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KOTLOSPAW DuoKo 15 Operation And Maintenance Manual

Central heating boilers with pellet and eco-pea coal burner
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Operation and maintenance manual
Operation and assembly instruction
Before installing and operating the boiler, read this manual carefully.
WARNING!
 Incorrect protection of the boiler may cause serious damage to the boiler and is
dangerous for the user
 The following protections should be used for DuoKo boilers
- in open-loop system according to PN-91/B-02413
- in closed-loop system according to PN-EN 12828
WARNING: You received the first version of manual, in case of any doubts or other
suggestions regarding the information in this manual, please contact us at info@kotlospaw.pl
Always install and operate the boiler in accordance with applicable regulations and standards
1
„KOTŁOSPAW"
63-300 Pleszew
ul. Szenica 38
Central heating boilers
with pellet and eco-pea coal burner
„DuoKo" ......... kW
Serial no. ................
Edition 1
May 2018

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  • Page 1 WARNING: You received the first version of manual, in case of any doubts or other suggestions regarding the information in this manual, please contact us at info@kotlospaw.pl Always install and operate the boiler in accordance with applicable regulations and standards...

  • Page 2: Table Of Contents

    TABLE OF CONTENT 1.INTRODUCTION ............................ 4 1.1. General information ........................4 1.2. General terms of use and warranty conditions ................4 1.3. Delivery specification ........................5 1.4.Transport of boiler ........................5 2. DESCRIPTION AND PURPOSE ......................5 3. TECHNICAL AND OPERATING FEATURES .................... 6 4.
  • Page 3 12.1. Pre-testing ..........................28 12.2 Firing up ............................. 28 12.3 Fuel refilling ..........................28 13. POWER ADJUSTMENT ........................29 14. ESSENTIAL CONDITIONS FOR SAFE OPERATION ................29 15. BOILER OPERATING INTERRUPTION- MOST FREQUENTLY OCCURRING PROBLEMS AND HOW TO SOLVE THEM............................29 16.

  • Page 4: Introduction

    1.INTRODUCTION 1.1. General information The Operation and Maintenance Manual is a manual for solid fuel boilers with automatic fuel feeding for users of central heating water-based boilers with a DuoKo-type pellet and eco pea coal burner. Familiarizing with the Operation and Maintenance Manual, which contains information about the construction, installation, and use of boilers is necessary for their proper and safe functioning.

  • Page 5: Delivery Specification

    operating and responsibility for safety is on the user, who should meet all requirements specified in the Operation and Maintenance Manual. In order to commission the boiler, carefully read the operating instructions for the burner, controller, and other equipment in order to understand the specifics of their operation, and strictly follow the provided terms of use.

  • Page 6: Technical And Operating Features

    natural environment. As fully automatic boilers, they are an economical alternative to both gas, oil, and coal boilers below class 5. 3. TECHNICAL AND OPERATING FEATURES The boilers have a simple integrated design. The operation of the boiler is simple and easy due to the use of an automatic and controlled fuel feeding system, which enables, among others, smooth adjustment of the boiler heat output and obtaining the outlet water temperature according to your needs.

  • Page 7: Construction Description

    For the version with an eco-pea coal burner, the basic fuel is hard coal in form of dry pea coal, energy pea with the parameters specified in the table below. In the event of using poor quality fuels, you should take into account the difficulties with combustion and reduction of boiler efficiency, as well as earlier destruction of the boiler and loss of warranty.
  • Page 8 and ash pan doors as well as cleaning the convection ducts. All closed hatches are heat- insulated doors or covers. The boiler also has thermal insulation. The mechanical and feeder drive parts are covered and do not endanger the safety of operating.
  • Page 9 on the left and right side, to be used depending on the needs. One of the return nozzles should be used in the system as a drain nozzle. In the upper part of the boiler, there are control and measurement nozzles of a temperature sensor, STB.

  • Page 10: Types Of Boiler Protections

    weather sensor readings. The possibility of cooperation with room thermostats, separate for each heating circuit, contributes to maintaining the comfort temperature in heated rooms. 6.1. Types of boiler protections The controller is equipped with emergency sensors and shuts down the boiler and signals emergencies with a light or sound on the desktop in the event of: - exceeding the max.

  • Page 11: Flue Gas Installation

    boiler positioning and installation. If necessary, you may remove the burner and bin that is located on to the body of the boiler. The way of moving and positioning the boiler should be adapted to the conditions of a room and surface, obstacles, inclines, etc.

  • Page 12: Central Heating System

    The draft required for particular boilers is specified in Table 2. The required draft should be supported by the designer with calculations and choosing chimney duct parameters (diameter and height), taking into account climatic zones and terrain conditions. A regulator or draft generator is recommended. Flue gas condensation does not occur in normal operation and work of the boiler.
  • Page 13 The manufacturer is not responsible for incorrect boiler operation caused by a faulty and non- compliant heating system. The refilling of the system with water can only be caused by losses due to water evaporation. Frequent refilling of water indicates leakage in the system and is not allowed. This may cause the boiler scale, which can lead to permanent damage to the boiler.
  • Page 14 Option 1 – top diagram boiler Option 2 – bottom diagram boiler Figure 1a Location of the expansion vessel above the highest point of the water circulation according to PN-91/B-02413 The L and H distances are given as standard...
  • Page 15 Figure 1b Scheme of the protection of the water heating system equipped in one boiler or heat exchanger, top view, pump mounted on the return according to PN91/B-02413 Figure 1c Scheme of the protection of the water heating system equipped in two or more boilers or heat exchangers, pump mounted on the return according to PN-91/B-02413.

  • Page 16: Protecting Boiler In Closed-Loop System

    7.5. Protecting boiler in closed-loop system The most important requirements for DuoKo boilers protected in a closed-loop system with an expansion vessel. In accordance with applicable regulations, DuoKo-type boilers meet the requirements of EU directives at the design and production stage. When it comes to the operation, they are subject to UDT conditions.

  • Page 17: Requirement Regarding Assembly

    integrated connection between reducing, filling, and blowoff valves. The filler valve connector/nozzle should be connected to the mains water source and the boiler return connector/nozzle, while the blowoff valve connector/nozzle should be connected to the boiler's supply connector/nozzle and drainage pipe. It is recommended to use an additional cooling system for hot water outflow from the boiler.
  • Page 18 WARNING! It is not recommended to connect the hydrophore water intake. Table no. 2 List of thermo-technical parameters of cooling valves for DuoKo boilers Boiler power [kW] Coil power [kW] (0,35 ÷ 0,4) Qk (0,4 ÷ 0,5) x Qk Initial water [°C] temperature Final water...
  • Page 19 7.5.7. Installation scheme NS- cooling vessel ZO – cutoff valve ZB – safety valve IG – heating system NP.- expansion vessel PO – circulation pump ZT – thermostatic valve Rys. 1. Schemat montażu kotła w układzie zamkniętym z zabezpieczającym wymiennikiem ciepła - naczynie schładzające z wężownicą...

  • Page 20: Requirements For Closed-Loop System Operation

    7.5.8. Requirements for closed-loop system operation Before commissioning, the manufacturer's or trained installer's service must check if all devices and equipment in a closed-loop system with an expansion vessel are working as they should. The check must be made by calling the simulated emergency condition in a controlled and safe manner. WARNING! During operation, the user is obliged to: - control of measuring instruments indications (manometer, thermometer),...

  • Page 21: Calculation Of The Expansion Vessel Size

    Table D.1 can be used as a guideline for choosing the size of the vessel. Please note that the values in Table D.1 refer to the maximum design temperature limit of 110°C and no reserve water capacity, that is, VWR = 0 liters; h) In cases where a chemical inhibitor is added to the heating medium, for example, to prevent corrosion in the system, pay attention to its effect on the expansion vessel and other components of the closed system.
  • Page 22 - water reserve capacity, V , in liters. In addition to the water capacity resulting from thermal expansion, the expansion vessel should have a minimum water reserve to compensate for possible water losses in the system. The expansion vessel with a capacity of less than 15 liters should have at least 20% of its capacity as a water reserve.
  • Page 23 Safety valve setting 3,0 bar 2,5 bar 2,0 bar Initial pressure of the vessel load 0,5 bar 1,0 bar 1,5 bar 0,5 bar 1,0 bar 1,5 bar 0,5 bar 1,0 bar total water content in the system, Capacity of the expansion vessel V liters Liters Liters...

  • Page 24: Causes Of Residual Risk And How To Eliminate It

    directives, standards, technical specifications, the current state of the art, recognized engineering practice. WARNING! In order to draw the user's and operator's attention, the boiler has been marked with appropriate symbols, signs, notes in the Operation and Maintenance Manual about the risk of unauthorized use - which the user must strictly observe.

  • Page 25: Filling With Water

    9. FILLING WITH WATER Before starting a fire in the boiler, fill the heating system with the boiler with water. The filling should be carried out in accordance with the instructions of the installer. To check whether the installation has been filled correctly, unscrew the valve on the signaling pipe for several seconds - the continuous flow of water from the signaling pipe means that the water fills the expansion vessel located at the highest point of the system, not just the signaling pipe.
  • Page 26 Table 4. Type of boiler Boiler power 4,5-15 6,5-24 8,5-34 11,5-45 Power range Container capacity pea coal Container capacity pellet 0-150* 150-240* 240-350* 350-450* Approximate area of the heated building 0-200** 200-320** 320-460** 460-600** Approximate area of the heated building Weight of the set without water Fuel Pellet 6 mm, granulate 5-10 mm...

  • Page 27: Commissioning Of The Boiler

    Fig.3 DuoKo Jm.u. 15 kW 24 kW 34 kW 45 kW 1459 1459 1459 1459 1173 1173 1230 1230 1354 1354 1354 1354 1854 1854 1854 1854 ø 1”Gw 1”Gw 1”Gw 1”Gw ø Tab. 5 12. COMMISSIONING OF THE BOILER Before the first commissioning and every subsequent start-up of the SlimKo boiler, check if it is correctly connected to the central heating, flue, electrical, and ventilation system.

  • Page 28: Pre-Testing

    personnel and, in justified cases, detailed instructions with written confirmation. It is also recommended to measure the emissions after the first commissioning. WARNING! When firing up a cold boiler, condensation may occur on the boiler walls, so-called sweating, giving the illusion that the boiler is leaking. This is a natural phenomenon that disappears after the boiler has warmed up.

  • Page 29: Power Adjustment

    If during loading dry and dusty fuel into the container dustiness is high, actions should be taken to reduce it to the minimum (for example by slow loading) or to use a closed fuel filling system for the container (for example screw conveyors, pneumatic transport). In necessary situations, use a system of appropriate sensors and dust signaling.
  • Page 30 burner manual • perform feeder test, • incorrect boiler check controller settings settings • check is nothing is • insufficient chimney blocking the flue and draft chimney duct • clean the boiler and • boiler is not clean heat exchanger (ducts)) •...

  • Page 31: Cleaning And Maintenance Works

    • check the efficiency • no ventilation or of the ventilation blocked ventilation in system and in there is the boiler room no ventilation make one take care of technical no inspection and condition - cleaning, cleaning of the boiler inspection, and burner maintenance...

  • Page 32: Fire Safety Conditions

    To remove them, open the front door and the cleanout covers. First, clean the flame tubes with a wire brush of the diameter adapted to the size of the flame tubes. Next, clean the vertical ducts of the reversing chamber taking down the contamination to lower surfaces of the convection ducts.

  • Page 33: Shutting Down The Boiler

    - turn off the power supply (remove the plug from the socket), which will stop the fuel feeder and remove ember from the furnace into the ash chamber or into container made of steel sheet. It is allowed to cover the embers with dry sand to quickly extinguish the fire. - make sure that you do not get burnt to be asphyxiated with carbon monoxide (spend short periods of time in the boiler room and if possible open doors or vents.

  • Page 34: Environmental Protection

    It is not allowed to make changes to the boiler and modifications in the heating system, supply, and ventilation, chimney, electrical and other installations that may affect malfunctions. The air and flue gas openings must not be covered. Qualified installers should be employed to carry out any changes and modifications. For safe and long-term use once a year an authorized service center must perform inspection.

  • Page 35: Conditions For Safe Operation Of Boilers

    - leaving the boiler during operation without supervision - carry out checks on the combustion process as necessary, at least several times a day. - successive checking of the operation protective measures of cooling system. - equip the boiler room with carbon monoxide and smoke detector. - making any modifications to the boiler, equipment devices, as well as the protection system.
  • Page 36 2. The repair based on the warranty will be carried out within 14 days from the date of reporting Reports can be made via phone call or email. 4. Complaints should be submitted to the seller or manufacturer. 5. The claimant is obliged to reimburse the cost of the call in case of: - boiler damage and repair damage due to the fault of the user, - calling service to perform works not covered by the warranty, for example.: correction of controller parameters depending on fuel types, fuse replacement,...
  • Page 37 NOTES ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………… ………………………………………………………………………………………………..
  • Page 38 CONFIRMATION OF INSTALLATION AND PROTECTION OF THE BOILER according to PN-91/B-02413 Type of boiler: ………………………….. Serial No.: ……………………... Year of production: ………………………. INSTALLER: Name of the company:……………………………………………………………………….. Address/phone number …………...………………………………………………………….. USER: First and last name:…………………………………………………………………….. Address/phone number:……………………………………………………………………….. ………………………………………………………………………………………. I, the undersigned, declare with full responsibility that the above-mentioned boiler has been leak-tested and installed in a unfaulty central heating system and protected in an open-loop system in accordance with PN-91/B-02413 "Protection for open-loop water-based heating systems"...
  • Page 39 BOILER PROTECTION CONFITMATION according to PN-EN 12828:2003 Type of boiler: ………………………….. Serial No.: ……………………... Year of production: ………………………. INSTALLER: Name of the company:……………………………………………………………………….. Address/phone number …………...………………………………………………………….. USER: First and last name:…………………………………………………………………….. Address/phone number:……………………………………………………………………….. ………………………………………………………………………………………. It is confirmed that the above-mentioned boiler installed as above has been protected in a closed-loop system meeting the requirements of PN EN 12828:2003.
  • Page 40 „KOTŁOSPAW” 63-300 Pleszew ul. Szenica 38 DECLARATION OF CONFORMITY Person authorized to issue technical documentation: Przemysław Wroński By signing this document, we declare with full liability that the central heating water boiler for solid fuels with automatic pellet feeding, low-temperature type: DuoKo protected in an open-loop or closed-loop system manufactured by our company Type: DuoKo...

  • Page 41: Warranty Card

    25. WARRANTY CARD 1. Central heating boiler name: Steel water-based boiler, with an automatic pellet burner Type: DuoKo …..[kW] Power Serial No......2. The warranty is granted from the date of purchase for …....months Boiler .……..….. months boiler with mixing valve* …....months burner …....months...

  • Page 42: Boiler Commissioning Protocol

    26. BOILER COMMISSIONING PROTOCOL BOILER COMMISSIONING PROTOCOL Serial Burner Boiler type: number: number: Date of Place of purchase/assembly purchase First and last name Phone of the user number Address E-mail Name of the Phone company installing number the boiler Stamp of the Stamp of the company company installing...
  • Page 43 Installation Open-loop system in accordance with Manual YES/NO Closed-loop system in accordance with Manual YES/NO Heat removing device (closed-loop system) - specify type Safety valve – specify type Return protection - specify type (short circuit pump, valve, clutch) Active return protection - YES/NO Pellet boiler Feeder capacity (kg/h) Cleaning intensity (%)
  • Page 44 Maximal boiler power Fuzzy Logic [%] Minimal boiler power Fuzzy Logic [%] CO [ppm] O2 [%] Flue gas analysis Chimney draft [Pa] Flue gas temperature [*C] Room controller YES/NO Controlling mode - STANDARD/FUZZY LOGIC CUSTOMER INSTALLER SERVICE TECHNICIAN I declare that the boiler has been installed in I declare that the boiler was I declare that I have read the warranty accordance with applicable law and...
  • Page 45 WE PROVIDE WARRANTY FOR ALL OUR BOILERS Additionally we are offering: transport of the boiler to the customer installment sale of boilers We ensure: short delivery time warranty and post-warranty service technical advice high quality and affordable prices...

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