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User Manual - MarineTec US

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1. 753 754 754 759 100 125 150 150 180 220 180 230 180 230 180 240 5 4 1 1 2 50 11 2 B012 2 B013 2 B014 2 B014 3 C015 3 0016 3 C017 0 85 1 00 1 25 1 50 19 7 29 40 7 51 1 29 40 7 52 3 63 9 3 3 3 7 5 2 6 5 5 5 5 5 3 3 3 3 118 140 155 178 18 23 26 36 35 90 35 90 35 90 35 90 50 50 50 50 HBO 1 HBO 2 diesel of gasolie 92 92 92 91 89 89 89 88 3 B 70 1165 487 508 314 699 70 385 708 961 180 180 240 2 2 B016 1 75 63 9 81 4 7 5 5 3 270 55 35 90 50 91 88 B 80 1165 487 508 314 839 70 385 858 963 180 180 250 Ei 2 B017 1 75 74 4 93 8 4 309 68 35 90 50 91 88 14 B 100 1165 488 498 314 1050 70 460 1058 963 200 180 260 2 2 00 93 116 3 10 3 445 82 35 90 50 91 88 Appendix B Parts Listed below you will find the most important parts of the boilers These parts can be ordered from your importer or Kabola Heating Systems stating type and serial number The numbers refer to the image 1 2 ONOOPRO 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 Room themmostat not shown in picture Boiler top cover Insulation Cover of boiler Boiler gasket Dashboard Thermometer Boiler thermostat On off switch Maximum thermostat Main connector Pump coupling Circulation pump Seal Knee inner x outer thread Pressure valve pressure gauge fill drain cock T connection KAZEN Fire
2. 12 17 25 35 45 55 70 to which this declaration relates complies with the following standards EN 303 1 EN 303 2 EN 304 EN 50081 1 EN 50082 1 EN 61010 following the provisions of the following EC directives 73 23 EEG 89 336 EEG 92 42 EEG amended by 93 68 EEG Nederland Oudewater 1 4 2005 An ee eeng gt Alles Directeur User manual Kabola B serie 1 4 2005 20
3. figure 10 Figure 10 4 Lift the bumer a little figure 11 according to 7A 5 Fasten bolt 7 figure 11 on the flange to clamp the burner 6 Fasten the hand tightened bolts on the mounting plate Attention Take care that the burner pipe is not damaged during installation Repairs to the burner pipe are very expensive and don t fall under warranty User manual Kabola B serie 1 4 2005 10 4 1 7 Connecting the oil filter and oil burner To connect the filter to the boiler follow the procedure below see also figure 11 Figure 11 Remove the burner cover 1 Connect the oil pump 2 to the oil filter 3 using the included fuel hoses Make sure that the flow directions on the pump comply with those on the filter 3 Connect the fuel line from the tank to the filter 5A The fuel line must have a outer diameter of 8mm and must be made from copper or steel The fuel has to be connected directly to the oil tank Correct functioning of the burner can not be guaranteed when a fuel manifold or T connection is installed 4 Connect the plug 4 from the boiler to the burner N Hint When the oil tank is situated below the boiler or when the oil supply line comes from below the boiler it is advisable to use a self bleeding oil filter This prevents unnecessary malfunctioning of the burner see figure 12 Figure 12 User manual Kabola B serie 1 4 2005 11 42 Starting your system When everything is con
4. flue Kabola can provide you with all components which may be required for installation S5 such as Cowls Flexible piping Figure 4 e Single and double walled chimney pipes Wall and deck flanges Silencers Water traps 4 1 4 Electrical installation Warning Disconnect the power supply from the boiler before you start installing the boiler Only use multiple stranded wire Electrical installation 230 Volts AC When a room thermostat has been supplied with the boiler take the following steps Connecting the room thermostat see figure 5 and electrical scheme in appendix C 1 Remove the cover of the main connector situated below the dashboard 2 Remove if present the wire between point 1 and 2 3 Connect point 1 of the connector to point L of the room thermostat Figure 5 User manual Kabola B serie 1 4 2005 8 4 Connect point 2 of the connector to point L1 of the room themostat Attention The core diameter of the connections mentioned above must be between 1 and 1 5mm The wires should be suitable for the voltage used Connecting the circulation pump see figure 5 and electrical scheme in appendix C 1 Connect the pump to points 3 and 4 ofthe connector 2 Connect point 5 to the ground connection on the pump 3 Replace the cover of the main connector Electrical installation 24 Volts DC Warning Never change the pole with pole on the battery See figure 6 1 The connection o
5. mm User manual Kabola B serie 1 4 2005 230 VAG inpuf Appendix D Electrical diagram B80 B100 230V B amp 0 B100 230 VAC 28 10 2004 White Elco casing 2 Mena Maximum Contralihernestat Sherman ed High low modulation cet cen ae 3 3 1 1 e DY N N NL LA 4 23 A BS T6 Tr T8 L T1 T2 S B4 Li Ti T2 s3 84 4 Ve Main es switch o Ll A 1 2 3 4 Pup 230 VAG ee 7 N g 2 2 BA 230VAG Black Brown Plug for burner 230 VAC input Dimensions wiring Power supply 1 1 5 mm A thermostat 1 1 5 mm User manual Kabola B serie 1 4 2005 y Maximaal Appendix E Electrical diagram B8 B45 24V B8 B45 24 VDC G Regel ihermoastast themnostaat 2 3 _ Q 2 CO 5 C CO A B A j 3 HEATING SYSTEMS D EK Hoofd 2 AT ee EE L D db e L T1 18 A 24 VDC g 1 2 3 groen geel input rood zwart li 6 N 12 el JA 10 mm to Kamer 24VDC voeding thermostaat
6. of your heating installation An incorrect fue gas outlet reduces the lifespan of your boiler considerably and has a negative impact on the efficiency Remember when installing the flue that even the best boiler won t work properly unless the flue is properly installed Warning Because the flue gas temperature lies between 180 240 C it is advisable to insulate the flue with heat resistant material in those parts where contact with human body parts is possible For a correct flue gas outlet the following points need to be observed Use the proper length diameter dimensions use a diameter equal to the diameter of the flue gas outlet on the boiler see also technical specifications Use double walled chimney pipe outside to prevent a rapid cooling of the flue gasses which might result in condensation in the chimney Hint When using a existing chimney ofa larger diameter than the diameter on the boiler you can install flexible piping of the corect diameter inside the existing chimney The fue can be installed in several different ways You must carefully consider under which circumstances the boiler will be used For sea going boats and sail boats we advise the installation of a vertical flue where the angles of the boat may be larger The following installation examples are most common Horizontal flue gas outlet It is possible to fit a horizontal flue gas outlet to the boiler The following points need to be observed W
7. to be done with a running pump Follow the points listed below to bleed the pump see figure 8 1 Check if the rotor can rotate without problems by tuming the pump by hand see manual pump 2 Loosen the screw on front of the pump to 1 turn with a screw driver 3 Fasten the screw when water comes out of the opening 4 The pump is bled Attention when locking pump couplings which are supplied Figure 8 with the boiler the adjusting grooves must point towards the pump see figure 9 4 1 6 Mounting the burner Hint Check if the inspection opening on the mounting plate can be reached If this is not the case the mounting plate can be turned 180 to reach the opening easier Fora B12 you need to saw an extra piece off the flange The mounting of the burner is done in the following way 1 Place the nut for the flange bolt in the dedicated position and place the gasket 2 Mount the flange with the 4 supplied M8 bolts hand tighten on the mounting Figure 9 plate The arrow on the flange should point upward Hint Smear some sealant in the crack in the flange to seal 3 1 Measure and set the distance from the back of the gasket mounted behind the mounting plate to the front of the flange using the table below and figure 10 Boiler type Distance in mm B12 B17 60 B25 B35 B45 155 B55 B70 B80 B100 160 3 2 Scribe the distance on the pipe 3 3 Push the burnerpipe gently in place up to the scribed position see
8. Gebruiksaanwijzing User manual Gebrauchsanweisung Kabola B series WY Kabola Heating Systems KABOLA Populierenweg 41 ed systems NL 3421 TX Oudewater Preface This user manual is written to enable the safe operation of the B Series central heating boilers The user must read this manual before installation of the boiler and must follow the instructions within this manual Therefore this manual must be kept with the boiler In chapter 2 the safety instructions are detailed which have to be complied with when installing and using the boiler In other chapters you will find safety instructions that can be identified in the following way Hint This gives the user suggestions and advises to facilitate the execution of certain tasks Attention Additional information is supplied to the user and possible problems are indicated Warning Watch out for possible life threatening injuries For any remarks wishes or omissions you can contact Kabola Heating Systems We also welcome any remarks to improve this manual We wish you a lot of pleasure from your purchase Kabola Heating Systems Populierenweg 41 NL 3421 TX Oudewater The Netherlands Phone 31 0 348 561277 Fax 31 0 348 562484 Web www kabola nl E mail post kabola nl Oudewater 1 4 2005 2005 Kabola Heating Systems Copying of parts of this manual is only allowed with written consent of Kabola Heating Systems User manual Kabola B serie 1 4 2005 2 Co
9. When the boiler will be scrapped take note ofthe points listed below Process the oil filter and the oil hoses as chemical waste Separate the metal from the plastic parts and dispose them separately Process any excess oil in an environmentally friendly way Transport the boiler according to the instructions in chapter 3 Recycle this manual User manual Kabola B serie 1 4 2005 13 Appendix A Technical specifications ZOTMOOB FA E Fue gas o Fluegas temp C C H connection IP value Burner 230 V 24 V Nozzle 60 Nom Capacity kW min max Max oil consumption kg h Testpressure in bar Operating pressure in bar Weight in kg Water volume in Temperature control range Isolation thickness in mm Fuel Burning efficiency in Waterside efficiency Standby loss B 8 505 343 356 235 320 70 310 336 400 80 160 200 4 2 B009 3 C012 0 30 8 11 1 1 5 3 50 9 35 90 30 96 92 B 12 600 347 115 361 243 343 70 325 361 480 80 180 240 T 2 BO10 3 0013 0 40 11 2 14 14 5 3 65 12 35 90 30 91 87 B 17 670 411 115 416 364 408 70 325 416 548 80 180 240 1 2 B011 3 C014 0 50 14 19 7 1 9 5 3 94 16 35 90 30 91 88 User manual Kabola B serie 1 4 2005 B 25 B 35 B 45 B 55 970 970 970 970 455 455 445 485 115 115 125 125 466 468 488 498 283 284 284 384 388 491 580 697 70 70 70 70 385 385 385 385 396 503 593 708
10. damage to the boiler if the safety instructions in this manual are not complied with The user must Have read and understood the chapter safety Avoid any actions which may lead to hazards to his health or others Awid any actions which may lead to damage to the boiler e Ensure that the boiler is only used when the boiler is in sound technical condition Ensure that the safety regulations are observed whilst operating the boiler Attention No alterations to the boilers may be done without the explicit written consent of Kabola Heating Systems 2 2 Safety instructions The safety instructions listed below must be complied with when operating the B Series boilers Measures for a safe installation Don t store any fammable and or gaseous products in the room where the boiler is installed to avoid explosions and fires Install the boiler in a non humid environment on a firm horizontal base Ensure that there is sufficient ventilation in the room where the boiler is installed See also 4 1 1 Make sure before you start connecting the boiler that the system is disconnected from the power supply Only use multiple stranded wire for electrical connections e Don t change the pole with the pole of the battery for the 24 Volt DC version Measures for a safe operation Never change the settings of the bumer Don t use any aggressive solvents which may affect the boiler like gas or turpe
11. enance and repairs may only be performed by personnel who have read and understood the information in this manual preferably an expert installer or mechanic from Kabola Every week Drain the water fom the water trap if installed Every year 1 lean the boiler Remove the burner see 4 1 5 Remove the burner mounting plate from the boiler Remove the top cover of the boiler be careful not to damage the earthing wire Remove the insulation Remove the 4 bolts on the boiler top Remove the boiler top Clean the inside of the boiler using a stiff brush Clean the space between the pipes with a thin metal strip Attention Don t use any aggressive solvents like thinner or gasoline 9 Clean the boiler with a vacuum cleaner 1 1 10 Replace the boiler top if necessary use a new gasket 1 11 Replace the 4 bolts and fasten these 1 1 C 1 1 1 1 1 1 1 1 OND b h 3 12 Replace the insulation 13 Replace the top cover of the boiler make sure the earthing wire is fitted correctly 1 14 Replace the burner mounting plate and remount the bumer see 4 1 5 Clean the chimney Clean the watertrap if installed Change the oil filter element Clean the bumer see manual of the burner N PES Hint Kabola Heating Systems has a standard set with replacement parts for the yearly maintenance see Appendix B Attention The old oil filter element has to be processed as chemical waste 7 End oflife of the boiler
12. f the room thermostat is identical to the connection for the 230 Volts version Use figure 6 instead of figure 5 2 Connect the circulation pump to points 3 and 4 ofthe main connector 3 The core diameter of the wires to points 5 and 6 of the connector should confom to the values in table 1 Table 1 Distance to the batte Core diameter 6 mm 4 1 5 Filling the central heating system The pressure in the system should Never be lower than 0 5 bar cold Never be higher than 2 5 bar hot Follow the procedure listed below for filling the CH system see figure 7 Switch off the boiler Turn the coupling nut below the pressure indicator to loosen it Pull the hose connection a little downwards Connect the hose with a hose clamp to the connection Fill the system slowly with water until the pressure indicator indicates a pressure of 2 bar 6 Fasten the coupling nut 7 Bleed the CH system 8 If necessary fill with water again up to 2 bar of pressure 9 Switch on the boiler and let the pump run for about 5 minutes 10 Switch off the boiler 11 Check the water pressure if it is too low repeat steps 5 through to 10 12 Remove the hose SP Figure 7 Hint The CH system can be filled with codling fluid suited for CH systems pH value 8 5 User manual Kabola B serie 1 4 2005 9 Bleeding the circulation pump The circulation pump can only be bled when the electrical Circuit is connected because this has
13. hen a burner with an after purge cycle is used the maximum allowed length is 6 metres A burner without an after purge cycle can be fitted with a maximum flue length of 2 metres plus the silencer Make sure that the outlet is positioned at a sufficient height above the waterline If this not possible use a swan neck bend in the pipe as in figure 3 User manual Kabola B serie 1 4 2005 7 Use hull flanges for installing the flue through a hullside Don t use more than 5 elbows of 90 Every elbow of 90 is comparable to 1 metre of straight pipe When a damper 80x60 is fitted the length of the 60 mm pipe may not exceed 1 metre Vertical flue gas outlet This way of installation is preferable for seagoing boats and sailing boats while these boats encounter bigger angles through waves and while under sail For this kind of flue gas outlet the following are important Install a proper stom cowl on top of the chimney this must stop rain entering figure 3 f Figure 3 Install a water trap for boilers bigger than B17 to trap possible water caused by condensation figure 4 Keep the chimney as vertical as possible Don t use more than 5 elbows of 90 The maximum allowed length is 10 metres Every elbow of 90 counts as 1 metre Outside use double walled chimney pipe Hint To reduce the noise resulting from flames it is wise to install a silencer in the horizontal flue and the vertical
14. inspection opening Oil burner Fibreglass or rock wool thickness App A No lamp in 24 V DC version 1 or bigger Two 1 or bigger Different per type 1x1 1x1 or 1 x1 Only for B 12 Comes with flange and gasket Burner mounting plate Gasket for mounting plate Boiler cover side front Boiler cover back Oil filter not shown in picture Following spare parts are available 25 Nozzle 19 B25 B100 max 25um P max 6 bar max capacity 200 I hour total 6000 I max vacuum 0 5 bar Imit TA3 See Appendix A For the yearly maintenance Kabola Heating Systems has compiled a set of spare parts often used during maintenance 26 Service set comprising of 4 23 25 User manual Kabola B serie 1 4 2005 15 Appendix C Electrical diagram B8 B70 230V 38 370 230 VAG Q gt N Y Y GE 28 10 2004 White Elco casing Boiler Maximum mM thermostat C coz 3 3 1 e Nm DAM Ir 1 2 3 4 1 2 Main le Ti T2 s3 34 A swith Li Ti T2 S3 B4 1 2 3 4 Li MIT Tz 82 M Plug with afler purge cycle Black Brown NE N AB Plug for burner Pump 230 VAC thermostal S80VAc Dimensions wiring Power supply 1 1 5 mm thermostat 1 1 5
15. lication ofthe latest European standards and directives 12 Range application The B Series boilers are designed to generate heat for the heating of water for a central heating system The dimensions of the rooms to be heated have to be taken into consideration These boilers are not designed for direct heating of the rooms in which they are installed 13 Product description The B Series boilers heat the central heating water by means of a pressure jet burner which is installed on front of the boiler The standard boilers operate from a 230 wolt AC Supply Boilers up to type B45 can also be supplied to operate on a 240 volt DC Supply All B Series boilers work in the same way the only difference is the dimensions and the capacities of the boilers see also the technical specifications in Appendix A As fuel diesel oil or kerosene has to be used At special request there is also a model available which operates on petroleum 14 Technical specifications The most important technical specifications are listed on the plate on the front of the boiler More technical details are listed in Appendix A User manual Kabola B serie 1 4 2005 4 2 Safety In this chapter we emphasise the safety related points for operating the boiler 2 1 General safety Warning Although Kabola Heating Systems designs and produces its products according to the current safety standards it is possible that dangers may occur which could lead to injuries or
16. n the room where the boiler is installed This is to ensure that no explosions or fires can occur 4 1 Installation 4 1 1 Fitting the boiler Install the boiler in a dry place Install the boiler on a frm horizontal base Make sure there is sufficient supply offresh air in the room where the boiler is installed see hint below Hint As a rule of thumb for the ventilation openings take 2 5 times the diameter ofthe flue gas outlet To avoid movement secure the base of the boiler by means of spotwelds or with nuts and bolts Keep a minimum distance of 250mm behind the boiler for the flue gas outlet see figure 1 Figure 1 User manual Kabola B serie 1 4 2005 6 Use a earthed plug socket for connecting the 230 V AC versions to the power supply 4 1 2 Comnection ofthe Central heating system Piping Take note of the following points when installing the piping Install the piping in such a way that the boiler cover and dashboard remains accessible Provide enough bleeding points in places where air might collect Attention Install a automated bleeding vale near the boiler Connect the piping to the boiler as follows see figure 2 1 Install the feeding to CH at point A 2 Install the return ofthe CH on point C Hint Install a shunt with pressure equaliser when themostatic radiator valves are applied 4 1 3 Flue gas outlet General Figure 2 The fue gas outlet is an essential part
17. nected follow procedure below 1 Connect the boiler to the power supply the earthed outlet for the 230V AC version and the battery forthe 24 V DC version 2 Switch the boiler on with the on off switch on the dashboard The lamp in the switch will indicate that the system is active This lamp is not present in the 24 V DC version Set the required boiler temperature between 55 and 90 C using the boiler thermostat Set the room thermostat so that it is switched on See manual of the room thermostat 5 Start the oil burner figure 11 5 1 Open the valve of the fuel tank 5 5 2 Open the valve on the oil filter 5A 5 3 Install the bleeding hose 3C on the bleeding opening of the filter 5 4 Start the oil burner 5 5 The burner switches on when the burner is fitted with a pre heating element this will take 1 5 minutes 5 6 Open the bleeding valve on the oil filter 5 7 Check if oil is coming out of the hose 5 8 Check all oil connections for leakage s 5 8 1 When the burner won t start the control light 8 will light 5 8 2 close the bleeding valve 3B on the filter 5 8 3 Wait approximately 3 minutes 5 8 4 reset the burner by pushing button 8 and retum to 5 4 repeat if necessary 5 9 Close the bleeding 3B when only oil and no bubbles come out of the hose mo Attention The oil burner is tested by the manufacturer not adjusted The adjustment of the bumer has to be done by an experienced installer because this requires expert k
18. nowledge To be eligible for warranty the boiler has to be adjusted by an approved installer Contact Kabola Heating Systems or your importer to make an appointment Never adjust the burner using your own initiative A correctly adjusted burner shows a clear white flame which is visible through the inspection opening 6 5 Operating the boiler When the boiler has been started and adjusted according to 4 2 operation ofthe boiler is very simple The required temperature is set with the room thermostat which regulates the boiler The operation of the thermostat is explained in the manual of the room themostat If problems arise with the operation of the boiler you will find a list of possible problems and solutions in Appendix D 6 Cleaning and maintenance 6 1 Points of attention Spare parts must be ordered through your importer dealer or from Kabola Heating Systems For warranty purposes only original spare parts may be used When ordering spare parts mention the type of the boiler and its serial number Kabola Heating Systems will then be able to deliver the correct parts In Appendix B the main spare parts are listed User manual Kabola B serie 1 4 2005 12 62 Cleaning and maintenance Warning Maintenance and repairs should only take place when the boiler is switched off this is because the boiler might start unexpectedly Take the plug from the wall socket Disconnect the power supply forthe 24 Volt version Warning Maint
19. ntents Preface Contents 1 Introduction 1 General Introduction 2 Range application 3 Product description 4 Technical specifications 2 Safety 2 1 General safety 2 2 Safety instructions 3 Transport and storage 3 1 Transport 3 2 Storage 4 Installing and preparing for first use 4 1 Installation 4 1 1 Fitting the boiler 4 1 2 Connection of the Central heating system 4 1 3 Flue gas outlet 4 1 4 Electrical installation 4 1 5 Filling the central heating system 4 1 6 Mounting the burner 4 1 7 Connecting the oil filter and oil burner 4 2 Starting your system 5 Operating the boiler 6 Cleaning and maintenance 6 1 Points of attention 6 2 Cleaning and maintenance 7 End of life of the boiler Appendix A Technical specifications Appendix B Parts Appendix C Electrical diagram B8 B70 230V Appendix D Electrical diagram B80 B 100 230V Appendix E Electrical diagram B8 B45 24V Appendix F Troubleshooting Appendix G CE declaration User manual Kabola B serie 1 4 2005 _ OO oO Oo JJ Oo oo Oo Oo Om Om Om P AAA RON N EA ER DER HEN VEER ER ER ch est EA deht Che DOANDARWWNHNNDND gt 1 Introduction 1 1 General Introduction Congratulations with your purchase ofthis Kabola boiler This user manual covers the B Series central heating boilers The B Series central heating boilers cover a wide range of boilers with a broad range of application By purchasing this boiler you have acquired a product which is of high quality through the app
20. ntine Don t damage the fire bricks Make sure that the boiler and bumer are checked annually by a skilled expert Make sure that before you start any work on the boiler that the system is disconnected from the power supply Make sure that any surplus oil is collected in case of oil spillage We advise you to have any maintenance or repairs carried out by skilled experts User manual Kabola B serie 1 4 2005 5 3 Transportand storage 31 Transport Take following precautions before transporting the boiler Drain the water from the boiler Uncouple the fuel system e Remove the burner see 4 1 5 replacing the burner While transporting the boiler take following precautions e Don t damage the boiler use a blanket to cover the boiler Transport the boiler lying down on its back For the boiler models B 25 onwards use the hoisting eye to move the boiler This hoisting eye is located below the top of the boiler cover 3 2 Storage Take the following precautions when the boiler is stored for a longer period of time Store the boiler and accompanying parts in a dry place Dismount the burner Store the boiler standing up Store the boiler on a firm horizontal base 4 Installing and preparing for first use In this chapter you will find directions and hints for a correct placement and fitting of the boiler and accompanying parts Warning Don t store any fammable and gaseous substances i
21. pomp Diameter bedrading Voeding lengte 0 6 m minimaal 6 mm 6 15 m minimaal 10 mm Steker branderautomaat Kamerthermostaat max 2 x 0 75 mm User manual Kabola B serie 1 4 2005 Appendix F Troubleshooting Listed below you will find a list with possible problems their reasons and solutions When you encounter problems not listed you should contact your dealer Never try solve problems on your own Possible reason Possible solution Burner won t start Oil supply interrupted Bleed the oil filter Change contaminated filter element Fillthe oil tank Power supply interrupted Check the fuses MEE EE Flame protection dirty photo cell Clean glass of flame protection a ee ar cell PoC Booilerdirty Clean boiler LO supplyintemupted See above PoC Nozzle defect Replace nozzle 2 Bumershowsemor Ir L eset bung BEER ie thermostat been removed room thermostat adjusted EEN NE NG Battery of room thermostat empty Replace battery Water is not pumped Pump couplings are closed Open pump couplings Py AL il N Supply SEE Re EE manual pump User manual Kabola B serie 1 4 2005 19 Appendix G CE declaration Kabola Heating Systems Populierenweg 41 3421 TX Oudewater Nederland KABOLA heating systems EC declaration of conformity Kabola Heating Systems Populierenweg 41 3421 TX Oudewater Nederland declare under our own responsability that the product Branderketel Kabola B8

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