Summary of Contents for Tetan KP 12S
- Page 1 Automatic boiler KP 12S KP 22S KP 62S KP 12 – ES KP 22 – ES KP 62 - ES Service and operation manual...
- Page 2 Automatic boiler for wood pellets 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.
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Page 3: Table Of Contents
Automatic boiler for wood pellets CONTENT COntent ..............................2 pictures............................... 3 TABle ................................4 IMPORTANT NOTES ..........................5 use of the boiler and its advantages ......................6 Technical data of the boilers KP x2S, KP X2 - ES ..................7 structural description of products ...................... -
Page 4: Pictures
Ceramic door casing ......................17 Picture No. 14 Feeder F1 ........................18 Picture No. 15 Jacketing KP 12S, KP 12 - ES ................... 19 Picture No. 16 Jacketing KP 22S, KP 22 - ES ................... 20 Picture No. 17 Jacketing KP 62S, KP 62 - ES ................... 21 Picture No. -
Page 5: Table
Automatic boiler for wood pellets TABLE Table 1 Thermal and technical parameters of products ................7 Table 2 Solid harmful substances in combustion ..................7 Table 3 Technical parameters of products ....................7 Table 4 Electrical parameters of products ....................7 Table 5 Fuel and its parameters ....................... -
Page 6: Important Notes
Automatic boiler for wood pellets IMPORTANT NOTES This product may only be put into operation by an installation organization 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. -
Page 7: Use Of The Boiler And Its Advantages
Automatic boiler for wood pellets 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: 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 including maximum saving of... -
Page 8: Technical Data Of The Boilers Kp X2S, Kp X2 - Es
Automatic boiler for wood pellets TECHNICAL DATA OF THE BOILERS KP X2S, KP X2 - ES Table 1 Thermal and technical parameters of products KP 12S KP 22S KP 62S Parameter Unit KP 12 - ES KP 22 - ES... -
Page 9: Structural Description Of Products
Automatic boiler for wood pellets STRUCTURAL DESCRIPTION OF PRODUCTS The structure adheres to the Czech standard ČSN – 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). PRODUCT MAIN PARTS –... -
Page 10: Boiler Body
Automatic boiler for wood pellets BOILER BODY, SCHEME OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS BOILER BODY 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, assisted by a system of turbulators. -
Page 11: Control Unit
Automatic boiler for wood pellets 4.2 CONTROL UNIT Boiler is equipped with the control system with touch screen. This control system enables automatic boiler operation through the control and regulation features (thermostats, sensors, etc.) in the requested modes. It also enables Diagnostics mode of control, which can be used for instance for boiler commisioning. -
Page 12: Boiler Function Module Hzs 521-G
Automatic boiler for wood pellets 4.2.1 Boiler Function Module HZS 521-G The heating system is modularly constructed. The HZS 521-G is a module for the boiler, which communicates with the CPU module and executes the transmitted instructions. The HZS is a simple component that is used to control automated processes in a heating system. - Page 13 Automatic boiler for wood pellets Picture No.4 HZS 532-1 HZS533 HZS533 HZS535 Picture No. 5 Other modules...
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Page 14: Technical Base Data
Automatic boiler for wood pellets 4.2.1.1 Technical base data HZS521-G Supply voltage 230 V AC +/- 10 % (Input voltage for the power transformer on the power board, input voltage for the STB, phase for the phase angle, relays and Triac outputs) Power supply fre- 45 - 65 Hz quency... -
Page 15: Terminal Hzs 555-S With Usb
Automatic boiler for wood pellets 4.2.2 Terminal HZS 555-S with USB Picture No. 6 Terminal with USB 4.2.2.1 Description The HZS 555-S is an intelligent terminal for programming and visualization of automated processes. Process diagnosis as well as operating and monitoring automated procedures is simplified using this terminal. A touch screen serves as the input medium for process data and parameters. - Page 16 Automatic boiler for wood pellets Display Type 5.7" LCD color display resolution VGA 640 x 480 Pixel Color depth 18-bit RGB (262K colors) LCD Mode TN / normal white LCD Polarizer Transmissive Pixel size 0.18 mm x 0.18 mm Active surface 115.2 mm x 86.4 mm Background lighting Contrast...
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Page 17: Burner Heating Chamber Incl. Feeder F1 With Independent Drive
Automatic boiler for wood pellets 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 The burner body 4.3.2 Feeder F2 including the drive 4.3.3 Impulse sensor 4.3.4 Flexible hose... -
Page 18: Ceramic Parts
Automatic boiler for wood pellets 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. -
Page 19: Feeder F1 With Independent Drive (From Fuel Storage)
4.5.1 Body of feeder with flange 4.5.2 Axle-less spiral (diameter 38mm in KP 12S, KP 12 - ES, KP 22S, KP 22 – ES; diameter 56mm in KP 62S, KP 62 - ES) 4.5.3 A small bar for mounting of the spiral 4.5.4... -
Page 20: Boiler Sheathing Including Heat Insulation
4.6.3. Upper cover 4.6.4. Front lower cover 4.6.5. Front upper coverí 4.6.6. Back cover – including covering 4.6.7. Door cover 4.6.8. Door 4.6.3 4.6.6 4.6.2 4.6.5 4.6.4 4.6.8 4.6.7 4.6.1 Picture No. 14 Jacketing KP 12S, KP 12 - ES... - Page 21 Automatic boiler for wood pellets Picture No. 15 Jacketing KP 22S, KP 22 - ES...
- Page 22 Automatic boiler for wood pellets Picture No. 16 Jacketing KP 62S, KP 62 - ES...
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Page 23: Cleaning System
Automatic boiler for wood pellets 4.6 CLEANING SYSTEM The automatic cleaning system of the boiler significantly affects time of service-free operation of the boiler. 4.6.1 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. -
Page 24: External Ash Container
Automatic boiler for wood pellets Picture No. 18 Exchanger ash container 4.6.3 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. -
Page 25: Standard Accessories
Automatic boiler for wood pellets 4.7 STANDARD ACCESSORIES Feeder F1 (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 ... - Page 26 Automatic boiler for wood pellets Note: during operation, the cover must be closed. Picture No. 20 Standard fuel bin sizes Chyba! Picture No. 21 Assembly guide...
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Page 27: Placement Of The Product In Boiler Rooms, Principles Of Installation
Automatic boiler for wood pellets PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION 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-flammable material, which ovelap min. 10 cm over the platform of installed quipment. -
Page 28: Fire Regulations
Automatic boiler for wood pellets Picture No. 22 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 resistant to humidity are recommended for appliances with temperature of combustion products from 30°C to 100°C.) 4.1.3 Fire regulations... -
Page 29: Putting The Products Into Operation
Automatic boiler for wood pellets 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 –... -
Page 30: Installation Of The Burner
Automatic boiler for wood pellets 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. 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 the non-flammable roupe is fitting evenly and very closely around circumference of the flange. -
Page 31: Instalation Of The Ceramic Catalytic Reflector
Automatic boiler for wood pellets 6.3 INSTALATION 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. -
Page 32: Installation Of Secondary Ceramic Grate
Automatic boiler for wood pellets 6.4 INSTALLATION OF SECONDARY CERAMIC GRATE Individual parts of secondary ceramic grate on the picture. Picture No. 26 Parts of secondary ceramic grate Function as such 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. -
Page 33: Installation Of Ceramic Shield
Automatic boiler for wood pellets 6.5 INSTALLATION OF CERAMIC SHIELD Picture No. 28 Ceramic shield Insert the ceramic shield flatways across the boiler space and fit the part on holders over the door from inside. Steps: Picture No. 29 Ceramic top placement guide 6.6 CONNECTION OF ELECTRICAL PARTS The electric parts connections can be performed by qualified personnel only. -
Page 34: Checking Tasks Before Boiler First Operation
Automatic boiler for wood pellets Connect: Connection terminal Feeder motor F2 X14- L, N, PE Impulse sensor F2 Electric ignition spiral X4-L, N, PE Primary Fan X11-L, N, PE Flue Fan (if used) X12-L, N, PE Feeder motor F1 X13- L, N, PE Impulse sensor F1 Flue thermometer Systém pump... -
Page 35: Boiler Service And Maintanance During Operation
Anticipated intervals: × in 6 month (KP 12S, KP 12S – ES,KP 22S, KP 22 - ES) when using wood pellets 1 × in 2 month (KP 62S, KP 62 - ES) 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. -
Page 36: Flue Gases Exchanger Cleaning
Automatic boiler for wood pellets 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. -
Page 37: Annual Audit
Automatic boiler for wood pellets 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 non-standard conditions in the next year of operation of the equipment. - Page 38 Automatic boiler for wood pellets 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.
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Page 39: Disposal Of Product After Teh End Of Its Service Life
Automatic boiler for wood pellets DISPOSAL OF PRODUCT AFTER TEH 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´s service life: Steel exchanger, jacketing, feeders, bin –... -
Page 40: Control Unit Operation
Automatic boiler for wood pellets CONTROL UNIT OPERATION 9.1 MAIN MENU Description of the basic control panel screen After switch on the main power switch, start program and after severat minutes will show the main menu. For easy operation are used: Buttons with names or pictograms Buttons with moving (setting of power and temperature) Boxis with informations (text, numbers or pictograms) -
Page 41: Operating Conditions - Main Menu
Automatic boiler for wood pellets 9.2 OPERATING CONDITIONS – MAIN MENU SELECTION OF OPERATING MODE User, before start operation of boiler, have to select operation mode – touch on the button is automaticaly changed mode: FIXED POWER Boiler operating automatically on the fixed power. User can set value of power (% or kW) and temperature (°C). MODULATION Boiler operating automatically. -
Page 42: Main Menu
Automatic boiler for wood pellets 9.3 MAIN MENU 9.3.1 Setting menu Button: Alarm list Button: Back on the previous screen 9.3.1.1 Info menu Software version No. dated Software version visualisation No. dated Operating hours Button: Move to second screen... -
Page 43: Menu Users Settings
Automatic boiler for wood pellets 9.3.1.2 Menu users settings... - Page 44 Automatic boiler for wood pellets Actual time: Time, date Hrs:min:sec Actual date Den.měsíc.rok Tine without screensaver Button: Password Showed: „Please insert your password“ After touch on the box for password : Insert password and enter. In the end confirm: If is password rihgt –...
- Page 45 Automatic boiler for wood pellets Cleaning an ash removeing Time window setting Skin...
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Page 46: Menu 3 Servis
Automatic boiler for wood pellets IP Adress Button: Password Showed: „Please insert your password“ After touch on the box for password : Insert password and enter. In the end confirm: If is password rihgt – button change on green color 9.3.1.3 Menu 3 Servis... - Page 47 Automatic boiler for wood pellets Diagnostics Manual mode Touch and start functionality Button: Password Showed: „Please insert your password“ After touch on the box for password : Insert password and enter. In the end confirm: If is password rihgt – button change on green color Note:...
- Page 48 Automatic boiler for wood pellets Actual values Configuration...
- Page 49 Automatic boiler for wood pellets Parametres The setting value of parameters are important for combusion quality, correct function and safety. The producer save changes of parameters by password. Is prohibited to make unqualified changes. Important note: The value of parameters on the pictures below are ONLY SAMPLES! Actual seting depend on the type of boiler! Producer and qualified service can make changes only! Next page...
- Page 50 Automatic boiler for wood pellets Next page: Previous page Maximum boiler temperature Temperatures Minimum exhaust temperature for heating Maximum exhaust temperature Temperature for activate pump Temperature for activate bypass pump Button for activate electric heating...
- Page 51 Automatic boiler for wood pellets Button for activate electric ignition. Ignition Boiler is operating in Stand-by and keeps the fire Fuel for ignition Time for pre heating of ignition spirel (without fan) Fan revolution Control tempereture Note: Control temperatur is important for fire control Fuel for stabilisation...
- Page 52 Automatic boiler for wood pellets Standby mode Time period, in which automatic boiler is not actively burning Time – fire life Setting temperature Time - Programs Button to select programs for settings Parameters for chosen program above Actual program for fix power ...
- Page 53 Automatic boiler for wood pellets PID regulation - recommended Modulation Parameters for regulations Feeders Time count impulses Note if it is set „0“ then there is no control of the motor Allowed errors On time feeder F2 before Off time feeder F2 of F2...
- Page 54 Automatic boiler for wood pellets Cleaning, Ash removing Time window setting...
- Page 55 Automatic boiler for wood pellets Load from USB Save on USB...
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Page 56: Menu - Heating Circuits
Automatic boiler for wood pellets 9.3.2 Menu – heating circuits Button for open window for addition heating circuits Button for confirmation... -
Page 57: Tank
Automatic boiler for wood pellets After confirmation: 9.3.2.1 Tank Demand for heating Time window setting Button for settings menu Button for manual functionality Visualisation of pump status Green - On Grey – Off... - Page 58 Automatic boiler for wood pellets Funkcion for setings of parameters Funkcion for manual control of pump...
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Page 59: Sanitary Water
Automatic boiler for wood pellets 9.3.2.2 Sanitary water Demand for heating Blue – heating Red – not heating Time window setting Button for settings menu Button for manual functionality Visualisation of pump status Green - On Grey – Off... - Page 60 Automatic boiler for wood pellets...
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Page 61: Heating Circuit
Automatic boiler for wood pellets 9.3.2.3 Heating circuit Demand for heating Blue – heating Red – not heating Time window setting Button for settings menu Button for ekviterm parameters Button for manual functionality Servo control: Servo location: Visualisation of White: Off White: closed pump status Green: On... - Page 62 Automatic boiler for wood pellets...
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Page 64: Error - Overheating, Emergency Thermostat
Automatic boiler for wood pellets Error states 9.4 ERROR - OVERHEATING, EMERGENCY THERMOSTAT The control unit is equipped with emergency circuit in case of overheating of the boiler. OVERHEATING fault condition occurs when the water temperature at the outlet exceeds a threshold of 95 ° C. In this situation, the emergency circuit is activated by the control unit and the boiler is shut down. -
Page 65: Error - Overheating, Operating Thermometer
Automatic boiler for wood pellets Commissioning: In order to put the control unit and the boiler to automatic operation it is necessary that the water outlet temperature fell below 65 ° C. If this condition is not fulfilled, the control unit will not start. When putting the boiler back into normal operation, proceed as follows: Leave the boiler so long out of operation until the outlet water temperature (see display) drops below 65 °... -
Page 66: Error From Low Temperature Of Water Or Combustion Products
Automatic boiler for wood pellets Possible causes Elimination Performed by blocked nozzles in the burner clean the burner as prescribed annual review service dirty heat exchanger clean heat exchanger service insufficient or reverse draft in the solution is suggested by professional company chimney service chimney Commissioning:... -
Page 67: Error - Exceeded Allowed Time Of Feeder F1 And F2 Run
Automatic boiler for wood pellets 9.9 ERROR – EXCEEDED ALLOWED TIME OF FEEDER F1 AND F2 RUN Control of feeder F1 is continual and if the running time exceeds running time allowed for more than 10s in particular feeder F1 mode of operation, the boiler will stop and the display will show an error message. Comment: Security features in case of infringements of electronic switching element. -
Page 68: Error - Lack Of Fuel In The Tank
Automatic boiler for wood pellets 9.12 ERROR – LACK OF FUEL 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 Possible causes Elimination... - Page 69 Automatic boiler for wood pellets The user can use the application unchanged as well as in particular modification to the best solution of heating system. This is primary responsibility of the designer and implementer of the heating system - which is why the Ponast company can not take over the guarantee for the functionality of a particular solution of heating system.
- Page 70 Picture No. 31 Principle of the modulation...
- Page 71 Picture No. 32 Dim. Req. for the placement of KPx2 in boiler room – exam. of using collecting troughs...
- Page 72 Picture No. 33 Directory information - consuption wood pellets for boiler family KP...
- Page 73 Picture No. 34 Circuit diagram – control unit...
- Page 74 Picture No. 35 Circuit diagram + modul HZS 533...
- Page 75 Picture No. 36 Circuit diagram - HZS 533, HZS 535...
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Page 76: Table 6 Settings - Service
Table 6 Settings - Service Menu Menu - name Menu – description-meaning Settings - values Alloved No.: KP 12S, KP 22S, KP 62S, MAIN MENU unit KP 12 - ES KP 22 - ES KP 62 - ES Info Informations producer 1.1. - Page 77 Menu Menu - name Menu – description-meaning Settings - values Alloved No.: KP 12S, KP 22S, KP 62S, MAIN MENU unit KP 12 - ES KP 22 - ES KP 62 - ES 3.3.2 Ignition Menu for ignition parameters setting...
- Page 78 Menu Menu - name Menu – description-meaning Settings - values Alloved No.: KP 12S, KP 22S, KP 62S, MAIN MENU unit KP 12 - ES KP 22 - ES KP 62 - ES Program No.2 40% of nominal boiler power...
- Page 79 Menu Menu - name Menu – description-meaning Settings - values Alloved No.: KP 12S, KP 22S, KP 62S, MAIN MENU unit KP 12 - ES KP 22 - ES KP 62 - ES Program No.9 95% of nominal boiler power...
- Page 80 Menu Settings - No.: Menu - name Menu – description-meaning values KP 12S, KP 22S, KP 62S, MAIN MENU unit KP 12 - ES KP 22 - ES KP 62 - ES service 3.3.7 Cleaning Cleaning parameters settings user Time period...