Operation and installation manual 2013.03.06 1 o
Contents
1. Fan 13 Ashpan 14 Boiler feet 9 Operation and installation manual part 2 2015 06 09 hy KLIMOSZ NOTE No alterations in the furnace chamber may be made which could negatively affect the life span of the boiler or flue gas emission Fan connector Air mixer Retort grate Screw feeding channel Anti smoke holes ct Un A U Nm Retort elbow Fig 5 Schematic diagram of a retort furnace in coal burning 5 1 Delivery and installation KLIMOSZ COMBI B boilers KLIMOSZ COMBI B boilers are supplied in parts on pallet which provides easy transport to the boiler room On the pallet is cast iron VIADRUS U22 boiler 1 Steel base with a retort burner 2 feeding tube 3 motoreducer 6 feeding screw 5 feet 4 fan 7 storage bin 8 controller to order chamotte plate set of screw Fig 6 KLIMOSZ COMBI B boiler components 5 2 Boiler accessories Operation and installation manual part 2 2015 06 09 10 hy KLIMOSZ Standard Installation and Operation Manual part 1 Installation and Operation Manual part 2 Regulator Operation Manual screws hardness class 8 8 as cotter pins of the feeder screw 2 items cast iron deflector above the burner of the KLIMOSZ COMBI boiler 1 item chamotte plates in the upper furnace in KLIMOSZ COMBI KLIMOSZ COMBI B see table Number of chamotte plates in the Klimosz Combi boiler protective plate covers the retort burner when the upper combust2. A CIFICATION AY KLIMOSZ KLIMOSZ AL DATA SP COMBI and OILERS TECHNIC KLIMOSZ s AND INSTALLATION MANUAL COMBI B B p ART 2 KLIMOSZ HEATI NG BOILER USER A KLIMOSZ For your comfort and safety we recommend to read carefully this manuall before use of the boiler A uw N Y Y Y Ww Sf Y W N T ORIGINAL MANUAL part 2 2 KLIMOSZ COMBI B boilers are supplied in parts on pallet which provides easy transport to the boiler room Advantages of the boiler e Automatic simple and quick boiler operation and maintenance e possibility of installing an automatic pellet lighter e possibility of burning wood and large grade coal in an extra grate e cost effective operation e a low level of noxious substances in flue gas tests in accordance with EN 303 5 1 Technical Data for KLIMOSZ COMBI Table 1a Dimensions and technical parameters of the KLIMOSZ COMBI boiler Klimosz Klimosz Klimosz Klimosz Combi Parametr Oo 80 m Nominal power pea coal pellets Efficiency pea coal Efficiency pellets Power regulation scope pea coal pellets Use of fuel at nominal power continuous heating pea coal 27 5 MJ kg pellets 18 MJ kg DONE bin volume pea coal 27MJ kg nominal power nnd power water Recommended working temperature for heating water Maximal working temperature for heating water Minimal temperature of wat
3. IMOSZ COMBI B boiler 7 Checking the leak tightness of the grate In order to achieve complete burning of fuel in the grate it is important to maintain leak tightness between the grate and the retort burner and absence of any blocking of the nozzles which supply air flow as well as the cleanliness of the mixer It may be necessary to seal the grate and clean the burner when fuel does not burn completely in the grate and f incompletely burnt fuel is removed to the ash pan the heat exchanging area of the heat exchanger gets soiled quicker than usual the flame is short and irregular when the boiler is being heated up fuel burns unevenly in the burner grate NOTE The burner grate should be fixed such that a false draught should not leak out from under it It should be fixed tightly with no possibility of turning Burner maintenance procedure Remove the cast iron ring to seal the grate The grate surface on which sealing will be applied should be cleaned thoroughly to ensure good contact of the material with the sealing The parts should be sealed with fireplace silicon with a working temperature of greater than 1200 C which should be applied evenly around the grate perimeter Put the grate with silicon slowly onto the other part of the burner Another obligatory action is to clean the mixer of any impurities which may have got there during the installation or dismantling of the grate 8 Notes about hand firing t
4. N N N uv uv g en oo oo oo ON ON g EM o lala BD e N N N S B Ne o0 ON Q El e 2 T S D S c Us va Ya Ya Ya B uv uv v uv uv uv Va Ya uv Ya E uv uv v uv v uv LL C uv uv v E ON ON ON 2 B a S c 74 E oO o6 oO o6 oO o6 LL N N N N d KLIMOSZ Operation and installation manual part 2 2015 06 09 E www klimosz pl kd KLIMOSZ Fig 2 Dimensions boilers KLIMOSZ COMBI B Ego ooo Tw a o n ont a ns ot at cs pee e nw se on e e omm m ow a mm wo sso a 6 5 0 mo son wo se m va we o n rn mo se o s o we s m n Operation and installation manual part 2 2015 06 09 he KLIMOSZ Combustion L IPIE emm emm COMBI 15 COMBI 20 8 8 COMBI 32 COMBI B 35 COMBI 49 410 625 89 7 Fig 3 Dimensions of the additional combustion chamber 5 Boiler description X icol N E al 9 le LO 09 e lel INTE m e D E fel ke e N le e la le INL I Fig 4 Description of the KLIMOSZ COMBI and KLIMOSZ COMBI B boilers 1 Flue gas thermometer optional 2 Boiler controller 3 Boiler cleaning hole 4 Storage bin 5 Chamotte plate 6 Upper combustion chamber 7 Inspection hole with the fire grate 8 Cast iron deflector 9 Storage bin cleaning hole 10 Retort burner 11 Measuring hole of feeding pipe 12
5. er returning to the boiler Maximal permitted level of heating material Safety valve bar a Operation and installation manual part 2 2015 06 09 hr KLIMOSZ c e e ZU mim alas alee NENNEN m om of 5 3s os 14 50 15 31 17 68 20 06 100 250 100 250 100 250 100 260 4 0 m 5 9 65 80 O EE a 3 R Connections of the boiler heating and returning water Resistance of water flow through the boiler At 20 C mbar lt 65 A 2 or 6 4 GZ 0 4 20 230V 50 Hz 180 80 IP 40 Electric energy consumption fan motor Electric energy consumption shot light option Electric insulation Table 1b Dimensions and technical parameters of the KLIMOSZ COMBI boiler mem s Power regulation scope pea coal Use of fuel at nominal power continuous heating pea coal 27 5 MJ kg pellets 18 MJ kg Storage bin volume dm pea coal 27MJ kg nominal power nominal power z Klimosz Combi NG 49 Klimosz Combi NG 42 A NE EN O 36 3 43 3 12 6 42 10 9 36 3 14 7 49 13 43 3 oe D ZU Z Im mx 2 azza 2 c c lt lt o wn N P 3 g s g s C N MN N Oo 120 260 120 260 Recommended working temperature for heating 5 water 613 Heating area of the boiler Diameter of fumes outlet seg s ON ON Y CA Oo Chimney draught lon S Water minimal working pressure Water maximal trial p
6. h for it to be impossible to crush a few fuel granules in a clenched fist preventing the feeder from getting jammed Light colour grades are recommended without bark which can cause deposit formation in the burner Table 4 Recommended fuel for burning in manual mode emergency combustion chamber of the KLIMOSZ COMBI and KLIMOSZ COMBI B boiler DEDIT ATTENTION MOISTURE CONTENT IN FUEL MUST NOT EXCEED 15 USING MOIST FUEL RESULTS IN A CONSIDERABLE REDUCTION IN THE BOILER S POWER CAPACITY EVEN BY AS MUCH AS 50 AND REDUCTION IN THE LIFE SPAN OF THOSE PARTS OF THE BOILER WHICH ARE IN CONTACT WITH MOIST FUEL USING IMPROPER QUALITY OR MOIST FUEL RESULTS IN LOSING WARRANTY RIGHTS WITH RESPECT TO THE PARTS EXPOSED TO CONTACT WITH SUCH FUEL 3 Construction of the KLIMOSZ COMBI KLIMOSZ COMBI B boiler The KLIMOSZ COMBI and KLIMOSZ COMBI B automatic boiler is not maintenance free it is therefore recommended that the user should carefully read the principles of its operation regulation and maintenance in order to avoid any problems related to its work Construction of the KLIMOSZ COMBI boiler makes it possible to use solid fuels in the automatic or traditional mode as well as to use liquid fuels The boiler has been constructed on the base of a cast iron exchanger of the multi purpose VIADRUS U22 boiler The cast iron part of the boiler which is called the upper combustion chamber can be used for burning coal coke or wood as substitu
7. he fuel in the upper combustion chamber 8 1 Types of fuel Klimosz boilers are equipped with another emergency combustion chamber which is used mainly for the occasional burning of solid unsorted fuels Wood used as fuel should not have more than a 20 moisture content The recommended fuel is wood wooden waste non caking briquettes with granulation of 30 to 80 mm When lighting a fire in a boiler and when the chimney is cold it is recommended that the chimney should be heated up with wooden firelighter After the boiler has been lit and when some fuel has been burnt the embers in the grate should be stirred The procedure should be interrupted when glowing fuel drops to the ash pan The operation is performed with a hook through the door of the upper combustion chamber After completing the Operation and installation manual part 2 2015 06 09 12 hy KLIMOSZ procedure top up the fuel without extinguishing the boiler Fuel can be added only when the blow in fan is switched off Larger unburnt pieces of fuel from the ash pan can be thrown back into the furnace Air inflow for combustion is regulated with a controller which regulates the fan operation and or by a flap on the fan In prolonged hand firing it is recommended that all the fuel pea grade coal or pellets should be removed from the fuel bin feeding screw pipe and the retort burner In this case the protective plate should also cover the retort burner hole This prevents soiling
8. ion chamber and the loading door must be tightly closed during the boiler operation NOTE When opening any of the boiler s doors stand in such a way as to prevent any hot gas from the boiler from causing harm to you or to anyone standing nearby 13 Operation and installation manual part 2 2015 06 09 o KLIMOSZ Adding more fuel switch off the fan first preferably by switching off the regulator After the fan is switched off and stopped open the lower door of the boiler Open the upper door of the boiler after a while unsealing it first and put in a layer of fuel After the upper and lower door is closed switch on the fan by pressing the button as above The boiler is now in normal operation mode Do not add too much fuel as it may cause the boiler to overheat quickly and it negatively affects the boiler s parameters as well as the parameters of emission of hazardous substances in flue gas 8 4 Boiler maintenance Remove ash to non flammable closed containers with increased resistance to corrosion for example zinc plated The boiler can be cleaned only after it has been extinguished and cooled down Cleaning the walls of the upper combustion chamber can be easily done through the open upper door Cleaning the smoke conduits is done through the inspection hatch under the casing the same as cleaning in automatic mode The boiler can be cleaned with the cleaning tools supplied with it A boiler that has been soiled with tarry
9. ion chamber is used 15 49 kW 1 item emergency extinguishing tank fire fighter only in KLIMOSZ COMBI paraffin fuse 1 item only in KLIMOSZ COMBI Required when biomass is used as fuel protecting valve e g STS Watts instead of the fire fighter required for all boilers 55 75 kW limit switch of the storage bin On request 6 Installation of the fire resistant catalyst regulator of boiler emergency extinguishing tank fire fighter for KLIMOSZ COMBI B paraffin fuse 1 item for KLIMOSZ COMBI B room thermostat manual 4 way mixer e g ESBE mixer actuator e g ESBE domestic water heater e g DRAZICE automatic pellet lighter up to 35 kW flue gas temperature sensor option aimed to activate the information that it is necessary to clean the boiler ATTENTION The boiler must not be operated without deflector in the retort furnace as it leads to accelerated depositing of soot on the boiler due to incomplete burning and to quicker wearing of the boiler s steel parts 11 Table 5 Number of catalysts chamotte in a KLIMOSZ COMBI and KLIMOSZ COMBI B boiler Plate mm EE EE ee ae eee ee KLIMOSZ COMBI COMBI B Chamotte plate Klimosz Combi NG 15 Combi B 15 2 pe Klimosz Combi NG 20 Combi B 20 Operation and installation manual part 2 2015 06 09 he KLIMOSZ ZZ Fig 8 Position of ceramic catalyst on the exchanger shelves in a KLIMOSZ COMBI and KL
10. nt of air is controlled electronically by the boiler regulator The inlet and outlet of heating water is situated at the back part of the boiler At the back of the boiler there is a smoke conduit which carries flue gas to the chimney The exchanger is insulated with mineral wool which reduces heat loss during combustion The steel casing is protected with high quality powder paint 3 1 Hand fired furnace of the KLIMOSZ COMBI and KLIMOSZ COMBI B boiler The KLIMOSZ COMBI and KLIMOSZ COMBI B boiler provides the possibility for burning solid fuels in the traditional mode After manual loading wood and coal as substitute fuel can be burnt in the upper part of the exchanger called the upper combustion chamber The upper combustion chamber is an emergency chamber in which burning throughout the heating season is not recommended due to the lower power capacity achieved as compared to the maximum power capacity of the boiler For burning in the upper chamber to run properly some conditions for chimney draught have to be met Operation and installation manual part 2 2015 06 09 6 hy KLIMOSZ mensions i 4 Boiler d Fig 1 Dimensions boilers KLIMOSZ COMBI NG q lt lt a N N N N N N ed en uv uv uv uv uv v am E 4 ey asami ec S o c eo pl o N g c
11. o the boiler Maximal permitted level of heating material Safety valve Connections of the boiler heating and returning water Resistance of water flow through the boiler At 20 C Electric energy consumption fan motor Electric energy consumption shot light option 0 20 0 0 20 0 3 3 co AID J r2 oo e CA m 8 0 Oo CA 4 5 17 68 V UA UA Ge m N iN m S 100 250 100 260 a psy a a 156 10 20 a B AK 156 10 20 Oo Oo CA A Fi lub 6 4 GZ 0 4 20 230V 50 Hz 180 80 IP 40 E G S B IE Operation and installation manual part 2 2015 06 09 he KLIMOSZ Fuel parameters e calorific value Q 15MJ kg e volatile matter content V gt 2896 e ash fusion point t 21200 C e caking properties RI lt 20 max 30 e low swelling e ashcontent A lt 12 e moisture content coal pellets W lt 15 wood W lt 20 ATTENTION The KLIMOSZ heating boilers are not intended for burning waste and no substances other than those recommended by the manufacturer can be burnt in them Table 3 Recommended fuel for burning in automatic mode Fuel type Granulation mm Calorific value MJ kg Gr II 8 20 LAS pea grade coal max 30 24 28 iced Fuel type Granulation mm Calorific value MJ kg Non caking non coking Sawdust granulate pellets should be at least hard enoug
12. of the retort burner 8 2 Lighting the boiler The boiler may be operated only by adults who know the principles of its operation and who follow this Operation Manual The following should be done before the boiler is lit e check whether there is enough water in the central heating and domestic water systems e check whether the grate ash pan and flue conduits are clean e remove the ceramic catalysts from the retort furnace chamber e put the protective plate on the retort burner this prevents lighting the fuel in the retort burner as a result of embers falling down from the upper grate to the ash pan e when burning in the upper chamber in the hand firing mode remove fuel from the retort in order to properly supply air for combustion When burning is continued for more than two weeks fuel should also be removed from the bin e switch on the hand firing mode hand firing in the burning type options on the regulator Put firelighter paper and wood through the charging door over the entire grate area Light the firelighter through the door of the combustion chamber Close the door and open slightly the ash pan door providing air supply to the combustion chamber Put a layer of fuel onto the burning wood After lighting the fire switch the regulator to the hand fire mode set the desired temperature and close the ash pan door When the fuel is burning well stoke the fire by putting in another portion of fuel switch off the bl
13. ow in fan on the regulator when loading in fuel Attention No flammable liquids can be used and the boiler cannot be overheated when lighting the fire No flammable materials can be left near the boiler 8 3 Boiler operation Fuel should be topped up as needed and in accordance with the intensity of burning Fuel should be added evenly so that it does not form a pyramid Ash and slag should be removed from the grate only when it starts to hinder combustion The procedure should be interrupted when during the grate cleaning with a hook embers start to fall down to the ash pan In the evening before burning in the boiler during the night the grate should be cleaned thoroughly In the morning after night burning remove caked coal with a hook to clear the air supply Put some fuel onto the embers and do not remove ash and caked fuel from the grate until the fuel is burning Then add fuel until the combustion chamber is full Each time you check the amount of fuel in the combustion chamber and each time before stoking the fire switch off the fan on the regulator preferably by switching off the regulator and delay opening the loading door until the fan stops the door is leak tight and you should first loosen it slightly wait until pressure in the combustion chamber equalises and only then can you open the door fully This will prevent hot flue gas from being blown out into the boiler room The lower door of the furnace the door of the lower combust
14. ressure 3 0 2 wather Recommended working temperature for heating eC 65 80 water Water maximal working pressure Suc d Fluid group O RET eee sls Maximal permitted level of heating material Su UA olo lt 65 A 2 or 6 4 GZ Maximal working temperature for heating water Safety valve Minimal temperature of water returning to the eC boiler 0 4 20 230V 50 Hz 250 80 IP 40 Resistance of water flow through the boiler At 20 C mbar Electric energy consumption fan motor Electric energy consumption shot light option Electric insulation Connections of the boiler heating and returning water 3 Operation and installation manual part 2 2015 06 09 hr KLIMOSZ 2 Technical Data for KLIMOSZ COMBI B Table 2 Dimensions and technical parameters of the KLIMOSZ COMBI B boiler Klimosz Klimosz Klimosz Parametr Combi B Combi B en B 15 N Nominal power pea coal pellets Efficiency pea coal Efficiency pellets Power regulation scope pea coal pellets N m ps s 82 5 9 6 32 6 0 20 0 5 0 15 0 5 0 16 0 Use of fuel at nominal power continuous kg h 2 5 heating pea coal 27 5 MJ kg pellets 18 MJ kg kg h 38 P bin volume 230 pea coal 27MJ kg nominal power joia power water Recommended working temperature for heating water Maximal working temperature for heating water Minimal temperature of water returning t
15. substances should be cleaned in two steps First tarry deposits should be burnt out with suitable agents for example Sadpal and then the heat exchange areas should be cleaned with a brush Cleaning semi liquid tarry deposits results in damage to the brush and is ineffective resulting only in spreading the tar over the boiler surface After the boiler surface and smoke conduits have been cleaned close the inspection hatch tightly NOTE Avoid accumulation of tarry deposits and soot on the heat exchanger areas and in smoke conduits This reduces the boiler s efficiency and poses a serious hazard of soot and tar ignition in the chimney duct which usually results in damaging the chimney and even the building walls and in fire Take care to make the boiler leak tight combustion chamber door ash pan door mixer cleaning hole fuel bin cover etc in order to avoid flue gas being expelled from the boiler into the boiler room If the boiler is not in use for more than 2 days for example after the heating season it must be cleaned and the fuel bin and the fuel feeding system emptied of fuel Leave the boiler with the doors and inspection hatch covers open to enable its ventilation and to avoid moisture condensation on the steel surfaces of the boiler Operation and installation manual part 2 2015 06 09 14 hy KLIMOSZ
16. te fuel after manual fuel loading KLIMOSZ COMBI boilers can be installed in a closed system up to working pressure 4 0 bar Under the water grate of the boiler heat exchanger of a U22 boiler there is an added steel combustion chamber with W version or without S version a water jacket There are the following cast iron parts in the 5 Operation and installation manual part 2 2015 06 09 hy KLIMOSZ lower combustion chamber a round grate a round deflector above the grate an elbow or retort and a steel chamber of the air mixer Fuel burning pea grade coal pellets in automatic mode takes place in the lower chamber Inside the fuel feeding retort there are holes which regulate the pressure of air needed for burning which prevents flames from reaching the fuel feeder during the burning process Under the combustion chamber there is an ash pan Next to the boiler there is a fuel storage bin with a feeder screw at the bottom The ash pan capacity is suited to the capacity of the fuel bin i e the ash pan should be filled with ash after the entire fuel from the bin has been burnt There is a water tank behind the fuel bin for emergency extinguishing when pea grade coal is used as fuel or a place for installing a thermostatic valve required when pellets are used as fuel a protective device in case flame gets to the fuel bin The fan which supplies air for combustion is situated before the fuel bin and is connected to the mixer The amou
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