Ponast KP 10 Instructions For Installation And Operation Manual
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Ponast KP 10 Instructions For Installation And Operation Manual

Automatic boiler for wood pellets
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  • Page 2 Automatic boiler for wood pellets Instructions for installation and operation Manufacturer: PONAST spol. s r.o., Na Potůčkách 163, 757 01 Valašské Meziříčí, CZECH REPUBLIC tel. +420 571 688 111 , fax +420 571 688 115, e-mail: ponast@ponast.cz Dear customer, accept kindly, please, our congratulations on your decision to buy this product and to ensure WARM FOR YOUR HOME by burning recoverable energy sources - WOOD PELLETS in this case.

  • Page 3: Table Of Contents

    Automatic boiler for wood pellets Instructions for installation and operation TABLE OF CONTENTS: IMPORTANT NOTICES USE OF THE BOILER AND ITS ADVANTAGES TECHNICAL DATA OF THE BOILERS KP 11, KP 11E, KP 21, KP 21E STRUCTURAL DESCRIPTION OF PRODUCTS BOILER BODY CONTROL UNIT OF THE BOILER 4.2.1 Connection of connectors of the control unit...
  • Page 4 Automatic boiler for wood pellets Instructions for installation and operation GUARANTEE AND LIABILITY FOR DEFECTS Guarantee conditions Records of performed repairs Picture part 39-46 Directory information -consuption wood pellets for boiler family KP Setting Control Unit from productions 48-49 Technical information - accessories 50-59 LIST OF FIGURES: Fig.n.

  • Page 5: Important Notices

    Automatic boiler for wood pellets Instructions for installation and operation IMPORTANT NOTICES 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 6: Use Of The Boiler And Its Advantages

    Automatic boiler for wood pellets Instructions for installation and operation 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 which ensures COMFORT for the user including maximum saving of fuel.
  • Page 7 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL DATA OF THE BOILERS Table number 1: Thermal and technical parameters of products Parameter Unit KP 10/10E KP 20/20E KP 50/50E KP 11/11E KP 21/21E Rated output 14,9 Output range 4,5 –...

  • Page 8: Structural Description Of Products

    Automatic boiler for wood pellets Instructions for installation and operation 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).

  • Page 9: Fig.n. 2 Control Unit Of The Boiler

    Automatic boiler for wood pellets Instructions for installation and operation Diagram of the products and description of the main parts Figure number 1 – Diagram of the product including description of the main parts...

  • Page 10: Control Unit Of The Boiler

    Automatic boiler for wood pellets Instructions for installation and operation 4.2 CONTROL UNIT OF THE BOILER Figure number 2 - Control unit of the boiler The control unit of the boiler is used to control the boiler automatically via control elements (thermometers, sensors, etc.) in required modes.

  • Page 11: Connection Of Connectors Of The Control Unit

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.1 Connection of connectors of the control unit Figure number 3 - Connection of connectors of the control unit Interconnection with the ambient is ensured by two connectors – X and X The connector X is used to connect the supply voltage and all power elements (motors of feeders,...

  • Page 12: Block Diagram Of The Control Unit

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.2 Block diagram of the control unit Figure number 4 - Block diagram of the control unit...

  • Page 13: Description Of The Control Panel

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.3 Description of the control panel Figure number 5 – Control panel 1 - The main circuit-breaker - has two positions off – the handle is in the lower position on –...

  • Page 14: Block Diagram Of Operation Of The Control Unit

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.4 Block diagram of operation of the control unit Figure number 6 – Block diagram of operation of the control unit...

  • Page 15: Manual Control

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.5 Manual control Attention! The mode of Manual control may not be used for permanent operation! Manual control is only used in the following cases: - start (ignition) of the boiler - change of any parameter of an operating mode The operator may put the control unit into the manual control mode either by: - depressing the key...

  • Page 16: Main Menu

    Automatic boiler for wood pellets Instructions for installation and operation 4.2.7 Main menu Having the control unit been turned on, the equipment will be put into that operating mode in which it was before turning off. Thus it may be in the manual and automatic mode. →.
  • Page 17 Automatic boiler for wood pellets Instructions for installation and operation MENU 5 – ADVANCE It is a time advance in seconds by which the feeder 2 will start running sooner than the feeder 1 starts working. The range of this parameter is determined within the interval of 0 – 10 sec. This parameter is selected to be 1 second for common operation with pellets of ∅...
  • Page 18 Automatic boiler for wood pellets Instructions for installation and operation MENU 8 – PROGRAMMES It makes possible to store 6 completed programmes necessary for the automatic operation of the boiler in memory of the control unit (1 – 5 heating, 6 heating service water) – see tab. 6. MENU 9 –...

  • Page 19: Burner Furnace Including The Feeder

    Automatic boiler for wood pellets Instructions for installation and operation 7) Priority heating of hot service water. Excellent properties of this function can fully be used, if the boiler is connected as per the figure number 15. This function will ensure heating of hot service water within a minimum time interval.

  • Page 20: Ceramic Parts

    Automatic boiler for wood pellets Instructions for installation and operation 4.4 CERAMIC PARTS - ceramic reflector – is installed on the surface of the burner - ceramic extension grate – is installed into the boiler body over the burner furnace - ceramic schield –...

  • Page 21: Optional Accessories

    Automatic boiler for wood pellets Instructions for installation and operation 4.8 OPTIONAL ACCESSORIES - Automatic ignition. - Semiautomatic cleaning of the heat exchanger. - Heating unit TJ M 48/2 of power output equal to 2.4; 3; 4; 4.5 and 6 kW. - Circulation pump.

  • Page 22: Fuel Bin

    Automatic boiler for wood pellets Instructions for installation and operation 4.9 FUEL BIN is supplied, for example, in a shape which is clear from the figure number 17. As its shape and version may vary in relation to the space options of customers, it is supplied as a piece of optional accessories. The displayed size of the fuel bin represents volume of 100, 400, 700 and 1400 l.

  • Page 23: Heating System And Boiler

    Automatic boiler for wood pellets Instructions for installation and operation The design has to adhere to the following standards and regulations: 5.3.1 Heating system and boiler: ČSN 06 0310 / 1983 – central heating, designing, installation. ČSN – EN 303.5./2000 – boilers for central heating, part 5. ČSN 06 0830 / 1996 –...

  • Page 24: Storage Of Fuel

    Automatic boiler for wood pellets Instructions for installation and operation 5.4 STORAGE OF FUEL Wood pellets have to be in a dry place protected against atmospheric effects because humidity damages them 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.

  • Page 25: Installation Of The Ceramic Catalytic Reflector

    Automatic boiler for wood pellets Instructions for installation and operation 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 ČSN 07 7401 / 1992 –...

  • Page 26: Installation Of The Ceramic Extension Grate

    This grate is installed into the boiler in such a way that individual parts (the left part, the right part) are passed through the middle open part of settling bars and shifted tightly to the wall of the furnace (KP 10, KP 11).

  • Page 27: Checks Before The Boiler Is Put Into Operation

    Automatic boiler for wood pellets Instructions for installation and operation 6.5 CHECKS BEFORE THE BOILER IS PUT INTO OPERATION 1) Check the water in the heating system for quantity. 2) Check whether the stop valves between the boiler and the heating system are open. 3) Check the heating system for leakage in all new joints.
  • Page 28 Automatic boiler for wood pellets Instructions for installation and operation ELECTRICAL IGNITION it is necessary In order to use the function of electrical ignition, for the boiler to be equipped with a burner furnace with a heating coil used to ignite pellets. 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.

  • Page 29: Automatic Operation

    Automatic boiler for wood pellets Instructions for installation and operation Note: If the boiler operates in the mode AUTO and any supply voltage failure happens, the boiler will resume with electrical ignition programme (if the programme has been installed) after the supply voltage delivery has been renewed.

  • Page 30: Maintenance And Attendance Of The Boiler During Operation

    Note: Large-volume bin can be installed to the boiler. 2) Ash pan emptying Assumed interval: ……………………………………1x 2 weeks (KP 10-20-11-21) ………………………………….. 1x 2 – 5 days (KP 50) Note: When removing ash, check visually whether the ash does not contain excessive quantity of unburnt fuel.

  • Page 31: Maintenance

    Automatic boiler for wood pellets Instructions for installation and operation 3) Clean the draughts of combustion products Cleaning of smoke draughts is performed by about 20 intensive swinging movements of the lever to its extreme positions. Assumed interval: ……………………………………1x a week or after spent fuel cca 200 kg Note: It proceeds if semiautomatic cleaning of the exchanger is installed in the boiler.

  • Page 32: Annual Audit

    - remove all parts of the ceramic extension grate - first pull out the middle parts (KP 20, KP 21, KP 50) and then both lateral parts (KP 10, KP 11). Lift the parts always perpendicularly up, then turn them 90° along the longitudinal axis and lower down through the opening in the placement bars which is approximately in the centre of the boiler.
  • Page 33 Automatic boiler for wood pellets Instructions for installation and operation 4/ Now dismantle the burner from the boiler - 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.

  • Page 34: Operating States - Basic Figure

    Automatic boiler for wood pellets Instructions for installation and operation 7.4 OPERATING STATES – BASIC FIGURE AUTO - the boiler works in the automatic mode as per values of parametres stored in the working register of the control unit (in menu 1-7). “AUTO”...

  • Page 35: Stop State - Due To Water Temperature Drop

    Automatic boiler for wood pellets Instructions for installation and operation Note: The most frequent cause of this situation is that the temperature of water in MENU 2 has been adjusted too high - for example over 90°C. Under these circumstances, the FALL state may convert into the ALARM state.

  • Page 36: Lack Of Pellets In The Fuel Bin

    Automatic boiler for wood pellets Instructions for installation and operation Note: The work connected with cleaning the transport routes should be entrusted to a specialized servicing company. Important notice: Mains supply has to be disconnected from the wall socket or the corresponding circuit breaker has to be reliably switched off in the switchboard, if any handling takes place in the transport route.

  • Page 37: Legal Entity

    Automatic boiler for wood pellets Instructions for installation and operation 9.2 LEGAL ENTITY shall perform disposal as per the Act number 185/2001 – Act on wastes as amended. Waste shall be sorted as per the kind and category (see main kinds of wastes) and handed over to an authorized entity for disposal.

  • Page 38: Records Of Performed Repairs

    Automatic boiler for wood pellets Instructions for installation and operation RECORDS OF PERFORMED REPAIRS guarantee and after-guarantee repairs Attachment to the letter of guarantee for user Stamp and signature User's Date Intervention performed of contractual service signature...

  • Page 39: Fig.n. 15 Recommended Wiring Diagram Of Boiler

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 14 – Recommended wiring diagram of boiler...

  • Page 40: Fig.n. 16 Recommended Wiring Diagram Of Boiler - Cascading Wiring

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 15 – Recommended wiring diagram of boiler...

  • Page 41: Fig.n. 17 Examples Of Fuel Bins, Placement Of Products And Requirement On Dimensions

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 16 - Recommended wiring diagram of boiler – cascading wiring...

  • Page 42: Fig.n. 18 Wiring - Option For Supply: 3+Pe+N, 50 Hz, 400/230 V, Tn-Cs

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 17 – Examples of fuel bins, placement of products and requirement on dimensions...

  • Page 43: Fig.n. 19 Wiring - Option For Supply 3+Pe+N, 50 Hz, 400/230 V, Tn-S

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 18 – Wiring - option for supply 3+PE+N, 50 Hz, 400/230 V, TN-C-S...

  • Page 44: Fig.n. 20 Schema Wiring El. Ignition + El. Heating

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 19 – Wiring - option for supply 3+NPE, 50 Hz, 400/230 V, TN-S...

  • Page 45: Fig.n. 22 Wiring Room Thermostat With Weekly Programme And Independent Drive Heating Huw

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 20 – Schema wiring el. ignition + el. heating Figure number 21 – Schema wiring electromotive control 4-way valve...

  • Page 46: Fig.n. 24 Directory Information - Consuption Wood Pellets For Boiler Family Kp

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 22 – Wiring room thermostat with weekly programme and independent drive heating HUW Figure number 23 – Working principle The Boiler in mode modulation...

  • Page 47: Directory Information -Consuption Wood Pellets For Boiler Family Kp

    Automatic boiler for wood pellets Instructions for installation and operation Figure number 24 – Directory information -consuption wood pellets for boiler family KP...

  • Page 48: Setting Control Unit From Productions

    Automatic boiler for wood pellets Instructions for installation and operation Table 6 Setting Control Unit from productions 1 Fan KP 10 Feeder 1 with endless screw, Burner No.20 2 Temperature 80°C 3 Feeder 1 ON 4 Feeder 1 OFF 45 s...
  • Page 49 Automatic boiler for wood pellets Instructions for installation and operation KP 10 Feeder 1 with spiral path 38 mm, Burner No.20 1 Fan 2 Temperature 80°C 3 Feeder 1 ON 4 Feeder 1 OFF 27 s 5 Advance Feeder 2...
  • Page 50 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL INFORMATION NUMBER 001/2006 Technical change: BOILERS FAMILY KP xx HAVE BEEN EXPANDED WITH COMBUSTION PRODUCTS THERMOMETER Properties achieved: Higher operating reliability has been achieved by installation of the combustion products thermometer. Burning of the boiler gets under control by temperature evaluation of the combustion products.
  • Page 51 Automatic boiler for wood pellets Instructions for installation and operation Description of operation: Boiler with automatic ignition: The whole automatic ignition routine will take place in the following programme steps after the boiler gets started (manual START Menu 10, with the room thermostat of the boiler, commend via the GSM port): Filling the burner with fuel.
  • Page 52 Automatic boiler for wood pellets Instructions for installation and operation Note: If the reference temperature value is adjusted to =0, the control routines are put out of operation (turned off)! Note: Changes in adjustment of values are accepted by the control unit after the RESET of the equipment - the control unit has to be truned off and on! Software change in circuitry - from the serial number 291/2006 on.
  • Page 53 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL INFORMATION NUMBER 002/2006 Technical change: BOILERS OF KPxx FAMILY HAVE BEEN EQUIPPED WITH TEMPERATURE CHECK IN THE FUEL ROUTE Properties achieved: Safety of boilers against blazing or retrothrust of combustion products via the fuel transport route is increased by installation of thermostat placed in the burner where the fuel enters the burner.
  • Page 54 Automatic boiler for wood pellets Instructions for installation and operation Description of operation: The emergency thermostat and the burner thermostat are connected in series. The burner thermostat is adjusted to the bottom regulation value of approximately 80 If a failure or gross negligence of the operator results in temperature increase up to approximately 80 C in the place where the probe is located, the thermostat will disconnect the electric contact and the control unit will stop operation of the boiler.
  • Page 55 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL INFORMATION NUMBER 003/2006 Technical change: SENSOR OF REVOLUTIONS OF THE FEEDER 1 A P 2 - TYPE: EA 198 Properties achieved: The sensor is a replacement for the sensors of revolutions used so far - induction probes. It is designed to check rotation of the shaft of the feeder P 1 or P 2.
  • Page 56 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL INFORMATION NUMBER 004/2006 Technical change: DAILY/WEEKLY FUEL BINS ARE EQUIPPED WITH AUTOMATIC FEEDING Properties achieved: Assurance of automatic replenishment of daily/weekly fuel bin from the seasonal fuel storage room, depending on the time adjustment and emptying of the daily/weekly fuel bin.
  • Page 57 Automatic boiler for wood pellets Instructions for installation and operation TECHNICAL INFORMATION NUMBER 005/2006 Technical change: BOILERS OF KPxx FAMILY HAVE BEEN EQUIPPED WITH O GSM MODEM Properties achieved: The GSM modem installed on boilers increases the comfort level of operation. The system of automatic reporting of error conditions guarantees quick service intervention.
  • Page 58 Automatic boiler for wood pellets Instructions for installation and operation Note: : Structure of the text message sent by the control unit is as follows: DISPLAY="AUTO 12:20" T=040 RT=1 HT=0 MODULATION=0 Fon=05 Foff=30 FAN=056 "256,60" with the following meaning: DISPLAY="AUTO 12:20" state - displayed on the control unit display T=040 boiler water temperature...
  • Page 59 Automatic boiler for wood pellets Instructions for installation and operation 2) the following menu is added: 12.1.6. Mobile number 1 and is used to enter the user's mobile number. The control unit will accept commands only from this telephone number and send any failure messages only to this number.

This manual is also suitable for:

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