Steel – water bottom burning boilers type
- PLUS
For drying, degassing and gassing, which means for using all kinds of solid fuel,
IRLEH boilers let you use many types of fuel
Operation and Maintenance Documentation
INSTRUCTION MANUAL
Attention!
Before mounting the boiler it is essential to read this DTR.
Manufacturer:
IRLEH sp. z o.o. sp. k.
ul. Poniatowskiego 29
64-200 Wolsztyn
Tel./fax. +48 (068) 384-23-15
+48 (068) 347-22-84
www.kotly.irleh.com.pl
e-mail:
Wolsztyn – 2009
Design of the boiler is patent protected
2
1. CONTENT
1. OMM Contents
2. General
3. Boiler application
4. Fuel
5. Description of the
- PLUS
boiler
6. Technical and operating parameters
7. Boiler installation
8. Connecting the boiler to the chimney
9. Connecting the boiler to the heating system
10. Filling the boiler with water
11. Lighting the boiler
12. Refueling the boiler
13. Boiler cleaning
14. Shutting the boiler down
15. Boiler maintenance and repairs
16. Boiler transportation
17. User obligations
18. Final remarks
19. Delivery specification
20. Boiler diagram
21. Declaration of conformity
22. Warranty card and acceptance inspection report
23. Practical advice to the user
24. Sample of central heating installation diagram
25. The regulation of the boilers door
2. GENERAL
Please read this Operation and Maintenance Manual to be able to use the boiler
properly and safely. Because this manual covers several boiler sizes before you continue
reading it, please read the boiler name plate to determine the boiler size and be able to use
this manual properly.
Before you connect the flue duct to the chimney you should get an approval
from an authorized chimney service pertaining the suitability of the specific chimney
duct you intend to use.
The
- PLUS
boiler is the only boiler available on the market with a shifted
convection chamber, i.e. the boiler part that receives heat from flue gas, which significantly
improves the combustion conditions and minimizes the amount of dust exhausted through
the flue into the atmosphere.
3. BOILER APPLICATION
The steel boilers of the
- PLUS
type are intended for ncentral heating
systems in residential houses, shopping centers, garages, commercial premises, office
buildings, service outlets, catering premises, etc.
The boiler water temperature must not exceed 100°C.
The boiler should be assembled by an authorized company or specialist, who is also
to provide boiler security features.
The
- PLUS
boilers can be used in with both gravity and pumped heating systems.
Thermal balance of heated rooms prepared based on valid national standard is a base to
match a proper boiler to the central heating installation.
The rated boiler calorific effect should be equal or slightly higher (up to 10%) than the
calculated water demand of the rooms heated.
3
Table 1 below can be used as rough reference for determining the size of rooms to be
heated with the
- PLUS
boilers.
Table 1
Boiler type Minimum
power in kW
Rated power in
kW
(recommended)
Approximate surface area of a
heated room
-
PLUS
20 6 20 65 – 100
-
PLUS
30 9 30 100 – 160
-
PLUS
40 12 40 130 – 240
-
PLUS
60 18 60 200 – 360
-
PLUS
80 24 80 300 – 480
The data are given for reference only and should be used for rooms 2.5 m high, with
the calculated heat loss index is 60 W/m
3
.
4. FUEL
The basic fuel for
- PLUS
boilers is dry firewood leafy or coniferous of
piece, the glade, chips, waste material of wood of the furniture industry in the form of blocks,
frameworks with the calorific value exceeding 12000 kJ/kg and 20% humidity (maximum
allowable 25%). When this fuel is used the manufacturer ensures the efficiency and
continuous burning specified in this manual.
Using inferior fuels, especially of higher humidity, ash content or low calorific value
can cause boiler efficiency loss and more labor-intensive boiler operation (more frequent
cleaning, loading, etc.).
Alternative fuels to be used with
- PLUS
boilers (keeping the humidity
recommended for the basic fuel) are:
- hard coal, with the heat value approx. 24000 kj/kg the diameter of grains 40-80 mm,
- brown coal, briquettes up to 40 mm,
- bark, shavings, dry twigs, sawdust, coaldust, chips (all these fuels should be
briquetted) Alternative fuels should be mixed with the basic fuel in the ration of 1 to 1.
5. DESCRIPTION OF THE - PLUS BOILER
(see the diagram of the layout of boiler components)
The boiler design ensures the performance of so called bottom burning process. All
the internal shell components are made of integrated boiler plates. The external shell is
made of welded structural sheet metals. On the outside the boiler is insulated with insulating
material and housed in a casing made of painted steel sheet. The temperature control and
fan are located on the upper boiler cover. The boiler is highly effective in burning all kind of
solid fuels because the controller and fan are installed in an integrated casing. It is very
simple to replace them in case of a failure. There is no need to disassemble any
components: it is just enough to unscrew four screws and replace the controlled with a new
or repaired one.
The boiler has a cast-iron grate made of bars. The loading chamber is separated from
convection ducts by a water compartment with a duct supplying so called secondary air to
the ceramic burner. Below the burner there is the fire bridge, which prevents burner
contamination by post-burning waste (ash, cinders) and maintains a layer of glowing embers
necessary to ignite gases generated at the first burning stage. Behind the burner there is an
after-burning chamber covered with ceramic fittings accumulating heat and improving flue
gas after-burning conditions.
6. TECHNICAL AND OPERATING PARAMETERS
Basic technical parameters of
- PLUS
boilers are listed in table 2.
4
Table 2. Basic technical parameters of
- PLUS
boiler range.
No.
Parameter Name Unit Range
1. Identification of boiler size type
- PLUS
20
- PLUS
30
- PLUS
40
- PLUS
60
- PLUS
80
2. Rated thermal power kW 20 30 40 60 80
3. Minimum thermal power kW 6 9 12 18 24
4. Optimum thermal efficiency when burning
- basic fuel
- alternative fuel
% ~ 87
~ 84
5. Water (calculated) parameters on boiler
inlet and outlet °C 95/70
6. Maximum boiler water temperature °C <100
7. Required flue draft mbar
Pa 0,25
25 0,27
27 0,29
29 0,35
35 0,35
35
8. Water capacity dm³ 125 150 180 250 300
9. Flue gas temperature
- rated power
- minimum power
°C
250
185
250
185
250
185
250
185
250
185
10.
Dimensions of the security connection
piece Ø
mm 25 25 25 32 32
11.
Dimensions of the flue gas connection
piece Ø
mm 160 180 180 210 210
12.
Dimensions of the inlet and outlet
connection piece pipes mm
inches 40
1½” 40
1½” 50
2” 50
2” 50
2”
13.
Burning time for wood
- rated power
- minimum power h
~ 4,5
~ 10,5
Burning time for coal
- rated power
- minimum power h
~16
~36
14.
Temperature control setting range °C 75÷90°C
15.
Fan control power setting range % 30÷100% rated power
16.
Minimum return water temperature
(on the boiler inlet) °C > 60°C
17.
Fuel: Type, humidity % 20% recommended 25% permitted
18.
Fuel storage capacity dm³ 90 140 180 330 390
19.
Max. length of glades with
thickness Ø 70-150
mm 400 400 400 550 550
20.
Electrical wiring As per the temperature control instruction manual, a
separate publication supplied with the boiler.
21.
Electric power supply V
Hz 230
50
22.
Max. input power
- fan
- circulation pump
W
W
80 at 100% power
100 at 100% power
23.
Permitted boiler water pressure Bar
MPa < 1,8
< 0,18
24.
Boiler weight without water kg 380 460 530 710 890
25.
Boiler overall dimensions
- length
- width
- height mm
1200
440
1350
1200
560
1350
1200
670
1350
1370
805
1500
1370
920
1500
26.
Approximate fuel consumption
- fuel wood Q
wr
> 12000 kJ/kg
- hard coal Q
w
rr
> 24000 kJ/kg kg/h 6,3
4,5 9,5
6,8 12,5
9,0 19,0
13,5 26,0
17,5
27.
Boiler class as of 06 March 2004 acc. to European classification 3 – the highest
7. BOILER INSTALLATION
The central heating system boiler should be installed in accordance to applicable
standards. Observing security rules in accordance to applicable standards is required for
safe and long-term boiler operation.
5
It is strictly forbidden to use closed vessels (e.g. diaphragm type vessels) for
-
PLUS
boilers without cooling coil !!!
Note!
- PLUS
boilers with cooling coil can be used with closed vessels under, if the
cooling coil is connected to the water-pipe installation in accordance to valid national
standards. Exemplary diagrams of such a connection is presented on the drawings attached
in point 24 to this Operation and Maintenance Documentation.
If applicable standards and recommendations included in this manual are not complied with,
the buyer’s warranty will be voided. The company or individual providing the boiler and
central heating installation service and not the boiler manufacturer shall be
responsible for the effects of incorrect installation.
The
- PLUS
boiler is delivered as an assembled unit. Read this manual
carefully before you start installing and connecting the boiler to the central heating system.
Make sure that all subassemblies are functional and if the boiler has complete equipment
and has not been damaged in transit. Installation of the boiler should be started with
installing the connecting piece with sockets on the supply pipe
The boiler does not require the use of any fixtures such as a heat bank, etc.
(however, they can be used). However, the installation of termoregulatory valve with
61°C on return is required, because it allows for continuous boiler operation with water
temperature ranging between 65 and 95°C, which significantly improves its efficiency and
useful life. Then the boiler can burn any biomass type at 30-120% rated power output.
To protect the boiler against overheating, connect it to a heat receiver capable of
receiving gravitationally the minimum theoretical boiler power (specified in table 2). The
simplest solution is to use a tap water heater without the use of a charging pomp. When
using the
- PLUS
boiler with the cooling coil, the cooling coil is a protection medium,
which shall be connected to the cold water installation. It is recommended to install the
manometer to simplify the monitoring the water condition in the central heating installation.
The boiler temperature control and fan should be installed after all the other
installation works are completed (when installing the fan, before you screw it on, apply a
gasket (included in the set) on the boiler casing to seal connection to the boiler).
The temperature control sensor and thermometer should be installed in connecting
piece pockets on the supply pipe, as instructed by the producer of the driver. An alternative
solution is to insulate it thermally and slightly tighten with a hose clamp on the supply outlet
pipe as close to the heating water connecting piece outlet as possible, making sure that the
sensor adheres closely to the pipe. After these procedures the whole connection has to be
insulated.
The boiler does not need to have a foundation. It can be placed directly on the floor, only in
such a case an insulation plate is required under the boiler, which should protrude before the
boiler to at least 500 mm. The boiler room, where the boiler is installed should meet fire
safety and building law requirements (especially with respect to natural ventilation system).
It is strictly forbidden to use mechanical exhaust ventilation (combustion gas can be
exhausted from the boiler into the boiler room).
The boiler should be placed in a way that ensures access from all sides, which is
necessary for its correct operation and cleaning.
8. CONNECTING THE BOILER TO THE CHIMNEY
The boiler should be connected to the chimney with the use of a breeching. It can rise
towards the chimney and be equipped with a cleanout. For practical reasons (ease of
cleaning operations), the breeching should have a large cross-section than the flue
connecting piece outlet cross-section. It is recommended to place the flue gas inlet into the
breeching about 7 cm below its bottom to create space for depositing soot and ash. It is also
recommended to insulate the breeching thermally.
Any bends in the flue flow direction have an adverse impact on boiler operation. If the
user is forced to use bends, the change in flue gas flow direction should be an obtuse-angle
curve.
6
NOTE: Pay attention that the breeching is not inserted to deep into the chimney duct. It can
reduce the diameter of the chimney and limit the chimney draft, what is a very often cause of
incorrect function of the chimney.
The breeching is to be made of steel sheet, at least 3mm thick.
The chimney should have cross-section and height that ensure adequate draft
(specified in table 2 - Basic technical parameters).
The diagram of the selection of the diameter of the kettle.
Effective height of the chimney in meters
The most favorable chimney cross-section is round, and thus for:
-
- PLUS
20 kW - Ø 185-200mm
-
- PLUS
30-40 kW - Ø 200-250mm
-
- PLUS
60-80 kW - Ø 250-300mm
Other cross-sections are allowed, e.g. square or rectangular, but the side size ration should
not exceed 1 to 1.5 (provided the required draft and chimney cross-section are ensured).
The cross-section should in no way be smaller than the flue connecting piece outlet
cross-section.
The manufacturer recommends to use a chimney liner protecting the chimney duct
against condensate infiltration and will not accept any responsibility for not observing this
recommendation and causing any damage.
9. CONNECTING THE BOILER TO THE HEATING SYSTEM
Protection of the installation must be in accordance with all national standards. The
manufacturer will not accept any responsibility for the effects of not providing safety features
in compliance with above mentioned regulations and standards.
T
he power rating
in
kW
Necessary draught in
Pa
Diameter of the chimney in mm
7
Boiler installation and connection should be carried out by a specialized, qualified
installer and be subject to applicable standards.
10. FILLING THE BOILER WITH WATER
Before you light the boiler, the central heating system and the boiler itself should be
filled with water, whose hardness should not exceed 2°n.
NOTE It is not allowed to fill up the boiler with cold water during its operation
when excessive water loss is found. Adding cold water on hot boiler walls
is dangerous for operators and can cause a very serious failure. It is
allowed only when the boiler is cooled down. Removing glowing embers
from the boiler is allowed only when the person removing them ensures the
assistance of another individual to be protected in case of fainting or other
incidents.
11. LIGHTING THE BOILER
The initial startup (lighting) after the boiler is installed can be carried out only
by a competent and authorized service technician. Failure to observe this requirement
may void your warranty. This must be confirmed by a signed and completed boiler
installation acceptance report (annexed to the warranty).
Note:
Before you startup the temperature control, the installer should check and adjust the
following boiler operating parameters (specified in a separate temperature control operation
manual).
boiler operation temperature should be set to 80°C,
circulation pomp switch-off temperature should be set to 65°C,
fan power should be set: about 40%.
Each subsequent boiler lighting operation carried out by the user during boiler use
can occur only if you make sure that the installation includes enough water and has not
frozen.
The sequence of lighting operations:
1. Open the boiler furnace (bottom) door.
2. Clean the grate (if necessary, also the burner)
3. Load the kindling onto the grate (paper, small pieces of dry wood) and then larger
pieces of dry wood up to 1/2 of the chamber volume.(see Figure No.1) Kindle the
kindling.
NOTE! It is recommended to use „mild” wood type like pine when required
level of fire is needed fast. “Hard” wood type like oak, acacia are recommended
for refueling, because these types of wood are burned much longer.
The kindling should be carried out slowly, with the fan off and the bottom door
(about 1 cm) ajar. When the chimney is cold, and consequently the draft is poor,
you can temporarily open the by-pass device(in order to avoid smoke).
4. After a dozen or so minutes, when glowing embers will be generated up to the
burner top,(see Figure No.2) open the by-pass device, close the furnace door
and open the fuel loading door. Fill the boiler up with fuel,(see Figure No.3). Close
the fuel loading door and then the by-pass device.
8
recommended
layer
of glowing
embers
Figure No.1 Figure No.2 Figure No.3
5. Switch temperature control on.
6. THE INSTALLATION MODE - acts mentioned in the point 6a) and 6b) can
be made only by the installator or the service agent during first firing of the
boiler.
6a) Adjust primary air. Accordingly to observe the length of the flame through the
open cleanout hole. He should reach to about the second shelf from below.
Depending on his length (slowly after ½ the turn {turnover}) to screw tight or
to open the primary air valve to the obtainment of required length of the flame.
6b) Adjust secondary air. Open (closed on the beginning) the valve of secondary
air on 1 turn and then slowly after ¼ turn. It should effect shortening the flame
and the change of his colour on the orange-violet and the lack of smoke from
the chimney.
7. Adjust secondary air supply (the user makes it during the possible change
of the fuel).
First it should be tighten the secondary air valve until feeling slight resistance,
then unscrew it about 1 turn. Then add secondary air gradually by manipulating
(unscrewing) the valve until smoke disappears from the chimney. During heavy
frost water steam can be emitted from the chimney. This is a normal
phenomenon. This operation, i.e. secondary air supply adjustment should be
carried out very slowly, turning the valve by ¼ turn, since you have to allow for the
burning process to stabilize. The adjustment effect should be lack of smoke
coming from the chimney. This process should be carried out with care, since
the correct determines boiler operation and efficiency and thus the heating costs.
Note: – Secondary air supply needs to be adjusted only in two cases:
after the boiler is installed at initial kindling by an authorized installer,
(according to the Installtion Mode)
by the user at fuel type change (e.g. when changing from coal to wood).
In other cases, when one fuel type is used (or rekindling the boiler after it has
gone out), there is no need to carry out any adjustments.
8. Check boiler tightness (fuel loading door, ashpit door and cleanouts) and if smoke
is leaking adjust the hinges.
The bypass device is opened each time before opening any of the door. To do so, the
lever should be set for open position, as it is show on the sticker. After you close the door,
close the by-pass device by putting the lever in closed position.
Fuel should not be thicker than Ø100mm for the 20kW boiler, Ø150mm for the size 30kW to
80kW boilers. It should also not be too small, see the diameters specified in Point 4. - fuel.
During supplement fuel should be arranget on the glowing embers along the boiler
(perpendicular to the burner).Please be careful so as not to cover the burner entirely with a
piece of fuel, especially during kindling.
9
NOTE: It is prohibited to kindle the boiler with flammable liquids, such as
gasoline, kerosene, solvents, etc.
12. REFUELING THE BOILER
NOTE: Fuel humidity should not exceed 25% (recommended humidity is about 20%).
Before you start refueling the boiler switch off the fan, open the by-pass device
and after a few seconds open the fuel loading door. Do these operations slowly. This will
allow for gently burning of gases collected in the fuel loading chamber. This will also prevent
“explosions” of gas. The flue gas coming out of the boiler during this operation indicates a
defective chimney, dirty boiler or a blocked burner.
Fuel should be refilled periodically by filling up the whole fuel loading chamber. The
fuel stock in the fuel loading chamber suffices for 4,5 to 10,5 hours depending on the fuel
used and boiler operating power. Before you add a fresh portion of fuel, remove ash and
cinder, if any from the boiler grate and burner. While cleaning, “we put the rake into the gap
between the furnace door and grate”. Due to that we can avoid of falling out from the boiler
bigger parts of burning medium.
Note: If after cleaning the grate you find out that the burner is partly or totally uncovered, it is
recommended that you proceed following the kindling procedure, i.e. load the chamber to
about ½ (if you use only wood fuel, you can load the fuel chamber full) with fuel (preferably
with dry wood) and leave the bottom door (about 1cm) and the by-pass device ajar for a few
or a dozen or so minutes until the entire burner is cover by glowing embers. If different fuel is
used instead of wood (or it has not been loaded full previously), e.g. coal, load the fuel
loading chamber full. Then close the door, the by-pass device and switch the temperature
control on. If you fail to do this, and there is little glowing embers, achieving the required
boiler operating temperature will take longer or the boiler can even go out.
Burning intensity (boiler output) is controlled by increasing or reducing the fan power
(see the control operation manual). Boiler water temperature decrease can indicate that the
boiler requires cleaning or improper fuel is used. Please remember that the burning time
depends on the weight of fuel loaded and not on its volume.
It is recommended that you refuel the boiler before the previously loaded fuel goes out
completely, so that the glowing ambers cover the entire burner (up to the burner top
edge), since then the fuel loaded gasification is significantly improved. During the periods of
low hot water consumption, adjust the blowing time and frequency so as to prevent boiler
going out completely by itself. Boiler water temperature (not to be confused with system
water temperature) should range between 65 and 95°C (± 10°C in relation to the set boiler
operating temperature of 80°C). For this purpose the temoregulatory valve with 61°C on
return, specified in Point 7, is required.
13. BOILER CLEANING
In order to ensure fuel economy make sure the combustion chamber and convection
ducts are kept clean. The boiler cleaning frequency depends mainly on burning intensity, fuel
quality (its humidity) and chimney condition.
The combustion chamber should be cleaned through the bottom door, while the
convection chamber through the cleanout from the rear side of the boiler, after removing its
covers. Soot and ash from the breeching is removed after opening the cleanout on the
breeching. The best method for removing dirt from convection ducts is to pull it down from
each shelf, starting through the cleanout and starting from the top. The dirt will fall down into
the after-burning chamber and can be removed through the burner with a special scraper into
the fuel loading chamber and from here down into the ashpit. Tar produced as a result of the
burning process is deposited on the fuel loading chamber side walls. This is typical for
bottom burning boilers.
10
However, because the fuel loading chamber surfaces take little part in heat exchange
processes, this phenomenon has no significant impact on boiler operation. It is
recommended to clean those surface only during post-heating season maintenance. Clean
them as needed if inferior fuel types are used.
NOTE! Moist or thick pitch layers at the boiler fuel loading chamber inform about incorrect
and to moist fuel or incorrect boiler regulation, especially when the boiler is working under
low temperatures. It is recommended to adjust the boiler according to instructions described
in the section 11 (lighting the boiler).
14. SHUTTING THE BOILER DOWN
After a heating season and putting the boiler down (unless hot tap water is to be
provided during summer), the boiler should be cleaned carefully and all the post-burning
residues are to be removed.
Leave the boiler open to ensure its ventilation, what can prevent to avoid water
condensation at the boiler walls
15. BOILER MAINTENANCE AND REPAIRS
Periodic boiler maintenance is to be carried out once a year. Accessory should be
overhauled and maintained on an ongoing basis.
Before you overhaul the boiler and determine the scope of repairs, if any, clean the boiler
carefully from any type of residues left over from the burning process. After the end of the
heating season, when the boiler is operated properly, it may just be necessary to remove
only minor failures, which can be removed by users themselves.
Any major boiler repairs resulting from incorrect operation and failures or mechanical
damage should be carried out immediately after a need to repair is found by a competent,
qualified company or specialist.
Any leaks should be sealed by welding and damaged components are to be replaced
by new ones. In case of any difficulties, please contact the distributor or maintenance service
technician.
16. BOILER TRANSPORTATION
The boiler is delivered as an assembled unit (except for the control and blowing unit).
The boiler manual and warranty document is stored the boiler fuel loading chamber and
protected properly against damage. The boiler should be transported in a vertical position.
The boiler must not be dumped from a vehicle, but removed carefully from it. In transit the
boiler needs to be protected properly to prevent its shifting or overturning.
17. USER OBLIGATIONS
1. Only fuel with parameters described within this Operation and Maintenance Manual
can be used.
2. Make sure boiler heatable surfaces are clean, flue and chimney ducts are not choked.
3. Remove any damage and boiler components failures on an ongoing basis.
4. Make sure the water used to fill in the heating system is of proper quality.
(hardness 2°n).
5. Carry out periodic boiler overhauls and maintenance.
6. After the heating season leave the water in the boiler and the system.
7. Any boiler mechanical damage requiring welding should be carried out by a qualified
specialist.
8. Clean the fan with a soft brush once a month.
11
9. Lubricate periodically the sealing cords with graphite grease or machine oil.
10. Adjust the door tightness (required due to cord compaction) by adjusting the hinges.
18. FINAL REMARKS
Bottom burning boilers for wood and wood-derivate fuels, such as sawdust, chips and
hard or brown coal have become popular recently and most users are still inexperienced in
their operation, even though they are appreciated due to relatively low operating costs.
Therefore we will appreciate receiving any comments and observations concerning the
- PLUS
boiler. Your feedback can help us improve the design or change the
operation manual.
19. DELIVERY SPECIFICATION
The
- PLUS
boiler is delivered as a complete assembled unit (apart from the
control and blowing unit) with an insulation shell, doors, flue outlet connecting unit. The unit
comes complete with:
1.
- PLUS
boiler
2. Control unit
3. Blowing unit
4. Operation tools
5. Operation and Maintenance Manual including a declaration of conformity
6. Warranty including warranty terms and conditions and boiler acceptance report
7. Control unit and blowing unit instructions manual including a warranty
8. Thermometer
9. Connecting piece with sockets for sensor and thermometer.
12
20. BOILER DIAGRAM
1.
Boiler body
2. Fuel loading door
3. Boiler ashpit door
4. Boiler furnace door
5. Water outlet connecting piece
6. Recirculated water connecting piece
7. Outlet of gas connecting piece
8. Cleanout holes
9. Cast iron grate
10. Secondary air duct
11. After-burning chamber
12. Insulation
13. Bypass device
14. Bypass device lever
15.
Convection chamber
gates
16. Secondary air valve
17. Primary air valve – top
18. Blowing unit
19. Casing
20. Fuel loading chamber
21. Burner
22. Heat-resistant fittings
23. Thermometer
24. Control unit sensor
25. Connecting piece with sockets
26. Breeching
27. Cooling coil
28. Control unit
14
IRLEH sp. z o.o. sp. k.
ul. Poniatowskiego 29
64-200 Wolsztyn
Tel +48 (068) 384-23-15
+48 (068) 347-22-84
www.kotly.irleh.com.pl
e-mail: [email protected]
Declaration of conformity
within the range Directive 97/23/WE
IRLEH sp. z o.o. sp. k.
ul. Poniatowskiego 29
64-200 Wolsztyn
Declare with full responsibility that the following products:
boilers fed manually with solid fuel
type - PLUS: 20,30,40,60,80
with rated power outputs: 20kW, 30kW, 40kW, 60kW, 80kW,
manufactured after 22 August 2008
to which this declaration pertains, in typical operating conditions is in conformity with
the following directives and standarts :
European Parliament and European Council Directive 97/23/WE pertaining to
pressurized equipment.
Standard PN–EN–303–5 Heating boilers for solid fuels, hand and
automatically fired, nominal heat output of up to 300 kW. Terminology,
requirements, testing and marking,
Wolsztyn day: …………… …………………
Signature Responsible Person
21.
15
22.
WARRANTY CARD
Name of the Device: Central heating boiler for solid fuel type IRLEH Plus ……….. KW
Production date: …………………… LOT no: ……………………….. Date of sale: ……………………………..
Warranty conditions
The warranty is given by the manufacturer based on below mentioned conditions, only when the boiler is mounted in
accordance to Operation and Maintenance Manual and valid standards, by authorized personnel.
If the boiler is to be mounted by other, not authorized person, the user is obliged to inform the manufacturer about the planned
date of first startup the boiler, because it can be done by authorized service employee, only. The service employee checks the
proper mounting of the boiler and after that he can fill in and sign the warranty card and receipt protocol, which is the integrated
part of this warranty. The filled in Protocol and Warranty Card must be stored till the end of warranty period and have to be
presented by any complaint procedure.
Not complete Warranty Card and Protocol, without dates, stamps and signatures or with any alterations made by not authorized
persons will not be valid and all warranty rights will be canceled.
1. The service employee is obliged to startup the boiler within 7 working days starting with the day of receiving the application
from the user. In a case of incorrect connection of the boiler (by the user) the user receives the copy of acceptance protocol
and the next startup date will be agreed by the user and service employee. All costs of the next startup(s) will be covered by
the user.
2. The first startup procedure includes:
- checking if all recommendations mentioned in the acceptance protocol Operation and Maintenance Manual are fulfilled,
- lighting,
- short instruction for the user how to use the boiler,
- filling in and signing the protocol and warranty card,
- regulation of all possible leakages of doors and covers.
3. All costs of procedures not mentioned in the point 2, which are connected with failures caused by incorrect mounting of the
boiler are covered by the user.
4. The warranty period is 24 months starting from the first startup but no longer than 27 months from the day of purchase. Any
failure and defects arisen as manufacturer’s failures / defects will be repaired for free without delay, within 14 working days
starting with the day of receiving the complaint from the user. Sending the complaint to the service or seller (via fax, post or
other way) the user is obliged to attached the copy of filled in “Boiler acceptance inspection protocol”.
5. Warranty doesn’t include:
a) boiler, not lighted by the authorized service employee,
b) any defects not caused by the manufacturer and any results of such defects if these defects have been caused by the
user, other person(s) or any other accident, especially if:
- the mounting instructions described within Operation and Maintenance Manual were not followed,
- incorrect handling, maintenance and using,
- using the boiler not according to the intended applications,
- any alterations or repairs of the boiler performed by not authorized personnel,
- incorrect adjusting the outlet parameters of the boiler,
- using incorrect fuel.
c) below mentioned components:
- ropes used for sealing the doors and covers,
- ceramic elements,
- fuses
- cast iron grate.
6. Any procedures performed by the user described within Instruction Manual and Operation and Maintenance Manual are not
treated as warranty repairs.
7. The manufacturer is not responsible for the chimney installation and central heating system of the user and any defects of
the boiler caused by them.
8. Any warranty and post-warranty repairs of the control and blowing unit will be made based on other warranty, given by its
producer.
NOTE:
All costs of drive of the service employee and possible reparation will be covered by the person who called the service
employee unjustifiable.
Before you call the service employee you should call or send a letter or e-mail to the service dept. or the seller. Above
mentioned warranty conditions are valid on the region of ……………………………….
Seller’s stamp
Readable signature and stamp
of the service employee
16
BOILER ACCEPTANCE INSPECTION REPORT
First and last name or company’s name of the user _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Address: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __ _ _ _ _ _
Manufacturer’s number of the boiler: _ _ _ _ _ _ _ _ _ Date of purchase: _ _ _ _ _ _ _ _ _
Date of first lighting: _ _ _ _ _ _ _ _ _ _ _
1. IRLEH - Plus boiler – output: _ _ _ _ _ _ _ kW
2. Ventilation system of the boiler room
□* proper □* not proper
3. Chimney duct draft for above mentioned boiler’s output (according to the declaration of the
authorized chimney’s company)
□* in accordance □* not in accordance
4. Protection of the chimney against condensate absorption
□* ceramic chimney inlay □* acid-resistance steel chimney inlay
□* heat-resistance steel chimney inlay □* no protection
5. Expansion tank type “open” in good condition
□* mounted □* not mounted
6. Tank type “closed” in good condition
□* mounted □* not mounted
7. Cooling coil with thermostatic valve SS20
□* mounted □* not mounted
8. Thermostatic valve with 61°C on return
□* mounted □* not mounted
9. Boiler output in accordance to the heated room(s) space
□* proper □* not proper
10. Additional fitting connected to the installation:
□* mixing valve □* other
11. Humidity of fuel 15-25%
□* yes □* not
12. First startup of the boiler performed by the authorized service employee
□* yes □* not
13. Remarks and recommendations (of the user, installer, service employee):
□* installation must be improved (service employee remarks) acc. To point
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
14. □* Warranty will be signed after reparation of defect(s) and falsit(ies) of installation mentioned
above and after repeated startup of the boiler.
NOTE! The user declares that he/she read the
Operation and Maintenance Manual
and Instruction
Manual of this boiler. In case of improper boiler connection, all costs of repeated startup(s) will be
covered by the user.
_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _
Date, signature and stamp of the User’s signature
person responsible for installation
of the boiler
FINAL RESOLUTION:
Herewith I confirm that the device was started up in accordance to valid technical regulations
and guidelines mentioned in the DTR. The boiler works properly
.
date and signater of the
authorized installer
*
) Please tick the box corresponding to the actual state !!
17
23. PRACTICAL ADVICE TO THE USER
Hygrometer
The manufacturer recommends having a hygrometer, which is very useful for checking wood
humidity at the time of its purchase or ongoing inspection of stored wood.
Why use a chimney liner?
Using solid fuels in traditional boilers, i.e. top burning boilers, a relatively large
amount of heat and a significant part of harmful gases is emitted into the atmosphere. This
way you spend your money, and these are quite large amount to heat the chimney and the
atmosphere. To change these proportions, i.e. transfer as large a portion of heat to radiators
(and thus dedicate it for room heating), we offer you a modern, environmentally-friendly
bottom combustion boiler. This way a huge portion of heat you have lost so far will heat what
you really want to, i.e. the space of rooms. Therefore it means that since we lose less heat,
but also the exhausted flue gas is much cooler, and thus stop heating the chimney.
Sometimes, however cooler flue gas exhausted through old, often leaky chimney condense,
which can cause chimney wall rising damp. To achieve maximum boiler operating efficiency
(i.e. cost-effective operation) and avoid any damage, just like any world-class bottom-
combustion boiler manufacturers, We recommend that chimney liner or other features
protecting the chimney against condensate absorption. Those manufacturers, who do not do
it, intentionally expose you to significant problems and unnecessary costs. You need to be
aware that if you want to incur low costs for heating, when you use a modern boiler, you
have to connect it to a modern chimney (just like with a car – lead-free fuel and the catalyst).
We guarantee that you will be very satisfied and the cost will be recovered instantly,
especially as the fuel prices keep growing and will continue to do so.
Chimney test for self-testing during chimney operation
1. Test if the boiler is clean (fire bridges, burners, grate, breeching).
2. Kindle the boiler.
3. Switch the blowing off.
4. Open fully the (top) fuel loading door.
5. Open the boiler furnace (bottom) door.
6. Close the by-pass device.
After completing these operations (dry!) fuel should burn intensely and no smoke should be
emitted through the fuel feeding door.
If it is otherwise, i.e. the fuel is burning slowly and smoke is emitted through open fuel
feeding door, it is indicative of an incorrect chimney operation. Call a chimney sweep.
The manufacturer will not be responsible for an incorrectly operating
chimney, or any related consequences.
The most frequent causes of wrong chimney operation:
1. The chimney should have the draft specified in the OMM (it will be defined precisely by the
chimney sweep).
2. Too small chimney cross-section.
3. Too low chimney.
4. The chimney does not protrude above the roof ridge (the highest roof point).
5. Chimney cornice – very often causes wrong chimney operation.
6. Various types of insertions increasing chimney height, but at the same time reducing its
cross-section.
7. Insertions in neighboring chimney ducts protruding above the boiler chimney duct of a
boiler for solid fuel. This often happens if two boilers are used. One burning oil, another
burning solid fuel.
8. A leaky chimney duct (crack, internal connection with other ducts, e.g. ventilation, a
cracked internal chimney partition, which you cannot identify by yourself).
18
9. Leaky chimney cleanout door.
10. Foreign objects in the chimney duct, e.g. a piece of a broken brick.
11. Other devices connected to the chimney duct, apart from the central heating boiler itself,
such as kitchen hearths, fireplaces, smokehouses, etc.
12. Dirty chimney duct. You cannot identify it visually, since more dirt is deposited in the
middle part of the chimney.
13. Internal chimney duct cross-section changes and offsets.
14. Too deeply inserted breeching.
15. A bend in the breeching (elbows, etc.) on the section connecting the boiler with the
chimney.
16. Too long breeching, i.e. the section of the flue gas duct connecting the heating boiler with
a chimney, which is additionally not insulated.
17. Wrong (too small) breeching cross-section – should be bigger than the cross-section of
the flue outlet fitting.
18. Mesh inserted on a chimney duct outlet.
19. Concrete caps finishing the outlet and causing lateral flue gas outlet.
20. Cold chimney – located outside a building (the chimney must be warm!!!)
21. Connecting sewage air vents into the chimney duct.
22. Lack of appropriate boiler room ventilation, especially air supply ventilation.
23. Use of mechanical exhaust ventilation (the use of which is unacceptable because it can
lead to flue gas being sucked into the boiler room).
Unfortunately, the majority of these failures can be found only by a master chimney
sweep.
We remind you that the chimney duct should be cleaned every 6 weeks!
An incorrectly working chimney cannot be the grounds for boiler warranty claim.
Typical boiler operation disorders
1. The causes of impossibility for obtaining full boiler efficiency can be the following:
a. too low chimney draft – chimney duct, breeching or boiler cleanout leaks
should be tightened, check chimney cleanout door tightness (a very frequent
cause),
b. bad fuel quality – inferior fuel should be burned during warmer periods, when
lower boiler efficiency is required,
c. dirt deposited in flue ducts – clean boiler ducts, breeching and chimney.
Check if a non-combustible object covers the inlet to the ceramic burner.
d. accumulation of a large amount of ash cinder on the grate causing air flow
constriction - this should be removed.
e. lack of air inflow to the boiler room -
ensure air inflow through a window or a ventilation duct.
f. too rapid or too slow burning process – incorrectly adjusted supply air – set
the fan and secondary air valves correctly.
g. wet walls of the fuel loading chamber – this phenomenon occurs particularly
intensely when the fuel is wet, at the same time reducing boiler output.
2. Very rapid water temperature growth on the boiler outlet at inadequate water
temperature on the inlet to radiators.
Cause: broken or limited water circulation in the heating system (reduced water level in the
expansion tank).
The system should be refilled with water. Check for water level reduction cause (see if there
are any leaks in the system).
An incorrectly completed (e.g. air-locked) system.
Incorrectly installed circulation pomp – short circulation.
19
Causes for not reaching rated boiler thermal power
1. Incorrect regulation of the boiler (especially primary and secondary air)
2. Insufficient chimney draft caused by chimney, breeching or cleanouts leaks, faulty
chimney (cross-section, height)
3. Bad fuel quality.
4. Dirty flue ducts.
5. Dirty grate.
6. Lack of air inflow to the boiler room.
7. Insufficient water quantity in the system.
8. Chocked up burner
NOTE: Any work related to boiler operation should be carried out in gloves, headgear and
protective goggles.
20
1.
Central heating
boiler type
IRLEH
2. Three-way valve
3. Circulation pump
4. Differential valve
5. Heater
6. Tap water heater
7. Inlet of cold water
8. Valve
9. Tap water outlet
10. Expansion tank “closed”
11. Connecting piece with
sockets
12. Filter
13. Thermoregulatory valve
type TERMOWAR 61
o
C
14. The naiant manageable
clack without the spring
15. Venting
16. Control valve
17. Cooling valve:
Honeywell TS130 – ¾ A
(95
o
C)
WATTS STS 20 (97
o
C)
18. Cold water inflow
2-6 bar, 10-15
o
C
19. Manometer
20. Security valve
WARNING!
–
If the security valve on a cooling
coil against overheating is installed, it is possible not to use the floating back flap at the bypass.
On special user demand the installation can be expanded with accumulation tanks (1,2 or 3 pieces even), room and outside temperature sensor or thermal outlet
protection. There’s also a possibility to combine two boilers within cascade. Such modification must be performed based on separate documentation of
installation designed by the authorized designer.
2
4
. S
ample central heating system
in
the
closed system
.
The schema No. 1
Basic - recommended by the producer Variant I Variant II Variant III
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