintains the preset operating temperature of the boiler water LCD display of the controller allows noticing deviations from the normal operation on time and an easy determination of cause of error 5 1 Ignition 5 1 1 Turn on the power switch 5 1 2 Set the combustion control thermostat to a minimum position 0 C temperature 5 1 3 Set the required operation temperature by an operation ther
3. cover status Close tank cover to continue firing the system 6 Operation Only adults well acquainted with the design of equipment and this manual are allowed to operate the boiler 6 1 Choosing the operation mode Operation mode of fuel supply and thus boiler s heat output is chosen depending on the required heat amount Switch the mode to a higher one by pressing the button 5 when the system continuously operates in heating mode but fails to reach the preset operation temperature And vice versa When the operation in standby mode duration exceeds that of the heating mode switch the operation mode to a lower one In any case after changing the fuel supply operation mode adjust the air supply damper according to the flame color see article 5 2 4 6 2 Adding fuel 15mm in diameter up to 15 moisture content pellets and up to 50mm length and 30 moisture content wood chips may be fired by a system Heat output and efficiency of the system depends on fuel quality and type omron Gia up ZEN 0 o 0 6 2640 Boiler Tank Control Panel Auger drive Air supply fan Air adjustment damper Burner Burner overheat sensor Auger 10 Burner cleaning cover 11 Draught adjuster 12 Fire grate 13 Fire extinguishing system 14 Fire protection thermostat 1935 SER NSURUNN 1250 p 3100 l Fig 2 Boiler control panel mounted on the boiler 1 Emergenc
4. see fig 1 Burner frame 7 is welded form the special grade of steel Air supplied by a fan is heated between external and internal frame shells before entering the combustion zone Bottom part of the burner contains a cleaning cover 10 Air supply fan 5 is on top of the burner Capillary thermostat 8 is attached to the top pat of the burner as well Tank with drive see fig 1 Tank 2 with auger 9 is used to store and supply fuel into burner Gear motor 4 is mounted at the beginning of the auger drive The elements of the boiler control panel are shown on fig 2 3 Transportation and storage Transportation of equipment is permitted only in vertical position by covered transport During dry weather transportation by an open transport is allowed It is prohibited to strike turn over equipment during the transportation or loading unloading procedures Equipment is to be stored in dry premises not containing vapors of chemically active materials 9 In order to avoid ignition process add fuel to the tank before it is all burnt When adding fuel switch to manual mode of operation button 7 or turn the operation mode off by button 2 Add fuel guickly and set the operation mode Before closing the cover of the fuel tank check if the edges are free from fuel bits and if the gaskets are good Tank cover has to be closed at all times during operation 6 3 End of firing When fuel in the tank is spent and the burner tempera
5. KALVIF UAB KALVIS Pramon s 15 LT 78137 iauliai Lietuva tel 8 41 540556 540558 540565 tel faks 8 41 540561 el p prekyba kalvis lt CENTRAL HEATING BOILER KALVIS 3 50 DS CONTROL AND MAINTENANCE MANUAL 10 10 Guarantee 10 1 Manufacturer guarantees that the product conforms to technical specifications and requirements of IST 144948958 13 2004 10 2 Manufacturer guarantees the following service terms from the date of sales to the consumer e Boiler frame 24 months e Complement 12 months e Consumables 6 months Manufacturer is obliged to remedy all defects that have risen due to his fault if the user has not violated the requirements for transportation storage connection and operation 10 3 In case of a malfunction fill in the guarantee application form and send it to the manufacturer manufacturer s authorized dealer or the company performing guarantee servicing In urgent emergency case make a call and deliver the application to manufacturer s representatives on arrival I got acquainted with the requirements of installation and operation and guarantee servicing conditions I was informed that if the system is installed and operated in violation to this manual I lose the right to guarantee service Purchaser name surname signature Boiler sold Company Date of sales Address Phone Boiler installed Company Address Phone Installer name surn
6. ame signature In case of Company malfunction Address please address Phone Manufacturer UAB KALVIS Pramon s 15 LT 5419 Siauliai Lithuania Telefonas 8 41 540565 540556 e mail prekyba kalvis It oe E INDEX MA weed ia ss a a ais cd i i i i cag es pated wana as ai 4 2 AVERT ES CLIP CLO ai i i ai D i i a a i upper k eauletadtted a a 4 37 Transportation and storage zur Sn reales as 4 4 Installation an ee a i R i a ee 5 4 Vie IKS POPC A eures 5 4 2 Electric installation requirements ae ae 6 4 3 Capillary thermostats installation iu af ea sel 7 AA Contre panel Connection ana ee a i aa a i a a a 7 D UEP ICI COME acs uo A io lee neun 7 DLE ias i aa i a I a d ak N i I a RT 7 5 2 Combustion ad US TCI uas ni ua sia a ak a a ia i a ks a Jai ai el 7 5 3 F els pply adj siment easi aaa Ia a ti i a i a i A A a 7 SA Apsaugos Mio avarini Fe ZU sis ai a a ia i a ks ia Jai ai a i 8 A II i a i i L A i a i N 8 TSE TOUS LS sense 8 8 Acceptance Certificaten as e Red Maia a i leven een 9 9 OTE TING IN Massstab a a E a a seus Se do dad e Ne e 9 10 ASTRAL ATE cc td aa AS A AA A a S 10 KALVIS 3 50 DS LT 2009 06 03 4 ATTENTION Get acquainted with this manual before installation 1 Technical data Central heating boiler with automated burner Kalvis 3 50 DS hereinafter referred to as the boiler is used for heating various premises with central heating with enforced circulation installed by firing solid in the burner table
7. ay be adjusted only in the 1 operation mode It is necessary to stop the program of the controller To stop the program press button 1 once When in menu choose the line STOP by buttons 2 or 5 and press button 1 again Display will read RUN Choose the line PARAMETER by buttons 2 or 5 and confirm your choice by button 1 Now you have entered menu shown in the fig 5 T1 ON TIMER duration of fuel supply to burner in heating mode fig 6 T1 OFF TIMER time of pause between the fuel supplies to the burner in heating mode Fig 7 and 8 for T2 respectively Set the blinking square on a parameter to be changed by buttons 2 3 4 or 5 and confirm the choice by button 1 Enter the desired value by buttons 2 3 4 5 and confirm it by button 1 After the parameters have been changed return to previous menu level by a single push of 0 button choose the line RUN and press button to run the controller program Only underlined parameters are permitted to be changed Tl WS A Tl WS A T2 W S A T2 W S A ON TIMER OFF TIMER ON TIMER OFF TIMER TRG TRG TRG TRG RES 00 50 RES 15 00 RES 00 50 RES 80 00 Fig 5 Fig 6 Fig 7 Fig 6 Note Stop the controller program when changing times Changing of other parameters is prohibited due to a possibility of equipment malfunction 5 4 Protection against malfunctions 5 4 1 Overheating protection If the temperature in the boiler reaches 100 C em
8. emble the system with the power on Remove clogs stir fuel and add fuel with the fuel supply system running Necessary e Clean fan and motor with a dry brush e Observe that the electric wiring is distanced from the heated surfaces of the system no less than 70mm 8 Acceptance certificate Central heating boiler with tank and burner Kalvis 3 50 DS factory No meets technical specifications and is ready for operation Date of manufacture Q A mark 9 Complement 1 Boiler Kalvis 3 50eD K 1 pes 2 Tank for granulated fuel with the burner 1 pes 3 Draught adjuster C20 25 1 pes 4 Scraper 1 pes 5 Ash scoop 1 pcs 6 Poker 1 pes 7 User s manual 1 pes 8 Boiler s Kalvis 3 50 user s manual 1 pes 9 Wooden pallet 2 pcs KALVIS 3 50 DS LT 2009 06 03 8 the operation mode has been chosen fan and fuel supply turn on automatically To turn the operation mode 1 4 press button 2 Pressing the button 7 again when display reads Man Mode will allow controlling the fuel supply auger manually Pressing and holding button 4 will allow the fuel to be supplied into the burner manually 3 button is used to manually reverse the rotation of the auger Note Only fuel supply auger may be controlled in a manual mode but not the fan Due to specifics of fuel or other reasons user may set his own fuel supply operation and pause times T1 heating T2 standby mode Times m
9. ergency thermostat is activated and the fuel and air supply are turned off Sound alarm is turned on and display notifies about activation of emergency thermostat error Emergency thermostat is reset manually by unscrewing the cap fig 1 p 8 and pressing the red button underneath it Reset is only available when the boiler water temperature drops below 65 C When the thermostat is reset display will stop informing you about malfunction sound alarm will be turned off After igniting and firing the system again find out the reason for emergency thermostat activation by monitoring the system operation 5 4 2 Fuel supply motor protection When fuel supply auger is stuck or when the maximum permissible load on the motor is exceeded three times in a row within one minute thermal relay of the motor is activated and the motor and air fan are turned off Display informs user about error i e about activation of the thermal relay and the sound alarm is turned on When thermal relay is activated turn off the power and remove the cause of sticking or overloading After removing the cause turn on the power supply and choose the operation mode 1 4 by pressing button 5 again 5 4 3 Tank protection against flame return In order to avoid ignition of the fuel in tank an end switch is mounted on the fuel tank Switch turns the fuel and air supply off and turns the sound alarm on when the tank cover is open during operation Display informs the user on the
10. g and standby modes respectively Depending on the temperature of the water in the boiler operated in heating or standby mode When water in the boiler heats up to the preset temperature system automatically switches to the standby mode where the combustion is only maintained In the heating mode fan runs continuously in standby mode only together with the fuel supply auger Boiler shall continue to operate in the standby mode until the temperature drops to 4 C less than the preset operating temperature Then cycle repeats Table 3 provides manufacturer s default values for fuel supply auger operation and pause times Table 3 Operation mode Heating mode Standby mode on S pause s on S pause s 1 15 2 Firing pellets 2 13 Firing pellets 2 80 3 Firing chips 8 8 Firing chips 4 4 5 5 These are optimal operating modes To choose one of the required operation modes choose Auto Mode by button 7 display will inform you about the choice made Choose the required operation mode 1 4 by pressing button 5 After KALVIS 3 50 DS LT 2009 06 03
11. mostat no less than 60 C recommended 5 1 4 Open the air supply damper fig 1 p 6 by about 50 5 1 5 Supply fuel manually until the fuel supply channel is filled 5 1 6 Turn offthe power switch and ignite the fuel in the burner 5 1 7 When fuel is well lit turn on the power switch and set the required operating mode see article 5 3 5 1 8 When boiler water temperature rises above 30 C set the combustion control thermostat to 50 C temperature 5 1 9 Adjust fuel and air supply see article 5 2 Note It is recommended to remove draught adjuster and fire grate p11 p 12 when constantly operating boiler with the burner 5 2 Combustion adjustment 5 2 1 When fuel is well lit adjust the output of the fuel supply auger by setting the mode of operation Observe that the unburned fuel bits do not fall out of the burner Reduce the mode of operation should that happen 5 2 2 Wait until the fuel is completely lit after such adjustment 5 2 3 Open the air supply damper more when the fuel is not completely burned in the burner or the flame is red and combustion produces soot 5 2 4 Close the air supply damper slightly when the air blows fuel out of the burner or the flame color is light blue Flame has to be yellow and burn evenly Note Adjust combustion again when the fuel type of it s humidity changes 5 3 Fuel supply adjustment Boiler controller has 4 programmable modes of fuel supply operation and pause in heatin
12. ture drops below 50 C the system turns off automatically and the display informs user that the burner has cooled down To turn of the system before the fuel is used up turn the mode of operation off by button 2 or turn the power off and wait until the temperature of the burner will drop below 50 C and the air supply fan stops Make sure there are no embers left Turn the fuel supply in manual mode on and push any glowing embers out of the burner into the boiler 6 4 Cleaning To ensure efficiency of the system periodically clean the slag in the burner and remove ash out of the boiler and clean boilers surfaces from soot Time span between cleaning depends on the quality of fuel F e when firing pellet with a large content of contaminants burner may have to be cleaned daily Burner should be cleaned prior to each ignition 7 Safety requirements Prohibited To disassemble the construction or electric installation and wiring Keep or dry easily flammable items near or on the system Ignite fuel with the help of kerosene gasoline or other flammable liquids Store fuel closer than 0 5 m from the system Fire system with open doors or covers Leave children without adult supervision near a running system Operate the system without grounding frame of the boiler and tank Open boiler doors suddenly during operation In case of need slightly open the door than slowly open it fully Operate system with tank cover open Clean or disass
13. y reads the activation of the fire prevention thermostat error and the sound alarm is turned on Only when the capillary of the thermostat cools down display will stop showing an error message and the sound alarm will be turned off When the pushed fuel is removed from the combustion chamber and the capillary of the thermostat cools down firing may be started again Attention It is prohibited to fire burner with wood dust due to a possibility of an explosion Note Boiler doors loading combustion and tank covers have to be closed tightly when firing boiler 55 5S 1414 IN Ci OMRON ZEN 10C1AR A V1 lAvar gt 110 C U Asa wis KM1 4 aw SV 4ew TA MN oo 2 a CUPL DLL ail A2 FM1 1 2 1 8A 45 2 Ni OE Si KiKi Xi 5 veo esa L tl J T eS 8 uj vi wiPei f i 4 pit AN WIS e ES IV ii 6 i MEISTE s 5 sos vo Y V LON 1 Alarm ZR1 f Fire protection End switch of the To thermostat box i7 X18 400 V 0 55 kW 230 VAC 230VAC thermostat fuel tank mounted on the boiler 1 58 A 80 W ng sat Fuel supply auger Air fan Fig 4 Control panel connection diagram 4 2 Electric installation requirements e boiler and tank frames must be grounded e electric installation may only be performed by persons qualified for such jobs and or in possession of relevant permits or licenses e installation works must be performed according to a project if relevant a A 4 3 Capillary thermostats installation There are
14. y thermostat reset button under cap 2 Operation thermostat used to set required temperature 3 Combustion control thermostat recommended to be set to 50 C temperature 4 Installation Equipment may only be installed in the premises conforming to relevant national requirements of the country of installation 4 1 Fire precautions e Minimal distances from the equipment to the walls of the premises 0 5 m e Equipment must to be mounted on incombustible base Distance to the flammable partitions may be no less than 0 8 m from sides and rear 1 2 m from front 2 m from top e Automatic extinguishing valve see fig 3 is mounted on the fuel supply channel to prevent backfiring from the burner to tank Temperature sensor activation temperature 95 C KALVIS 3 50 DS LT 2009 06 03 68 Pressure in the water mains may not exceed 0 5 Mpa 1 Auger drive 2 Drain valve 3 Temperature sensor 4 Capillary 5 Closing damper 6 Manometer with tap 7 Filter Form the water main fig 3 Automatic fire extinguishing system To prevent fuel ignition in the fuel supply channel a fire prevention thermostat is mounted on the channel When temperature on the fuel supply channel reaches 75 C fuel supply auger shall operate for 30s to prevent the expansion of flame into fuel tank Ignited fuel will be pushed into the combustion chamber When thermostat is activated air supply is stopped automatically displa
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