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Untitled - PONAST spol. s r.o.

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1. 92 Hydraulic scheme 1 x SWH ne nnn n nn i in 93 Electric connection of hydraulic scheme 1 x HC SWH 1 09 31 94 Hydraulic scheme 1 x HC SWH nennen nennen nnnm nnn nnne nnne n nn n 95 Electric connection of hydraulic scheme 1 x HC SWH Tank 96 Hydraulic scheme 1 x HC SWH Tank aa ann 97 Hydraulic scheme 1 x HC SWH nennen rine nnn n n in 98 Hydraulic scheme 2 HC SWH Tank 99 Electric connection of hydraulic scheme 2 x HC SWH Tank 1 2 2 mnm 100 Hydraulic scheme Cascade 2 HC SWH 1 1 21 4 nennen 101 Electric connector OLI BIS culos is cune aider Uere E Eb PE REY 102 Recommended installations of the boiler connection combine heating 103 Block scheme of boiler el connection Kpx2 clips 104 Block scheme of EXPANDER connection Kpx2 clips description 105 Electrical installation version for input 3 PE N 50 Hz 400 230 V 5 106 Electri
2. 89 10 9 FLUE GASES TEMPERATURE SENSOR ERROR e nn 90 STOFPAGE NOT S dac imis a dU 90 10 11 TUELSOGHORTAGEJN THE TANK a aul delis E INI ne USE DM UNES 90 CLEAN TAE t mE 91 1l GUARANTEE AND LIABILITY FOR DE EG DOE anne 91 Automatic boiler for biomass Service manual LIST OF FIGURES Picture 1 Picture 2 Picture 3 Picture 4 Picture 5 Picture 6 Picture 7 Picture 8 Picture 9 Picture 10 Picture 11 Picture 12 Picture 13 Picture 14 Picture 15 Picture 16 Picture 17 Picture 18 Picture 19 Picture 20 Picture 21 Picture 22 Picture 23 Picture 24 Picture 26 Picture 27 Picture 28 Picture 29 Picture 30 Picture 31 Picture 32 Picture 33 Picture 34 Picture 35 Picture 36 Picture 37 Picture 38 Picture 39 Picture 40 Picture 41 Picture 42 Picture 43 Picture 44 Picture 45 Picture 46 Picture 47 Picture 48 Picture 49 Picture 50 Picture 51 Picture 52 Picture 53 Picture 54 Picture 55 Picture 56 Diagram of the products and description of the main parts 1 1 9 decer HP Em 10 E2008 Control x oss erat 11 RJIE2008 CONTO SETTE 13 RJE2008 Control unit
3. JL JL Automatic boiler for biomass KP 12 KP 12 KP 22 KP 22E KP 62 KP 62E ay PONAST s spol s Service manual CZECH REPUBLIC tel 420 571 688 188 fax 420 571 688 115 e mail ponast ponast cz Automatic boiler for biomass Service manual Manufacturer tel 420 571 688 188 fax 420 571 688 115 e mail ponast ponast cz We would like to focus your attention mainly on the following chapters number 1 Important notes number 6 Putting the product into operation number 7 Maintenance and attendance of the boiler during operation The boiler has been approved for operation in the Czech Republic and in 27 EU countries by the State Testing Institute state testing plant number 202 TABLE OF CONTENTS i i a Eat Ip ko me rrr erc 1 IST nn sav MEM UAE RI DU MEE E MU M aM etna MUN OL MM 3 mere Tc mr 4 MEN L8 401 WEITE rcc 5 4 THE BOILER AND ITS ADVANTAGE en ee ae 6 3 INE BJILER KP 7 5 STRUCTURAL DER OF PRODUC AV GERE FR Dua 8 4 1 BOILER BODY SCHEMA OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS 10 DONTBOLGISTEM OF THE BOIER eee er er ee 11 4 2 1 COTO AE 20 gt r E
4. 12 4 2 2 TE ZOOS Te ITI 16 4 2 3 Epad 2 DR M 17 4 3 BURNER HEATING CHAMBER INCL FEEDER F1 WITH INDEPENDENT DRIVE eene 19 0 Je err 22 49 F1 FEEDER WITH INDEPENDENT DRIVE FROM FUEL STORAGE nn a a TAa EA AE 23 4 6 BOILER SHEATHING INCLUDING HEAT INSULATION 23 ZLEITING 1 HER 26 4 7 1 Fe MOV all seen S 26 4 7 2 Heat exchanger Cleaning an 26 4 7 3 CONAM OT t TODO r 27 FLORE N 28 qo STANDARD ALU CES ORIEC Mu Miam ipM Ed uM EDAM MU 28 4 10 LE een een ee 29 4 11 gt a ee er 29 5 PLACEMENT OF THE PRODUCT IN BOILER ROOMS PRINCIPLES OF INSTALLATION 31 Sd PLACEMENT OF PRODDGTS IN DOLLER ROOMS nt FP o PHAR IE SUP TER 31 5 2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL 2 ee 31 5 rnc 31 5 3 1 Heating System ana DOE EO Ot E 31 5 3 2 er 31 5 3 3 saccis oui ende 32 5 3 4 csi 32 5 3 5 Protection against er
5. UN INS DTERUUR DEN INT UE E OD UO I MIN IVSUE 32 nC ENT 32 BOILER ROOM VENTILA po 32 PULING THE PRODUCTS INTO OPERA ei ee 33 DI CONNECTION TO THE Eee AE 33 NT IN OF THE BURNER nee 34 6 3 INSTALLATION OF THE CERAMIC CATALYTIC REFLECTOR 2 u ea 35 6 4 INSTALLATION OF SECONDARY CERAMIC ERATE ee ee 35 on E Apo SE TION NEL een 36 CONNECHON OF ELECTRICAL PARTS een 37 5 7 CHECKING TASKS BEFORE BOILER FIRST OPERATION ee 37 7 BOILER SERVICE AND MAINTANANCE DURING OPERATION 2 2 1 1 1 6 6 nnns 38 18 90 38 7 1 1 Molise es 38 7 1 2 Emptying the external ash CONCAINCIS a 9 38 7 1 3 Flue gases exchanger cleaning 39 Je MAINTENAN Rt et 39 7 2 1 Burnt gases exchariger en 39 7 2 2 Burner grate ClOAMING 2559 x denset cnet eI nr ae nem nee 39 7 2 3 Ceramic Grane Cleaning S LI IUE 39 7 2 4 ANNUAL QUIGIG ETE OO EET 40 Automatic boiler for biomass Service manual 7 3 OPERATING CONDITIONS
6. Papst Type5 RG14S Manufacturer ZIEL ABEGG Type6 RG12S Manufacturer ZIEL ABEGG The selected mode in which the fan will be used by the control unit will be confirmed by pushing the key ENTER The following script will appear shortly on the display unit Control unit will than return to menu gt 1 main fan lt Important Selection of the correct type of fan is important for harmony of the adjusted air quantity on the display unit with the real rotations of the fan If a wrong type has been selected this dependence is not linear and may result in incorrect aeration and thus in wrong operation of the boiler in course of burning Note Check of the correct selection of fan can also be done by listening Change the rotations of fan by 10 9o see chapter 5 in the manual operation and check whether the adjustment of the control unit is changed linearly If the type of fan has been adjusted incorrectly step change of rotations appears at certain adjustment 9 4 9 2 Menu 11 9 2 fan type In this menu the manufacturer or the service technician will set the flue fan type being used MENU 11 9 2 Flue fan type will show on the display by using the f U arrows We enter the menu by pushing the ENTER button gt 1 Select FI lt After pushing the ENTER button the display will show the currently selected flue fan type We can switch to different type by pushing U arrows The ma
7. Temperature lower limit lower limit of the temperature for the parameter Temperature ue DO DO 55 Temperature upper limit upper limit of the temperature fot the parameter Temperature AG 80 80 80 Number of samples Set up number of samples for reading and followed by temperature display Feeder 1 limits time limits for running of the boiler in needed output levels Feeder on low limit lower limit of the parameter F1 turn on Sec 5 5 5 Feeder on upper limit upper limit of parameter F1 turn on sec 5 9 8 Feeder off low limit lower limit of parameter F1 turn off sec 24 25 20 Feeder off upper limit upper limit of parameter F1 turn off Sec 90 60 61 Pump limits temperature limits for start of circulation pump of the system Lower limit lower limit for temperature range for parameter Pump on Temp C DO 55 Upper limit upper limit for temperature range for parameter Pump on Temp 70 70 Absolut limit temperature in which the pump is allways in running aside from other conditions of the boiler running C 85 85 Pump run out time period in which is pump in running after changeover of the boiler into STANDBY state min 4 6 SWTank pump limits Temperature limits for starting SWTank pump of the system Lower limit lower limit of the temperature range for SWTank pump on 55 DO Upper limit upper limit of the temperature range for parameter SWTank pump on 70 70 Absolut limit temperature during which is allways circulation pump in running aside from other condit
8. Automatic boiler for biomass Service manual If the key ESC is depressed before the first or second confirmation of PIN this PIN will not be accepted return back to the main menu will be performed The original PIN will remain in force Note The service PIN is set by manufacturer Note the PIN has been changed by the user this code has to be stored well If the PIN is lost an intervention of the producer s employee is necessary Note The PIN may contain digits 0 9 lower case letters from the a z alphabet and upper case letters from the A Z alphabet It is not possible to break through via the trial and error method a PIN entered by means of this combination 9 4 9 Menu 11 9 Setup Fans The producer or the service engineer will adjust in this menu the type of the fan used The user does not work with this parameter MENU 11 9 Select Fan will appear on the display unit after the PIN for the Producer menu has been correctly entered By pushing key ENTER we will got to menu 9 4 9 1 Menu 11 9 1 SELECT FAN The following script will appear on dispay By pressing key ENTER the following script will shortly appear This menu may be changed into a different type with cursor arrows 10 The producer may deliver one of the following types of fans ES 30 98 Manufacturer REGULUS Type2 ES 108 Manufacturer REGULUS Type3 RGL 97 Manufacturer EBM Papst Type4 G2E120 Manufacturer EBM
9. ENTER button we turn the function ON The previous function will be turned off automatically Note If this function is selected the name of the output in Menu 1 7 Direct control will be changed It will say TO1 ON OFF Note If this function is selected the output function XV9B will changed The output will perform the room thermostat PO2 function Return to MANUAL mode by repeatedly pushing AESC button or you can continue in your menu selection with the U arrows We switch functions by pushing the ff U arrows By pushing the ENTER button we turn the output function ON The previous function will be turned off automatically Note If this function is selected the name of the output in Menu 1 7 Direct control will be changed It will read switching pump ON OFF Note for configutation of K17 2 follow same instruction as for K15 1 output configuration 9 4 14 2 Menu 11 14 2 Configuration K17 2 There are the same instruction for configuration of output K 17 2 flue fan as are for K15 1 74 Automatic boiler for biomass Service manual 9 4 14 3 Menu 11 14 3 Diference of return If there is a configuration of any outputs KP 15 od KP 17 2 as a shorting pump tenperature diference set up between water output from the boiler and temperature of return affects switching of the pump If the temperature difference will higher than the set up difference the pump will be operating Note The boile
10. It is prohibited to notify the user or unqualified operator of the PIN Unskilled intervention in adjusted parameters may result in operation of the boiler outside the permitted operating conditions MENU 11 The service will show on the display after a short note MAIN MENU The setting can be changed by the f arrows gt 11 Service lt By pushing the ENTER button display will show Use the cursor arrows f gt to determine the user s PIN number code combination or the value of a particular parameter ff increases the number value in steps of 1 reduces the number value in steps of 1 gt moves to the neighbouring digit to the right moves to the neighbouring digit to the left Confirm the adjusted number by pushing the key ENTER The adjusted value is not accepted by pushing the key ESC or we will return back to the previous menu It is possible to change a blinking value or digit A parameter value confirmed by the key ENTER will stop blinking and is accepted for operation of the control unit If the PIN value entered is correct the following script will appear shortly on the alphanumeric display unit If the PIN value has been entered incorrectly the following script will shortly appear on the alphanumeric display unit Access to the menu for SERVICE is not allowed Note The service PIN is set by a manufacturer Note If the PIN has been changed by the servic
11. Operation of Feeder 1 is turned off by pushing the key ENTER Note Because of operation reliability and safety Feeder1 can be turn on only if Feeder2 is running 9 3 1 2 Menu 1 2 Control of feeder F2 The following will be displayed on the display unit Turn the Feeder 2 on by pushing the key gt ENTER The following will be displayed on the display unit Operation of Feeder 2 is turned off by pushing the key ENTER Note Manual control of the feeder has to be used if you run out of fuel and all transportation ways are empty see chapter 7 10 LACK OF PELLETS IN THE BIN 48 Automatic boiler for biomass Service manual 9 3 1 3 Menu 1 3 Control of fan The following will be displayed on the display unit The value of revolutions may be changes by cursor arrows gt increases revolutions of the fan by 1 reduced revolutions of the fan by 1 Keys has a autorepeat function in after a longer pressing automatic repeating of pressing The fan will be turned on after the key gt gt ENTER is depressed The following will be displayed on the display unit The value of revolutions of the fan may be increased gt or reduced during operation Operation of fan is turned off by pushing the key ENTER 9 3 1 4 Menu1 4 _ Flue fan control The display will show vv currently selected fan revolutions We can change the revolution value with the cursor arrows 2
12. We enter the menu by pushing the 0U arrows By pushing ENTER button to enter the time lag in minutes after which the control unit will carry out comparison between the boiler water temperature and that of burnt gas Range TT 0 99 The time lag is adjusted in the same procedure as mentioned above in this chapter Note When the boiler is leaving the STADBY state The value of At Reference temperature is always assessed after the boiler leaves the STANDBY state for the mode AUTO AUTOx under the working modes of MODULATION or SW Tank at the previously programmed instant of time If the At Reference temperature is exceeded the boiler resumes its operation if the value is lower than or equal to At Reference temperature the control unit will stop operation of the boiler and the script STOP no ignition will appear on the display unit Note Measurement of burnt gas temperature is only in operation if the reference temperature is adjusted to gt 0 MENU 11 5 8 If the reference temperature is adjusted to 0 the check programs are put out of operation switched off Important Neither the user not the operator are allowed to have access to this menu and they may not change the parameters adjusted 64 Automatic boiler for biomass Service manual 9 4 6 Menu 11 6 Pump on temp Will determine the boiler water temperature at which the circulation pump of the system will start working MENU 11 6 Pump on temp will
13. Wi Wi wi wi lt number of WL identification P 1 cross section 5Cx2 5 4 5 2 5 junction box cross section schematic symbol equipment identification name of equipment location of equipment NOTE type of version closed protection IP55 switchboard Boiler KP xxE switchboard central grouding boiler 2 4 3 0 kW protective r bod 2 4 3 0 kW connecting switchboard min 3 2 kW switchboard bonding 2 4 3 0 kW as per possibilities 5 per location and location in the building boiler room as per possibilities of the building as per possibilities and location in the building as per the customer s requirement in the building open protection 1 20 Voltage system dimensions 3 PE N 50Hz 400 250 V TN S division Protection against dangerous contact voltage supply from the top via automatic disconnection from the source outlets down Increased protection operation by electrically instructed persons via additional bonding Picture 53 Electrical installation version for input 3 PE N 50 Hz 400 230 V TNS 90T 3 PE N 50Hz 400 250 V TN C S EP1C2510 FA 1 L7 25 3 B m 0 p number of WL WL identification P 1 2 CYKY CSSS CSSS cros
14. message FLUE SENSOR ERROR The boiler operation will not be stopped Faulty temperature sensor Replace sensor Reactivation After faulty temperature sensor replacement by authorized service the error indication will automatically disappear 10 10 STOPPAGE NOT IGNITED This is an error message informing that during the electric ignition process the needed flue gases temperature increase did not occur This situation is evaluated as if the boiler was not working This situation is indicated by a display message Insufficient fuel volume in the burner Check fuel supply in the tank Check feeders functioning Check setting of the parameter Period of adding fuel extend it Fuel not ignited in the burner Time period in parameter Heating period too short extend it Fan output too high lower it Faulty ignition spirals replace Error indication even when boiler is Lower the parameter value Control temperature burning 10 11 FUEL SHORTAGE IN THE TANK This will cause boiler fire extinction This is not a dangerous occurrence This state is not indicated in any way on the boiler control panel The boiler will assess the fuel shortage with a certain delay If the water temperature drops because of boiler fire extinction this situation is assessed as If the boiler runs out of fuel before switching to the stand by mode and the boiler fire becomes extinct in this mode this is assessed as Insufficient amo
15. FlueF100 on6 off38 F035 FlueF070 7 off35 F045 FlueF080 off29 F055 FlueF080 on8 off28 F070 FlueF080 on8 off26 F085 FlueF090 0 8 off24 F090 FlueF090 on8 off22 F095 FlueF100 on8 off20 F100 FlueF100 on5 off28 F051 FlueFO onb off24 F055 FlueF0 on9 off29 F051 FlueFO on9 off25 F057 FlueFO on8 off24 F090 FlueF090 on8 off20 F100 FlueF100 SWT Tank program Program chimneyer settings parameters F1 off F1 on FAN settings parameters F1 off F1 off FAN Advance set time period in which F2 starts before F1 113 Ruin set time period in which F2 stops later than F1 Standby time time period in which automatic boiler is not actively burning for 90 of nominal boiler output for heating HUW for 100 of nominal boiler output for temp of exhaust gas Sec Sec min 11 5 Firing parameters parameters for automatic mode of el Ignitions 11 5 1 Red hot time time when heating spirals are working min 15 15 15 15 11 5 2 Feed time support overthrust of optimal quantity of fuel into burning area for ignition Sec 180 200 200 200 11 5 3 Fan turning on or off of the fan while in ignition 1 1 1 0 11 54 Fan revolution set up of quantity of air which is needed for ignition and flare of the boiler 40 40 11 5 5 Flue fan turning on or off of the fan while in ignition 0 0 1 1 11 5 6 Fan revolution turning on or off of the fan while in ignition and flare of the boiler XXX XXX 60 50 11 97
16. 13 3 We enter the menu by pushing the 0U arrows Here we set the number of Nr 1 feeder cycles after which exchanger cleaning will commence The outfeed spiral screw will operate for a period defined in the following menu Select this menu by pushing the ENTER button and this message will appear 11 By pushing the gt ENTER button again we switch to the time period setting of the outfeed spiral screw time is set in minutes cc is the current value CC is the new desired value and it is flashing The current time period of the ash outfeed spiral screw can by adjusted by the ff arrows Set value confirm by pushing key gt ENTER Return to Menu 11 13 3 by pushing the ESC button We enter the menu by pushing the U arrows Here we set a time window in which we allow regular flue sweeping It is not recommended to perform flue cleaning at night because of possible noise Enter the time period setting function by pushing the ENTER button The desired time parameter can be set by pushing the gU arrows 1 increases the desired time parameter by 1 min decreases the desired time parameter by 1 min switches to previous time value 2 switches to following time value Confirm the newly set value by pushing ENTER button The time value will stop flashing and will be saved in the boiler memory for automatic mode operation Return to Me
17. 15 Automatic boiler for biomass Service manual OPENTHERM connector XV3B is a standard physical layer linking elements supporting the HVAC Heating Ventilation Air Condition interface 4 2 1 4 Description of programming interfaces Programming of the control unit can be done either by the ISP interface service connector XV10 or by JTAG interface connector XV14 For programming and monitoring from a PC it is necessary to use the PROG3 programmer 4 2 2 TE2008 terminal The TE2008 terminal in the E2008 system is equipment programmable by a customer designated as a man machine interface It is designed for placement on the front of the equipment for communication with the boiler operator or the service technician 4 2 2 1 Technical data Supply DC 24V Input from source max 1A type 0 5A Dimensions 182 x 142 x 25 Weight 0 9kg Protection class pursuant to norm CSN 33 2000 4 41 ed 2 2007 II voltage SELV Shielding pursuant to CSN 60529 IP31 independent unit IP65 after integration Basic characteristics setting pursuant to norm CSN 33 2000 3 AA5 temperature 5 40 C AB5 temperature 5 40 C humidity 15 100 BA5 people skills knowledgeable BC3 contact with ground frequent Described in detail in E2008 documentation This equipment is designed in accordance to norms CSN EN 60335 1 and CSN EN 60335 2 Classification in accordance to CSN EN 55014 2 Category II 4 2 2 2 Descri
18. 2 K18 1 SIFH 3Gx1 MODEM EXPANDER MC 35i EEX2008 230 V 40 90 VA EEX X4 X9 Picture 49 Electric connection others COT Picture 50 Sol rn stanice u ab m Regulace sol rn ho syst mu Recommended installations of the boiler connection combine heating 2 gt C2 lt C CO C CO C3 C3 C2 CO C2 SCHEMATIC DIAGRAM INSULATING BARRIER 1 os 4 s FRONTSIDE OF THE BOILER 2 Ir gt 2 222222222 INSULATING BARRIER 2 Y 3 lt 24 0 2211 5 2 XV13B ES 1 ge T ed 1 38 zt T gt POWER SUPPLY 24 BUHL Bg IN x nn Ps 0 5 2 2 COMMUNICATION LINE RS485 0 ki S le 4 LAMBDA PROBE 0 gt MEATSENSORWATERINPUT 4 1 i 24 _ EM E 1 HEAT SENSOR AFTER MIX i JURNER HEAT SENSOR HEAT SENSOR FOR CONBUSTION 525 JTAG MAIN SWITCH i 0 j PROGRAMMING LINE 1 ETHERNET 7 1 1 0 0 i 1 1 lt i i AQDAO ZPD E Ela 4 l 0 0 t EIL 2 K28 i 1 I DS2Y S DC24V ris B PE 13 0 I K28 0 en i 4 05232 MODEM ul RUM BETES ZEN i yyqqu 37 IHE SENSOR OF
19. 50Hz The core of the system is the RJE20068 unit Control is possible either by specialized terminal TE2008 or by a touch screen terminal MTSO6TV Communication with the RJE2008 control unit is provided by the MODBUS communication protocol and it can use the physical layer RS485 for its communication The terminal is power supplied from the control unit which contains DC 20 24V max1A supply source If we use a different terminal from the one supplied by the manufacturer the terminal may have different electrical supply Tf the supply voltage or the maximum terminal demand is outside the listed range special supply must be provided The number of inputs and outputs control of remote units reading data from a distance can be increased by using the EEX2008 expanders The communication between the expander and the control unit is provided by the RS485 bus The E2008 algorithms can operate in real time A remote control and incorporation to a higher up system are possible with the help of a standard communication interface Even mobile phone service is implemented The option of recording all activities by BLACKBOX is built into the system 4 2 1 Control Unit RJE 2008 The mechanical construction of the control unit is based on a standard 19 case terminals have a panel type design and are encased in the equipment covering with a high degree of shielding To communicate with outside units the E2008 control unit is equipped with the f
20. 7 2 FUEL No 2 12 7 3 FUEL No 3 12 7 4 FUEL No 4 12 7 5 FUEL No 5 12 8 RROTARY SENSORS 12 9 GSM MASTER 12 8 1 51 TIME 12 10 CANCEL SERVICE PIN 12 8 2 RS1 PULSES 12 8 1 RS2 TIME 12 8 2 RS2 PULSES Picture 38 Operational block diagram Producer 76 Automatic boiler for biomass Service manual The producer or an authorized service engineer adjust in this Menu types of connection equipment limits of individual parameters so that they correspond to a particular product and prevent the operator from setting parameters which might damage the product for example by output overload MENU 12 Producer will appear on the display unit after a short notification MAIN MENU and adjustment to this menu with the cursor arrows U The following script will appear when the key gt ENTER is pushed A script in the following format will appear by pushing the key ENTER The PIN producer s number code combination which enables access to the user menu is determined by the cursor arrows U The adjusted value is confirmed by pushing the key gt ENTER If the entered PIN value is wrong the following script will shortly appear on the alphanumeric display unit The program will get back to the level The PIN entering procedure has to be repeated If the entered PIN value is correct the following script will shortly appear on the alphanumeric display unit Note The PIN may contain d
21. BASIC DISPLAY en 42 8 DISPOSAL OF PRODUCT AFTER THE END ITS SERVICE LIFE anne 43 p MER 43 LCS zs PRA dU 43 DUREE GE TEEN Ru Era ERE 00 44 91 USER SETTINGS MAIN MEN iecotitrkcxnaunndxtvad ae ea nena ERA AER E DH RA cvi 44 92 OPERATION MODE SELECTION ee dva REI DNO d tuU EQ dT ME Ya GR 46 2 ret 48 9 3 1 Menu I TT ACN 48 9 3 2 Menu 2 Output water temperature setup 1 1 1 nn nnne nnn nnn ne nnn 51 9 3 3 Menu Language selection 51 9 3 4 Menu g 51 9 3 5 Menu 5 SW Tank active 52 9 3 6 Menu G o o D ITEM 53 9 3 7 Menu 7 Suplemental electric rien nenne nnn nnn nnns 53 9 3 8 Menu 9 GSM issus sura senate anna Fama PI RCM UR 54 9 3 9 Menu 9 The equithermal 56 9 3 10 Menu
22. EMT ut 57 SERVIS ubi NINE piii des Ru PUER 57 9 4 1 Menu 11 1 Prog ANS energie ee 59 9 4 2 MIS M MEAE N C 60 9 4 3 Menu 11 3 IR ea ie eu ticles ola IR PEE Pe bes 61 9 4 4 Menu LLA Rr Q 61 9 4 5 Menu 11 5 FIImnd DararBeleE S ein ana aka dd la diri Fa PUN CHE Kad bU D CE 61 9 4 6 Menu 11 6 Putnp on 65 9 4 7 Menu 11 7_SW Tank pump On e euere 65 9 4 8 Menu 118 Tete TO Dtm 65 9 4 9 Menu 11 9 Setup Fans ico ites a a ME dvi 66 9 4 10 Me nu 11 10 BOUNCE OUT U Einer 67 9 4 11 Menu 11 11 Equithermal regulation 01 2 2 6 6 6 nun nennen nnn nennen 68 9 4 12 Menu 11 12 an ON ee een 70 9 4 13 MEM ILIS CEANN sorka EO 72 9 4 14 Menu 11 14 COMM OUIATON sun na a na nw vba ee vu rS TRES 74 9 4 15 Mener 11 15 PISA ETE ETT mm 75 Sa lee SERE 76 9 5 1 EI I m m e 77 9 5 2 Menu 12 2 Water temperature 77 9 5 3 Menu 12 3 Feeder 1 MMS QUE cuv RE a Kw E Er weY Ek EQ PERI en eh EK T 78 9 5 4 Menu 12 PUA een een 79 9 5 5 Menu 12 5 5W Tank nennen 81 9 5 6 Menu 1
23. FEEDER 2 4 e 3 SENSOR OF FEEDER 1 ME XV11B gt 0 KT 2 RESERVE 4 c eS f bs2v s oczav 4 ei XV8B amp gy XV9A 22 ime ul RESERVE 1 MEE 5 XV9B 39 Fre 3 EE B et 7 s 5 2 Q Um id i Lee deep rds eu emi S omm mri Zn lt lt 1 iuga P 3 PUMP X ae eee ERN m 13 16 i I 3 DRAUGHT CLEANING K14 PE L ASHREMOVAL 9 E PE 5 L 0 P en L men 1 Q x PE K23 2 4 15 2 i I SERVOMOTOR D 2 pUMPOFSWTANK 1 LBS 2 E 7 I 3 FLUE FAN E PI y m LE nil mm 2 o 1 x rd 6 1 I EMERGENCY THERMOSTAT OF FUEL TRACKS L t POWER SUPPLY 230V 104 Picture 51 EXPANDER 2008 L x RS 485 o ser He PE 0 4 L BINARY INPUTS EXTERNAL with support power of 12V PROTECTION FU 1 XV2 O openen collector 16B 3 O RELAY OUTPUT 3 4 OUTPUT 2301 6A O 3 OUTPUT 230V 12A Picture 52 Block scheme of EXPANDER connection 2 clips description m 3 PE N 50Hz 400 250 V TN S FA 1 L7 25 3 B
24. FROM FUEL STORAGE F1 feeder delivers fuel from fuel storage to the burning chamber It comprises of a pipe delivery path with an overflow part and an end sleeve The feeder is built into the fuel storage under an angle which cannot exceed 450 If the angle was any bigger fuel could be dispensed inaccurately The transporter has its own electric drive which is controlled by the control unit The feeder is supplied in various lengths accommodating specific types of storage tanks Feeder F1 and F2 gearboxes are equipped with impulse sensors which ensure safe operation of the boiler Feeder F1 set comprises of 4 5 1 Body of feeder with flange 4 5 2 Axle less spiral diameter 38 mm in KP12 KP22 diameter 56 mm in KP62 4 5 3 A small bar for mounting of the spiral 4 5 4 Motor and gearbox 4 5 5 Connecting hose to F2 feeder 4 5 6 Impulse revolution sensor 4 5 2 4 5 4 lt p 4 5 6 A Toj 4 Picture 17 Feeder 1 4 6 BOILER SHEATHING INCLUDING HEAT INSULATION The product sheathing is manufactured from steel sheet metal It is painted with durable paint applied with the powder painting technology KOMAXIT which is highly resistant to outside conditions and ensures long term perfect look of the product Heat insulation 2 or 8 cm thick is done with heat insulation ROCKWOL boards The sheathing consists of the following parts 4 6 1 Left side plate including coverings 4 6 2 Right side plate including co
25. MODE on the keyboard and also directly control individual parameters with cursor arrows lt If IV AUTO MANUAL Switching between automatic operation and manual mode is done with this button Yellow LED near the button is on in the AUTO mode MODE By pushing this button repeatedly we can select the boiler operation mode The display will successively show these signs Currently selected mode is confirmed by pushing the gt ENTER button The control system will switch to MANUAL MODE Switching to automatic mode is done by pushing the button AUTO MANUAL AUTO mode represents automatic boiler operations based on firmly set output the output value is selected by the service personnel MOD mode represents automatic boiler operation The control unit automatically changes the immediate output to one of ten output levels to fit the needs of the heating system in the best possible manner EQT mode is an automatic boiler operation with heating water of defined temperature being let in the heating system The heating water temperature depends on the outside temperature and heat properties of the facility being heated The control unit automatically changes the immediate output to one of ten output levels to fit the needs of the heating system in the best possible manner Note We can switch modes in any random moment of boiler operation Note If a mode with automatic output change MODx EQTx is selected the yellow LED n
26. NN CN 9 4 12 Menu 11 12 Modulation Power output modulation is an automatic mode of the boiler in which the control unit changes the power output as well as the other operating parameters automatically as per the existing need for temperature in the building The goal of this operating mode is to reach a balance between the heat requirement of the building and the amount of heat manufactured by the boiler The program uses automatically the power output values set up in memories 1 10 so that the frequency of undesirable Standby states Important note Some parameters is set for the specific fuel type for the mode modulation The fuel is selected up front in menu 10 MENU 11 12 Modulation will appear on the display unit after the PIN for the Producer menu has been correctly entered and after set uo to this menu has been done by cursor arrows 11 After pushing the ENTER button a short message will appear return to set the program on which the boiler will start to heat after starting the moduation 9 4 12 1 Menu 11 12 1 Starting program We enter the menu of starting program by pushing the ff arrows By pushing key ENTER we will enter set up of the program where the boiler starts heating after modulation has been turned on Using the cursor arrows lt gt determine the new number of the starting program which will be in force after it has been confirmed Confirm the newly set up val
27. Tank is active see chapter 6 SW TANK ACTIVE 42 Automatic boiler for biomass Service manual 8 DISPOSAL OF PRODUCT AFTER THE END OF ITS SERVICE LIFE Product is made out of materials the waste of which does not have any hazardous properties The following main kinds of waste will be generated after the end of the product 5 service life Steel exchanger jacketing feeders bin waste code 170405 category O Heat insulation ROTAFLEX SIBRAL waste code 170604 category O Ceramic grate reflector and plates on door waste code 170103 category O Control unit with sensing and control elements waste code 200136 category O 8 1 NATURAL PERSON Shall perform disposal of the product as follows 8 1 1 Steel waste shall be sold to the nearest scrap yard 8 1 2 Heat insulation and ceramic parts shall be disposed of as mixed municipal waste 8 1 3 The control unit with sensing and control elements is subjeck to return collection Return collection takes place in seller s plant where was this product purchased or at the manufacturer of the boiler Return collection is free of charge In accordance with current requirements of environmental protection the electronic parts of the poduct does not contain lead Still do not dispose el equipment as a municipal waste 8 2 LEGAL ENTITY Shall perform disposal as per Act no 185 2001 Act on wastes as amended Waste shall be sorted as per the kind and category see main
28. boiler is operating in mode of electrrical ignition by values of parameters in specific program set up in MENU 6 and service menu AUTO gt I lt blinking boiler is operating in the mode of electrical ignition and el spirals are in this process MOD1 2 10 Boiler is operating in automatic modul mode by values of parameters stored in memory of CU in MENU 2 5 6 and service menu EQT1 2 16 Boiler is operating in automatic equitherm regulation mode by values of parameters stored in memory of CU v MENU 2 5 6 9 and service menu and by outside temperature SW Tank the boiler is working in the automatic mode of hot service water priority heating as per the values of parameters saved in the memory P10 MENU 5 5 and service menu MANUAL Boiler is not not working in manual mode In Menu 1 Direct control is possible to control individual parts of the boiler and monitor inputs stages STANDBY quiet mode of the boiler when the boiler is not burning actively Boiler is ready on the basis of implus from surrounding equipmnts thermostats GSM Modem to restore the supply of heat AUTO blinking indicates an ongoing process of adding and igniting of fuel in the boiler operating mode without automatic ignition under the STANDBY state B indicates situation when the heater s thermostat is switched in active Blinking letter B will be displayed on the display unit outside the periods of time adjusted in the MENU 5 SW
29. burning or not The ongoing routine of Automatic Ignition may be terminated only by the operator by switching over to the mode MANUAL Service is than responsible for the correct set up to a automatic operation Note If the boiler is working in the mode AUTOx MODx EQTx or SW TANK and power supply is interrupted the boiler will start with the electric ignition routine after the power supply is resumed CHIMNEYER the key is used for service measurement during periodic checks of combustion products Having the key been depressed the boiler will start heating at the adjusted output of the boiler and on the programme entered in the service menu as program chimney 47 Key CHIMNEYER is possible to press in any automatic modeu AUTO C SETUP 4g CHIMNEYER 11 22 MIX 045 SRV 008 AUTO MANUAL wor E 0 sam J peiie MODULATION SETUP 4g CHIMNEYER 11 22 MIX 045 SRV 008 E o moe o o staat 8 Automatic boiler for biomass Service manual GSM FAN MAIN FLUE 1 EQUITHERM SETUP 4g CHIMNEYER 11 22 MIX 045 SRV 008 AUTO MANUAL moe ourPur EJ m staat 8 preii By re pressing key CHIMNEYER boiler goes in to mode in which it was before mode CHIMNEYER Note The control unit only operates in this mode if the boiler is not in the STANDBY state chapter 8 For correct operation it is necessary to
30. for information and depends on the precision of fuel dosing Note Conversion of output is always carried out after a change of fuel dosing or after the RESET of the control unit Note Constant values of the feeder F1 for some types of feeders screw D38mm gear 1 56 K1 0700 wood pellets screw D56mm gear 1 56 1340 wood pellets It is possible then to ascertain easily the constant K1 by weighing a defined quantity of doses of fuel converted to 1 second The factor K1 should be modified as per the following formulation if a fuel the caloric value of which substantially differs from that of wood pellets is used 1 K1 xx MJ 17 MJ where xx is caloric value of fuel in MJ caloric value of wood is 17 MJ Enter the value K1upr into the control unit 67 Automatic boiler for biomass Service manual 9 4 11 Menu 11 11 Equithermal regulation Equithermal regulation is an automatic boiler operation mode which allows heating water of defined temperature to enter the heating system The heating water temperature depends on the outside temperature and the heat properties of the heated building The control unit automatically changes the immediate boiler output between 10 output levels in order to match the requirements of the heating system in the best possible way The program automatically uses output values preset in programs 1 10 in order to minimize frequency of undesirable stand by modes This is a similar mode to output mo
31. for switching the pump is temperature which determine when the boiler is going to be swicthed on Swtcing the pump and cooling down the boiler is as a safeguard agains boiler overheating 9 5 6 Menu 12 6 Fan run out Fan run in is a parameter which defines the working time of the fan after the boiler has entered the STANDBY state Setting makes it possible to improve emission parameters and optimizes fuel burnout Important Note Parametrs for the mode fan run out we set up to a specific fuel type We select the fuel type in Menu 10 pro rezim dob h ventil toru nastavujeme pro dany typ paliva Palivo zvol me predem v Menu 10 MENU 12 6 Fan run out will appear on the display unit after the PIN for the Producer menu has been correctly entered and after set up to this menu has been done by cursor arrows 1 By pushing key ENTER to go to the selection of the time parameter for the fan run in Where dd is the existing set up value DD is the newly required set up value and is blinking The required run out value of the fan can be set up with the cursor arrows f U Confirm the newly adjusted value by pushing the key ENTER The value DD will stop blinking and will be saved in the working register for boiler operation in the automatic mode The values dd and DD are identical now The value DD will start blinking again by repeated pushing the key gt ENTER and may be changed Return back to the menu gt 6 Fan run out lt b
32. is for the equithermal curve selection The equithermal curve defines the relation of the heating water temperature flowing to the heating system and the current outside temperature It is generally true that the worse insulation properties of the heated building the steeper the selected curve Curve 1 fits a building with bad insulation curve 16 reflects a building with a very good insulation MENU 9 The electric supplemental heating will show on the display after a short note MAIN MENU The setting can be changed by the f U arrows By pushing the gt ENTER button display will show Where ee is the current value EE is the new value and it is flashing The desired equithermal curve can be set with gU arrows increases the desired value by 1 decreases desired value by 1 Confirm the newly entered value by pushing gt ENTER button The EE value will stop flashing and will be saved in the boiler operation working register in the EQTx mode The ee and EE values are now identical By pushing the ENTER button again the EE value starts flashing again and can be changed By pushing AESC button you can return to the main menu The EE value is accepted for further use if the new value is confirmed by gt ENTER button the EE value is not flashing If the EE value is flashing it will not be accepted after return to the main menu and the original value ee will be used instead Note The p
33. must have outside protection The relay output X7 expander terminals is designated for general use The maximum load capability of each output is up to 6A and the total current limitation for EXE2008 is 16A Important note This output must have outside protection Note This output can be used as a support of the triac output X5 or X6 to minimize heat loses on the triac Description of expander communication line RS485 line for general use connector X4 and X9 It is connected as a standard two conductor 120 Ohm impedance connector The inner resistance of the receiver is standard 12 kOhm and enables a theoretical connection for 32 line participants Signals A B are spaced to an inactive level by resistors 820 Ohm The line is loaded by an end resistor 120 Ohm 4 2 3 4 Description of EEx2008 expander use The expander and its properties can be used for Control of pneumatic transfer including the turbine soft start Control of pumps for multiple heating circuits Control of spiral feeder motors 18 4 3 Automatic boiler for biomass Service manual BURNER HEATING CHAMBER INCL FEEDER F1 WITH INDEPENDENT DRIVE The heating chamber is depicted in picture Nr 1 and is comprises of these parts 4 3 1 4 3 2 4 3 3 4 3 4 4 3 5 4 3 6 4 3 7 4 3 8 4 3 9 The burner body F2 feeder including the drive Impulse revolution sensor Adapters for installation of a flexible hose Adapter for fan installation
34. of these parts is as follows increase turbulence of combustion products before entry to the exchanger use additionally the so far unburnt residues of the gaseous combustible on the ceramic burning surface direct the flow of combustion products through the exchanger Installation of grate in to working surfase is done trought cleaning door of the boiler Individual parts has to lift in the angle and place in back part of the burning chamber upwards After is pushed all the way up to ceiling of a burning chamber the front side of the ceramic has to lift up in to a horizontal level and than place the ceramic part downwards in to s grooves Grooves of the ceramic grate are in front and back side of a burning chamber Steps Picture 32 Ceramic grate parts placement guide 6 5 INSTALLATION OF CERAMIC SHIELD Picture 33 Ceramic shield Insert the ceramic shield flatways across the boiler space and fit the part on holders over the door from inside See picture no 34 Steps Picture 34 Ceramic top placement guide 36 Automatic boiler for biomass Service manual 6 6 CONNECTION OF ELECTRICAL PARTS The electric parts connections can be performed by qualified personnel only Connect the particular appliances 6 6 1 6 6 14 to corresponding terminals according to drawing in picture 51 During connecting the equipment must be shut down with the main switch or disconnected from power supply by pulling the electric cord from
35. 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 ms x hour of fresh air has to be ensured if a boiler of approximately 20 kW of power output is operated 32 Automatic boiler for biomass Service manual 6 PUTTING THE PRODUCTS INTO OPERATION 6 1 CONNECTION TO THE SYSTEM Connection to the system is performed in a usual manner see the below given installation dimensions of products Recommended connection of the boiler to the heating system see pict no 40 52 Important With boilers KP 62 KP 62E it is important to have both water output connect Picture 28 Installation dimensions of boiler Filling the system with water takes also place in a standard way and the following principles have to be adhered to at the same time water for the heating system has to be clean free from any admixtures Its hardness has to meet the Czech standard CSN 07 7401 1992 if the hardness does not meet this standard it has to be treated with a corresponding softener if extremely hard water is used there is a risk of scale formation which is to the detriment of heat exchange KP 12 12 1 Output of heating water G 1 1 2 2 Heating tube 0130 mm 3 Input of return water G 1 1 2 4 Eletric heater M 48 2 5 Outlet valve G 1 2 KP 22 22 1 Output of heati
36. power and connecting parts 0 00 13 PROCESSOR xin T 13 DEseription or LSP ROO DD QE 16 2 2 ette net e Xo a iesu a Epi 17 Burner bOSKP12 KP22 ne elut RES 19 BUMEFKPOZ mieri ET cui DUM fmc MR ELE 20 KP62 with cleaning Ur P rA IATER 20 Cer reflector NP 12 22 een 22 Twuospart cer Fetlector KPOZ a ee Ee PR Eco t 22 Ceramic SING IG ren 22 Ceramic secondary Gl ale 22 22 Rost Tr 23 drap EE ETE 24 JACKEN KP22 MEE 24 E 25 E AO 26 Exchanger cleaning System 3 vata skin kx AE nn nun naar 27 External dspeontaltler 27 Fue eet
37. pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 12 Note The principle of the operation of the boiler in the modulation mode is obvious from the attached diagram on the picture no 50 Important If we change the regulation period for example in case of small heating systems or on the contrary in case of large ones it is also necessary to change the values of temperature gradients in order to preserve the regulation dynamics 9 4 13 Menu 11 13 Sweeping cleaning 9 4 13 1 Menu 11 13 1 Burner cleaning This menu is not used for operation of KPx2 model line boilers The function must remain OFF during the whole operation time 9 4 13 2 Menu 11 13 2 Ash The program of this Menu provides automatic ash take out from the burning chamber into external ash container The ash volume depends on the type of used fuel on the boiler output and the heating time period Therefore the activation of the outfeed spiral scroll is directly tied to the number of Nr 1 feeder cycles We enter the menu by pushing the f 0U arrows When you push the ENTER button We will enter the Menu in which we either allow or prohibit the ash removal function By pushing ENTER button we enter the ON OFF switch for ash removal By repeatedly pushing ENTER button we will select the desired ON OFF mode By pushing the ESC button
38. resistant to humidity are recommended for appliances with temperature of combustion products from 30 C to 100 C 5 3 3 Fire regulations CSN 73 0823 1984 fire and technical properties and combustibility grades CSN 06 1008 1997 fire safety of heat installations structure of boilers from fire safety aspect 5 3 4 Electrical Government Regulation no 17 2003 Coll CSN EN 60 335 1 ed 2 20073 Electrical appliances for domestic and other similar use Safety General requirements CSN EN 60 335 2 102 2007 Safety Part 2 102 Special requirements for appliences burning gas petroleum and solid fuels containing electrical connections 5 3 5 Protection against noise Government Regulation no 148 2006 Coll product is fullfilling all requirements 5 4 STORAGE OF FUEL Wood pellets have to be in a dry place protected against atmospheric effects because humidity damages the and aggravates their burning parameters Excessive humidity completely destroys pellets They should be stored in a different room than the boiler or at least 1 500 mm from the boiler Operating stock of fuel may be stored in a special central bin which has to be manufactured from non combustible material Bins supplied by the manufacturer meet operating and safety requirements 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
39. thermostat reset button You must hear the trigger click The red reset button is accessible without any tools by removing the top boiler cover and unscrewing the black coverings Shut down the control unit with the switch for about 5 seconds and then turn it on again Now the control unit is ready for further operation in the MANUAL mode After that it is possible to switch to automatic boiler operation by pushing the START and ENTER buttons if the equipment was shut down for a long time by pushing the AUTO MANUAL button if the boiler is still burning 10 2 STOPPAGE OVERHEATING OPERATION THERMOMETER The control unit has a program routine which stores the emergency thermostat control If the operation thermometer indicates a temperature higher than 1009C the boiler control unit will assure the boiler is shut down This situation is indicated on the display by this message Only the circulatory pump is running for heat removal from the boiler exchanger Under normal conditions boiler overheating does not occur therefore this situation is considered an emergency 86 Automatic boiler for biomass Service manual Faulty emergency thermostat Replace the emergency thermostat The emergency thermostat probe is not Insert and tighten the emergency thermostat inserted in its well probe in the well Service personnel attention is required because it has to be determined why this state of failure occurred and
40. to prevent escape of flue gases Chimney and boiler connection must have valid inspection 6 7 5 Check functionality of circulatory pump and its deaeration 6 7 6 electrical grid outlet must be always accessible New electrical outlet must have a valid inspection 6 7 7 Check the heating chamber and ash receptacles Clean from possible dirt 6 7 8 Check tank filling by specified fuel 6 7 9 Check operating parameters for the specific boiler type 7 BOILER SERVICE AND MAINTANANCE DURING OPERATION Service and maintenance intervals are directly dependent on the type and quality of used fuel If recommended fuel wood pellets with clearly guaranteed quality parameters is used service and maintenance of the product during operation is very simple 7 1 SERVICE Pellet boiler service comprises of only two tasks The necessary presumption is use of guaranteed fuel endorsed by the manufacturer As a standard use wood pellets with the 6mm or 8mm diameter 7 1 1 Refueling The fuel level must be maintained in such height that there is always a minimum of 10cm pellets above the F1 feeder inlet Insufficient pellet volume may result in irregular dispensing or boiler fire extinction You will be told the presumed refueling interval by the service technician according to your specific configuration Note The refueling interval cannot be prescribed ambiguously It depends on Fuel bin size The average boiler output in the particular
41. 2 6 Fan run out issseoscsias na eie pEr EY ou Pia RE ER VE 82 9 5 7 Menu 12 7 Flue fart sinisen een EYE WE RO etw ea M SOC Fr 82 9 5 8 Menu 12 9 Rotary SCNSONS ee een P EUP TID LC LEE 82 9 5 9 Menu 12 9 GSM Emm 84 9 5 10 Menu 12 10 Service PIN meme nennen nes 84 9 5 11 Merig 12 11 Charge OF anna anna re rn aan era 84 26 MENU SOFTWARE VERSION en ea ee erden 85 9 7 MENU 14 CODE ENTERING ea ea ne SE ee 85 6 EIER ALINA co MUST FM CMM RU NM MUNI AU RR nee ONCE 86 10 1 STOPPAGE OVERHEATING EMERGENCY THERMOST T 1 rien rn rina rk ru rn rk a n n rr 86 10 2 STOPPAGE OVERHEATING OPERATION THERMOMETER na 86 10 3 STOPPAGE OVERHEATING IN THE FUEL 87 10 4 STOPPAGE BECAUSE OF FAULTY ATTENDANCE 5 52 5 naar ak aima y aima a aura rn rax n irai 88 10 5 STOPPAGE BECAUSE OF LOW WATER nene nennen nennen nnns 88 10 6 STOPPAGE BECAUSE OF LOW FLUE GASES TEMPERATURE 88 10 7 SER TE EN ENT T Rm 89 10 8 TEMPERATURE SENSOR 2
42. 50Hz Control unit supply max 40VA Total maximum input 2kW depending on outputs Dimensions 450 x 155 x 50 Weight 2 8 kg Protection class pursuant to CSN 33 2000 4 41 ed I 2 2007 Protection from dangerous touching of live parts pursuant to CSN 33 2000 4 41 ed 2 2007 Protection from dangerous touching of non live parts automatic disconnection from pursuant to CSN 33 2000 4 41 ed 2 2007 basic source Protection from dangerous touching of non live parts pursuant to CSN 33 2000 4 41 ed 2 2007 increased By connecting amended Shielding pursuant to CSN 60 529 IP31 By covering and insulation Basic characteristics setting pursuant to norm CSN 33 2000 3 5 temperature 5 40 5 temperature 5 40 C humidity 15 100 BA5 people skills knowledgeable BC3 ground contact frequent Described in detail in E2008 documentation This equipment is designed in accordance to norms CSN EN 60335 1 and CSN EN 60335 2 Classification is in accordance to CSN EN 55014 2 Category II 4 2 1 1 Description of RJE2008 inputs Unless specified otherwise the majority of inputs is connected directly or through a converter to the processor module and may not be connected to power circuits and outside sources of dangerous voltage The input terminals are protected against outside conditions EMC but they are galvanically connected with the terminal See the VN barriers in the drawing picture No 53 Therm
43. 8 GSM modem will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows ff U 8 GSM modem By pushing the ENTER button display will show By pushing the ENTER button display will show Or By pushing ENTER Button we change GSM modem function By repeatedly pushing the ENTER button you can change the ON OFF setting Further menu selections are available by pushing the pU arrows We will use this MENU to adjust the number the control unit will communicate with Failure SMS reports will be sent to this number A twelve digit number including national area code will appear by pushing the key 2 ENTER for example Adjust the required number by cursor arrows Jf increases the value of the number in step of 1 reduces value of number in step of 1 lS moves to the neighbouring digit to the right es moves to the neighbouring digit to the left Add character after last valid number By this you will define amount of valid numbers Confirm the adjusted number by pushing the key ENTER The following script will appear of the display unit Having this been confirmed by pushing the key ENTER the control unit in cooperation with the modem will make a check call to the selected telephone number This state is indicated by the following message while the number is being dialled and ringing Finish the check ca
44. Connecting hose from inflammable material Main fan Electrical resistance spirals for automatic ignition Cleaning equipment for the burner in KP62 agro burner for burning less efficient fuel Picture 9 Burner 50 KP12 KP22 19 Automatic boiler for biomass Service manual 4 3 3 Picture 10 Burner KP62 Picture 11 Burner KP62 with cleaning 20 Automatic boiler for biomass Service manual The burner body is a hollow weldment made from highly legated material with a bottom transversal fuel inlet The fuel is delivered by a built in 2 feeder driven by an electric motor with a gearbox A set of slit and round jets in the burning grill ensures inflow of air in order to facilitate controlled full burning of delivered fuel during its stay in the burner chamber The burned out fuel is subsequently pushed over the edge of the chamber into the ash receiver The inner space of the burner body is connected to an a r fan whose revolutions can be regulated within a large range depending on the required boiler output or the type of fuel being used See MENU 11 9 Fans chapter 9 4 9 Impulse revolution sensor The gearboxes of the F1 and F2 feeders are equipped with impulse sensors which ensure safe operation of the boiler Connecting hose to the F1 feeder made of inflammable material connect feeder 1 and feeder 2 It is part of the transfer fuel lines It must meet strict installation rules It cannot have signific
45. ELIGNITION PUMP SWT PUMP SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 CYSY 4x0 5 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH 36x p eb Gr 4 My 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 90 VA 90 VA 90 VA 90 VA 40 90 VA 500 VA 500 VA 45 VA 45 VA Picture 41 Electric connection of hydraulic scheme 1 x HC SWH Tan v6 j E 1 j PERS a ea Gay 1 4 1 E ES E ua nn R E i i m 1 I s 1 4 T lc i iiie Picture 42 Hydraulic scheme 1 x HC SWH Tank 56 XV11B XV11A XV5B XV3A XV6B XV13B RSENS1 RSENS2 T MIX TRETW GAS ROOM THER SWT THERM SYKFY 2x0 8 SYKFY 2x0 8 12V DC 12V DC 192 19 1 142 Kis1 iK 18 2 K 48 1 K 16 1 Ki152 23 1 232 132 Ki62 __ gt gt L FEEDER 1 FEEDER2 ASH SWEEPING SERVO EL IGNITION ELIGNITION PUMP SWT PUMP SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 CYSY 4x0 5 SIFH3Gx1 SIFH3Gx1 SIFH3Gx1 SIFH 36x p eb Gr 4 My 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 90 VA 90 VA 90 VA 90 VA 40 90 VA 500 VA 500 VA 45 VA 45 VA Picture 43 Electric connection of hydraulic scheme 1 x HC SWH Tank 96 Hydraulic scheme 1 x HC SWH Tank P
46. Flare time time set up in which fuel must be provided to a burner for perfect fire through all surface of burner min 2 2 4 4 11 5 8 Referent temp the minimum values of differences between water and flue gas temp at the end of ignition process C 10 10 10 10 11 5 9 Check burnt time out after changeover from STANDBY state after which CU makes reference temp measuring min 7 7 10 10 e determine value of boiler water temp when the pum will start to circulate water in the system C 1 7 SWT pump on determine value of boiler water temp when the pum will start to circulate water in the system for SWT C 1 8 Change of service PIN posibility of service PIN change in each boiler Fans set up of the type of used fan Main fan type Selection of main fan type control by used fan Flue fan type Selection of flue fan type control by used fan Boiler output menu for calculation of output data on display Output rated output of the boiler KW 19 29 weight of the fuel supplied by feedeer F1 per 1 second g sec 10 0 a OD Constant of feeder Without Flue fan 11 11 TATA 11 11 2 11 11 3 11 11 4 11 11 5 11 11 6 Equithermal regulation Starting programs Gradient low Gradient upper zone zone Regulation period Modulation Starting programs Gradient low Gradient upper zone zone Regulation period Parametrs for automatic mode when CU ch
47. If both switches are simultaneously activated by operator mistake or by a program failure both outputs will remain without voltage The maximum load of each output is up to 6A and the current total limitation for RJE2008 is 10A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals show grid voltage The setup of the prongs enables for instance connection of a SERVA four way valve in solid fuel boilers 4 2 1 3 RJE2008 communication lines description RS485 line to the terminal XV2 connector This line is connected as a standard two wire conductor to 120 Ohm impedance The inner resistance of the receiver is standard 12 kOhm and enables theoretical connection for 32 line participants Signals A B are spaced to an inactive level by resistors 820 Ohm The line is loaded by an end resistor 120 Ohm RS485 line for general use XV4A connector This line is connected as a standard two wire conductor to 120 Ohm impedance The inner resistance of the receiver is standard 12 kOhm and enables theoretical connection for 32 line participants Signals A B are spaced to an inactive level by resistors 820 Ohm The line is loaded by an end resistor 120 Ohm RS232 line connector XV12A contains RxD TxD and RING channels The fourth connector pin is GNS The line is designated for general use voltage levels are standard 10 to 12V Transfer speed up to 115 kBit
48. TUP 4g AUTO7 11 22 045 SRV 008 AUTO GSM MANUAL oO MAM FLUE me 8 DUTPUT stant CHIMNEYERL START If the automatic ignition is permitted ba the programme the main MENU 6 the following scripts will gradually appear by pressing the key ALARM GSM FAN MAIN FLUE T 44g AUTO7 AUTO C SETUP MIX 045 SRV 008 AUTO MANUAL ourputr START CHIMNEYERLJ 11 22 GSM FAN MAIN FLUE I MODULATION SETUP 4g AUTO 11 22 045 SRV 008 AUTO MANUAL Oo START I EQUITHERM SETUP ug AUTO7 11 22 MIX 045 SRV 008 aa E wor ourPur EJ START _ If we confirm this offer by pressing the key ENTER the boiler will start themode of automatic ignition which is indicated by blinking script AUTO and gt I lt If automatic ignition is prohibited by the programme the main MENU 6 the following script wiil gradually appear by pressing the key and control unit will return back to mode MANUAL Note The programme routine of Automatic Ignition has absolute priority to be carried out in full extent If the routine is activated it is not possible to interrupt or stop it in any way This fact is an important condition for reliable operation of the boiler because it is then possible only to ascertain indirectly from further behaviour of the boiler whether it is
49. The minimum and maximum CC values are limited by the producer Note The recommended temperature to switch the SW Tank pump in is 60 Hot service water is predominantly heated up to this temperature If the pump is switched in at lower temperature the water heated in the heater will be cooled down through the boiler 9 4 8 Menu 11 8 Pin change The service engineer may use his her own PIN in case of a particular boiler Thus he she is sure that the operating parameters adjusted by him her will not be changed by the user MENU 11 8 PIN Change will appear on the display unit after the PIN for the menu SERVICE has been correctly entered and after adjustment to this menu with the cursor arrows ff By pushing the button ENTER to select this menu and the following script will appear 0 is blinking at the same time The PIN user number code combination which enables access to the service menu is determined by the cursor arrows gt The adjusted PIN value is confirmed by pushing the key gt ENTER The following script will appear on the display unit 0 is blinking at the same time The operator has to enter identical PIN again The adjusted PIN value is confirmed by pushing the key gt ENTER again The PIN will be compared with the previously entered PIN and if both of them are identical the new PIN value will be accepted and the following script will shortly appear on the alphanumeric display unit 65
50. able by pushing the ff U arrows Note Serviceman or a manufacturer will set this value by the technical requirements of the boiler When using he function of Suplemental electric heating t s necessary to equip boiler with heating spirapls build in the boiler Note The electric supplemental heating spirals output is defined by the user or the designer The manufacturer will equip the boiler with the proper spirals based on an order Professional firm can perform the spirals mounting later 53 Automatic boiler for biomass Service manual By pushing ESC button we are returning to mode MANUAL AUTOx MODx EQTx BOILER or it is possible to continue by pushing 0 ff arrows to future menu selection Note If the output Menu 11 4 Configuration is used for different function than electric heating an attempt to set this function will result in a not installed message 9 3 8 Menu 8 GSM modem Activity of the control unit for cooperation with GSM modem is adjusted in the menu Authorized participants for operation of the boiler are determined by defining telephone numbers for communication The system enables remote control and monitoring of individual boilers as well as a network of boiler rooms The function of an order activated via the GSM modem is active until the moment of the next operation of the control unit with the keyboard Modem is installed by manufacturer or a service organization by the customer needs MENU
51. able material which ovelap min 10 cm over the platform of installed quipment Floor in front of the cleaning door has to be out of non flammable material and min 60 cm The necessary height over the boiler to the ceiling of the boiler room is approximately 450 mm 600mm with KP62 for cleaning of the boiler 5 2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL COMBUSTIBILITY GRADE OF MATERIALS Grade A non combustible stone concrete bricks plasters etc Grade B hardly combustible inorganic insulation Rotoflex glass wool basalt insulation wood wool slabs etc Grade C1 low combustible formica versalit fibreboard hardwood beech oak Grade C2 moderately combustible soft wood spruce chipboard rubber floor covering Grade easily combustible asphalt tar paper PVC paper etc Minimum safe distance from bulk flammable materials of the type and is 200 mm in course of installation of the boiler as well as during its operation This distance is double i e 400 mm for easily combustible materials C3 As regards relation to the electrical network it is necessary to ensure that the wall socket where the boiler is connected is always accessible 5 3 LEGISLATION IN FORCE The product may only be installed by an organization trained by the manufacturer with authorization Electric parts may only be connected by an authorized person CZ the regulation number 50 1978 on professional c
52. after run of the burner s feeder F2 of the automatic solid fuel boiler can be controlled with the cursor arrows U This feature of the control unit is of use in case of boilers with two stage solution of transport routes of fuel The run in time determines the period of time in which the burner s feeder is in operation longer time then the primary feeder F1 This feature of regulator facilitates passage of fuel and maintains transport routes without fuel This has effect on safe operation of the boiler and prevents from blazing the fuel in the transport routes The adjustment procedure is the same as that in the previous chapter Note The range of values RR is determined within the interval of 10 xx s where xx has to be a value less than the sum of the values feeder off feeder on run in The software checks this value and will not allow its adjustment outside the above mentioned range Note The adjusted value of run in is in force for all programs 9 4 4 Menu 11 4 Standby Is an operating condition of the boiler when there is no requirement to deliver heat energy See chapter 8 Automatic operation MENU 11 4 Standby Time will appear on the display unit after the menu SERVICE has been entered and after adjustment to this menu with the cursor arrows U gt 4 StandbyTime lt By pushing the gt ENTER button display will show where uu is the existing adjustment value UU is the newly required adjustment value and is blin
53. anges output and temperature of output water Program set up when boiler will start after equitherm regulation turn on 5 lower limit of steepness of regulation curve C 9 upper limit of steepness of regulation curve C 12 temperature interval during its reaching the output goes down by other output stage C temperature interval during its reaching the output goes down by 1 output stage C 5 period for evaluation of set up and reached output parameters min 10 parameters for auto mode during which CU auto change output according to actuall thermal need Program set up when boiler will start after equitherm regulation turn on 5 lower limit of steepness of regulation curve 9 upper limit of steepness of regulation curve 12 temperature interval during its reaching the output goes down by other output stage 3 temperature interval during its reaching the output goes down by 1 output stage 9 period for evaluation of set up and reached output parameters 11 13 Sweeping cleaning set up paramenters for cleaning mechanism of the boiler 11 13 1 Cleaning of the burner this menu is not used has to be permanetly disabled m a off 11 13 2 11 13 21 11 13 22 11 13 2 3 11 13 3 11 13 3 1 11 13 3 2 11 13 3 3 11 13 3 4 11 13 9 5 CTI Ash ON OFF Number of feeding Feedend time Flue gas sweeping ON OFF Number of feeding Feedend time Time zone Flue fan revolution Configuration Config K15 1 Conf
54. ant folds which would block smooth fuel movement and must be built with an inclination of minimum 50 in a relation to horizontal plane Attachment to both adaptors must be tight Cleaning of KP62 burner provides removal of excessive ash or cinder volume from the burner when burning lower quality fuel The drive of the cleaning mechanism is works together with ash cleaning Note Use of alternate fuels requires change of the burner type and also change of boiler program setup Note The cleaning mechanism burner drive and its installation are depicted in chapter 4 7 Cleaning system 21 Automatic boiler for biomass Service manual 4 4 CERAMIC PARTS These parts are an inseparable component of the combustion chamber of the boiler and they have a major influence on the quality of burning 4 4 1 Ceramic reflector placed on the top of the burner 4 4 2 Ceramic secondary grate placed in the boiler body above the burner heating chamber 4 4 3 Ceramic plate placed above the door 4 4 4 Ceramic door jacketing mounted on the door y 1 4 ET y Mw x 2 QUEE Picture 12 Cer reflector KP 12 KP 22 Picture 13 Two part cer reflector KP62 KP 62 A AA Picture 15 Ceramic secondary grate Picture 14 Ceramic shield Picture 16 Ceramic door casing 22 Automatic boiler for biomass Service manual 4 5 F1 FEEDER WITH INDEPENDENT DRIVE
55. appear on the display unit after the PIN for the menu SERVICE has been correctly entered and after adjustment to this menu with the cursor arrows 12 By pushing ENTER button to select this menu and the following script will appear Where cc is the existing adjustment value CC is the newly required adjustment value and is blinking The current temperature of the output water which will turn the circulation pump on can be changed with the cursor arrows Note The minimum and maximum CC values are limited by the producer Note The value ofthe pump temperature is set by manufacturer to 55 CH Note Run up of the pump from a temperature higher than the so called condensation temperature approximately 55 has a significant effect on the service life of boilers 9 4 7 Menu 11 7 SW Tank pump on Will determine the boiler water temperature at which the circulation pump to heat the hot service water will start working MENU 11 7 SWTank pump on will appear on the display unit after the PIN for the menu SERVICE has been correctly entered and after adjustment to this menu with the cursor arrows U By pushing the button ENTER to select this menu and the following script will appear Where cc is the existing adjustment value CC is the newly required adjustment value and is blinking The current temperature of the output water which will turn the SW Tank pump on can be changed with the cursor arrows U Note
56. articular building has an equithermal curve constant which is defined by the building construction The equithermal curve must be changed only after changes such as windows replacement adding of insulation heating system remodeling etc Note The equithermal curve is generally set by assumption and is adjusted based on test runs After correct setting it is not changed anymore 100 L ERIT TEMPERATURE OF THE HEATING WATER 4LLLLLLLLLLLLLLLLLL jt 0 35 32 29 26 23 20 17 1 8 5 2 16 19 TEMPERATURE Picture 36 Equithermal curves 1 16 56 Automatic boiler for biomass Service manual 9 3 10 Menu 10 Fuel selection This MENU is for selection of fuel MENU 10 Fuel will show on the display after a short note MAIN MENU The setting can be changed by the DV arrows By pushing the ENTER button the display will show the currently selected fuel type and the type of the selected fuel Different type of fuel can be set by the arrows Change the new fuel setting from OFF to ON by pushing the ENTER button This way a new type of fuel is selected The previously used fuel type is automatically turned off By pushing ESC button you can return to the main menu Note Boilers of the KP x2 model line are adapted for burning of different fuels Feasibility of fuel other than the guaranteed type must always be consulted with the manufacturer or with an authorized se
57. as been correctly entered and after setting to this menu has been done by cursor arrows ff 0U 9 5 3 1 Menu 12 3 1 Feeder on lower limit The following script will appear by pushing the key ENTER By pushing key gt ENTER to go to the selection of the lower value of the operation time of the feeder F1 Where dd is the existing adjustment value DD is the newly required adjustment value and is blinking Use the cursor arrows U to adjust the required value for the lower limit of operation time for the feeder Fi Confirm the newly adjusted value by pushing the key gt ENTER The value DD will stop blinking and will be saved in the working register for boiler operation in the automatic mode The values dd and DD are identical now The DD value starts blinking by repeated pushing the key gt ENTER and may be changed Depress the key ESC to return to the menu gt 1 F on low li The value DD has been accepted for further use provided the new value has been confirmed with the key ENTER the value DD is not blinking If the value DD is blinking it will not be accepted after the return to the MAIN MENU and the original adjustment value dd will still be used 78 Automatic boiler for biomass Service manual 9 5 3 2 Menu 12 3 2 Feeder on upper limit We will enter the following menu by means of the cursor arrows U By pushing key gt ENTER to go to the adjustment of the upper limit of the operati
58. c ee Tree 28 Collapsible bin assembly nennen nnne nnn nnn 30 PREG CSG CUTIE tcp E T 32 Installation dimensions of DOG sisse eno a Sar oca Ro E x Ka e Pe e o p e RED EE 33 Burner installation in Doller eset ouv ve Eee Cia MEC Y dba kr C RE EO ERI 34 Ceramic lated ene iN ee 35 Parts of secondary ceramic 6 35 Ceramic grate parts placement 4 4 36 S rne 36 Ceramic top placement guide 1 66 nnne manne sanae nnne nnn nuns 36 Operation block diagrarm e 45 EduithermalculVes 16 mre up MR TR MT ME M IM UM EE 56 Operational block diagram Service nennen nun nun nennen nnn ne nnn nnn 58 Operational block diagram Producer 76 Principle OF EMG
59. cal installation version for input 3 PE N 50 Hz 400 230 V 5 107 Dim for the placement of 2 in boiler room exam of using collecting troughs 108 Directory information consuption wood pellets for boiler family 109 Automatic boiler for biomass Service manual LIST OF TABLES Table 1 Thermal and technical parameters of 7 Table 2 Solid harmful substances in combustion eene nenne nnne nnn nnn nnns 7 Table 3 Technical parameters of products 1 1 1 7 Table 4 Electrical parameters Of DLOGLIGEUS us cse Ease rp E DES URN ES 7 Table 5 Fuel and Is Daralmietels ossisqqat diria iu ra C x PAR LEN MEL eT Ld 7 Table 6 senings SEF Ver Ve Dad wa rater uas ter dip prada oni E E 110 Table 7 setings Service TT oos secs PEERS EE 111 Table 8 Settings Producer ver een 113 Automatic boiler for biomass Service manual 1 IMPORTANT NOTES This product may only be put into operation by an installation organizatio
60. control unit Pa EI Protection ofthe boilers wing Po Table 5 Fuel and its parameters Wood pellets diameter 6 0 8 5 mm approximately 16 18 MJ kg Water content Up to 10 96 Ash content Up to 1 0 8 1 0 Bulk weight 0 6 0 64 kg dm3 Fuel delivery system PE PP bags 15 25 kg bags Big Bag by 800 1100 kg loose fill cistern As a guaranteed fuels for all KP boilers are wood pellets with parameters specified in table 5 Automatic boiler for biomass Service manual Boliers KP x2 are adapted for a burning of different kinds granulated fuels Correct use of other than granulated kind of fuel has to be always consulted with a manufacturer or an authorized service center Authorized service center will make a professional set up of the boiler for the type of the fuel which was specified by you 4 STRUCTURAL DESCRIPTION OF PRODUCTS The structure adheres to the Czech standard CSN EN 303 5 2000 i e boilers for central heating part 5 boilers for central heating with automatic fuel feed of rated heat output up to 300 kW Main parts of the boiler are 4 1 Boiler body 4 2 Control unit of the boiler E2000 4 2 1 control unit RJE 2008 4 2 2 control terminal TE2008 4 3 Burning chamber 4 3 1 feeder F2 with independent drive 4 3 2 connecting flexible house 4 3 3 main fan 4 3 4 spirals for el ignition 4 4 Ceramic parts 4 4 1 ceramic reflector 4 4 2 secondary ce
61. d the telephone mode is turned off Note The REM ON and REM OFF commands require installation and interaction with the room thermostat Siemens REV 23 Note After receiving a text message and switching the control unit to remote control the LED diode GSM will be on The remote control is ended by receiving a NORMAL text message or by pushing any button on the control unit boiler attendants are at home Note The control unit communicates only with telephone numbers which the service personnel and the service organization have put into it Note The text message structure sent by the control unit is as follows DISPLAY AUTO8 12 20 T2040 PT 1 BT 0 MODULACE 0 Pon 05 Poff 30 V 056 Tsp 145 256 60Kc The meaning is Tsp 145 Current burnt gases temperature 256 60Kc Remaining SIM card balance V 056 Current setting of the fan 56 55 Automatic boiler for biomass Service manual Note The error text message structure sent by the control unit is as follows DISPLAY STOP STAGEx 12 20 status control unit display DISPLAY STOP TEPL gt 95 status control unit display DISPLAY STOP TEPL gt 100 status control unit display DISPLAY STOP NO FIRE status control unit display DISPLAY Blocked FEEDER x status control unit display DISPLAY STOP EMER THERMx status control unit display Errors description is listed in Chapter 10 Error messages 9 3 9 Menu 9 The equithermal curve This MENU
62. dulation Important role is assumed by the servomotor The boiler water temperature value at which the boiler switches to the STAND BY mode is flexible and is by 159C higher than the required heating water equithermal temperature The low value is limited to 609C Important note Some parameters for the modulation mode are set for the given fuel type Fuel is selected beforehand in Menu 10 MENU 11 11 Modulation will appeared on the display after correctly entering PIN in the service menu and setting by using QU arrows After pushing the ENTER button a short message will appear We enter the program settings the boiler will use for heating after modulation start 9 4 11 1 Menu 11 11 1 Start program We enter the menu by pushing the f U arrows Select the program the boiler will start heating after modulation activation by pushing gt ENTER button Set the new start program number valid after confirmation by pushing the ff gt U arrows Confirm the newly selected parameter by pushing gt ENTER button The value NN will stop flashing and will be saved in the boiler memory for automatic mode operation Values nn and NN are now identical By pushing the ENTER button again the NN value starts flashing again and can be changed By pushing MESC button you can return to the main menu is accepted for further use if the new value is confirmed by the ENTER button
63. e SW TANK s thermostat in the adjusted time period and the boiler will operate in the mode SW TANK The signal from the SW TANK will be ignored outside these time periods This state is indicated by blinking letter B on the display unit before the value of time MENU 5 SW TANK active will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows f U The following script will appear by pushing the key gt ENTER on the display unit and after a short script MAIN MENU and after setup to this menu with cursor arrows OU The following script will appear by pushing the key gt ENTER The script will appear by repeated pushing of the key gt ENTER and hh is blinking hh is the time value in hours of the bottom limit for the time period 1 mm is the time value in minutes of the bottom limit for the time period 1 HH is the time value in hours of the top limit for the time period 1 is the time value in minutes of the top limit for the time period 1 The current state of hours or minutes may be changed by cursor arrows ff IV 0 increases the value of hours in step of 1h g reduces the value of hours in step of 1h If the bottom limit value in hours is adjusted go on to the setup of minutes by pushing the cursor arrow or by pushing the key ENTER Oo ft increases the value of minutes in step of 1min g 0 reduces the value of minute
64. e advance is significant to ensure fire safety of the boiler MENU 11 2 Advance will appear on the display unit after the menu SERVICE has been entered and after adjustment to this menu with the cursor arrows U The following script will appear by pushing the key ENTER 22 Advance By pushing gt ENTER button display will show Where aa is the existing adjustment value AA is the newly required adjustment value and is blinking Adjustment of the required advance operation time of the burner s feeder of the automatic solid fuel boiler can be controlled with cursor arrows fl 2 This feature of the control unit is of use in case of boilers with two stage solution of transport routes of fuel The advance time determines the period of time in which the burner s feeder F2 will start working before the feeder F1 This feature of regulator facilitates passage of fuel and maintains transport routes without fuel This has effect on safe operation of the boiler and prevents from blazing the fuel in the transport routes nn increases the required advance time of the feeder in steps of 1s ov reduces the required advance time of the feeder in steps of 1s We will confirm the newly adjusted value by pushing the key gt ENTER The value AA will stop blinking and is stored in the working register for operation in the automatic mode of the boiler The values of aa and AA are identical now The value AA will get blinking agai
65. e engineer this code has to be stored well If the PIN is lost an intervention of the producer s employee is necessary 9 4 1 Menu 11 1 Programs Timing of feeders and rotations of the fan are adjusted in this menu in order to adjust outputs and optimum combustion MENU 11 1 Programs will appear on the display unit after the correct PIN has been entered in the menu Service Depress the key ENTER to get into the menu to adjust operating values of the boiler for individual programs Fuel x is possible to select in menu 10 If you want to set a power of the boiler and using a specific kind of fuel first select this fuel in menu 10 chapter 9 3 10 Use the cursor arrows it is possible to select program no 1 10 Boiler program Chimney program Note SW Tank program gets activated upon a request to deliver heat into the tank for the hot service water Note Chimneyer program gets activated under the mode of CHIMNEYER adjusted by pushing the key on the keyboard By puching the key ENTER to change parameters of a selected programs where the value 05 is blinking ON is the value of feeder 1 operation in seconds OFF is the idleness time of the feeder 1 in seconds V is the value of fan s rotations in Flue itis a value of the flue fan revolutions Fuel 1 number of currently selected fuel type 59 Automatic boiler for biomass Service manual New values for feeder 1 and the fan can be set by usi
66. ear the button is turned on The control unit switches automatically between ten output levels according to a preset mode x is the number of current output AUTO MODULATION EQUITHERM 48 EQT1O 11 22 045 SRV 008 mL EE SETUP Er ALARM C SETUP ALARM Ag AUTO7 11 22 MIX 045 SRV 008 E AUTO AUTO GSM 1 mama El AN FAN MAIN FLUE MAIN FLUE MODE EJ staat E CHIMNEYEREZ MODE EJ sam 8 OUTPUT Manual setting of the output level can be done in the following manner a Select the AUTO mode and confirm by pushing the ENTER button The boiler switched to the MANUAL mode b Push the OUTPUT button the current output setting can be changed by the arrows You can select one of 10 preprogrammed outputs levels The new setting is confirmed by pushing the gt ENTER button C By pushing the AUTO MANUAL button we switch to the AUTOx mode 46 Automatic boiler for biomass Service manual Note If the control unit operates in an automatic mode AUTOx MODx EQTx BOILER the display will show the current output after pushing the OUTPUT button AUTOx PP kW nn x number of currently selected program PP boiler output corresponding to the selected program nn relative number showing the percentage in relation to nominal boiler output AUTO C SE
67. ect the fuel in Menu 10 Fan revolutions and the consequent needed air volume may be different for different fuel types Needed air volume setting is done the same way as above in this chapter Return to MANUAL mode by repeatedly pushing the AESC button or you can continue in your menu selection with the ff arrows 9 4 5 5 Menu 11 5 5 fan We enter the menu by pushing the U arrows Select the desired flue fan mode ON or OFF by pushing the ENTER button in the automatic ignition mode Select the desired fan mode ON or OFF by pushing ENTER button again Return to Menu 11 5 5 by pushing the ESC button 9 4 5 6 Menu 11 5 6 fan revolutions We enter the menu by pushing the f U arrows Select the desired flue fan revolution mode by pushing gt ENTER button in the automatic ignition mode Important note Fan revolutions are set for a particular fuel type First we select the fuel in Menu 10 Fan revolutions and the consequent needed air volume may be different for different fuel types 1 Needed air volume setting is done the same way as above in this chapter Return to MANUAL mode by repeatedly pushing the ESC button or you can continue in your menu selection with the 0 t DU arrows 9 4 5 7 Menu 11 5 7 Flare time We enter the menu by pushing the f U arrows By pushing ENTER button we will enter adjustment of the pe
68. ering of the building in an alternate program Heating units are protected from frost damage to the boiler and the heating system The heating unit TJ M 48 2 output 2 4 3 4 4 5 a 6 kW Circulatory pump Three way four way valve with a servomotor Flue fan for KP12 KP22 and KP62 boilers Digital room thermostat Tank for heating warm water 80 350 Accumulation vessels for instance 500 750 I 1 000 Seasonal large volume fuel storage tanks Spiral fuel feeder from seasonal tank ensures automatic fuel refilling in the daily tank Automatic fuel feeding from the seasonal tank ensures automatic operations of the spiral feeder from seasonal tank Pneumatic fuel feeder from seasonal tank for fuel refilling in the daily tank from a longer distance Automatic control of another three loops circulatory pump GSM modem for remote control and monitoring of boiler operation Module for boiler connection to Ethernet communication network Internet Outside temperature sensor for equithermal regulation Surface temperature sensor in the fuel intake area Surface temperature sensor temperature measuring behind the mixing valve Surface temperature sensor temperature measuring of returning water Connector outlet 2 pin Connector outlet 4 pin Compact hydraulic modules REGPON SYS Compact hydraulic modules REGPON SWH Compact hydraulic modules REGPON F Note Optional accessories are not included in the bo
69. erminals 14 Automatic boiler for biomass Service manual Emergency thermostats K3 connector and copper capillary running through an opening Both thermostats are serially connected and deactivation disconnection of either one of them leads to disconnection of all outputs except outputs on terminal K13 2 Reactivation of the emergency thermostat may be done by qualified personnel only Before reactivation the service worker must assess the reason for this occurrence The LAMBDA probe XV4B connector is a specialized input designated for connection of the residual oxygen sensor in burnt gases in the E2008 system The terminals of this connector have a supply voltage 12V 1 5A for the heating spiral of the probe and two terminals for controlled value input 4 2 1 2 RJE2008 outputs description All control unit outputs are active and if they are switched on their terminals will show grid voltage phase or total Three prong relay outputs terminals K14 1 K14 2 K15 1 K23 1 K23 2 K16 2 are designated for general use The maximum load of each output is up to 6A and the current total limitation for RJE2008 is 10A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals will show grid voltage Three prong relay outputs terminals K13 1 K13 2 are designated for general use The maximum load of each output is up to 6A and the current total limitation for RJE2008 i
70. ers sensors et al in the respective modes It also enables MANUAL MODE of control which is used for instance during the boiler initial operation The control system is comprised of the performance part located on the side of the boiler position 4 2 1 and of the control terminal position 4 2 2 The terminal also comes in a different model with a two line foil keyboard display or it may be equipped with a touch screen The control system construction and its electrical shielding IP 45 make safe and reliable operation possible even under the demanding operational and climatic conditions common to boiler rooms E i UN Picture 3 E2008 Control System The boiler modular set is comprised of these parts z Terminal with mechanical buttons zZ Terminal with touch color display including connector cable Get MTSOSTV V Module V Module V GSM modem cable modem antenna ape Control unit and terminal connection PK z L Control unit and main switch and emergency thermostat connection PKo2 zZ Z basic control system set V optional parts of the control system S service equipment lt lt NIN 11 Automatic boiler for biomass Service manual E2008 is supplied from the electrical power network voltage is 230V
71. es Where dd is the existing set up value DD is the newly required set up value and is blinking Adjustment of the run out time for the circulation pump of the system will be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key Note Pump run out is removing excess heat from the boiler 80 Automatic boiler for biomass Service manual 9 5 5 Menu 12 5 SW Tank pump limits The producer will set up in this menu the upper and lower limit of the temperature range in which the circulation pump of the heating system is turned on to heat the hot service water The service engineer will be allowed to change setting only within these limits in the chapter 6 Menu 10 7 MENU 12 5 SW Tank pump limits will appear on the display unit after the PIN for the Producer menu has been correctly entered and after adjustment to this menu has been done by cursor arrows U 9 5 5 1 Menu 12 5 1 Lower limit The following script will appear by pushing the key ENTER By pushing key ENTER to to the selection of the lower temperature limit for the output water in order to turn on the circulation pump of the heating system Where dd is the existing set up value DD is the newly required set up value and
72. f the AT value for reference temperature in by which the temperature of burnt gas has to be higher than that of the boiler water Range KK 0 99 typically 159C Adjustment of the boiler water temperature increase is performed in the same procedure as mentioned above in this chapter Note The electric ignition program routine is completed with a 3 minute interval in which the boiler heats at the output level corresponding to the starting program after the MODULATION mode has been initiated v Menu 11 5 10 Having this interval been finished the boiler enters the mode AUTO AUTOx or SW Tank The control unit is evaluating at this moment whether the temperature of burnt gas is higher than that of water by the At value temperature of burnt gas temperature of water This value is adjusted to 150C by the producer If the temperature of burnt gas is higher than the adjusted value At Reference temperature the boiler will resume its operation If the value is lower than At Reference temperature the control unit will make another attempt to ignite without supply of new fuel the ignition course will then again be evaluated via another measurement If the value At Reference temperature is exceeded the boiler will resume its operation if the value is lower or equal the control unit will stop operation of the boiler and the following script will appear on the display unit STOP no ignition 9 4 5 9 Menu 11 5 9 Check burnt gas
73. g coil Important note Time of the fiiring is given by selected fuel Select the fule in Menu 10 Time of the firing is specific to a selected fuel there could be big differences where zzz is the existing adjustment value ZZZ is the newly required adjustment value and is blinking The required lower value to preheat preheating coils can be adjusted with the cursor arrows f increases the required red hot time in steps of 1min reduces required red hot time in steps of 1min We will confirm the newly adjusted value by pushing the key gt ENTER The value ZZZ will stop blinking and is stored in the memory for boiler operation in the automatic mode of the boiler The values of zzz and ZZZ are identical now The value ZZZ will get blinking again by pushing the key ENTER and may be changed By pushing n ESC key to return back to the menu gt 1 Red hot time lt The value ZZZ is accepted for further use provided the new value has been confirmed by the key gt ENTER the value ZZZ is not blinking If the value ZZZ is blinking it will not be accepted when we return back to the MAIN MENU and the original setting value zzz will still be used 9 4 5 2 Menu 11 5 2 Feed time By using cursor arrows f we go to menu By pushing ENTER key to enter the adjustment of the operation time of the feeders F1 and F2 Thus we ensure delivery of optimum quantity of fuel into the burner boiler for ig
74. g is a complex set of technical and program means which ensure removal of solid waste from warm water boiler exchanger pipes in regular intervals The cleaning is performed by linear movement of turbulators in the exchanger pipes It is driven by an electric motor through a lever gearbox The heat exchanger cleaning system can be mounted on the left or on the right side Assembly of the particular version is done in the manufacturing facility based on an order A professional service firm can perform a change left right at the boiler location The drive motor is connected with the control unit to terminals K14 1 N PE 26 Automatic boiler for biomass Service manual Picture 22 Exchanger cleaning system 4 7 3 External ash container The external receiver provides space for long term ash collection outside the burning chamber It enables long term service free operation even when using fuel with high ash content It is attached to the boiler with a detent lever During boiler operation the lever must be in the lower position and the connecting piping between the boiler and the ash receiver must be tight Also the receiver cover must be tightly closed Both of these requirements prevent burning fumes release to the boiler room The receiver is removed by moving the detent lever to the upper position and pulling it away from the boiler Dispensing of the contents to the waste disposal container is best done by two people because of its
75. g maximum saving of fuel 2 Automatic ash removing and heat exchanger cleaning ensures a long time maintanance free and maximum comfort of heating while keeping high burning efficiency 3 CONTROL UNIT with modern design controls operation of the boiler ensures automatic operation high operational reliability and long distance control 4 PRIORITY HEATING of hot service water is secured by the structure and software package of the boiler without any need for other control elemets 5 MODULATION PERFORMANCE of the boiler allows adjust production of the heat to an actual needs of the building 6 Heating by EQUITHERM regulation of the water temperature to a needed temperature lowers the cost of the heating 7 The burne 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 product and also excellent ecological parametrs with the minimum content of harmful sustances in combustion products 20 50x less than in case of classic boilers 8 SAFETY OF OPERATION given by separated structure of transport routes for fuel and by the selected transport mode 9 The boiler makes it possible to ensure economical MODERATE HEATING of building by a suitably selected syst m using electric power 10 DESIGN AND SURFACE Jacketingof the product is coated with heavy duty COMAXITE COATING which i
76. g of system pump and its deaeration 6 6 27 Functioning of boiler pump and its deaeration 6 6 28 Functioning of motor and correct rotation direction of ash removal spiral screw 6 6 29 Functioning of exchange cleaning motor 6 6 30 Functioning and correct rotation direction of servomotor 6 6 31 Functioning and timing of servomotor between limit positions and agreement of timing with SW setting 6 6 32 Correct functioning of electric ignition spirals 6 6 33 Correct functioning of attached thermometers check with the button ESC on the LCD display 6 6 34 Correct functioning of GSM communication menu menu 8 chapter 9 3 8 6 6 35 Setting of a proper equithermal curve menu 9 chapter9 3 9 6 6 36 Setting or changing servomotor timing menu 11 15 chapter 9 4 15 6 7 CHECKING TASKS BEFORE BOILER FIRST OPERATION The authorized service technician preparing the boiler for its initial operation must perform the following tasks before start up He will record results of all checking tasks will fill a Certificate of Introduction to Service see appendix 6 7 1 Checking water volume in the heating system and corresponding water pressure 6 7 2 Check whether fittings between the boiler and the heating system are open 6 7 3 Check the heating system for leaks at all new connections pressure test done by a professional firm 37 Automatic boiler for biomass Service manual 6 7 4 Check the chimney connection must be tight and safe
77. h cursor arrows ff U The following script will appear by pushing the key ENTER The following script will appear by pushing the key ENTER Using the cursor arrows ff user will choose the corresponding language version for communication with the operator from the following options gt Cestina lt gt English lt Deutsch Polski gt Espanol lt gt Italiano lt Svenska gt Francais lt gt lt Confirm the selection by pushing key ENTER Return back to the main menu gt 3 Select Lang by pushing the key a ESC Return back to the mode MANUAL or AUTO by repeated depression of the key ESC or continue in selection of the next menu by cursor arrows f 9 3 4 Menu 4 Setup time MENU 4 Setup time will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows f U The following script will appear by pushing the key gt ENTER The following script will appear by pushing the key gt ENTER And the value HH is blinking The current state of hours may be changed by cursor arrows f IV 51 Automatic boiler for biomass Service manual Jf increases the value of the number in step of 1 g U reduces the value of the number in step of 1 If the value of hour has been adjusted go to the setup of minutes by pushing the cursor arrows or confirm the total setup
78. he first range near the calculated water temperature at which the boiler would automatically switch to the STAND BY mode When the boiler reaches this range temperature the boiler will automatically decrease its output by one degree We enter the menu by pushing the f arrows Select the first temperature difference from the set output boiler water temperature at which the boiler will automatically change its output by pushing the ENTER button First temperature difference setting is done the same way as above in this chapter Return to MANUAL mode by repeatedly pushing AESC button or you can continue in your menu selection with the U arrows 9 4 11 5 Menu 11 11 5 Range II This is the second range near the calculated water temperature at which the boiler would the automatically switch to the STAND BY mode When the boiler reaches this range temperature the boiler will automatically decrease its output by another output degree We enter the menu by pushing the f U arrows Select the second temperature difference from the set output boiler water temperature at which the boiler will automatically change its output by pushing the ENTER button Second temperature difference setting is done the same way as above in this chapter Return to MANUAL mode by repeatedly pushing ESC button or you can continue in your menu selection with the D 1 U arrows 9 4 11 6 Menu 11 11 6 Regulati
79. he ignition spirals stop working only the sign AUTO is flashing depending on the current mode The second line will read M 045 E 045 S120 temperature behind the mix valve required equithermal temperature servomotor position mode EQT MIX 045 SRV 120 temperature behind mix valve servomotor position mode AUTO MOD or after pushing n ESC SPAL 142 VST 050 burnt gases temperature behind the boiler temperature of returning water recuperation or after pushing a ESC Ven 12 HOR 050 outside temperature burner temperature at fuel intake Note The required equithermal temperature value is displayed only in the EQTx mode Outside temperature and burner temperature will show correct value only if thermometers are on Note S120 SRV120 is the position of the servomotor in sec The limit positions are set by the service technician 44 Automatic boiler for biomass Service manual Boiler control by the user is possible within the framework shown in the following drawing BLOCK DRAWING OF CONTROL UNIT OPERATION TH Cem CHiMNEYER 8 1 8 2 MOBIL No 1 8 3 MOBIL No 2 8 4 CREDIT No 8 5 SMS INFO ON OFF SERVICE PIN 18 SW VERSION EI I NN Picture 35 Operation block diagram User 4 Automatic boiler for biomass Service manual 9 2 OPERATION MODE SELECTION The service personnel can choose the boiler operation mode with the button
80. he lower limit of the output water temperature for the automatic boiler Confirm the newly adjusted value by pushing the key gt ENTER The value DD will stop blinking and will be saved in the working register for boiler operation in the automatic mode The values dd and DD are identical now The DD value starts blinking by repeated pushing the key gt ENTER and may be changed By pushing key ESC to return to the menu gt 1 Lower limit lt The value DD has been accepted for further use provided the new value has been confirmed with the key gt ENTER the value DD is not blinking If the value DD is blinking it will not be accepted after the return to the MAIN MENU and the original set up value dd will still be used 77 Automatic boiler for biomass Service manual 9 5 2 2 Menu 12 2 2 Temperature upper limit We will enter the following menu by means of the cursor arrows 0U By pushing ENTER to enter the selection of the upper limit for the output water temperature Adjustment of the upper limit for output water temperature shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL by repeated pushing the key N ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 1 Note The maximum temperature of the boiler water is limited to 900C Note 1f it is not desirable for the user to ha
81. how to fix the problem Reactivation For automatic operation activation of the control unit and consequently the boiler the output water temperature must dropped below 99 C If this condition is not met the control unit want will not be able to function After that it is possible to switch to automatic boiler operation by pushing START and ENTER buttons if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 10 3 STOPPAGE OVERHEATING IN THE FUEL PATHWAY By adding a thermostat placed in the burner at the place of fuel entry the boiler safety can be increase and guard against burned gases back draft through fuel pathways This measure exceeds requirements of the safety norm CSN EN 33 5 If the temperature at the plastic flexible hose connection to the burner increases to about 859C the emergency thermostat disconnects and the control unit stops the boiler operation This state is indicated by a red ALARM control light position 5 at the control panel and also by a message on the display screen STOP EMERG TERM2 An acoustic signal will sound at the same time Under normal conditions boiler overheating does not occur therefore this situation is considered an emergency Service personnel attention is required because it has to be determined why this state of failure occurred and how to fix the problem Plugged up jets in the burner Clean the burner a
82. icture 44 97 5 a mt _ 4 oma i a LT Q9 asl L IK ml 9 Picture 45 Hydraulic scheme 1 x HC SWH Tank 86 Sans ETE gen l Oo im nes LI Qo B Picture 46 Hydraulic scheme 2 x HC SWH Tank 66 XV11B XV11A XV5B XV3A XV6B XV13B XV9B XV7B RSENS1 RSENS2 T MIX W GAS 1 ROOM TH2 SWT THERM SYKFY 2x0 8 SYKFY 2x0 8 SYKFY 2x0 8 12V DC 12V DC MS 02 MS 02 NTC 10000 NTC 10000 PT 1000 K192 K191 K142 14 1 K18 2K18 1 161 4 K152 K231 K232 132 K151 K162 es NENNEN NN 1 FEEDER2 ASH SWEEPING SERVO EL IGNITION EL IGNITION PUMP1 PUMP2 SWTPUMP SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 CYSY 4x0 5 SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 SiFH 3Gx1 M M Qf D 1 1 15 1 py A 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 230 V 90 VA 90 VA 90 VA 90 VA 40 90 VA 500 VA 500 VA 45 VA 45 VA 45 VA Picture 47 Electric connection of hydraulic scheme 2 x HC SWH Tank OOT T f okuhi Do okrun Hydraulic scheme Cascade 2 x SWH Tank Picture 48 101 XV12A K18
83. ig K17 2 set up parametrs for ash removing allow or prohibit ash removing ash removing is repeating always by the amount of feeder F1 rotations set up time of the ash removing mechanism parameters set up for flue sweeping allow or prohibit flue sweeping on ash removing is repeating always by the amount of feeder F1 rotations 250 set up time of the flue gas sweeping mechanism 3 time zone set up where flue gas cleaning is permited 8 00 22 00 set up of the flue fan revolutions while in flue gas cleaning 0 choice of multi purpose use of force output set up function output K15 1 heating TO2 zkrat pump El Heating set up function output K17 2 flue fan TO2 zkrat pump Flue fan 11 15 setting servo time running between the outermost positions 10 off on 250 3 8 00 22 00 0 El Heating Flue fan off on 150 3 8 00 22 00 0 El Heating Flue fan Table 8 Settings Producer ver 1 1 Menuno Menu name Menu description meaning SETTINGS VALUES VERSION 6 x gear1 56 auger 38mm KP62 auger 55mm KP12 KP22 KP 62 PRODUCER unit EFIE Locking licence for running of the boiler for limited time Time lock turn on turn off time lock function off off off Code code for unlocking of time lock Time to lock set up time until locking of the automatic running of the boiler Temperature limits limits of temperatures in which it is possible to set up parameter Temperature
84. igits 0 9 lower case letters from the a z alphabet and upper case letters from the A Z alphabet 9 5 1 Menu 12 1 Locking Functions in this menu ensure time limited operation of the boiler if required so by the interest of the producer If the control unit displays the Menu 14 Code entering the boiler is put into operation with time lock activation for a limited period of time The time lock may be cancelled after entering a 6 point alphanumeric code differentiates upper case letters and lower case letters in the menu 14 before the adjusted period of time elapses The control unit requires automatic entering after the period of time elapses 9 5 2 Menu 12 2 Water temperature limits The producer shall set up the lower and upper limit for the temperature range for operation of the boiler in this menu The user will be allowed to change setting only in these limits in Menu 2 MENU 12 2 Temp limits will appear on the display unit after the PIN for the Producer menu has been correctly entered and after setting to this menu has been done by cursor arrows 11 9 5 2 1 Menu 12 2 1 Temperature lower limit The following script will appear by pushing the key ENTER By pushing key ENTER to enter the selection of the lower limit for the output water temperature Where dd is the existing adjusted value DD is the newly required adjustment value and is blinking Use the cursor arrows f to change the required value for t
85. iler price 4 11 The tank is supplied as optional accessory in sizes 100 400 700 and 1 400 The 400 tank has a special modification for pneumatic transfer Atypical tank finish can be delivered based on special order after consultation with the manufacturer The tank can be refilled up to full volume without limitations Fuel refilling of tanks supplied by the boiler manufacturer is safe because the tank construction ensures safe distance of the operator from moving parts During automatic boiler operation the filling tank cover must be closed 4 9 1 4 9 2 4 9 3 4 9 4 4 9 5 4 9 6 4 9 7 4 9 8 FUEL BIN Bin 100 Bin 400 for pneumatic transfer Bin 4001 Bin 700 Bin 1 400 Bin based on customer request made to order Bin 400 folding Bin 7001 folding 29 Automatic boiler for biomass Service manual 4 9 5 4 9 4 4 9 3 4 9 2 4 9 1 Y Z X 1500 mm 1000 lt 4000 mm 51900 mm 1520 mm 1320 mm Yz iple mm Z 500 m 1275 mm 7500 m Z 200 mm Picture 25 Standard fuel bin sizes Je lll 4 JEn s 010 7713 Picture 26 Collapsible bin assembly guide 30 Automatic boiler for biomass Service manual 5 PLACEMENT OF THE PRODUCT IN BOILER ROOMS PRINCIPLES OF INSTALLATION 5 1 PLACEMENT OF PRODUCTS IN BOILER ROOMS Minimum distances determine the space necessary to perform the operation and maintenance of the equipment Boiler must be placed on horizontal non flamm
86. ill appear on the display unit after the PIN for the Producer menu has been correctly entered and after adjustment to this menu has been done by cursor arrows f U By pushing key gt ENTER we go to menu The number required by us will be adjusted with cursor arrows 1 ft increases the number value in steps of 1 U reduces the number value in steps of 1 i moves to the neighbouring digit to the right lt moves to the neighbouring digit to the left Add character after last valid number By this you will define amount of valid numbers Confirm the adjusted number by pushing the key ENTER The following script will appear on the control unit After this has been confirmed by pushing the key ENTER the control unit will make a check call in cooperation with the modem to a selected telephone number Dialling and ringing is indicated by the following script Control call will be terminated by pushing the key ENTER Note The ring through function may only be used after the modem has been connected and initiated Note The modem will be initiated by the control unit when the power supply is turned on and if the GSM modem function ON is enabled The modem has to be connected to the power supply before the control unit is turned on Note The telephone number must include the national area code Note Control unit has phone number of the modem given by manufacturer By that there is secured monitori
87. increases fan revolutions by 1 decreases fan revolutions 1 The buttons gt lt have a built in autorepeat function automatic repeat if the button is pushed for a prolonged time After pushing ENTER button the fan will switch on The display will show During operation fan revolutions can be increased with gt or decreased with The flue fan can be turned off by pushing the ENTER button Note Depending on selected configuration the display may mean TO2 pump short circuiting pump which does not enable pump revolution control 9 3 1 5 1 5 CONTROL OF THE HEATING SYSTEM PUMP The following will be displayed on the display unit Turn the pump on after pushing the key ENTER The following will be displayed on the display unit Operation of pump is turned off by pushing the key ENTER 9 3 1 6 Menu 1 6 CONTROL OF THE STORAGE WATER TANK PUMP The following will be displayed on the display unit Turn the SW TANK pump on after pushing the key ENTER The following will be displayed on the display unit Operation of the SW TANK pump is turned off by pushing the key ENTER 9 3 1 7 Menu 1 7 CONTROL OF ELECTRIC IGNITION The following will be displayed on the display unit Turn the ignition on after pushing the key ENTER The following will be displayed on the display unit Operation of ignition is turned off by pushing the key ENTER Note A
88. ing the key gt ENTER The value DD will 79 Automatic boiler for biomass Service manual stop blinking and will be saved in the working register for boiler operation in the automatic mode The values dd and DD are identical now The value DD will start blinking again by repeated pushing the key gt ENTER and may be changed Return back to the menu gt 1 Lower limit lt by pushing the key ESC The value DD has been accepted for further use provided the new value has been confirmed with the key ENTER the value DD is not blinking If the value DD is blinking it will not be accepted after the return to the MAIN MENU and the original set up value dd will still be used 9 5 4 2 Menu 12 4 2 Upper limit We will enter the following menu by means of the cursor arrows By pushing key ENTER to go to the selection of the upper temperature limit for the output water in order to turn the circulation pump of the heating system on Where hh is the existing adjustment value HH is the newly required set up value and is blinking Adjustment of the upper limit for the output water temperature to turn the circulation pump of the heating system on shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL by repeated pushing the key ESC or it is possible to continue with the cursor arrows gt ESC in selection of the next menu after pushing the key ft No
89. ions of the boiler running 2 90 90 mi Fanrun out time of running of the fan after changeover of the boiler into STADBY state min Flue fan Run in time of the flue fan operation after boiler go to STAND BY min Rotary sensors set up of control parameters for the function of feeders F1 and F2 RS 1 time set up of time period in which CU counts incoming pulses of feeder F1 Sec RS 1 pulses set up of number of incoming pulses of feeder F1 which is expected in set time period ks RS 2 time set up of time period in which CU counts incoming pulses of fedder F2 Sec RS 2 pulses set up of number of incoming pulses of feeder F2 which is expected in set up time period 129 GSMmaster enables operating settin up and monitoring of the boiler by the service centre 12 10 Reset service PIN set up service PIN on the value 1111 1211 P ono 4 c m O 7 5 p 5 aem a 420 604 295 525 plus service number 1492 1492 1492 RKP2 15 RKP2 15 RKP2 15 IN change enables set up original producer PIN 13 information about software version used in CU 14 Entercode Menu for time lock unblocking by entring correct pin the boiler will unlock ETT
90. is about one ceramic Work carrefully so you do not damage all parts Cleaning the draughts of combustion products If there is automatic cleaning installed there just has to removed a dust above exchanger by a vacuum cleaner or by forfeiture dust throught pipes of heat exchanger in to a burning chamber proceed as follows close the burner door so that the boiler does not contaminate the boiler room too much when we will clean the draughts remove lid of the jacketing dismantle the lid of the boiler body 4 screws and place it on the floor When you mount it back later remove slightly ash from it and be careful not to damage insulation during this operation now release ash from turbulators and vacuum dust from the space above exchager Note With advantage we use ash separator and regular vacuum cleaner Dismantling of the burner remove the fan from the extension pipe on the flange of the burner dismantle the flanged joint 4 screws from the drive of the spiral chute feeder 2 remove the complete feed screw and place aside Check it for wear and tear at the same time dismantle now the whole burner flange 4 screws and remove the burner Clean the whole inside surface of the burner carefully with a wire brush mainly in the place of the feeder s outlet and also in all places of round and slotted nozzles These places are most susceptible to sedimentation of solid products of burning 40 Automatic boiler for biomass Ser
91. is blinking The required lower limit value of the output water temperature of the automatic boiler for solid fuel can be set up with the cursor arrows Confirm the newly set up value by pushing the key gt ENTER The value DD will stop blinking and will be saved in the working register for boiler operation in the automatic mode The values dd and DD are identical now The value DD will start blinking again by repeated pushing the key gt ENTER and may be changed Return back to the menu gt 6 Fan run out lt by pushing the key ESC The value DD has been accepted for further use provided the new value has been confirmed with the key ENTER the value DD is not blinking If the value DD is blinking it will not be accepted after the return to the MAIN MENU and the original set up value dd will still be used 9 5 5 2 Menu 12 5 2 Upper limit We will enter the following menu by means of the cursor arrows ff U By pushing key ENTER to go to the selection of the upper temperature limit for the output water in order to turn on the circulation pump of the heating system Where hh is the existing set up value HH is the newly required set up value and is blinking Set up of the upper limit for the output water temperature to turn the circulation pump of the heating system on shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated p
92. isplay will show Servomotor close is turned off by pushing the ENTER button Note In order to avoid servodrive damage functions Servomotor ON OFF block each other 9 3 1 13 Menu 1 13 Display of inputs The display will show x can have value 0 or 1 value 1 means active state value 0 means inactive state RT room thermostat WT boiler thermostat RS F1 and F2 feeder rotation sensors ET emergency thermostat burner thermostat BI state of binary inputs for service purposes only BI xxxx1 heating loop 2 room thermostat BI xxx1x heating loop 3 room thermostat Note After returning from direct control by pushing the ESC button or by time out after 60 seconds without touching the keyboard all outputs will switch to the initial mode OFF and the boiler will switch to the MANUAL mode 50 Automatic boiler for biomass Service manual 9 3 2 Menu 2 Output water temperature setup Output water temperature settings allows the user to adjust the operating mode requirements of the boiler heating system or temporary conditions in the heating requirements Note Minimum and maximum 77 value is limited by mynufacturer MENU 2 Temperature will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows f U The following script will appear by pushing the key ENTER After pushing the key ENTER we will get into
93. ive and lever mechanism and must lubricate cleaning drives if needed Anticipated intervals 1 x per year when using wood pellets 1 x per month when using alternative pellets 7 2 2 Burner grate cleaning During checking it is necessary to pay attention to burning grate cleaning in order to avoid plugging of the burner air jets Always perform cleaning when a continuous layer of ash exceeds 4cm Clean the burner grate with jets simply by moving a scraper along the burner grate area Anticipated intervals 1 x in 3 10 day wood pellets 1 x daily alternative pellets 7 2 3 Ceramic grate cleaning The ceramic grate construction has a self cleaning feature Dust particles do not stick to the grate after burning pellets Nevertheless check cleanliness of these parts If needed you can get rid of the dust particles by slightly shaking the individual parts of the ceramic grate After this procedure check correct placement of ceramic parts Anticipated intervals 1 xin 4 month wood pellets 1 x month alternative pellets Note Perform this check when the burned gases temperature repeatedly or permanently exceeds 2009C Important note Ceramic parts could be extremely hot Use a proper tool or protective gloves 39 Automatic boiler for biomass Service manual 7 2 4 Annual audit Every boiler of the KP series should undergo annual audit after the end of the main heating season This audit is necessary in order to prevent from possible no
94. ivery of electric current is restored The manufacturer does not assume any liability for errors and subsequent damage caused by unskilled operation of the equipment or by infringement of principles given in these Instructions for installation and operation or by infringement of generally binding standards and regulations or by using inadequate fuel If the boiler is moved or otherwise handled with safety regulations which apply to handling with heavy loads have to be adhered to It is prohibited to place heavy loads on jacketed boiler and to step on it It is recommended toremove the protective transport after all the building and installation work has been completely finished External ashtray has to be firmly connected to a boiler fitiing while in the operation Cover of this ashtray has to be closed There could be a dangerous escape of combustion products in to a boiler room Automatic boiler for biomass Service manual 2 USE OF THE BOILER AND ITS ADVANTAGES The series of automatic hot water boilers for wood pellets is designed mainly to heat family houses small municipal buildings cottages and small plants or business buildings The main advantages of products 1 AUTOMATIC OPERATION ensured by the control unit which cooperates with the indoor thermostat thermostat of SW tank for hot watter outside thermometer in the mode of equitherm regulation eventually by superior control system which ensures COMFORT for the user includin
95. kinds of waste and handed over to an authorized entity for disposal Exception is represented by control with sensing and control elements is subject to return collection ehich is directly performed by the seller s plan where the product was bought or by the manufacturer of the boiler Return collection is free of charge In accordance with current requirements of environmental protection the electronic parts of the poduct does not contain lead 43 Automatic boiler for biomass Service manual 9 CONTROL UNIT OPERATION 9 1 USER SETTINGS MAIN MENU Control panel description SETUP Lg AUTO7 11 22 48 MIX 045 sauna O lt E ON GSM COME LE OW OFF ourPUT E _ ENTER I Esc The boiler control unit can be turned on by pushing the lever to I position at the main switch located on the boiler panel The bold red display will show the immediate water temperature for instance 048 The first line of the alphanumeric display 2 will show The sign MANUAL in format AA mm The temperature display 3 show immediate boiler water temperature or B Signs AUTOx MODx EQTx BOILER or STAND BY in case the control unit was turned off in one of these modes and automatic ignition is not allowed by the program or C Flashing sign AUTO and gt I lt if the unit is equipped with electric ignition and automatic ignition is allowed by the program From the moment t
96. king Adjustment of the required standby time of the automatic solid fuel boiler can be controlled by cursor arrows ft 0 The standby period determines the period of time when the automatic boiler is not burning actively This mode makes it possible to keep the automatic solid fuel boiler in the standby state under minimum costs and fuel consumption Only minimum quantity of burning fuel is kept in the burner space and full operation of the boiler can be restored at any time if necessary If the adjusted standby period is exceeded the boiler will restore automatic operation for a period of 2 minutes and will then enter the standby state again Note The range of UU values has been determined by the producer within an interval of 720 70 minutes Note The adjusted value of standby is in force for all programs 9 4 5 Menu 11 5 Firing parameters Adjusts parameters for automatic mode of boiler ignition Time parameters adjusted in this program have to ensure reliable ignition when the boiler is started cold MENU 11 5 Firing param will appear on the display unit after the menu SERVICE has been entered and after adjustment to this menu with the cursor arrows 1 gU 9 4 5 1 Menu 11 5 1_ Red hot time gt 5 Firing param lt By pushing ENTER key we will go to menu 61 Automatic boiler for biomass Service manual By pushing the key ENTER to enter selection of the time value for red hot time operation time of heatin
97. ll appear on the alphanumeric display unit by pushing the key ENTER where ddmmrr is the date of software creation in the following format day month year 9 7 MENU 14 CODE ENTERING If the control unit displays Menu 14 Code Entering the boiler is put into operation with activation of the time lock activation for a limited period of time If the adjusted time lock period gets exceeded this is indicated by the following script on the display unit To enter the code is possible in the boiler operation Code incleudes small and big letters and numbers After the correct code is entred MENU will disappear 85 Automatic boiler for biomass Service manual 10 ERROR MESSAGES 10 1 STOPPAGE OVERHEATING EMERGENCY THERMOSTAT The control unit is equipped with an emergency circuit for boiler overheating The state of failure OVERHEATING comes about when the water temperature at the boiler exit exceeds the 959C level At this point the emergency circuit of the control unit is activated and the boiler is shut down This state is indicated by a red ALARM control light position 5 at the control panel and also by a message on the display screen STOP EMERG TERM1 An acoustic signal will sound at the same time Only the circulating pump is working to ensure the heat removal from the boiler exchanger Under normal conditions boiler overheating does not occur therefore this situation is considered an emergency Service pe
98. ll by pushing the key ENTER Note The ring out function may only be used after the modem has been connected and activated Note Modem will be activated by the control unit when the power supply is turned on and provided the GSM function modem ON is allowed The modem has to be connected to the power supply before the control unit is turned on Further menu selections are available by pushing the f gU arrows This MENU is used to adjust the second number the control unit will communicate with No failure messages will come to this number unlike the mobile number 1 The mobile number 2 is adjusted in the same way as mentioned in the MENU 8 2 Mobile number 1 Further menu selections are available by pushing the ff arrows This MENU may be used to adjust the number of operator the control unit will communicate with in case of query about the residual credit on a prepaid telephone card Note Information on the current credit level will be sent to the user with every SMS message sent by the control unit 54 Automatic boiler for biomass Service manual Note Number for information on credit may be found out from the operator Example T mobile 101 Further menu selections are available by pushing the arrows This function will allow or inhibit sending any report in case of any failure on the equipment The following script will appear by pushing the key ENTER Or depending on the last cur
99. menu selections are available by pushing the f U arrows Note Service engineer or the manufacturer will adjust this value as per the technical equipment of the boiler In order to use the function of electrical ignition it is necessary for the boiler to be equipped with a burner boiler with a heating coil used to ignite pellets Note The course of electrical ignition takes place as per the time parameters which are adjusted by a service engineer when the boiler is being put into operation Note If electric ignition is gt OFF lt the routine for direct mode START is not active Important there is a failure of EZ components boiler can work in reserve mode See Chapter 7 10 fault stages 9 3 7 Menu 7_ Suplemental electric heating serves as protection against freezing of the heating system for instance in unattended buildings in case of failure or fuel shortage MENU 7 The electric supplemental heating will show on the display after a short note MAIN MENU The setting can be changed by the f gU arrows By pushing the ENTER button display will show or depending on the last current setting The setting of the electric heating function can by changed by pushing the gt ENTER button By repeatedly pushing the ENTER button you can change the ON OFF setting Select the desired setting and return to the MANUAL AUTOx MODx EQTx or BOILER modes by pushing NESC button Further menu selections are avail
100. n after 5485 with a superordinate system 4 2 3 Expander EEx2008 The expander is designated for the increase the number of inputs and outputs in the RJE2008 control unit EXPANDER EEX2008 EasySoft SS ae ro Kk Picture 8 Expander EEx2008 It is designed as a DIN bar module where it occupies six positions Its application is suggested in a remote distributor where sufficient shielding will be ensured The expander has its own power supply 4 2 3 1 Technical data Supply 230V 50Hz Control unit supply 5 VA Dimensions 105 x 90 x 59 Weight 0 35 kg Protection class pursuant to CSN 33 2000 4 41 ed I 2 2007 Protection from dangerous touching of live parts pursuant to CSN 33 2000 4 41 ed 2 2007 Protection from dangerous touching of non live parts automatic disconnection from pursuant to CSN 33 2000 4 41 ed 2 2007 basic source Shielding pursuant to CSN 60 529 IP31 By covering and insulation 17 Automatic boiler for biomass Service manual Basic characteristics settings pursuant to norm CSN 33 2000 3 AA5 temperature 5 40 C AB5 temperature 5 40 C humidity 15 100 BA5 people skills knowledgeable BC3 contact with ground frequent Described in detail in E2008 documentation The equipment is designed in accordance to norms CSN EN 60335 1 and CSN EN 60335 2 Classification is in accordance to CSN EN 55014 2 Category II 4 2 3 2 Description of bina
101. n by pusching the key gt ENTER and may be changed Return to the main menu will be performed by pushing the key ESC The value AA has been accepted for further use provided the new value has been confirmed with the key ENTER the value is not blinking If the value AA is blinking it will not be accepted when we return back to the MAIN MENU and the original setting value aa will still be used Note The range of values AA is determined within the interval of 70 xx s where xx has to be a value less than the sum of the values feeder off feeder on advance The software checks this value and will not allow its adjustment outside the above mentioned range Note The adjusted value of advance is in force for all programs 60 Automatic boiler for biomass Service manual 9 4 3 Menu 11 3 Run in Determines a period of time by which the feeder F2 burner s feeder will stop operating sooner than the feeder F1 The fuel is safely slid out into the burner The run in is significant to ensure fire safety of the boiler MENU 10 3 Run in will appear on the display unit after the menu SERVICE has been entered and after adjustment to this menu with the cursor arrows f U The following script will appear by pushing the key gt ENTER By pushing ENTER button display will show where rr is the existing adjustment value RR is the newly required adjustment value and is blinking The required time of
102. n standard conditions in the next year of operation of the equipment If the annual audit is not performed as per the below mentioned programme this may be considered by the manufacturer to be the reason for rejection of guarantee conditions in the second year of use At the same time the user gets exposed to a risk of any failure which may cause loss of operating certainty or large physical damage Annual audit due to demanding activities has to be entrusted to a trained servicing company which will make record of the audit in the documentation of the boiler We proceed as follows during the annual audit Turn off the main switch of the control unit disconnect the boiler from network by pulling the mains cord from the wall socket or by turning the socket circuit off in the switchboard As we will also work inside the boiler let us the boiler 2 3 hours to cool down before we start next work After the boiler gets cooled down we will start dismantling of ceramic parts through the burner door i e remove the ceramic shield over the burner door by gradual moving to the left and release it then to the bottom right side from the fixation aperture remove the ceramic reflector by simple pulling forward remove all parts of ceramic burning out grate Lift the back side to a maximum possible hights front side lower down and remove the part out Now remove all ash buildups by steel brush from ceramic parts Note Do not forget that it
103. n trained by the manufacturer This product may only be operated by adult persons duly acquainted with the way the product is controlled and duly acquainted also with these Instructions If you adhere to the below mentioned principles the product will serve you reliably to your full satisfaction 1 2 3 4 5 6 7 8 9 10 11 N 12 13 14 15 It is prohibited to intervene in any way in the structure or electrical installation of products Having the equipment been disconnected from the electric network the power supply cord has to be plugged from the mains outlet It is prohibited to use inflammable liquids for ignition No inflammable materials may be stored on the boiler neither may they be stored within the distance of 1 500 mm from the boiler except for operating stock in the metal bin In order to preserve long term service life of the boiler body it is not recommended to operate the boiler frequently under the temperature of 60 C if the boiler is not protected with a primary circuit The temperature of 60 C should be considered as the minimum temperature The check how the boiler is filled with fuel is only visual Any verification with touch is prohibited as it may result in injury Never open door of the boiler if there is a ignition process Blinking AUTO will apear on display in this stage The door of the boiler has always to be close shut Should you perform any check o
104. n which boiler will heat for heating SWH Time period 2 setting of 2 time period in which boiler will heat for heating SWH Time period 3 setting of 3 time period in which boiler will heat for heating SWH Electric ignition turn on turn off el ignition mode including heater coil function Electric heating turn on turn off el heating mode tempering GSM modem for cooperation with GSM Modem insert of mob numb for communication set competent users On Off turn on turn off GSM communication of user with CU Mobil No 1 number with which will CU communicate This number willl recieve failure SMS info Mobil No 2 second number with vhich CU will communicate this number will not receive failure SMS info Credit No operator number for request of credit balance of paid mobile card SMS info allow or prohibit SMS sending when there is contingent equipment failure 8 5 9 2 Equithermal curve Selection of Equithermal curve for the specific object 1 16 10 Fuel Selection of the fuel type 1 5 OTI 00 00 24 00 00 00 00 00 00 00 00 00 KP22 KP 62 00 00 24 00 00 00 24 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 00 Table 7 Settings Service ver 1 1 SERVICE menu blocked by PIN contains a set of commands and settings acessible to service technicians Menu description meaning SETTINGS VALUES 1 VERSION 6 x gear1 56 auger 38mm KP62 auger 55mm for set up time of feeding and ro
105. ng and asistence with boilers with GSM modem 9 5 10 Menu 12 10 Service PIN cancellation Enter the menu 10 SERVICE and use this menu if you do not know the user s PIN MENU 12 10 Reset PIN will appear on the display unit after the PIN for the Producer menu has been correctly entered and after set up to this menu has been done by cursor arrows U Short message will appier on the alfanumeric display by pushing key ENTER The service PIN is hereby set up to the value of 1111 and is available for a service intervention 9 5 11 Menu 12 11 Change of PIN The PIN adjusted by the producer may be changed in this menu The service organization or service engineer may use their own PIN if there is an option that the PIN adjusted by the producer can be abused Thus he she is sure that the operating parameters adjusted by him her will not be changed 84 Automatic boiler for biomass Service manual MENU 12 11 Change will appear on the display unit after the PIN for the menu Producer has been correctly entered and after set up to this menu with the cursor arrows U We will enter the following menu by pushing the key ENTER Using the cursor arrows gt we will determine the new PIN code combination which will be in force after confirmation The adjusted PIN value is confirmed by pushing the key ENTER The control unit will prompt us to confirm this number by means of the following note We will e
106. ng the gt li buttons Note The boiler output can be set by adjusting the z and v values It is recommended that the output setting in the individual programs is done in ascending order the lowest output in Program Nr 1 the highest one in Program Nr 10 Important note The ascending order is mandatory in the Modulation mode Example Menu 11 1 1 Fuel 1 Program No 1 on05 off90 F30 FlueF40 minimum output 6 0 kW 11 1 2 Fuel1 Program No 2 0 05 off60 6 FlueF40 8 5 kW 11 1 3 Fuel1 Program No 3 0 05 off50 F40 FlueF45 10 0 kW 11 1 4 Fuel 1 Program No 4 0 05 off38 F48 FlueF45 13 0 kW 11 1 5 Fuel 1 Program No 5 0 05 off28 F50 FlueF45 17 0 kW 11 1 6 Fuel 1 Program No 6 0 09 off41 F53 FlueF50 20 0 kW 11 1 7 Fuel 1 Program No 7 on09 off34 F59 FlueF50 23 5 kW 11 1 8 Fuel 1 Program No 8 on09 off29 F64 FlueF55 26 0 kW 11 1 9 Fuel1 Program No 9 0 09 off27 F68 FlueF55 28 0 kW 11 1 10 Fuel 1 Program 10 on09 off25 F75 FlueF55 Nominal output 29 kW 11 1 11 Fuel 1 SWT Program 0109 off41 F64 FlueFt50 20 0kW 11 1 12 Fuel 1 Chimneyer Pr on09 off25 F75 FlueF55 Nominal output 29 kW Important note Values ON and OFF can be changed only within limits set by the manufacturer Values V and V odt can be changed from 30 to 100 9 4 2 Menu 11 2 Advance Determines the period of time by which the feeder F2 burner s feeder starts operating sooner than the feeder F1 Fuel falls into the running screw Th
107. ng water G 1 1 2 2 Heating tube 0150 mm 3 Input of return water G 1 1 2 4 Eletric heater M 48 2 5 Outlet valve G 1 2 KP 62 62bE 1 Output of heating water G 1 1 2 2 Heating tube 0160 mm 3 Input of return water G 1 1 2 4 Eletric heater M 48 2 5 Outlet valve G 1 2 and causes tension in the boiler body and this tension may cause damage to the homogeneity of the body Attention Impurities and sediments which might jeopardize failure free operation of pumps have to be thoroughly rinsed before the system is finally filled with water 33 Automatic boiler for biomass Service manual 6 2 INSTALLATION OF THE BURNER The burner of the boiler is configured into one unit the body of the burner screw feeder gear unit motor 2 spirals for electric ignition including needful cable se picture no 9 10 11 Burner has to be placed in a flange on the back side of the boiler and fasten it by nuts M 10 with washers so that Horak nasad me na pr rubu na zadn stran kotle a pripevnime maticemi M 10 s podlozkami tak aby t snic the non flammable roupe is fitting evenly and very closely around circumference of the flange Connect the cable of the feeder F2 on clip K19 1 kabel of the fan on clip K18 1 K18 2 picture 51 Place the fan in flange On the flange determined to a pellet supply connect by flexible hose and attach with fastener Insert a boiler thermostat sensor in to a tube placed
108. nition Important note The feeding time are to a specific fuel Select the fuel in Menu 10 Feed time is needed for each fuel different and it can be a big difference Adjustment of the operation time of the feeders F1 and F2 is performed in the same way as mentioned above in this chapter We will return back to the mode MANUAL AUTO MODX by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 12 Note Operation of the feeder F2 is smooth operation of the feeder 1 has the following rhythm 10 seconds on 10 seconds off This will achieve easier operation of the feeder F2 The operation of the feeder F2 exceeds by 15 seconds that of the feeder F1 in order to clear the transport route from fuel 9 4 5 3 Menu 11 5 3 Fan We enter this menu by pushing the 1 arrows In the automatic ignition mode we switch to shutting the main fan ON or OFF by pushing the ENTER button Select the desired fan mode ON or OFF by pushing gt ENTER button again Return to Menu 11 5 3 by pushing the ESC button 9 4 5 4 Menu 11 5 4 Fan revolutions We enter the menu by pushing the arrows In the automatic ignition mode we switch to fan revolution setting by pushing ENTER button 62 Automatic boiler for biomass Service manual Important note Fan revolutions are set for a particular fuel type First we sel
109. nking it will not be accepted after the return to the MAIN MENU and the original adjustment value cc will still be used 9 5 8 2 Menu 12 8 2 1 NUMBER OF PULSES We will enter the following menu by means of the cursor arrows V Go to the adjustment of the number of pulses from the feeder F1 which is expected in the adjusted time window in the previous menu by pushing the key ENTER Expected number of pulses is set up by the same procedure as mentioned above in this chapter We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC it is possible to continue with the cursor arrows a ESC in selection of the next menu after pushing the key 010 9 5 8 3 Menu 12 8 3 F2 MEASUREMENT TIME We will enter the following menu by means of the cursor arrows f We will enter the set up of the time window to measure pulses of the feeder 2 by pushing the ENTER Upper temperature gradient set up will be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key D 12 9 5 8 4 Menu 12 8 4 F2 NUMBER OF PULSES We will enter the following menu by means of the cursor arrows f U Go to the adjustment of the number of pulses from the feeder F2 which is expected in the adjusted time windo
110. nter the identical combination of numbers of the newly selected PIN using the above mentioned procedure We will confirm by pushing the key gt ENTER Acceptance of this new PIN will be confirmed by the control unit by a short note on the alphanumeric display unit If the identical PIN combination is not entered in the Check mode the new PIN will be not accepted and the control unit will notify it with a short note on the alphanumeric display unit The whole above mentioned procedure has to be repeated for successful change of the PIN Important There is an option left by the producer how to enter the menu Producer in case the PIN is not known or if the PIN is forgotten However RESET of the control unit is carried out if this emergency option is used and the producer s default values are adjusted in all registers Recommendation The adjusted and tested values of operating parameters should be recorded in the operating og book of the boiler Note The PIN may contain digits 0 9 lower case letters from the a z alphabet and upper case letters from the A Z alphabet It is not possible to break through via the trial and error method a PIN entered by means of this combination 9 6 MENU 13 SOFTWARE VERSION This MENU is used to identify the software version easily MENU 9 Software version will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows U A following short script wi
111. nu 11 13 3 by pushing the ESC button 73 Automatic boiler for biomass Service manual We enter the menu by pushing the f 0U arrows Here we select the desired flue fan revolutions during flue cleaning Tt is not recommended to perform flue sweep when the boiler is hot or when the flue fan revolutions are high Solid burning remains could enter the environment By pushing the gt ENTER button we switch to flue fan revolutions setting in the flue sweeping process Important note Fan revolutions are set for a particular fuel type First we select the fuel in Menu 10 Fan revolutions and the consequent needed air volume may be different for different fuel types Needed air volume setting is done the same way as above in this chapter The newly set value is confirmed by pushing ENTER button Return to MANUAL mode by repeatedly pushing the AESC button or you can continue in your menu selection with the ff DU arrows 9 4 14 Menu 11 14 Configuration The control system E2008 offers the option of a multiple use of the inputs and outputs 9 4 14 1 11 14 1 Configuration K15 1 We enter the menu by pushing f U arrows We enter the menu by pushing gt ENTER button Here we can choose the function of this relay output Another push of the ENTER button will display the current output function The next function can be selected with the ff gU arrows By pushing the
112. nufacturer uses these fans for boilers of the KPx2 model line Type7 R2E150 manufacturer EBM PAPST Type8 R2E180 manufacturer EBM PAPST Type9 R2E210 manufacturer EBM PAPST 66 Automatic boiler for biomass Service manual Confirm the selected flue fan type by pushing the ENTER button The display will briefly show the selected fan type The control unit will return to menu item 2 Flue fan type 9 4 10 Menu 11 10 Boiler output Data on the rated output of the boiler as well as parameters of fuel feeders are entered in this menu Values entered in this way are used by the control unit to calculate the momentary output of the boiler for a particular adjustment of operation of feeders and will display these data upon the operator s request These set values will not effect on actual boiler power output Even with wrong set up boiler will work in correct power set in menu 11 1 Program MENU 11 10 Boiler output will appear on the display unit after the PIN for the Producer menu has been correctly entered and after adjustment to this menu has been done by cursor arrows f U By pushing key ENTER to enter the adjustment of rated output of the boiler the control unit is used for Enter the adjustment of rated output of the boiler by pushssing the key ENTER where xx is the existing adjustment value XX is the newly required adjustment value and is blinking The new value of rated output of the boiler is adju
113. of time by pushing the key ENTER and return back to the menu moves to the neighbouring digit to the right moves to the neighbouring digit to left The current state of minutes may be changed by cursor arrows f IV ft increases the value of the number in step of 1min 0 reduces the value of the number step of 1min If the value of minutes has been adjusted go to the setup of seconds or return back to the repeated setup of hours or confirm the total setup of time by pushing the key gt ENTER and return back to the menu gt 4 Setup of time moves to the neighbouring digit to the right le moves to the neighbouring digit to the left The current state of seconds may be changed by cursor arrows f U ft increases the value of the number in step of 15 g 0 reduces the value of the number in step of 1s If the value of seconds has been adjusted by pushing the cursor arrows go to the setup of hours or return back to the setup of minutes Confirm the setup of time by pushing the key gt ENTER The programme will return back to the menu gt Setup time Return back to the mode MANUAL or AUTO by repeated depression of the key ESC or continue in selection of the next menu by cursor f pY 9 3 5 Menu 5 SW Tank active Up to three time periods for heating hot service water may be determined in this MENU Note The control unit will accept the signal from th
114. ollowing a General inputs Analog 4x range 0 to 2 5V resolution 10bit Binary 2x log zero OV to 2V log one 3V to 5V Binary 2x log zero OV to 5V log one 7V to 12V Binary expander 2 log zero OV to 2V log one to 5V b Specialized inputs thermometers PT 1000 2x thermometers NTC 10000 3x emergency thermostat 2x thermostat 1x LAMBDA probe 1x C Power outputs 9x ON OFF active contact relay AC 8A 230V 2 ON OFF active semiconductor switch AC 6A 230V 2x phases regulated synchronized with supply voltage AC 230V max 6A d Communication lines RS485 2x RS232 1x 1x Ethernet WIFI 1x SPI 1x JTAG 1x Auxiliary supply voltage output 1x DC 24V max 0 1A The unit is constructed as an integrated 19 module The unit is built in vertically either to the left or right side of the lateral boiler covering depending on the space possibilities of the boiler room 12 Automatic boiler for biomass Service manual Picture 4 RJE2008 Control unit The unit itself consists of two modules The power part is affixed to the unit cover Picture 5 RJE2008 Control unit power and connecting parts E2008 Module processor is removable Picture 6 Processor E2008 Both modules are connected by a connector cable 13 Automatic boiler for biomass Service manual TECHNICAL DATA Supply 230V
115. ometer inputs NTC10000 PT1000 connector markings XV3A XV5A XV5B XV2 XV6A XV6B are connected as voltmeters A D conversion 10BIT range OV to 2 5V The decrease of sensor resistance is measured with constant electrical current Binary inputs connectors XV7A XV7B XV8A XV8B XV9A XV9B are equipped with PULL UP resistors 10 kOhm connected to 5V voltage and ready for control by type OC open connector sensors or passive contacts Binary inputs with supply supports connectors XV11A XV11B are three pronged they have an extra terminal with supply voltage 12V and they are ready for sensor control of the OC type open connector while the load PULL UP resistor is expected in the sensor Room thermostat connector XV13B is a specialized input output This is an active input which is ready for a metallic switch If switched on constant pulsating 10 ms is on 10 ms is off current range 0 to max 5 mA open circuit voltage approximately 6 to 8 runs through the circuit If this input is equipped on its side by an E1074 adaptor this channel can be used also as an output A 10 ms time window when electrical current is not running through the circuit is used to transfer additional information This function can be used for instance to control the room thermostat by GSM This communication channel input output is floating in relation to the other control unit circuits Only equipment with SELV may be connected to these t
116. ompetence in electrical engineering and trained by a manufacturer Installation company or person installing the boiler has to adhere the following standards and regulations apart from other things or yours national equivalents 5 3 1 Heating system and boiler CSN 06 0310 1983 central heating designing installation CSN EN 303 5 2000 boilers for central heating part 5 CSN 06 0830 1996 security systems for central heating and heating of hot service water CSN EN ISO 12100 2 2004 structure and versions of boilers 5 3 2 Venting CSN EN 1443 Chimneys general requirements 734200 9 2004 CSN 73 42 01 Chimneys and fume ducts designing implementation and connection of fuel consumers 02 2008 Pressure and temperature conditions necessary for safe operation of heat installations are described in the following standards CSN 73 4201 and EN 13 384 1 and EN 13 384 2 Recommended draught of chimney has to be within the range specified by the manufacturer See picture 27 in connection with the installed power output of the boiler 31 Automatic boiler for biomass Service manual 0 3 DRAUGHT mbar gt x 9 9 1 8 9 10 20 30 40 50 60 70 RATED OUTPUT OF HEAT Q kW Picture 27 Required chimney draft Chimney systems resistant to humidity in which condensation of water vapour is permitted are recommended in order to ensure long term trouble free and safe operation of the boiler Chimneys
117. on flange for pellet supply With burner KP62 attach a security thermostat by two straps on a pipe of the fuel input in to a burner Picture 29 Burner installation in boiler 34 Automatic boiler for biomass Service manual 6 3 INSTALLATION OF THE CERAMIC CATALYTIC REFLECTOR The ceramic catalytic reflector is manufactured from highly heat resistant material 1800 C It has two functions directs the flow of combustion products through the boiler body assists very efficiently to burn out carbon substances and thus to reduce considerably harmful substances in combustion products The reflector is placed outside the combustion space during transport in order to prevent from any damage The shape of the reflector reminds a hollow semi cylinder with one face closed see picture no 30 Picture 30 Ceramic reflector The reflector is installed into the boiler on the surface of the burner boiler with the stop on its rear side and symmetrically to its centre line While in operation ceramic reflector has to touch the back part of isolation desk of the burner If you do not keep it there is a chance of burner damage or a Boiler Check regulary 6 4 INSTALLATION OF SECONDARY CERAMIC GRATE Individual parts of secondary ceramic grate on the picture no 31 KP 12 ZA kP 22 A KP 62 A AA Picture 31 Parts of secondary ceramic grate 35 Automatic boiler for biomass Service manual Function as such
118. on period The regulation period is the boiler activity time interval in the EQTx mode in which water temperature increase or decrease is monitored and their immediate relation to the values of the lower gradient Menu 11 12 2 and the upper gradient Menu 11 12 3 is assessed We enter the menu by pushing the f 0U arrows Select the period setting in minutes by pushing the ENTER button The control unit uses this period for evaluation of preset and current parameters and performs a regulatory interference if needed Regulation period setting is done the same way as above in this chapter Return to the MANUAL mode by repeatedly pushing ESC button or you can continue in your menu selection with the arrows Note The principle of the boiler operation in the equithermal mode should by easy to see in the attached chart 69 Automatic boiler for biomass Service manual Important note If we change the regulation period for instance in small or very large heating systems it is necessary to change also the temperature gradient values in a proper ratio in order to maintain regulation dynamics Comb Gas T MIX T T of ret Water of out of in CD SERVO Outside T Wk Room Therm SWT Therm oo CO C CN OQ Pump gt T ALS BSSLALAISLAR SWT pump o 0 9 o 99 n 3 28 gt 28 2SSRgaqn NN NN
119. on time of the feeder F1 Adjustment of the upper limit for operation time of the feeder F1 shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL by repeated pushing the key a ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 10 9 5 3 3 Menu 12 3 3 Feeder off lower limit We will enter the following menu by means of the cursor arrows U By pushing key ENTER to go to the adjustment of the lower limit of the idleness time of the feeder F1 Adjustment of the upper limit for idleness time of the feeder F1 shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL by repeated pushing the key a ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 1 U 9 5 3 4 Menu 12 3 4 Feeder off upper limit We will enter the following menu by means of the cursor arrows ff U By pushing key ENTER to go to the adjustment of the upper limit of the idleness time of the feeder F1 Adjustment of the upper limit for idleness of the feeder F1 shall be performed in the same way as mentioned in this chapter above Note It is not recommended to reduce the upper limit of the turn on time under 5 s Important Set up of the upper limit of the switch in time together with the adjusted lower limi
120. onal for reliable and mainly safe operation of automatic boilers Rotary sensors ensure higher level of this check It is possible to define the time window to count pulses in this menu independently for every sensor as well as the number of pulses which take place within this defined period of time 82 Automatic boiler for biomass Service manual MENU 11 8 Rotary sensors will appear on the display unit after the PIN for the Producer menu has been correctly entered and after set up to this menu has been done by cursor arrows ff U 9 5 8 1 Menu 12 8 1 F1 MEASUREMENT TIME The following script will appear by pushing the key ENTER By pushing key ENTER we will enter set up of time window in sec and we will count the incoming pulses in this time window for the feeder F1 Using the cursor arrows f we will determine the new time value which will be in force after its confirmation Confirm the newly set up value by pushing the key gt ENTER The value CC will stop blinking and will be saved in the memory for boiler operation in the automatic mode The values cc and CC are identical now The value CC will start blinking again by repeated pushing the key gt ENTER and may be changed Return back to the menu 1 RS1 time by pushing the key ESC The value has been accepted for further use provided the new value has been confirmed with the key ENTER the value CC is not blinking If the value CC is bli
121. ote Fuel transportation pathways cleaning and electric parts work should be done by professional service personnel Important note During any manipulation in the fuel pathway the main boiler switch must be turned off or otherwise disconnected from electric supply 10 8 TEMPERATURE SENSOR ERROR The boiler operation is affected by the operation thermometer to a large degree In case it is damaged the boiler cannot work properly If temperature sensor error is detected the boiler operation is stopped This situation is indicated by a sign on the display TEMP SENSOR ERROR The boiler stoppage prevents incorrect boiler operation Faulty temperature sensor Replace sensor Boiler reactivation After temperature sensor replacement by an authorized service personnel it is possible to switch to automatic boiler operation by pushing the START and ENTER button if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 89 Automatic boiler for biomass Service manual 10 9 FLUE GASES TEMPERATURE SENSOR ERROR The boiler burning check is done by measuring the flue gases temperature The temperature sensor error is indicated by a flashing error message This failure does not present danger and the boiler operation is not stopped The display message reads If the flue gases temperature measurement mode is on pushing of the a ESC button will result in this
122. pathways Check remove blockage which prevents fuel entry into feeder Insufficient boiler output Increase boiler output up to maximum nominal output Incorrectly selected boiler output Check the heating system size and the boiler output preferably by a professional firm Boiler reactivation After this it is possible to switch to automatic boiler operation by pushing START and ENTER button if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 10 6 STOPPAGE BECAUSE OF LOW FLUE GASES TEMPERATURE If the boiler had been in a STAND BY mode for only a short time and the boiler burns out anyway and switches into the automatic operation AUTOx MODEx EQTx or boiler modes the boiler adds fuel to a burned out burner After a short time the boiler will analyze the flue gases temperature and it will realize that the boiler is not burning and stop it and signal an emergency state on the display STOP STATE3 Note This boiler procedure works only if electric ignition is banned by the program 88 Automatic boiler for biomass Service manual Note If electric ignition is allowed by the program the service personnel mistake is eliminated by activation of routine electric ignition at the moment the boiler realizes it is not burning After ignition the boiler works in a standard manner Low quality fuel Replace fuel supplier Stand by period is set inco
123. pen the door carefully to prevent from getting jeopardized by gathered products 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 If any work which generates inflammable vapours takes place in the boiler room glueing the floor etc the boiler has to be out of operation and the fire has to be burnt out in the boiler Having the heating season been finished clean the boiler thoroughly as per the chapter 7 Maintenance Products of combustion stuck to the walls of the exchanger may act corrosively for the whole period of time when the boiler will be out of operation If the burner is not cleaned this may have effect on faulty combustion We recommend to hire a specialized company to perform this work If you work on or near to the mechanically movable parts fuel feeder etc ensure safe disconnection of the equipment from electric voltage There is a risk of injury You should always operate the boiler only under parameters and in harmony with recommendations given in these Instructions for installation and operation If the boiler works in the AUTO mode and if there is a failure of current the boiler will start operation again with the electric firing programme if this programme has been installed after the del
124. ption AUTO 7 11 22 MIX 045 SRV 008 MANUAL FAN 4 MAIN FLUE 4 e lt ourpur START B CHMNEYERI Picture 7 Description of terminal 16 Automatic boiler for biomass Service manual Control panel contains pos 1 column indicators 2x10 LED tapes pos 2 alphanumeric display 2x16 characters pos 3 three digit seven segment LED pos 4 foil keyboard with mechanical click and inserted indication diodes pos 5 accentuated red indicator pos 6 control indicators pos 7 The main switch is placed on the front panel of the boiler near the terminal The foil keyboard is especially designed for easy replacement of keys description by paper tabs insertion into the individual spaces pockets This design enables a universal functional use and easy national versions of the keyboard description The keyboard is comprised of eleven buttons with a mechanical click Every button has a light indicator diode The diodes are lit by using a particular button or by operation of the equipment which is controlled by the button From the design viewpoint this is an application controlled by a microprocessor and communicating with a superordinate system after the RS485 interface The terminal supply is provided from the superordinate system RJE2008 4 2 2 3 Description of the connectors XZ62 input ISP entry programming terminal XV61 terminal supply communicatio
125. r has to be equipted with input water thermometer 9 4 15 Menu 11 15 Servomotor This menu serves for servomotor operation period setting between two limits Correct setting of this time period is necessary for the correct temperature control function of output water equithermal regulation and closing and opening of the servomotor MENU 11 15 SERVO appears on the display after entering the Service Menu Setting is done by using the gU arrows After pushing the ENTER button the alphanumeric display will read sss is the current value SSS is the newly set value and it is flashing Confirm the newly set value by pushing the gt ENTER button 75 Automatic boiler for biomass Service manual 9 5 MENU 12 PRODUCER This MENU is accessible only to a manufacturer or TOP service technicians It is safeguarded by four number PIN code 12 PRODUCER PIN ENTER 12 1 1 TIME LOCK 12 2 TEMPERATURE LIMITS 12 2 1 TEMP LOWER LIMIT 12 2 2 TEMP UPPER LIMIT 12 2 3 No OF SAMPLES 12 3 FEEDER 1 LIMITS 12 3 1 FEEDER ON LOWER LIMIT 12 3 2 FEEDER ON UPPER LIMIT 12 3 3 FEEDER OFF LOWER LIMIT 12 3 4 FEEDER OFF UPPER LIMIT 12 4 1 LOWER LIMIT 12 4 2 UPPER LIMIT 12 4 3 ABSOLUT LIMIT 12 4 PUMP LIMITS 12 5 SWT PUMP LIMITS 12 6 FAN RUN OUT 12 6 1 FUELNo 1 12 5 2 UPPER LIMIT 126 2 FUELNo 2 12 5 3 ABSOLUT LIMIT 1263 Fims 12 7 1 FUEL No 1 12 6 5 FUEL No 5 12
126. r must be tightly attached in the right place to the boiler during operation Important note After each visual check of burning or after ash removal you must always make sure that the boiler door is tightly closed to avoid being stricken by flames from the burning chamber Ajar or slightly opened door will cause increased fire hazard and also negatively affect the fuel burning processes 7 1 3 Flue gases exchanger cleaning Cleaning of the gas flue is done automatically in intervals set by the control unit program Proper setting is done in the manufacturing facility or later by an authorized service technician Exchanger cleaning is performed repeatedly several times per day depending on burning intensity Exchanger cleaning can be limited by time It is not feasible to use exchanger cleaning for instance during night time Note In case the boiler shows signs of faulty burning smokes when the door is open or the burnt gases temperature is rising check the efficiency of exchanger cleaning Change the cleaning interval 7 2 MAINTENANCE 7 2 1 Burnt gases exchanger cleaning Is done automatically electric motor drives lever cleaning mechanism Operation interval set by the program differs by fuel types It is also possible to remove ash from the burning chamber by turning on the ash removing drive in the Menu The service technician checks correct function of the equipment checks turbulators for damage correct function of the dr
127. ramic grate 4 4 3 ceramic shield 4 5 Feeder F1 with independent drive from fuel bin 4 6 A Jacketing of the boiler including heat insulation 4 7 Cleaning system 4 7 1 ash removing 4 7 2 heat exchager cleaning 4 7 3 external ashtray 4 8 fan with KP12 22 is as a option Other parts which can be delivered 4 9 Standard accessories 4 10 Optional accessories 4 11 Fuel bin by needs of customer Automatic boiler for biomass Service manual DIAGRAM OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS 4 1 4 11 BOILER BODY 4 4 2 FUEL BIN CERAMIC SECONDARY GRATE 4 2 2 CONTROL PANEL 4 7 3 ASH CONTAINER 4 1 2 DOOR 4 4 1 CERAMIC REFLECTOR 4 7 2 AUTOMATIC CLEANING SYSTEM 4 8 WITH TURBULATORS FLUE GAS EXHAUST WITH FAN 4 2 1 4 5 E 2008 FEEDER F1 CONTROL SYSTEM 4 3 2 CONNECTING FLEXI HOSE 4 3 1 4 3 FEEDER F2 BURNER CHAMBER 2 4 7 1 MOTOR FOR ASH REMOVING 4 3 4 FE EL IGNITION 7 BE 7 EL HEATERSFOR 4 3 3 MODERATE HEATING MAIN FAN Picture 1 Diagram of the products and description of the main parts 4 1 Automatic boiler for biomass Service manual BOILER BODY SCHEMA OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS is made of top quality steel metal sheets and pipes for boiler in form of a weldment Its shape is adapted in such a way so that combustion products are cooled down efficiently at individual levels of power output which is moreover as
128. rent setting By pushing ENTER Button we change SMS info function By repeatedly pushing ENTER button you can change the ON OFF setting Note A warning SMS message informing on any failure or operating conditions preventing from normal operation of the boiler is sent to the mobile number 1 and to the number of the service workshop if entered as a GSM Master in the menu Manufacturer Note The control unit sends the following failure conditions STOP STOP NOT IGNITED STOP TEMP gt 95C STOP TEMP gt 100C BLOCKED FEEDER 1 BLOCKED FEEDER 2 By pushing ESC button we are returning to mode MANUAL AUTOx MODx EQTx BOILER it is possible to continue by pushing 0 ff arrows to future menu selection Description of activity The control unit program software is fitted with functions for receiving and transmitting short text messages A set of defined commands assures simple boiler operation STATUS The control unit will respond with current status information START This command will start the boiler room thermostat virtual contact is permanently ON STOP This command will switch the boiler to the stand by mode room thermostat virtual contact is permanently OFF NORMAL The boiler accepts the real time room thermostat status REM ON The control unit will send a signal to the room thermostat which is then switched to the telephone mode REM OFF The control unit will send a signal to the room thermostat an
129. riod in minutes the fuel in the burner boiler has to be provided with in order to burn through well The fuel has to burn on the whole surface of the boiler for further automatic operation Important note The flare time is given for the specific fuel Fuel can be selected in Menu 10 Plare time can be different dipends of fuel type Adjustment of the burning up period of the automatic boiler is done in the same procedure as mentioned above in this chapter Note The adjusted time period to get the boiler burning will be repeated twice After the adjusted time interval RR elapses the boiler will add more fuel shortly 5 s and another RR interval will follow Note If modulation of the boiler output is allowed the boiler will start heating on the starting program adjusted in the modulation menu chapter 9 4 12 1 MENU 11 12 1 after the program routine of automatic ignition is finished Important Adjustment of parameters for electric ignition is partially dependent on the fuel used The service engineer responsible for correct adjustment of these parameters is obliged to test the equipment for 63 Automatic boiler for biomass Service manual functionality repeatedly The demands for time result from the need to start the boiler from the state of being completely burnt out and cold 9 4 5 8 Menu 11 5 8 Reference temperature We enter the menu by pushing arrows By pushing key ENTER to enter adjustment o
130. rrectly Service technician will set longer stand by period Boiler reactivation This happens only when electric ignition is off Turn on the electric ignition in Menu 6 and fix it Check possible causes for boiler burn out After this it is possible to switch to automatic boiler operation by pushing the START and ENTER button if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 10 7 BLOCKED FEEDER The attendant is informed about this situation by a message on the display This is a motor protection feature and an important fire protection point In case the F2 feeder is blocked the whole fuel pathway could be filled with fuel and the fuel could burn through all the way to the tank Stoppage prevents overload of the particular feeder motor and its possible destruction Foreign object in the fuel Clean fuel pathways Unsuitable fuel crumbling pellets Secure standardized fuel Faulty motor or faulty motor power supply Check functionality of motor check power supply Faulty gearbox Replace gearbox Faulty impulse sensor Check sensor function replace if needed Boiler reactivation After blockage removal by an authorized service it is possible to switch to automatic boiler operation by pushing the START and ENTER button if the equipment was shut down for a long time by pushing the AUTO MANUAL buttons if the boiler is still burning N
131. rsonnel attention is required because it has to be determined why this state of failure occurred and how to fix the problem Boiler water temperature is set to a high Lower the boiler water output temperature Menu 2 for value around 909C instance to 809C Insufficient heat removal from the boiler Check the circulatory pump you may switch to a higher output circulatory pump is not running 27 Close the particular valves and clean the filter cleaning filter is plugged up Faulty hydraulics of the heating circuit Change the heating circuit settings change the heating circuit all thermal heads are closed wiring Check temperature increase in the STAND BY mode and make the time period longer STAND BY MENU 11 4 This should be done by professional service personnel Large volume of unburned fuel in Carefully clean the burning chamber and perform professional burning chamber adjustment of burning Stand by time is to short in a boiler with electrical ignition turned off Initial operation For automatic operation activation the output water temperature must drop below 659C If this condition is not met the control unit will not be able to function Boiler operation reactivation is done in the following steps 1 We leave the boiler idle until the output water temperature drops below 659 see display To speed up this process we leave the pump running 2 After that we push the safety
132. rvice center The authorized service center will perform professional adjustment of the boiler according to the fuel type you selected Important note Do not willfully change the fuel type unless the boiler is professionally adjusted for that particular fuel Boiler damage or dangerous operation status may result The service organization must record the adjustment to a different fuel type 9 4 MENU 11 SERVICE This MENU is accessible only to manufacturer staff or by professional service organizations The access is blocked by four blocked PIN code agains a wrong use 5 Automatic boiler for biomass Service manual PIN ENTER gt U 11 4 STANDBY TIME 11 6 PUMP 11 7 SW TANK PUMP ON 11 8 CHANGE SERVICE 11 9 1 FAN TYPE 11 9 2 FLUE FAN TYPE 11 11 EQUITHERM REGULATION 11 12 MODULATION 11 11 1 STARTING PROGRAM 11 12 1 STARTING PROGRAM 11 11 2 GRADIENT LOW 11 12 2 GRADIENT LOW 11 11 3 GRADIENT UPPER 11 12 3 GRADIENT UPPER 11 1 4 ZONE sis 11 125 Z0ONE2 11 11 6 REGULATION PERIOD 11 14 CONFIGURATION 11 12 6 REGULATION PERIOD Picture 37 Operational block diagram Service 58 Automatic boiler for biomass Service manual The Menu is PIN encoded It contains a file of adjustments accessible to service engineers Output stages corresponding to the air quantity in course of burning and parameters ensuring safe and reliable operation of the boiler are adjusted in individual menus
133. ry inputs of the expander Binary inputs supporting X1 X2 expander are three prong they have one 12 V terminal and they are prepared for control by OC open connector sensor 4 2 3 3 Description of EEx2008 expander outputs Triac motion sensor active output expander terminals X5 is designated for general use The maximum load of each output is up to 6A and the current total limitation for EXE2008 is 16A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals show grid voltage The angle of connection can be entered as percentage value or this value can be part of the expander inside algorithms Important note This output must have outside protection Triac motion sensor active output expander terminals X6 is designated for general use The maximum load of each output is up to 12A and the current total limitation for EXE2008 is 16A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals show grid voltage The angle of connection can be changed from zero to 909 after that the relay is on This function enables start up of a motor with large input this eliminates heat load for the semiconductor This output can be run for lower outputs as a standard controlled output It can be activated from the control unit or this value can be part of the expander inside algorithms Important note This output
134. s step of Imin If the bottom limit value in minutes is adjusted go on to the setup of the top limit value in hours for the time period by pushing the cursor arrow gt or by pushing the key ENTER The top limit in hours and minutes for the time period is adjusted in the same way 52 Automatic boiler for biomass Service manual Return back to the menu 5 SW TANK ACTIVE or to the modes MANUAL AUTOx MODx or SW TANK by repeated pushing the key a ESC The same provisions apply for setup of the bottom and top limit for the time periods 2 and 3 Time period 2 Time period 3 Note For the correct function check the time set up in Menu 4 Note The time zone cannot cross midnight so it must be set accordingly 9 3 6 Menu 6_Electric ignition Permits and inhibits function of electric ignition heating coils and the use of routines to start extinguished boiler automatically MENU 6 Electric ignition will appear on the display unit after a short script MAIN MENU and after setup to this menu with cursor arrows ff IV By pushing the ENTER button display will show Or or depending on the last current setting The setting of the electric ignition function can by changed by pushing the ENTER button By repeatedly pushing ENTER button you can change the ON OFF setting Select the desired setting and return to the MANUAL AUTOx MODx EQTx or BOILER modes by pushing NESC button Further
135. s 10A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals show grid voltage This output is in RJE2008 used in the solid fuel application as a main switch of the circular pump It is the only unit output which is live even when the emergency thermostat is inactive Triac motion sensor relay passive outputs terminals K19 1 K19 2 are designated for general use The maximum load of each output is up to 6A and the current total limitation for RJE2008 is 10A If the unit is meeting the activation conditions program manual control and active emergency thermostats these terminals show grid voltage The K19 2 output is dependent on the K19 1 output Voltage can be present on the K19 2 terminal only if terminal K19 1 had been switched on before that Triac motion sensor relay active outputs terminals K17 1 K18 2 are designated for general use The maximum load of each output is up to 6A and the current total limitation for RJE2008 is 10A If the unit is meeting activation conditions program manual control and active emergency thermostats these terminals show grid voltage The angle of connection can be entered as a percentage value or this value can be part of the algorithms Four prong relay terminals K15 2 K16 1 connects two outputs which can be used for independent switching They have only two common terminals PE and N These outputs are mutually blocked
136. s perfectly resistant to environment effects and ensures perfect appearance of products on long term basis Design of whole solution is using a modern shape elements 11 This SUBSIDIED ABLE PRODUCT is fullfilling all required conditions for obtaining subsidies in many states of the European Union 12 LONG DISTANCE CONTROL and monitoring by internet or GSM connection Automatic boiler for biomass Service manual 3 TECHNICAL DATA OF THE BOILER KP X2 Table 1 Thermal and technical parameters of products Parameter Tune KP ARNE KP 2272 62 62 Efciency rated output 912 908 906 in heating value 17 5MJ Kg and efficiency 9096 Table 2 Solid harmful substances in combustion Parameter Uni KP ADE KP 2322 KP 6262 Average mass flow rate solid elements g hrs 0 36 0 65 22 pollutions at rated power Table 3 Technical parameters of products Parameter Unit KP 2222 KP 62 62 160 Connections heating and return water Heating surface Dimensions w d without ashtray 47 7x 980 614x980 45x1360 Dimensions h Working overpressure of water Hydraul loss AT 10K Hydraul loss AT 20K 2 77 Required draught Recom operating temp of heating water Lowest temp of incoming water Table 4 Electrical parameters of products Parameter Umi KP12 2E KP 2222 62162 Connecting votas 20 10 SOHzi2Hz _ EI Protection ofthe
137. s prescribed by annual check up Plugged up chimney flue Clean boiler chimney flue Insufficient flue pull or back draft Call professional chimney sweep solution must be designed by professional firm Initial operation For automatic operation activation the output water temperature must dropped below 659C If this condition is not met the control unit will not be able to function Boiler operation reactivation is done in the following steps We leave the boiler idle until the output water temperature drops below 659C see display To speed up this process we leave the pump running After that we push the safety thermostat reset button You must hear the trigger click The red reset button is accessible without any tools by removing the top boiler cover and unscrewing the black coverings Shut down the control unit with the switch for about 5 seconds and then turn it on again Now the control unit is ready for further operation in the MANUAL mode After that it is possible to switch to automatic boiler operation by pushing the START and ENTER button if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 87 Automatic boiler for biomass Service manual 10 4 STOPPAGE BECAUSE OF FAULTY ATTENDANCE If the boiler was switched to MANUAL mode and remained in this mode for too long the boiler fire burned out If the attendant now switches into automa
138. s section 4Bx2 5 4 50x25 65x25 junction box cross section schematic symbol switchboard Boiler KP xxE switchboard central grouding identification equipment switchboard boiler switchboard bonding as per possibilities boiler room as per possibilities as per location as per the location of equipment NOTE type of version closed protection IP55 in the building customer s requirement and location in the building as per possibilities of the building and location in the building open protection 1 20 Voltage system dimensions E 3 PE N 50Hz 400 250 V TN C S division Protection against dangerous contact voltage supply from the top via automatic disconnection from the source outlets down Increased protection operation by electrically instructed persons via additional bonding Picture 54 Electrical installation version for input 3 PE N 50 Hz 400 230 V TN C S LOT THE SPACE FOR BOILER WITH ASH CONTAINER SAMPLES OF TRANSPORTATION BY COLLECTING THROUGH SETS COLLECTING THROUGH SET Picture 55 Dim Req for the placement of KPx2 in boiler room exam of using collecting troughs 80T Boiler output kW Picture 56 60T 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Wood pellets consumption kg hour DIRECTORY INFORMATION CONSUMPTION WOOD PELETS FOR BOILERS TYPE KP AT ACHIEVEMENT 4 5 62 kW Director
139. sisted 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 Boiler body i fitted with the following 4 1 1 4 1 2 4 1 3 4 1 4 4 1 5 4 1 6 4 1 7 4 1 8 4 1 9 4 1 10 4 1 3 steel weldment with turbulator heat exchanger 1 pc of door allowing inspection of conbustion and burner while in operation installation of all ceramic parts before starting the operation and possible cleaning of the burning chamber flue gas exhaust diametr of the flue 130 150 160 mm fot individual types which are in table 3 output of heating water 112 inside thread input of return water 112 inside thread rear flanged orifice in order to install the burner syst m an outlet of Y2 order to install an inlet outlet valve extension piece with inside thread M48 x 2 mm in order to make it possible to install an electrical heating unit turbulators event with system of semiautomatic cleaning of the heat exchanger opennig on top for cleaning covered by a lid of the boiler s body 4110 4 1 8 4 1 5 Picture 2 Boiler body 10 Automatic boiler for biomass Service manual 4 2 CONTROL SYSTEM OF THE BOILER The Boilers are equipped with the E2008 control system This control system enables automatic boiler operation with the help of control and regulation features thermomet
140. sted with the cursor arrows gt U Confirm the newly adjusted value by pushing the key ENTER The value XX will stop blinking and will be saved in the memory boiler operation in the automatic mode The values xx and XX are identical now The XX value starts blinking by repeated pushing the key gt ENTER and may be changed Depress the key a ESC to return to the menu gt Power KW The value has been accepted for further use provided the new value has been confirmed with the key ENTER the value XX is not blinking If the value XX is blinking it will not be accepted after the return to the MAIN MENU and he original adjustment value xx will still be used We will enter the following menu by means of the cursor arrows Enter the adjustment of the F1 feeder s factor by pushing the key gt ENTER This factor gives the average dose of fuel delivered into the boiler for 1 second The factor is adjusted with cursor arrows in usual way We will return back to the mode MANUAL AUTOX MODX or SW TANK by repeated pushing the key ESC Important note constant feeder setting for the type of fuel Fuel choose in advance in Menu 10 Constant feeders reflects both the amount of fuel dose for 1 sec but also the calorific value of fuel used Note Entered values of the boiler output and factor of the feeder F1 are used by the control unit to calculate the output indirectly The value stated is only
141. switch in the contact of the room thermostat or cool the boiler down for example by turning the circulation pump on see chapter 5 1 direct control under the temperature value of the outlet water Menu 2 chap 6 9 3 MAIN MENU 9 3 1 Menu 1 Direct control Pressing the key ENTER after short blinking of the Main Menu CU goes over to MENU1 Direct control The MENU 1 makes it possible to control very simply all outputs and to check the state of input signals It is beneficially used to put the boiler into operation or in case of service interventions Note Direct control of feeders has to be used when the fuel runs out and the fuel feeders are empty see chapter 7 10 Lack of pellets in the bin Using the cursor arrows ff we may go to the next or previous MENU we can return to the previous menu or we can leave the menu by repeated depression of the key ESC 9 3 1 1 Menu 1 1 Control of feeder Fi After a next pressing ENTER appears xxx The period of feeder operation in sec we may change the operation period of the feeder 1 by cursor arrows gt increases the operation period by 10sec reduces the operation period by 10sec Turn on the Feeder 1 after the key gt ENTER has been depressed The following will be displayed on the display unit Feederi ON The feeder will stop when the value 000 is reached The operation period of Feeder 1 may be increased or reduced during operation
142. t for idleness of the feeder F1 has to ensure that the dosing which corresponds to the maximum power output of the boiler will not be exceeded 9 5 4 Menu 12 4 Pump limits The producer will set up in this menu the upper and lower limit of the temperature range in which the pump of the heating system is turned on The service engineer will be allowed to change setting only within these limits kapitola 6 Menu 10 6 Producer shall set up also the absolute temperature under which the pump will always be turned on regardless of ambient conditions This mode of the pump control increases operating reliability of the boiler and prevent from boiler overheating in case of wrong adjustment of the boiler for example short standby period MENU 12 4 Pump limits will appear on the display unit after the PIN for the Producer menu has been correctly entered and after setting to this menu has been done by cursor arrows WU 9 5 4 1 Menu 12 4 1 Lower limit The following script will appear by pushing the key ENTER By pushing key ENTER to go to the selection of the lower temperature limit for the output water in order to turn the pump of the heating system on Where dd is the existing set up value DD is the newly required set up value and is blinking The required lower limit value of the output water temperature of the automatic boiler for solid fuel can be set up with the cursor arrows f U Confirm the newly set up value by push
143. tations of fan for setting of outputs and optimal burning settings parameters settings parameters settings parameters settings parameters Program 1 Program 2 Program 3 Program 4 Program 5 Program 6 Program 7 Program 8 Program 9 Program 10 settings parameters settings parameters settings parameters settings parameters settings parameters settings parameters F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN F1 off F1 on FAN for 3096 of nominal boiler output for 4096 of nominal boiler output for 5096 of nominal boiler output for 6096 of nominal boiler output for 7096 of nominal boiler output for 8096 of nominal boiler output for 85 of nominal boiler output for 9096 of nominal boiler output for 9596 of nominal boiler output for 10096 of nominal boiler output ond off90 F030 FlueFO ond off66 F033 FlueFO ond off53 F036 FlueFO ond off45 F040 FlueFO ond off38 F042 FlueF0 ond off33 F045 0 ond off30 F047 FlueF0 ond off28 F051 FlueFO ond off26 F054 FlueF0 ond off24 F055 FlueF0 ond off60 F030 FlueFO off60 F030 FlueFO on9 off60 F034 FlueFO on9 off48 F037 FlueF0 on9 off40 F040 FlueFO on9 off34 F043 FlueFO on9 off32 F046 FlueF0 on9 off29 F051 FlueFO on9 off27 F054 FlueF0 on9 off25 F057 FlueF0 ond off61 F030 FlueF100 ond off40 F030
144. te Maximum temperature level of the boilers water is limited to 70 fro starting a pump so it pevents boier overheating Minimum temperature must be kept above value condensing temperature 559C 9 5 4 3 Menu 12 4 3 Absolut limit We will enter the following menu by means of the cursor arrows 02 By pushing key ENTER to go to the selection of the absolute temperature of the output water in order to turn the pump of the heating system on Where aa is the existing set up value AA is the newly required set up value and is blinking Adjustment of the upper limit for the output water temperature to turn the pump of the heating system on shall be performed in the same way as mentioned in this chapter above We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC or it is possible to continue with the cursor arrows a ESC in selection of the next menu after pushing the key ony Note The maximum temperature of the boiler water to turn the pump on is limited to 700C in order to prevent the boiler from overheating The minimum temperature has to be maintained above the condensation temperature 550C 9 5 4 4 Menu 12 4 4 Pump run out time We will enter the following menu by means of the cursor arrows D U By pushing key ENTER to go to the selection of the time in minutes for run out time of the pump of the syst m after he boiler enter the Standby state default value 4 minut
145. the outlet Connect Connection terminal 6 6 1 Feeder motor F2 K19 1 N PE 6 6 2 Impulse sensor F2 XV11A 6 6 3 Electronic ignition spiral cables K23 1 K23 2 N PE 6 6 4 Fan K18 2 K18 1 PE 6 6 5 Flue fan if used K17 2 K17 1 PE 6 6 6 Feeder motor F1 K19 2 N PE 6 6 7 Impulse sensor F1 XV11B 6 6 8 Flue thermometer XV6B 6 6 9 System pump K13 2 N PE 6 6 10 Boiler pump K16 2 N PE 6 6 11 Servomotor 3 4 way valve K15 2 K16 1 N PE 6 6 12 Room thermostat cable XV13B 6 6 13 Boiler thermostat cable XV7B 6 6 14 Surface temperature sensor XV5B 6 6 15 Surface temperature sensor of returning water XV3A 6 6 16 Outside temperature sensor XV5A 6 6 17 Module ETHERNET XV10 6 6 18 GSM Modem XV12A 6 6 19 Module Expander XV4A Important note Fan 6 6 4 and flue fan 6 6 5 are controlled proportionally The fan neutral conductor must be connected to blue terminal K17 1 or K17 2 It may not be connected to the common neutral conductor blue terminal N With the help of MENU 1 direct control to be checked by qualified personnel 6 6 20 F1 feeder motor function and correct rotation direction 6 6 21 F2 feeder motor function and correct rotation direction 6 6 22 Correct functioning of F1 feeder impulse sensor and simultaneously 6 6 23 Correct functioning of F2 feeder impulse sensor 6 6 24 Functioning of fan and linearity of its regulation 6 6 25 Functioning of flue fan and linearity of his regulation if used 6 6 26 Functionin
146. the NN value is not flashing If the NN value is flashing it will not be accepted after return to the main menu and the original value nn will be used instead 9 4 11 2 Menu 11 11 2 Lower gradient The lower temperature gradient is the required minimum temperature increase in a monitored time interval If the increase is lower the boiler will automatically increase its output in the next time interval We enter the menu by pushing the arrows Select the lower temperature gradient setting by pushing the ENTER button Lower temperature gradient setting is done the same way as above in this chapter Return to MANUAL mode by repeatedly pushing ESC button or you can continue in your menu selection with the D 1 U arrows 9 4 11 3 Menu 11 11 3 Upper gradient The upper temperature gradient is the required minimum temperature increase in a monitored time interval Tf the increase is upper the boiler will automatically decrease its output in the next time interval We enter the menu by pushing the f U arrows Select the upper temperature gradient setting by pushing the gt ENTER button Upper temperature gradient setting is done the same way as above in this chapter 68 Automatic boiler for biomass Service manual Return to MANUAL mode by repeatedly pushing the ESC button or you can continue in your menu selection with the ff DU arrows 9 4 11 4 Menu 11 11 4 I This is t
147. the axis of the pipe and should not thus drag against the wall of the pipe which is one of reasons why smooth operation is blocked The joint has to be treated with a sealing paste before the flange of the drive is installed which is an important measure against smoke penetration Individual part of the extension grate have to be placed precisely in their correct order The ceramic reflector has to be placed symmetrically in the corresponding bed of the burner and plugged in the stop to the rear side Individual bearing surfaces of the burner and reflector have to be in mutual contact Having the back installation been done completely check via gradual visual check whether all parts are installed correctly Finally try operation of the spiral chute feeder Its operation has to be calm and without any disturbing noise Re entry into service After the maitenance is done connect boiler to a power line a trun on main switch Check if feeders are fill with a fuel and that the pellets are transported in to a burner Press buttn START and confirm by pressing button ENTER If the boiler is not going to be used in summer time like heating of service water we keep the main switch off 41 Automatic boiler for biomass Service manual 7 3 OPERATING CONDITIONS BASIC DISPLAY AUTO1 2 10 Boiler is operationg in automatic mode by values of parameters in specific program v MENU 2 5 6 and service menu AUTO blinking
148. the menu where we may change output water temperature where tt is the existing setup value TT is the newly required setup value and is blinking The required output water temperature of the automatic boiler may be adjusted with cursor arrows This temperature is a significant parameter to control the operation of the boiler If the output water temperature reaches the adjusted value the boiler will get to a so called STANDBY MODE see chapter 7 9 Hf increases the required output water temperature in step of 1 reduces the required output water temperature in step of 1 We will confirm the newly adjusted value by pushing the key ENTER The value TT will stop blinking and is stored in the working register for operation of the boiler in some of the automatic modes The values of tt and TT are identical now The value TT will get blinking again by repeated depression of the key gt ENTER and be changed Depress the key a ESC to return to the main menu The value TT is accepted for further use if the new value has been confirmed by the key gt ENTER the value TT is not blinking However If the value TT is blinking it will not be accepted when we return back to the MAIN MENU and the original setting value tt ill still be used 9 3 3 Menu 3 Language selection MENU 3 Language selection will appear on the display unit after a short script MAIN MENU and after setup to this menu wit
149. tic operation by pushing the AUTO MANUAL button the boiler will add fuel into a burned out burner After a short time the boiler will analyze the flue gases temperature and it will realize that the boiler is not burning and stop it and signal an emergency state on the display Note This boiler procedure works only if electric ignition is banned by the program Note If electric ignition is allowed by the program the service personnel mistake is eliminated by activation of routine electric ignition at the moment the boiler realizes it is not burning After ignition the boiler works in a standard manner Faulty attendance Ignite the boiler manually Boiler reactivation After this it is possible to switch to automatic boiler operation by pushing the START and ENTER button if the equipment was shut down for a long time or by pushing the AUTO MANUAL buttons if the boiler is still burning 10 5 STOPPAGE BECAUSE OF LOW WATER TEMPERATURE If the boiler does not reach 459C temperature within 30 minutes after switching to automatic operation or if during operation the temperature drops below 409C for more than 30 minutes the control unit will assess this situation as non standard and will stop the boiler operation This is indicated by a display message Low quality fuel Check the fuel by a professional firm change if need it Shortage of fuel Add fuel to the tank and fill pathways by manual feeder control Blocked
150. time interval Quality of used fuel Anticipated interval see anticipated burning times in table 1 Note seasonal tank may be installed to the boiler Refueling is controlled automatically or manually 7 1 2 Emptying the external ash containers It is generally true that ash must be removed any time the ash level exceeds 2cm level below the side edges of the external ash container Before you remove the external ash container switch the boiler to the MANUAL mode by pushing the AUTO MANUAL button This way you will avoid spontaneous commencement of ash removal and escape of burnt gases during time when there is no external ash container in place Anticipated intervals 1 xin 6 month KP12 KP22 when using wood pellets 1xin 2 month KP62 when using wood pellets It is also possible to remove ash from the burning chamber by turning on the ash removing drive in the Menu Note The ash container removal interval depends on the following Equipment output volume of used fuel per given time period Quality of fuel When using alternative fuel this interval shortens significantly Correct boiler adjustment Type of boiler installed Important note After checking the ash volume in the container or after ash removal always close the receptacle cover carefully This way you will prevent escape of burnt gases to the boiler room 38 Automatic boiler for biomass Service manual Important note The external ash containe
151. to set the water temperature Menu 2 is the value of water temperature at which the boiler automatically reduces power by one degree We enter the menu by pushing the f U arrows By pushing key ENTER we will enter the adjustment of the second temperature deviation from the adjusted temperature of the output water in the boiler at which the power output of the boiler will be changed automatically Adjustment of the second temperature deviation shall be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 12 71 Automatic boiler for biomass Service manual 9 4 12 6 Menu 11 12 6 Regulation period Regulation periond is boiler time frame in the mode MODx which monitors the increase or decrease water temperature and its immediate relationship to the value of the lower gradient menu 11 12 2 the upper gradient menu 11 12 3 We enter the menu by pushing the f DU arrows By pushing key ENTER we enter setup period in minutes With this period control unit is evaluating set parameters and those which were achieved and it does a possible regulation intervention The regulation period set up shall be performed in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated by
152. turer immediately after having been ascertained 6 If the conditions described in the items 1 5 have been not met the above mentioned guarantee may not be required from the manufacturer The manufacturer reserves the right of product innovations which may not be part of this manual Important note Hydraulic connection schemes as you see are based on actual experiences of Kp boiler operations User can use this scheme as it Is or it can modified it to his needs But that is up to the person who is in charge of the heating system like project manager or installation company therefore PONAST is not liable for its correct solution and functionality 91 MODULATION OFF MODULATION ON BOILER OPERATING WITHOUT AUTOMATIC HEAT DEMAND BOILER OPERATING WITH AUTOMATIC POWER REGULATION HEAT OUTPUT IS TIME POWER REGULATION HEAT OUTPUT IS REGULATED MODE ON OFF BOILER OUTPUT REGULATED BY THE HEAT DEMAND Picture 39 Principle of the modulation c6 Hydraulic scheme 1 x HC SWH Tank Picture 40 93 XV11B XV11A XV5B XV3A XV6B XV13B RSENS1 RSENS2 T MIX TRETW GAS ROOM THER SWT THERM SYKFY 2x0 8 SYKFY 2x0 8 12V DC 12V DC 192 19 1 142 Kis1 iK 18 2 K 48 1 K 16 1 Ki152 23 1 232 132 Ki62 __ gt gt L FEEDER 1 FEEDER2 ASH SWEEPING SERVO EL IGNITION
153. turer provides guarantee for the boiler on a period of 24 months from the date of putting into operation however not longer than 30 months from the date of shipment from the manufacturing plant for the boiler body on a period of 60 months from the date of putting into operation ceramic parts are not covered by the warranty GUARANTEE CONDITIONS 1 User is obliged to ensure installation 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 be used wood pellets 6 8 5 mm free from any admixtures and foreign object 3 If the user wants to claim any form of guarantee he she has to submit duly filled in letter of guarantee number 2 4 The user is obliged to demonstrate that the product was maintained in regular intervals which are described in the chapter MAINTENANCE Regualr annual maitenance has to be done by trained pesrson who is also responsible for the record of it within 14 days list is part of manual service intervention or repaire has to be correctly recorded and sended to a manufacturer 5 Every notification of defect has to be done in writing to the address of the manufac
154. ue by pushing the key gt ENTER The value NN will stop blinking and will be saved in the memory for boiler operation in the automatic mode The values nn and NN are identical now The value NN will start blinking again by repeated pushing the key gt gt ENTER and may be changed Return back to the menu gt 1 Start progr by pushing the key ESC The value NN has been accepted for further use provided the new value has been confirmed with the key ENTER the value NN is not blinking If the value NN is blinking it will not be accepted after the return to the MAIN MENU and the original set up value nn will still be used 70 Automatic boiler for biomass Service manual 9 4 12 2 Menu 11 12 2 Lower gradient Lower temperature gradient is requered minimum grow of the temperature in monitored time passage If the grow is lower the boiler will aoutomatically raise its power output for the next time passage of operation We enter the menu by pushing the f arrows By pushing key ENTER we will enter set up of the lower heat gradient program Lower temperature gradient adjustment will be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 9 4 12 3 Menu 11 12 3 Upper gradient Upper temperature gradient is req
155. uered maximum grow of the temperature in monitored time passage If the grow is higher the boiler will aoutomatically lower its power output for the next time passage of operation We enter the menu by pushing the f U arrows By pushing key ENTER we will enter set up of the upper heat gradient program Upper temperature gradient adjustment will be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 9 4 12 4 Menu 11 12 4 ZoneI The first approach zone to set the water temperature Menu 2 is the value of water temperature at which the boiler automatically reduces power by one degree We enter the menu by pushing the arrows By pushing key ENTER we will enter the set up of the first temperature deviation from the set up temperature of the output water in the boiler at which the power output of the boiler will be changed automatically Adjustment of the first temperature deviation shall be carried out in the same way as mentioned above in this chapter We will return back to the mode MANUAL by repeated pushing the key n ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 12 9 4 12 5 Menu 11 12 5 Zone II The second approach zone
156. unt of fuel in the tank Refill the fuel bin Reactivation e Fill the F1 feeder with fuel by running the F1 feeder see MENU 1 e Ignite the boiler by using the electric ignition routine or ignite the boiler manually e After this it is possible to switch to automatic boiler operation by pushing START and ENTER buttons 90 Automatic boiler for biomass Service manual 10 12 CLEAN THE BOILER This is not a true error state The boiler control unit only points out neglected maintenance If the flue gases temperature exceeds the 2509C temperature for a short time normal operation temperatures are below 2009C the boiler will assess this situation as dirty exchanger The boiler must be cleaned immediately This situation is indicated by a flashing display message At the same time the control system will lower the boiler output by one degree in order to prevent further increase of the flue gases temperature If the flue gases temperature reaches high value again the boiler output will be lowered again Dirty boiler heat exchanger Complete boiler cleaning see annual inspection psit Shorten the boiler flue cleaning period service technician Unsuitable fuel type Complete boiler cleaning see annual inspection Shorten the boiler flue cleaning period service technician High boiler output Lower fuel dispensing values service technician 11 GUARANTEE AND LIABILITY FOR DEFECTS The manufac
157. ushing the key a ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key 010 Note Maximum temperature level of the boilers water is limited to 70 fro starting a pump so it pevents boier overheating Minimum temperature must be kept above value condensing temperature 559C Note Recomended temperature for switching the pump of SW tank is 60 C This is the temperature which is used for preheating of the SW Tank hot water If the pump is going to switch by lower temperature hot water from SW Tank will cool down trough the boiler 9 5 5 3 Menu 12 5 3 Absolut limit We will enter the following menu by means of the cursor arrows U By pushing key ENTER to go to the selection of the upper absolute temperature for the output water in order to turn on the circulation pump of the heating system Where aa is the existing set up value AA is the newly required set up value and is blinking Adjustment of the upper limit for the output water temperature to turn the circulation pump of the heating system on shall be performed in the same way as mentioned in this chapter above 81 Automatic boiler for biomass Service manual We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key nf Note Maximum value
158. utomatic turning off will take place after 60 seconds in order to prevent from damage to heating coils in case of omission 49 Automatic boiler for biomass Service manual 9 3 1 8 Menu 1 8 CONTROL OF HEATING The following will be displayed on the display unit Turn heating on by pushing the key ENTER The following will be displayed on the display unit Operation of the heating is turned off by pushing the key ENTER Note Automatic turning off will take place after 60 seconds in order to prevent from damage to heating coils in case of omission Note By the choosen configuration the output can have meaning of control Pump TO2 constrictive pump 9 3 1 9 Menu 1 9 Boiler flue sweeping The display will show Flue sweeping is turned on by pushing the ENTER button The display will show Flue sweeping is turned off by pushing gt ENTER button 9 3 1 10 Menu 1 10 Ash removal The display will show Ash removal is turned on by pushing the ENTER button The display will show Ash removal is turned off by pushing the gt ENTER button 9 3 1 11 Menu 1 11 Opening servomotor The display will show Servomotor opening is turned on by pushing the gt ENTER button The display will show Servomotor opening is turned off by pushing the ENTER button 9 3 1 12 Menu 1 12 Closing servomotor The display will show Servomotor closing is turned on by pushing the gt ENTER button The d
159. ve an option to change the operating temperature of the boiler adjust the lower and upper temperature limit to the same required value 9 5 2 3 Menu 12 2 3 Temperature of samples Displayed temperatures boiler water temperature outside temperature flue gases temperature etc are measured and analyzed periodically by the control unit as an average value calculated from a set number of samples MENU 12 2 3 Number of samples will appear on the display after you enter the correct PIN in the Manufacturer Menu You can reach it with the arrows Switch to the selection of the number of samples for the calculation of the average value of the displayed temperatures by pushing the ENTER button Suitable number of temperature measurements samples can be selected with the ff gU arrows Note If the number of selected samples is incorrect the temperature value may flash Incorrect number of samples may cause excessive measurement time Return to MANUAL mode by repeatedly pushing the AESC button or you can continue in your menu selection with the ff arrows 9 5 3 Menu 12 3 Feeder F1 limits Time limits and limits adjusted in this program have to ensure operation of the boiler at the necessary power levels Boiler Output is unambiguously given by the quantity of fuel delivered to the boiler during a unit of time MENU 12 2 3 Feeder 1 limits will appear on the display unit after the PIN for the Producer menu h
160. verings 4 6 3 Upper cover 4 6 4 Front lower cover 4 6 5 Back lower cover 4 6 6 Back cover including covering 4 6 7 Door cover 4 6 8 Terminal KP62 cover 23 Automatic boiler for biomass Service manual 4 6 3 3 0 4 6 6 AA N 4 p e Wu auo a gt SN N eo Ya E M 4 6 5 28 1 1 4 6 4 x 4 6 1 4 6 7 Picture 18 Jacketing KP12 4 6 2 4 6 3 Picture 19 Jacketing KP22 Automatic boiler for biomass Service manual Picture 20 Jacketing KP62 25 Automatic boiler for biomass Service manual 4 7 CLEANING SYSTEM The automatic cleaning system of the boiler significantly affects time of service free operation of the boiler 4 7 1 Ash removal Ash removal is a complex set of technical and program means which ensure ash removal from burner heating chamber to external ash receiver in a regular intervals The ash is taken out by a spiral conveyor It is driven by an electric motor through a toothed chain transmission The ash removal system can be mounted on the left or on the right side Assembly of the particular version is done in the manufacturing facility based on an order A professional service firm can perform a change left right at the boiler location The motor is connected to the control unit with terminals K14 2 N PE Picture 21 Ash removal system 4 7 2 Heat exchanger cleaning Heat exchanger cleanin
161. vice manual finally remove all solid waste located inside the air box of the burner Tilt the burner gradually in order to pour out all impurities from the burner through the pipe of the fan Work until the burner is completely cleaned if automatic ignition is installed on the burner dismantle both spirals and remove all impurities from the air box of the burner through the installation apertures Cleaning of burning chamber In order to prevent from increased dustiness we recommend to place the lid of the boiler body on the boiler for this time While cleaning we may not forget about the placement bars of the extension grate which have to be perfectly cleaned so that individual parts of the extension grate can be precisely placed on them back After complete assembly of all boiler parts remove ash to the external ash container by manually turning on the ash removal drive in manual control in Menu 1 Remaining ash can be removed by scraper from a burning chamber in to a auger Back installation of all parts Should be done in reverse order Ensure mainly the following in course of this activity Electric resistance coils Maximum tightness has to be ensured between the flange of spirals and the wall of the burner The flange of the burner has to be put precisely so that the packing cord of the flange fits tightly on the protruding ribs of the body all over the circumference The spiral chute feeder should be anchored precisely in
162. w in the previous menu by pushing the key ENTER Expected number of pulses is set upd by the same procedure as mentioned above in this chapter We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC it is possible to continue with the cursor arrows a ESC in selection of the next menu after pushing the key 0170 Note It is permitted for the time window to be longer than the operation time of a feeder one feeding cycle period The control unit totals the operation times 83 Automatic boiler for biomass Service manual Note If the recorded number of pulses in the time window is higher than or equal to the set up number the operation of feeders is permitted If the number is lower the control unit will stop the operation of the boiler and the following failure message will appear on the alphanumeric display unit Blocked feeder x Important The set up number of pulses to the value of 000 turns off sensors of rotations of the feeder F1 or F2 This may result in dangerous operating conditions of the boiler 9 5 9 Menu 12 9 GSM Master Having been completed with the GSM modem the control unit makes it possible to manage adjust and monitor the boiler by the service centre The service centre s telephone number is entered in this menu Operating parameters of the boiler may be changed and operating instructions may be entered from this telephone number MENU 12 9 GSM Master w
163. we return to Menu 11 13 2 We enter the menu by pushing the f OU arrows Here we set the number of Nr 1 feeder cycles after which ash removal will commence The outfeed spiral screw will operate for a period defined in the following menu Select this menu by pushing the gt ENTER button and this message will appear 72 Automatic boiler for biomass Service manual By pushing the ENTER button again we switch to the time period setting of the outfeed spiral screw The time is set in minutes cc is the current value CC is the new desired value and it is flashing The current time period of the ash outfeed spiral screw can by adjusted by the f U arrows 9 4 13 3 Menu 11 13 3 sweeping The program of this Menu provides automatic boiler heat exchanger cleaning The exchanger cleaning frequency depends on the type of used fuel on the boiler output and the heating time period Therefore the flue sweeping activation of the outfeed spiral screw is directly tied to the number of Nr 1 feeder cycles We enter the menu by pushing the f U arrows When you push the ENTER button We will enter the Menu in which we either allow or prohibit the flue sweep function By pushing gt ENTER button we enter the ON OFF switch for flue sweeping By repeatedly pushing ENTER button we will select the desired ON OFF mode pushing AESC button we return to Menu 11
164. weight Picture 23 External ash container 27 Automatic boiler for biomass Service manual 4 8 FLUE FAN The flue fan can significantly contribute to a problem free and reliable boiler operation in case the natural chimney flue is low When using the flue fan the chimney must be tight and without outlets above the flue fan connection Fan revolutions and consequently the required flue can be set in menu 11 1 Programs If the flue behind the boiler is too high it is unfavorable for optimal burning and the manufacturer recommends maximum flue regulation by the particular flue reducer Keep connections recommended by the manufacturer The flue fan is connected to terminals K17 2 and the ground wire to K17 1 Picture 24 Flue fan assembly 4 9 STANDARD ACCESSORIES Feeder Nr 1 the feeder length corresponds to the fuel bin and the particular installation used Outside temperature sensor for equithermal regulation Surface temperature sensor measuring of temperature behind the mixing valve Surface temperature sensor measuring of temperature of returning water Cleaning tools scraper for manual cleaning of the boiler body Outlet inlet valve 2 KP boiler operation and service manual Quality and completeness certificate of the product Warranty Certificate 28 4 10 Automatic boiler for biomass Service manual OPTIONAL ACCESSORIES Fuel storage elective size Electric heating unit for temp
165. y information consuption wood pellets for boiler family KP FUEL 1 PELLETS FUELS Table 6 Settings User ver 1 1 Menuno Menu name Menu description meaning Settings values KP12 oe Main menu VERSION 6 x gear1 56 auger 38mm KP62 auger 55mm 1 Direct control menu serving to direct control of connected equip and control of input signals and processes Feeder 1 start of feeder 1 function Feeder 2 start of feeder 2 function Fan start of air of combustion fan function 30 100 Flue fan Start of flue fan function 30 100 Pump start of heating system pump function SWTank Pump start of SW Tank pump system function EI Ignition start of electric ignition of boiler only for control system El function Heating start of electric tempering of heating system only for control system EH function Flue sweep Start flue sweep function Ash removing start ash removing function to external ash container Servo open start servomotor open function Servo close start servomotor close function Check out inputs control of state of input signals Room Therm SWTank Therm Rotary Sensors F1 F2 setting required value of maximum temperature of boiler output water Select language setting of language SW version of control unit CU Setuptime setting of the right time on CU SW tank activate possibility of setting three time periods for heating of hot service water SWH Time period 1 setting of 1 time period i
166. y pushing the key ESC The value DD has been accepted for further use provided the new value has been confirmed with the key gt ENTER the value DD is not blinking If the value DD is blinking it will not be accepted after the return to the MAIN MENU and the original set up value dd will still be used We will return back to the mode MANUAL AUTOX MODX SW TANK by repeated pushing the key ESC or it is possible to continue with the cursor arrows ESC in selection of the next menu after pushing the key ft U 9 5 7 Menu 12 7 Flue fan run out Fan rundown is a parameter which defines the time of fan operation after the boiler switches to the STAND BY mode The setting enables to improve emission parameters during boiler stoppage and optimizes fuel afterburning and ensures exhaust of burned gases Important note The parameters for flue fan rundown mode are set for the particular fuel type Fuel is selected beforehand in Menu 10 MENU 12 7 Flue fan rundown will appear on the display after you enter the correct PIN in the Manufacturer Menu You can reach it with the DU arrows Switch to the fan rundown time parameter selection the pushing gt ENTER button dd id a current value DD is the newly selected value and it is flashing Same notes apply as in the preceding chapter 9 5 8 Menu 12 8 Rotary sensors It is absolutely necessary to ensure operation of feeders and to know whether they are really functi

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