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BENEKOV K25 Operation And Installation Manual

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BOILER OPERATION AND INSTALLATION
GUIDE
BENEKOV K14
BENEKOV K20
BENEKOV K25

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Summary of Contents for BENEKOV K25

  • Page 1 BOILER OPERATION AND INSTALLATION GUIDE BENEKOV K14 BENEKOV K20 BENEKOV K25...
  • Page 2 Dear customer, Thank you for purchasing an automatic wood pellet boiler BENEKOV models K14, K20 and K25 and thus showing confidence in the company BENEKOVterm Ltd. Horní Benešov. To get used to the correct handling of your new product right from the start please read these operating instructions, mainly chapters 7 and 8.

  • Page 3: Table Of Contents

    12. Instructions for disposal of the product after its service life............. 37 13. Warranty and damage liability ......................37 ATTENTION! ............................39 Appendix to the “Warranty Certificate” for customer - user ..............40 Declaration of Conformity for K14, K20 and K25 boilers ............... 41 - 3 -...

  • Page 4: Boiler Use And Advantages

    1. Boiler use and advantages Use of the boiler: The BENEKOV K14 hot water boiler is designed to heat small or low-energy houses, chalets and other buildings whose thermal loss does not exceed 15 kW. The BENEKOV K20 hot water boiler is designed to heat small or low-energy houses, chalets and other buildings whose thermal loss does not exceed 20 kW.

  • Page 5: Recommended Boiler Fuel

    Electrical input power at minimum output Electrical input power in STAND BY mode 3. Boiler fuel specifications Chart 3 specifies required (warrantied) types of fuel for BENEKOV K14, K20 and K25 boilers: Chart 3 Required fuels C1 – wooden pellets...

  • Page 6: Boiler Description

    4. Boiler description 4.1. Construction of the boiler The boiler design meets the requirements of: EN 303-5: 2013 - Boilers for central heating - Part 5: Boilers for central heating for solid fuels, with manual or automatic delivery, rated thermal outputs up to and including 500 kW - Terminology, requirements, testing and marking.
  • Page 7 Fig 1 Front and rear view of the BENEKOV K14 boiler 1. fuel store lid 9. fuel overflow 17. boiler control unit distribution board 2. fuel store 10. rotary burner 18. emergency thermostat 3. chain to secure the feeder 11. boiler body door 19.
  • Page 8 Fig 2 Front and rear view of BENEKOV K20 and K25 boilers 1. fuel store lid 9. throttle flap locking bolt 17. emergency thermostat 2. fuel store 10. rotary burner 18. boiler body 3. chain to secure the feeder 11. boiler body door 19.
  • Page 9 Fig 3 BENEKOV K14 boiler basic dimensions - 9 -...
  • Page 10 Fig 4 BENEKOV K20 and K25 boiler dimensions - 10 -...

  • Page 11: Burners Description

    4.2. Burner description The burner is designed to burn solid fuel in the form of pellets. These must meet exact requirements - see chap. 3. Burner operation is automatic and does not normally require supervision. The system of the refractory rotary furnace prevents the slag, one of the components of the burning process, to adhere to it. By rotating the furnace the ash and slag are moved forward until they are completely removed from the burner.
  • Page 12 Fig 6 Feeder and burner scheme 1 – rotary burner kde: 2 – rotary aeration chamber 3 – insulation 4 – bearing 5 – aeration chamber 6 – connecting elbow to the fuel feed 7 – fuel overflow (flexible hose) 8 –...

  • Page 13: Operation, Control And Safety Features Of The Boiler

    • Throttle flap is located between the second and third levels at the top of the fin plate heat exchanger and is used to control the temperature of flue gases at the boiler outlet. Boiler K14: When operating the boiler where the temperature of the flue gases is above 100 ° C, the throttle flap must be closed which means the flap lever on the top of the boiler must be moved as far back as possible and secured with the locking bolt.

  • Page 14: Boiler Accessories

    • the boiler operating and installation manual which includes the Warranty Certificate • operating instructions for the boiler programmer • addendum to the BENEKOV boiler operating and installation instructions - Installing the fuel store for the BENEKOV K14, K20 and K25 boilers •...
  • Page 15 ČSN 73 4201:2010 Chimneys and flues - Design, implementation and connection of fuel appliances C) fire regulations ČSN 06 1008:1997 Fire safety of thermal equipment ČSN EN 13 501-1+A1:2010 Fire classification of construction products and building structures - Part 1: Classification according to the results of reaction to fire tests D) power supply ČSN 33 0165: 1992...

  • Page 16: Boiler Position Options

    F) machinery CSN EN 614-1 + A1: 2009 Safety of machinery - Ergonomic design principles - Part 1: Terminology and general principles ČSN EN 953 + A1: 2009 Safety of machinery - Protective covers - General requirements for the construction and manufacture of fixed and movable guards EN 1037 + A1: 2008 Safety of machinery - Prevention of unexpected start-up ISO 12100: 2011...
  • Page 17 Fig 7 Position of the K14 boiler in a boiler room - 17 -...
  • Page 18 • AA5 / AB5 basic setting rating according to ČSN 33 2000-1 ed.2:2009 • minimum of 600 mm handling space must be left in front of the boiler (applies for K14 boiler) and 1000 mm (applies for K20 and K25 boilers) •...

  • Page 19: Connection To The Chimney

    ČSN 73 4201:2010 Chimneys and flue pipes. • Connect BENEKOV K14 boiler to the chimney by a metal pipe with a diameter of 118 or 120 mm. • Connect BENEKOV K20 and K25 boilers to the chimney by a metal pipe with a diameter of 145 or 150 6.

  • Page 20: Connecting Dimensions

    6.1. Connection dimensions Fig 9 BENEKOV K14 boiler connection dimensions Fig 10 BENEKOV K20 and K25 boilers connection dimensions - 20 -...

  • Page 21: Installation Of The Ceramic Parts Into The Combustion Chamber

    Press this plate as far back as possible closely to the first plate and secure it against falling. BENEKOV K20 and K25 boilers (1 x ceramic fitting + 1 x ceramic plate): • Place the ceramic fitting on the beams into the lower part of the combustion chamber to cover its side wall.

  • Page 22: Commissioning The Boiler

    Should it be necessary to add water to the heating system we do so when the boiler is cooled down to avoid damage to the steel heat exchanger. b) airtightness of the heating system c) connection to the chimney – must be approved by a chimney-sweeping company d) installation of the ceramic parts in the combustion chamber e) power supply connection The sockets are connected so that the protective pin is at the top and the phase wire is connected to the...

  • Page 23: Lighting The Boiler Up

    The boiler feeder value for BENEKOV K14 must not be less than 4 kg/hr. The boiler feeder value for BENEKOV K20 must not be less than 5 kg/hr.

  • Page 24: Boiler Decommissioning

    If the temperature of the heating water reaches 95 to 100°C the emergency thermostat responds by shutting the boiler off separately from the programmer. The programmer then displays signal overheating. The emergency thermostat can be switched back on by unscrewing the black emergency thermostat cover and pressing the colour button only when the temperature drops below the set value by approx.

  • Page 25: Residual Risks And Their Prevention

    7.5. Residual risks and preventing them The risks arising from the use of the boiler under anticipated conditions and logically predictable incorrect use have been minimized by available technical means. Despite implemented construction and technical measures some residual risks are still present during the boiler operation.

  • Page 26: Burner Maintenance, Settings And Service

    3.) During continuous operation of the boiler it is recommended to clean the heat exchanger surface of the boiler body once a month. The heat transfer surfaces can become clogged, which can greatly affect the heat transfer and thus the efficiency of the boiler. After the end of heating season the boiler must be thoroughly cleaned.
  • Page 27 When removing the flange (8) remove the ignition coil (12) from the bushing. Place the disassembled parts in a safe place taking extra care with the ignition coil. Locate and loosen the locking bolt (5). If you cannot see the bolt, manually rotate the outer pipe (1) in direction marked "Z"...

  • Page 28: Setting Up Airflow Into The Furnace

    Fig 12 Cleaning of the tubular aeration rotary chamber – view 2 18. Tighten the locking bolt (5) – it is important to ensure the bolt is positioned outside the pipe ribs (1) and is fully tightened. 19. Attach the flange with the drives. (8). Whilst doing this place the ignition coil (12) into the bushing so that it is properly secured.

  • Page 29: Lubricating Furnace Bearings

    Fig 13 Setting up airflow into the furnace 9.4 Lubrication of the furnace bearings To ensure longer burner life regular lubrication of the furnace bearings is recommended. Depending on the frequency of the burner operation it is recommended to lubricate the bearings every 6 – 12 months. Follow these instructions –...
  • Page 30 Fig 14 Furnace bearings lubrication - view 1 Fig 15 Furnace bearings lubrication - view 2 Disconnect the power supply to the burner and feeder external cable from the programmer. Loosen the screws (1) that secure the burner cover - 2 pcs. Remove the burner cover (2).

  • Page 31: Replacing The Ignition Coil

    Remove the air chamber cover (7) together with the frame (8), the T-piece (9), the drive shaft (14) and the rotating partition shaft (15). If necessary remove the locking bolt of the T-piece. 10. Lubricate the bearings of the combustion chamber (10) at several points along the entire circumference by applying grease between the race and the cage of the bearings.

  • Page 32: Diagram Of Burner Electrical Connection

    Fig 16 Replacement of the ignition coil 9.6 Diagram of burner electrical connection R2, R4 - rotary burner cleaning S2, S4 - feeder in the burner W2, W4 - fan F2, F4 - optical sensor F4, C4, Z2 - Hall probe C2, C4 - feeder temperature sensor Z2, Z4...
  • Page 33 Fig 17 Diagram of electrical connection of XS20 burner of the K14 boiler - 33 -...
  • Page 34 Fig 18 Diagram of electrical connection of XS26 burner of the K20 and K25 boilers - 34 -...

  • Page 35: Troubleshooting

    10. Troubleshooting If there are problems operating the boiler try using this reference chart: PROBLEM CAUSE SOLUTION The display is not showing The boiler is not Connect the boiler to the mains (230V/50Hz) via any data. connected to the power a cable with plug.
  • Page 36 instructions. The burner is clogged by Clean the burner. ash and dust. The fan is damaged. Replace the fan. * The ash in the burner is Other than specified fuel Replenish the store with specified fuel type (see being baked in. is used for burning.

  • Page 37: Guidelines For Compliance With The Environmental Parameters Of The Product

    If the boiler is used in accordance with this „Boiler operating and installation guide“, no specialist service is required. „Certificate of quality and completeness of BENEKOV boiler” serves as “Warranty Certificate” after it is filled in by the service company.
  • Page 38 Failure to comply with these conditions the manufacturer voids the warranty. The warranty does not apply to instances resulting from improper use of the equipment, non- compliance with technical conditions for the equipment operation, normal wear and tear, intentional damage and damage caused by inevitable situation and force majeure (fire, floods, theft, intentional damage, etc.) The warranty is also void if the “Warranty Certificate”...

  • Page 39: Attention

    ATTENTION! This Warranty Certificate is for the manufacturer of BENEKOV K14, K20 and K25 boilers. Fill in properly and send by return to the following address: BENEKOVterm Ltd. Masarykova 402 793 12 Horní Benešov - 39 -...

  • Page 40: Appendix To The "Warranty Certificate" For Customer - User

    Appendix to the „Warranty Certificate“ for the customer – user Record of warranty and post-warranty repairs and product checks Date of repair or Works carried out Contractual service Customer signature check organization (signature, stamp) - 40 -...

  • Page 41: Declaration Of Conformity For K14, K20 And K25 Boilers

    Declaration of Conformity for K14, K20 and K25 boilers Declaration of Conformity in accordance with the provisions of § 13, Para 2, of Act No 22/1992 of “Coll.”, regarding technical requirements for products, as amended by later legislation and in accordance with the provisions of § 13 of Government Order No 163 of “Coll.”, which sets out the technical requirements for selected construction...
  • Page 42 BENEKOVterm Ltd. Masarykova 402 CZ - 793 12 Horní Benešov Tel.: +420 554 748 008, Fax :+420 554 748 008 E-mail: info@benekov.com, www.benekov.com Issue: 2017/10 - 42 -...

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