Ponast KP 12S Service And Operation Manual

Brand: Ponast

Model: KP 12S

Category: Stoves

Type: Service And Operation Manual

This manual is also suitable for

Automatic boiler for wood pellets

Manufacturer address:

PONAST spol. s.r.o., Na Potuckach 163, 757 01 Valasske Mezirici, CZECH REPUBLIC

http://www.ponast.cz

We would like to focus your attention mainly on the following chapters:

No. 1 – Important notes

No. 5 – Putting the product into operation

No. 6 – Maintenance and attendance of the boiler during operation

The boiler has been approved for operation in the Czech Republic and in 27 EU countries by the State Testing Institute,

state testing plant number 202.

General information on CAA and smoke control

The Clean Air Act 1993 and Smoke Control Areas

Under the Clean Air Act local authorities may declare the whole or part of the district of the authority to be a smoke

control area. It is an offence to emit smoke from a chimney of a building, from a furnace or from any fixed boiler if

located in a designated smoke control area. It is also an offence to acquire an "unauthorised fuel" for use within a smoke

control area unless it is used in an "exempt" appliance ("exempted" from the controls which generally apply in the smoke

control area).

The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to authorise smokeless fuels or

exempt appliances for use in smoke control areas in England. In Scotland and Wales this power rests with Ministers in

the devolved administrations for those countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981,

applies in Northern Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas have

been "authorised" in Regulations and that appliances used to burn solid fuel in those areas (other than "authorised"

fuels) have been exempted by an Order made and signed by the Secretary of State or Minister in the devolved

administrations.

The KP12S, KP22S, KP52S, KP62S , KP82S boilers have been recommended as suitable for use in smoke control areas

when burning wood pellet.

Further information on the requirements of the Clean Air Act can be found here: http://smokecontrol.defra.gov.uk/

Your local authority is responsible for implementing the Clean Air Act 1993 including designation and supervision of

smoke control areas and you can contact them for details of Clean Air Act requirements.

Automatic boiler for wood pellets

CONTENT

1 USE OF THE BOILER AND ITS ADVANTAGES ...................................................................................................... 5

2 STRUCTURAL DESCRIPTION OF PRODUCTS ....................................................................................................... 6

3 BOILER BODY, SCHEME OF THE PRODUCTS AND DESCRIPTION OF THE MAIN PARTS ......................................... 7

3.1 BOILER BODY............................................................................................................................................ 7

3.2 CONTROL UNIT ......................................................................................................................................... 8

3.2.1 Boiler Function Module HZS 521-G ..................................................................................................... 9

3.2.1.1 Technical base data .................................................................................................................... 11

3.2.2 Terminal HZS 555-S with USB ......................................................................................................... 12

3.2.2.1 Technical data ............................................................................................................................ 12

3.3 BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE ................................................ 14

3.4 CERAMIC PARTS ...................................................................................................................................... 15

3.5 FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)................................................................. 15

3.6 BOILER SHEATHING INCLUDING HEAT INSULATION .................................................................................. 17

3.7 CLEANING SYSTEM .................................................................................................................................. 18

3.7.1 Ash removal .................................................................................................................................. 18

3.7.2 Heat exchanger cleaning ................................................................................................................ 18

3.7.3 External ash container .................................................................................................................... 19

3.8 STANDARD ACCESSORIES ........................................................................................................................ 20

3.9 OPTIONAL ACCESSORIES ......................................................................................................................... 20

3.10 FUEL BIN ............................................................................................................................................. 20

4 PLACEMENT OF THE PRODUCT IN BOILER ROOMS, PRINCIPLES OF INSTALLATION ............................................ 22

4.1 PLACEMENT OF PRODUCTS IN BOILER ROOMS .......................................................................................... 22

4.2 SAFE DISTANCE FROM COMBUSTIBLE MATERIAL ....................................................................................... 22

4.3 LEGISLATION IN FORCE ........................................................................................................................... 22

4.3.1 Heating system and boiler .............................................................................................................. 22

4.3.2 Venting ......................................................................................................................................... 22

4.3.3 Fire regulations .............................................................................................................................. 23

4.3.4 Electrical ....................................................................................................................................... 23

4.3.5 Protection against noise .................................................................................................................. 23

4.4 STORAGE OF FUEL .................................................................................................................................. 23

4.5 BOILER ROOM VENTILATION ................................................................................................................... 23

5 PUTTING THE PRODUCTS INTO OPERATION .................................................................................................... 24

5.1 CONNECTION TO THE SYSTEM ................................................................................................................. 24

5.2 INSTALLATION OF THE BURNER ............................................................................................................... 24

5.3 INSTALATION OF THE CERAMIC CATALYTIC REFLECTOR ........................................................................... 25

5.4 INSTALLATION OF SECONDARY CERAMIC GRATE ...................................................................................... 26

5.5 INSTALLATION OF CERAMIC SHIELD ........................................................................................................ 28

5.6 CERAMIC DOOR JACKETING ..................................................................................................................... 28

5.7 CONNECTION OF ELECTRICAL PARTS ....................................................................................................... 29

5.8 CHECKING TASKS BEFORE BOILER FIRST OPERATION ............................................................................... 31

6 BOILER SERVICE AND MAINTANANCE DURING OPERATION .............................................................................. 31

6.1 SERVICE ................................................................................................................................................. 31

6.1.1 Refuelling ...................................................................................................................................... 31

6.1.2 Emptying of the external container .................................................................................................. 31

6.1.3 Flue gases exchanger cleaning ........................................................................................................ 32

6.2 MAINTANANCE ........................................................................................................................................ 32

6.2.1 Burnt gases exchanger cleaning ...................................................................................................... 32

6.2.2 Burner grate cleaning ..................................................................................................................... 33

6.2.3 Ceramic grate cleaning ................................................................................................................... 33

6.2.4 Annual audit .................................................................................................................................. 34

7 DISPOSAL OF PRODUCT AFTER TEH END OF ITS SERVICE LIFE......................................................................... 36

7.1 NATURAL PERSON ................................................................................................................................... 36

7.2 LEGAL ENTITY ......................................................................................................................................... 36

8 CONTROL UNIT OPERATION ........................................................................................................................... 37

8.1 MAIN MENU ............................................................................................................................................ 37

8.2 OPERATING CONDITIONS – MAIN MENU ................................................................................................... 38

8.3 MAIN MENU ............................................................................................................................................ 39

8.3.1 Setting menu ................................................................................................................................. 39

8.3.1.1 Info menu .................................................................................................................................. 39

8.3.1.2 Menu users settings .................................................................................................................... 40

8.3.1.3 Menu Service .............................................................................................................................. 43

8.3.2 Menu – heating circuits ................................................................................................................... 53

8.3.2.1 Tank .......................................................................................................................................... 54

Automatic boiler for wood pellets

8.3.2.2 Sanitary water ............................................................................................................................ 56

8.3.2.3 Heating circuit ............................................................................................................................ 58

9 GUARANTEE AND LIABILITY FOR DEFECTS ...................................................................................................... 61

10 APPENDIX 1 - TECHNICAL DATA OF THE BOILERS KP X2S................................................................................. 67

10.1 INSTALLATION DIMENSION OF BOILER ................................................................................................. 67

10.2 TECHNICAL DATA ................................................................................................................................. 69

11 APPENDIX 2 - REPORT ON THE PUTTING THE BOILER KP INTO OPERATION ...................................................... 72

12 APPENDIX 3 - SELF-ADHESIVE LABEL - IMPORTANT SAFETY INFORMATION ....................................................... 73

PICTURES

Picture No. 1 Boiler body ................................................................................................................................6

Picture No. 2 Boiler body – description of the main parts .............................................................................7

Picture No. 3 Control unit - configuration ......................................................................................................8

Picture No. 4 HZS 521-G Connector and terminal electronics layout ............................................................9

Picture No. 5 Module HZS 532-1.................................................................................................................. 10

Picture No. 6 Other modules ........................................................................................................................ 10

Picture No. 7 Terminal with USB ................................................................................................................. 12

Picture No. 8 Burner ..................................................................................................................................... 14

Picture No. 9 Feeder F1 ................................................................................................................................ 16

Picture No. 10 Jacketing KP 12S .................................................................................................................. 17

Picture No. 11 Ash removal system ............................................................................................................. 18

Picture No. 12 Heat exchanger cleaning ...................................................................................................... 19

Picture No. 13 External ash container ......................................................................................................... 19

Picture No. 14 Standard fuel bin sizes ......................................................................................................... 21

Picture No. 15 Assembly guide ..................................................................................................................... 21

Picture No. 16 Required chimney draft ........................................................................................................ 23

Picture No. 17 Burner installation ................................................................................................................ 24

Picture No. 18 Ceramic reflector .................................................................................................................. 25

Picture No. 19 Parts of secondary ceramic grate ........................................................................................ 26

Picture No. 20 Ceramic grate parts placement guide .................................................................................. 27

Picture No. 21 Ceramic shield ...................................................................................................................... 28

Picture No. 22 Ceramic top placement guide .............................................................................................. 28

Picture No. 23 Main menu – sample of visualisation ................................................................................... 37

Picture No. 24 Principle of the modulation .................................................................................................. 62

Picture No. 25 Directory information - consumption wood pellets for boiler family KP ............................ 63

Picture No. 26 Circuit diagram – control unit .............................................................................................. 64

Picture No. 27 Circuit diagram + module HZS 533...................................................................................... 65

Picture No. 28 Circuit diagram - HZS 533, HZS 535 .................................................................................... 66

Automatic boiler for wood pellets

IMPORTANT NOTES

This product may only be put into operation by an installation organization trained by the manufacturer.

This product may only be operated by adult persons, duly acquainted with the way the product is controlled and duly

acquainted also with these Instructions. If you adhere to the below mentioned principles, the product will serve you

reliably to your full satisfaction.

1) It is prohibited to intervene in any way in the structure or electrical installation of products. Having the

equipment been disconnected from the electric network, the power supply cord has to be plugged from the

mains outlet.

2) It is prohibited to use inflammable liquids for ignition.

3) No inflammable materials may be stored on the boiler; neither may they be stored within the distance of 1,500

mm from the boiler (except for operating metal fuel bin).

4) In order to preserve long-term service life of the boiler body, it is not recommended to operate the boiler

frequently under the temperature of 55°C, if the boiler is not protected with a primary circuit. The temperature of

55°C should be considered as the minimum temperature.

5) The check how the boiler is filled with fuel is only visual. Any verification with touch is prohibited as it may result

in injury.

6) Never open door of the boiler if there is an ignition process.

7) The door of the boiler has to be always tightly closed. If you´ll perform any check, open the door carefully to

prevent from getting jeopardized by gathered products of combustion or to prevent any sparks flying out from

the boiler from being the cause of any accident. Open the door slowly in order to get the combustion chamber

aerated towards the chimney. This procedure has to be adhered to when the ash is being removed from the ash

pan's space.

8) If any work which generates inflammable vapours takes place in the boiler room (glueing the floor, etc.), the

boiler has to be out of operation and the fire has to be burnt out in the boiler.

9) Having the heating season been finished, clean the boiler thoroughly as per the chapter Maintenance. Products of

combustion stuck to the walls of the exchanger may act corrosively for the whole period of time when the boiler

will be out of operation. If the burner is not cleaned, this may have effect on faulty combustion. We recommend

hire a specialized company to perform this work.

10) If you work on or near to the mechanically movable parts (fuel feeder, etc.), ensure safe disconnection of the

equipment from electric voltage. There is a risk of injury.

11) You should always operate the boiler only under parameters and in harmony with recommendations given in

these instructions for installation and operation. If the boiler works in the AUTO mode and if there is a failure of

current, the boiler will start operation again with the electric firing programme (if this programme has been

installed) after the delivery of electric current is restored.

12) The manufacturer does not assume any liability for errors and subsequent damage caused by unskilled operation

of the equipment or by infringement of principles given in these instructions for installation and operation or by

infringement of generally binding standards and regulations or by using inadequate fuel.

13) If the boiler is moved or otherwise handled with, safety regulations which apply to handling with heavy loads

have to be adhered to.

14) It is prohibited to place heavy loads on jacketing boiler and to step on it. It is recommended to remove the

protective foil after all the building and installation work has been completely finished.

15) External ashtray has to be firmly connected to a boiler fitting while in the operation. Cover of this ashtray has to

be tightly closed. There could be a dangerous escape of combustion gases into a boiler room.

Automatic boiler for wood pellets

1 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:

1) AUTOMATIC OPERATION ensured by the control unit which cooperates with the indoor thermostat, thermostat of

SW tank for hot water, outside thermometer in the mode of equitherm regulation, eventually by superior control

system, which ensures comfort for the user including maximum saving of fuel.

2) Automatic ASH REMOVING and heat EXCHANGER CLEANING ensures long time maintenance free and maximum

comfort of heating while keeping high burning efficiency.

3) CONTROL UNIT with modern design – controls operation of the boiler, ensures automatic operation, high

operational reliability and long distance control.

 Colour TFT display 5.7" with touch screen.

 Remote control over TCP/IP

 USB

 User friendly controlling

 Operation modes: Equitherm, Modulation or Fixed power

 Two heating circuits and sanitary water in basic configuration

 Possibility to control accumulation tank or solar system – maximum 7 heating circuits

 Upgrading software over USB stick

4) PRIORITY HEATING of sanitary water – is secured by the structure and software package of the boiler without

any need for other control elements.

5) MODULATION PERFORMANCE of the boiler allows adjusts production of the heat to an actual need of the

building.

6) Heating in EQUITHERM regulation mode lowers the cost of the heating.

7) The burner system used with two independent feeders and with a system of ceramic catalytic reflector and grate

ensures perfect SMOKELESS FUEL COMBUSTION, which supports high thermal efficiency of the product and also

excellent ecological parameters with the minimum content of harmful substances in combustion products (20-50x

less than conventional boilers).

8) SAFETY OF OPERATION ensured by separated structure of fuel transport routes and by the selected transport

mode.

9) DESIGN AND SURFACE – jacketing of the products is coated with a heavy-duty COMAXITE COATING which is

perfectly resistant to environment effects and ensures perfect appearance of products on long-term basis. Design

of whole solution is using modern shape elements.

10) This SUBSIDIED ABLE PRODUCT – is fulfilling all required conditions for obtaining subsidies in many states of the

European Union.

11) LONG DISTANCE CONTROL and monitoring by internet or GSM connection.

Automatic boiler for wood pellets

2 STRUCTURAL DESCRIPTION OF PRODUCTS

The structure adheres to the standard EN 303.5 / 2000 i.e. boilers for central heating - part 5 (boilers for

central heating with automatic fuel feed of rated heat output up to 300 kW).

PRODUCT MAIN PARTS – FRONT SIDE

PRODUCT MAIN PARTS – BACK SIDE

Picture No. 1 Boiler body

Control unit – boiler function modules

External ashtray

Connection flexible hose

Primary fan

Boiler cover

Terminal with USB

Cleaning mechanism

Inspection door

Cleaning motor

Feeder F2

Exhaust pipe

Heating water output

Feeder F1

Backwater input

Automatic boiler for wood pellets

3 BOILER BODY, SCHEME OF THE PRODUCTS

AND DESCRIPTION OF THE MAIN PARTS

3.1 BOILER BODY

is made of top-quality steel metal sheets and pipes for boiler in form of a weldment. Its shape is adapted in such a way

so that combustion products are cooled down efficiently at individual levels of power output, which is, moreover, assisted

by a system of turbulators. The exchanger is shaped in such a way so that the exhaust pipes of combustion products can

be cleaned individually and efficiently.

Picture No. 2 Boiler body – description of the main parts

Steel weldment

with heat exchanger

Inspection door

Exhaust pipe  130, 150 or 160 mm

Heating water output water G 1½“

(inside thread)

Backwater input water G

1½“(inside thread)

Rear flanged hole

to install the burner system

Pipe G ½“to install filling valve

Pipe with inside thread M48x2

mm to install an electrical

heating unit (optional)

Flanged hole to install ash

removing system

Opening on top for

cleaning covered by a lid

of the boiler´s body

Thermo well for sensor

and thermostat

Emergency thermostat holder

Automatic boiler for wood pellets

3.2 CONTROL UNIT

Boiler is equipped with the control system with touch screen. This control system enables automatic boiler operation

through the control and regulation features (thermostats, sensors, etc.) in the requested modes. It also enables

Diagnostics mode of control, which can be used for instance for boiler commissioning.

The control system construction and its electrical shielding (IP 45) make safe and reliable operation possible even under

the demanding operational and climatic conditions common to boiler rooms.

Basic configuration Optional configuration

Picture No. 3 Control unit - configuration

Configuration:

Name

Type

Options

Order code

Control unit - boiler function module

HZS 521-G

Standard

Terminal (touchscreen)

HZS 555-S

Standard

Module extension

HZS 532-1

Standard

Module heating circuit / accumulation tank

HZS533

Optional

Module solar

HZS535

Optional

Type and number of circuit

Type and number of module

HC1

SWT

HZS 521-G

HZS532-1

HC1

HC2

SWT

HZS 521-G

HZS532-1

HC1

HC2

HC3

SWT

HZS 521-G

HZS532-1

1 pc

HZS 533

HC1

HC2

HC3

HC4

SWT

HZS 521-G

HZS532-1

2pcs

HZS 533

HC1

HC2

HC3

HC4

HC5

SWT

HZS 521-G

HZS532-1

3pcs

HZS 533

HC1

HC2

HC3

HC4

HC5

ACU

HZS 521-G

HZS532-1

3pcs

HZS 533

HC1

HC2

HC3

HC4

ACU

SOL

HZS 521-G

HZS532-1

2pcs

HZS 533

HZS 535

HC – heating circuit

SWT – sanitary water tank

ACU – accumulation tank

SOL – solar system

Automatic boiler for wood pellets

3.2.1 Boiler Function Module HZS 521-G

The heating system is modularly constructed. The HZS 521-G is a module for the boiler, which communicates with the

CPU module and executes the transmitted instructions. The HZS is a simple component that is used to control automated

processes in a heating system.

All interfaces and connections for controlling of the boiler are located on the control board.

Picture No. 4 HZS 521-G Connector and terminal electronics layout

Ambient temperature sensor

HC1 mix temp

Backwater temp

Sanitary water temp

Exhaust temp

Sanitary water top

Sanitary water bottom

Room thermostat 3

Room thermostat 2

SWT thermostat

Room thermostat 1

Impulse sensor 2

Impulse sensor 1

Room thermostat 4

Antifrost protection

Servo open

Servo close

SWT pump

Bypass pump

Ignition

HC1 pump

Primary fan

Exhaust fan

Feeder 1

Feeder 2

Automatic boiler for wood pellets

The control unit always contains modules HZS 521-G and HZS 532-1.

Picture No. 5 Module HZS 532-1

HZS533 HZS533 HZS535

Picture No. 6 Other modules

Automatic boiler for wood pellets

3.2.1.1 Technical base data

HZS521-G

Supply voltage

230 V AC +/- 10 %

(Input voltage for the power transformer on the power board, input

voltage for the STB, phase for the phase angle, relays and Triac outputs)

Power supply fre-

quency

45 - 65 Hz

Current

consumption of

supply (230 V AC)

Total current consumption 200 mA + current consumption of the

connected loads (max. 16 A)

Power supply transformer

Supply for the power board and CPU electronics

Supply for Heater Lambda sensor: 200 mA

The power supply is switched of STB, L-STB

Loads connected over fuse F4 (3,15 AT):

X11 primary fan: maximum

690 W/ maximum 3 A

Loads connected over fuse F5 (10 AT):

X14

Screw: maximum 690W/ maximum 3 A

Loads connected over fuse F6 (10 AT):

X9 Turbine: maximum 2300 W/ maximum 10 A

Loads connected over fuse F7 (10 AT):

X8 Ignition: maximum 2300 W/ maximum 10 A

Loads connected over fuse F8 (10 AT):

X5 heat exchange cleaner: maximum 690 W/ maximum 3 A

X6 grate open: maximum 690 W/ maximum 3 A

X7 grate closed: maximum 690 W/ maximum 3 A

The power supply not switched over STB, L

Loads connected over fuse

F9 (10 AT):

X10 boiler circuit return flow pump: maximum 2300 W/ maximum 10 A

HZS532-1

Internal

electronics power

supply

+24 V (from HZS 511), must be connected to the expansion

controller

Relay power

supply

230 VAC

Fuse

10 A for relay outputs

+24 V current

consumption

HZS 532-1: maximum 60 mA (without relays) Maximum

120 mA (with relays) HZS 532-1 with 5 expansion modules,

maximum 350 mA

HZS533, HZS535

Internal

electronics power

supply

+24 V (from HZS 511), must be connected to the expansion

controller

Relay power

supply

230 VAC

Fuse

5 A for relay outputs and/or 3 A for solar module

+24V current

consumption

HZS 533 maximum 15 mA (without relays) Maximum 40

mA (with relays)

Automatic boiler for wood pellets

3.2.2 Terminal HZS 555-S with USB

Picture No. 7 Terminal with USB

Description

The HZS 555-S is an intelligent terminal for programming and visualization of automated processes. Process

diagnosis as well as operating and monitoring automated procedures is simplified using this terminal.

A touch screen serves as the input medium for process data and parameters. The output is shown on a 5.7" SVGA

TFT color display.

Cleaning the Touch Screen

CAUTION!

Before cleaning the touch screen, the terminal must first be turned off to avoid unintentionally triggering

functions or commands!

The terminal's touch screen can only be cleaned with a soft, damp cloth. To dampen the cloth, a screen-cleaning

solution such as antistatic foam, water with detergent or alcohol should be used. First spray the cleaning fluid on the

cloth and not directly on the terminal. The cleaning solution should not be allowed to reach the terminal electronics, for

example, through the ventilation slots.

No erosive cleaning solutions, chemicals, abrasive cleansers or hard objects that can scratch or damage the touch screen

may be used.

If the terminal is soiled with toxic or acidic chemicals, quickly and carefully clean the terminal to prevent corrosion.

3.2.2.1 Technical data

Supply voltage

Typically +24 V DC

MIN +18V DC MAX +30V DC

Current

consumption of

voltage supply

Typically 440 mA (pro + 24 V) ,

Maximum 650 mA

Standby

Typically 0.56 W

Starting current

Maximum 25 A for 20 μs

Automatic boiler for wood pellets

Display

Type

5.7" LCD colour display

resolution

VGA 640 x 480 Pixel

Colour depth

18-bit RGB (262K colours)

LCD Mode

TN / normal white

LCD Polarizer

Trans missive

Pixel size

0.18 mm x 0.18 mm

Active surface

115.2 mm x 86.4 mm

Background lighting

LED

Contrast

600

Brightness

Typically 350 cd/m²

Angle CR >= 10

Left, right, below 75°, above 60°

Environmental conditions

Storage temperature

-10 – +85 °C

Operating temperature

0 – 50 °C

Humidity

10 - 90 %, uncondensed

EMV stability

EN 61000-6-2: noise immunity

EN 61000-6-4: noise emission

Vibration - tolerance

EN 600068-2-6

2 - 9 Hz: Amplitude 3.5 mm

9 – 200 Hz: 1 g (10 m/s²)

Shock resistance

EN 60068-2-27

15 g (150 m/s²)

Protection Type

EN 60529 Protected

through the housing

Front: IP54

Cover: IP20

Automatic boiler for wood pellets

3.3 BURNER HEATING CHAMBER INCL. FEEDER F1 WITH INDEPENDENT DRIVE

The heating chamber is depicted in picture Nr. 1 and is comprises of these parts:

4.3.1 The burner body

4.3.2 Feeder F2 including the drive

4.3.3 Impulse sensor

4.3.4 Flexible hose

4.3.5 Primary fan

4.3.6 Electric resistance spiral for automatic ignition

4.3.7 Cover of spiral

4.3.8 Burner grate

Picture No. 8 Burner

The burner body – is a hollow weldment made from highly legated material with a bottom transversal fuel inlet. The

fuel is delivered by a built-in

F2 feeder

driven by an electric motor with a gearbox.

A set of slit and round jets in the burning grill ensures inflow of air in order to facilitate controlled full burning of delivered

fuel during its stay in the burner chamber. The burned out fuel is subsequently pushed over the edge of the chamber into

the ash receiver.

The inner space of the burner body is connected to an

air fan

, whose revolutions can be regulated within a large range

depending on the required boiler output or the type of fuel being used.

Impulse revolution sensor

The gearboxes of the F1 and F2 feeders are equipped with impulse sensors, which ensure safe operation of the boiler.

Connecting hose to the F1 feeder made of inflammable material connect Feeder F1 and Feeder F2. It is part of the

transfer fuel lines. It must meet strict installation rules:

It cannot have significant folds, which would block smooth fuel movement and must be built with inclination of minimum

50º (in a relation to horizontal plane).

Attachment to both adaptors must be tight.

Cleaning burner provides removal of excessive ash or cinder volume from the burner when burning lower

quality fuel. The drive of the cleaning mechanism works together with ash cleaning.

4.3.3

4.3.1

4.3.8

4.3.2

4.3.4

4.3.5

4.3.6

4.3.7

Automatic boiler for wood pellets



Note:

Use of alternate fuels requires change of the burner type and also change of boiler program setup.



Note:

The cleaning mechanism burner drive and its installation are depicted in chapter 4.7 – Cleaning system.

3.4 CERAMIC PARTS

These parts are an inseparable component of the combustion chamber of the boiler and they

have a major influence on the quality of burning.

4.4.1 Ceramic reflector – placed on the top of the burner

4.4.2 Ceramic secondary grate – placed in the boiler body above the burner heating chamber

4.4.3 Ceramic plate – placed above the door

4.4.4 Ceramic door jacketing– mounted on the door, or on the sides of the boiler body (at KP 82)

(See cap. 5.3 – 5.6)

3.5 FEEDER F1 WITH INDEPENDENT DRIVE (FROM FUEL STORAGE)

F1 feeder delivers fuel from fuel storage to the burning chamber. It comprises of a pipe delivery path with an overflow

part and an end sleeve. The feeder is built into the fuel storage under an angle, which cannot exceed 45º. If the angle

was any bigger, fuel could be dispensed inaccurately. The transporter has its own electric drive, which is controlled by

the control unit. The feeder is supplied in various lengths accommodating specific types of storage tanks.

Feeder F1 and F2 gearboxes are equipped with impulse sensors, which ensure safe operation of the boiler.

Feeder F1 set comprises of:

4.5.1 Body of feeder with flange

4.5.2 Axle-less spiral (diameter 38mm in KP 12S, KP 22S, KP 52S; diameter 52mm in KP 62S, KP 82S)

4.5.3 A small bar for mounting of the spiral

4.5.4 Motor and gearbox

4.5.5 Impulse revolution sensor

Automatic boiler for wood pellets

Picture No. 9 Feeder F1

4.5.1

4.5.2

4.5.3

4.5.4

4.5.5

Automatic boiler for wood pellets

3.6 BOILER SHEATHING INCLUDING HEAT INSULATION

The product sheathing is manufactured from steel sheet metal. It is painted with durable paint applied with the powder

painting technology (KOMAXIT), which is highly resistant to outside conditions and ensures long-term perfect look of the

product. Heat insulation 8 cm thick is done with heat insulation ROCKWOL boards.

The sheathing consists of the following parts:

4.6.1. Left side plate – including coverings

4.6.2. Right side plate – including coverings

4.6.3. Upper cover

4.6.4. Front lower cover

4.6.5. Front upper cover

4.6.6. Back cover – including covering

4.6.7. Door cover

4.6.8. Door

Picture No. 10 Jacketing KP 12S

4.6.1

4.6.2

4.6.3

4.6.4

4.6.7

4.6.8

4.6.5

4.6.6

Automatic boiler for wood pellets

3.7 CLEANING SYSTEM

The automatic cleaning system of the boiler significantly affects time of service-free operation of the boiler.

3.7.1 Ash removal

Ash removal is a complex set of technical and program means, which ensure ash removal from burner heating chamber

to external ash receiver in a regular intervals. The ash is taken out by a spiral conveyor. It is driven by an electric motor

through a toothed chain transmission.

The ash removal system can be mounted on the left or on the right side. Assembly of the particular version is done in the

manufacturing facility based on an order. A professional service firm can perform a change (left/right) at the boiler

location.

The motor is connected to the control unit.

3.7.2 Heat exchanger cleaning

Heat exchanger cleaning is a complex set of technical and program means, which ensure removal of solid waste from

warm water boiler exchanger pipes in regular intervals. The cleaning is performed by linear movement of turbulators in

the exchanger pipes. It is driven by an electric motor through a lever gearbox.

The heat exchanger cleaning system can be mounted on the left or on the right side. Assembly of the particular version is

done in the manufacturing facility based on an order. A professional service firm can perform a change (left/right) at the

boiler location.

The drive motor is connected with the control unit.

Picture No. 11 Ash removal system

Automatic boiler for wood pellets

3.7.3 External ash container

The external receiver provides space for long-term ash collection outside the burning chamber. It enables long-term

service-free operation even when using fuel with high ash content. It is attached to the boiler with a detent lever. During

boiler operation the lever must be in the lower position and the connecting piping between the boiler and the ash

receiver must be tight. Also the receiver cover must be tightly closed. Both of these requirements prevent burning fumes

release to the boiler room.

The receiver is removed by moving the detent lever to the upper position and pulling it away from the boiler.

Dispensing of the contents to the waste disposal container is best done by two people because of its weight.

Picture No. 12 Heat exchanger cleaning

Picture No. 13 External ash container

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Ponast KP 12S Service And Operation Manual

Brand: Ponast

Model: KP 12S

Category: Stoves

Type: Service And Operation Manual

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