Kabola B serie - Kuranda Marine
Contents
1. Maximum Misi rum Gentralthermestat Zemmer Tem High low modulation Ge coz 4 3 3 1 d M DANAN N LY 1 2 3 4 B5 T T T8 L 1 T2 83 B4 L 1 T2 83 B 4 Va Main m switch L A B 1 a 3 4 Li N T 2 83 M Reoni Pump 230 VAG themostat 380VAC Black Brown Plug for burner 230 VAG Input Dimensions wiring Power supply 1 1 5 mm thermostat 1 1 5 mm User manual Kabola B serie oktober 2009 17 Appendix E Electrical diagram B8 B45 24V B8 B45 24 VDC Regel thermestaat ST Ss 2 23 9 2005 2 NS thermestaat 2 5 OL 3 HEATING SYSTEMS gt A s Hoofd 2 AT Gees EE L 12 a L T1 16 A 24 VDC 1 2 3 groen geel input rood zwart li N 12 ad al B 10 mm E x 24VDC voeding pomp Diameter bedrading Steker branderautomaat Voeding lengte 0 6 m minimaal 6 mm 6 15 m minimaal 10 mm Kamerthermostaat max 2 x 0 75 mm User manual Kabola B serie oktober 2009 Appendix F Troubleshooting Listed below you will find a list w2. 1 Introduction General Introduction Range application Product description Technical specifications 2 Safety E 2 1 General safety 2 2 Safety instructions 3 Transport and storage 3 1 Transport 3 2 Storage 4 Installing and preparing for first use 4 1 Installation 4 1 1 Fitting the boiler 41 2 Connection of the Central heating system 4 1 3 Flue gas outlet 4 1 4 Electrical installation 4 1 5 Filling the central heating system 4 1 6 Mounting the burner 4 1 7 Connecting the oil filter and oil burner 4 2 Starting your system 5 Operating the boiler 6 Cleaning and maintenance 6 1 Points of attention 6 2 Cleaning and maintenance 7 End of life of the boiler Appendix A Technical specifications Appendix B Parts Appendix C Electrical diagram B8 B70 230V Appendix D Electrical diagram B80 B100 230V Appendix E Electrical diagram B8 B45 24V Appendix F Troubleshooting Appendix G CE declaration User manual Kabola B serie oktober 2009 EE ESO 1 Introduction 1 1 General Introduction Congratulations with your purchase of this Kabola boiler This user manual covers the B Series central heating boilers The B Series central heating boilers cover a wide range of boilers with a broad range of application By purchasing this boiler you have acquired a product which is of high quality through the application of the latest European standards and directives 1 2
3. 35 90 35 90 35 90 50 50 50 HBO 1 HBO 2 diesel of gasolie 92 91 91 89 88 88 3 User manual Kabola B serie oktober 2009 B 80 1165 487 508 314 839 385 858 963 180 180 250 2 B017 1 75 74 4 8 4 309 35 90 50 91 B 100 1165 488 498 314 1050 460 1058 963 200 180 260 2 00 116 3 10 3 445 35 90 50 91 14 Appendix B Parts Listed below you will find the most important parts of the boilers These parts can be ordered from your importer or Kabola Heating Systems stating type and serial number The numbers refer to the image Om RW NA co 10 11 12 13 14 15 16 17 18 24 Room thermostat not shown in picture Boiler top cover Insulation Fibreglass or rock wool thickness App A Cover of boiler Boiler gasket Dashboard Thermometer Boiler thermostat On off switch No lamp in 24 V DC version Maximum thermostat Main connector Pump coupling 1 or bigger Circulation pump Seal Two 1 or bigger Knee inner x outer Different per thread type 1x1 1 1 or 1 x1 Pressure valve pressure gauge fill drain cock T connection Only for B 12 1x7 ak Fire inspection opening Oil burner Comes with flange and gasket Burner mounting plate Gasket for mounting plate Boiler cover side front Boiler cover back Oil filter not shown in picture Following spare parts are available 25 Nozzle max 25um Pmax 6 bar
4. Range application The B Series boilers are designed to generate heat for the heating of water for a central heating system The dimensions of the rooms to be heated have to be taken into consideration These boilers are not designed for direct heating of the rooms in which they are installed 1 3 Product description The B Series boilers heat the central heating water by means of a pressure jet burner which is installed on front of the boiler The standard boilers operate from a 230 volt AC Supply Boilers up to type B45 can also be supplied to operate on a 240 volt DC Supply All B Series boilers work in the same way the only difference is the dimensions and the capacities of the boilers see also the technical specifications in Appendix A As fuel diesel oil or kerosene has to be used At special request there is also a model available which operates on petroleum 1 4 Technical specifications The most important technical specifications are listed on the plate on the front of the boiler More technical details are listed in Appendix A User manual Kabola B serie oktober 2009 4 2 Safety In this chapter we emphasise the safety related points for operating the boiler 2 1 General safety Warning Although Kabola Heating Systems designs and produces its products according to the current safety standards it is possible that dangers may occur which could lead to injuries or damage to the boiler if the safety instructions in thi
5. be required for installation ce such as Cowls Flexible piping Single and double walled chimney pipes SSES Wall and deck flanges Silencers Water traps 4 1 4 Electrical installation Warning Disconnect the power supply from the boiler before you start installing the boiler Only use multiple stranded wire Electrical installation 230 Volts AC When a room thermostat has been supplied with the boiler take the following steps Connecting the room thermostat see figure 5 and electrical scheme in appendix C 1 Remove the cover of the main connector situated below the dashboard 2 Remove if present the wire between point 1 and 2 3 Connect the wires from the room thermostat at T1 amp T2 as Figure 5 pointed at the sticker in the connector Attention The core diameter of the connections mentioned above must be between 1 and 1 5mm The wires should be suitable for the voltage used User manual Kabola B serie oktober 2009 8 Connecting the circulation pump 1 Connect the pump to points L1 and N of the connector under the dashboard 2 Connect the wires at the circulation pump 3 Replace the cover of the main connector Electrical installation 24 Volts DC Warning Never change the pole with pole on the battery See figure 6 1 The connection of the room thermostat is identical to the connection for the 230 Volts version Use figure 6 instead of figure 5 2 Connect the circulatio
6. max capacity 200 I hour total 6000 I max vacuum 0 5 bar Imit TA3 See Appendix A For the yearly maintenance Kabola Heating Systems has compiled a set of spare parts often used during maintenance 26 Service set comprising of 4 23 25 User manual Kabola B serie oktober 2009 15 Appendix C Electrical diagram B8 B70 230V B B70 230 VAC 28 10 2004 W nite Elco casing gt ZN BOLA IG SYSTEMS Beiler Masimumn thermostat thermostat Co CO2 3 1 N Dv wow 1 2 3 4 1 2 Main ri 2 83 B4 _ switch L Ti T2 S3 B4 1 4 3 4 Li N 1 T2 8 B4 Plug with after purge cycle Black Brown E a Aer Plug for burner Pump 230 VAG thermostat 230VAC o o Dimensions wiring Power supply 1 1 5 mm thermostat 1 1 5 mm User manual Kabola B serie oktober 2009 230 VAG input 16 Appendix D Electrical diagram B80 B100 230V 380 B100 230 VAC Vd 28 10 2004 White Elco casing 14 G SYSTEMS
7. maximum allowed length is 6 metres A burner without an after purge cycle can be fitted with a maximum flue length of 2 metres plus the silencer Make sure that the outlet is positioned at a sufficient height above the waterline If this not possible use a swan neck bend in the pipe as in figure 3 User manual Kabola B serie oktober 2009 7 Use hull flanges for installing the flue through a hullside Don t use more than 5 elbows of 90 Every elbow of 90 is comparable to 1 metre of straight pipe When a damper 80x60 is fitted the length of the 60 mm pipe may not exceed 1 metre Vertical flue gas outlet This way of installation is preferable for seagoing boats and sailing boats while these boats encounter bigger angles through waves and while under sail For this kind of flue gas outlet the following are important Install a proper storm cowl on top of the chimney this must stop rain entering figure 3 Install an for boilers bigger Figure 3 than B17 to trap possible water caused by condensation figure 4 Keep the chimney as vertical as possible Don t use more than 5 elbows of 90 The maximum allowed length is 10 metres Every elbow of 90 counts as 1 metre Outside use double walled chimney pipe Hint To reduce the noise resulting from flames it is wise to install a silencer in the horizontal flue and the vertical flue Kabola can provide you with all components which may
8. User manual Kabola B serie Kabola Heating Systems BV Placotiweg 1E 4131 NL Vianen Utr Nederland Preface This user manual is written to enable the safe operation of the B Series central heating boilers The user must read this manual before installation of the boiler and must follow the instructions within this manual Therefore this manual must be kept with the boiler In chapter 2 the safety instructions are detailed which have to be complied with when installing and using the boiler In other chapters you will find safety instructions that can be identified in the following way Hint This gives the user suggestions and advises to facilitate the execution of certain tasks Attention Additional information is supplied to the user and possible problems are indicated Warning Watch out for possible life threatening injuries For any remarks wishes or omissions you can contact Kabola Heating Systems We also welcome any remarks to improve this manual We wish you a lot of pleasure from your purchase Kabola Heating Systems Placotiweg 1E NL 4131 NL Oudewater The Netherlands Phone 31 0 347 320030 Fax 31 0 347 355688 Web www kabola nl E mail info kabola nl Vianen oktober 2009 2005 Kabola Heating Systems Copying of parts of this manual is only allowed with written consent of Kabola Heating Systems User manual Kabola B serie oktober 2009 2 Contents Preface Contents
9. and burner are checked annually by a skilled expert Make sure that before you start any work on the boiler that the system is disconnected from the power supply Make sure that any surplus oil is collected in case of oil spillage We advise you to have any maintenance or repairs carried out by skilled experts User manual Kabola B serie oktober 2009 5 3 Transport and storage 3 1 Transport Take following precautions before transporting the boiler Drain the water from the boiler Uncouple the fuel system Remove the burner see 4 1 5 replacing the burner While transporting the boiler take following precautions Don t damage the boiler use a blanket to cover the boiler Transport the boiler lying down on its back S For the boiler models B 25 onwards use the hoisting eye to move the boiler This hoisting eye is located below the top of the boiler cover 3 2 Storage Take the following precautions when the boiler is stored for a longer period of time Store the boiler and accompanying parts in a dry place Dismount the burner Store the boiler standing up Store the boiler on a firm horizontal base 4 Installing and preparing for first use In this chapter you will find directions and hints for a correct placement and fitting of the boiler and accompanying parts Warning Don t store any flammable and gaseous substances in the room where the boiler is installed This is to ensure that no explosion
10. asten the hand tightened bolts on the mounting plate Attention Take care that the burner pipe is not damaged during installation Repairs to the burner pipe are very expensive and don t fall under warranty User manual Kabola B serie oktober 2009 10 4 1 7 Connecting the oil filter and oil burner Figure 11 To connect the filter to the boiler follow the procedure below see also figure 11 1 Remove the burner cover 1 2 Connect the oil pump 2 to the oil filter 3 using the included fuel hoses Make sure that the flow directions on the pump comply with those on the filter 3 Connect the fuel line from the tank to the filter 5A The fuel line must have a outer diameter of 8mm and must be made from copper or steel The fuel has to be connected directly to the oil tank Correct functioning of the burner can not be guaranteed when a fuel manifold or T connection is installed 4 Connect the plug 4 from the boiler to the burner Hint When the oil tank is situated below the boiler or when the oil supply line comes from below the boiler it is advisable to use a self bleeding oil filter This prevents unnecessary malfunctioning of the burner see figure 12 Figure 12 User manual Kabola B serie oktober 2009 11 4 2 Starting your system When everything is connected follow procedure below 1 Connect the boiler to th
11. by personnel who have read and understood the information in this manual preferably an expert installer or mechanic from Kabola Every week Drain the water from the water trap if installed Every year 1 Clean the boiler 1 1 Remove the burner see 4 1 5 1 2 Remove the burner mounting plate from the boiler 1 3 Remove the top cover of the boiler be careful not to damage the earthing wire 1 4 Remove the insulation 1 5 Remove the 4 bolts on the boiler top 1 6 Remove the boiler top 1 7 Clean the inside of the boiler using a stiff brush 1 8 Clean the space between the pipes with a thin metal strip Attention Don t use any aggressive solvents like thinner or gasoline 1 9 Clean the boiler with a vacuum cleaner 1 10 Replace the boiler top if necessary use a new gasket 1 11 Replace the 4 bolts and fasten these 1 12 Replace the insulation 1 13 Replace the top cover of the boiler make sure the earthing wire is fitted correctly 1 14 Replace the burner mounting plate and remount the burner see 4 1 5 Clean the chimney Clean the watertrap if installed Change the oil filter element Clean the burner see manual of the burner o RON Hint Kabola Heating Systems has a standard set with replacement parts for the yearly maintenance see Appendix B Attention The old oil filter element has to be processed as chemical waste 7 End of life of the boiler When the boiler will be scrapped take note of the points listed bel
12. e gas outlet reduces the lifespan of your boiler considerably and has a negative impact on the efficiency Remember when installing the flue that even the best boiler won t work properly unless the flue is properly installed Warning Because the flue gas temperature lies between 180 240 C it is advisable to insulate the flue with heat resistant material in those parts where contact with human body parts is possible For a correct flue gas outlet the following points need to be observed Use the proper length diameter dimensions use a diameter equal to the diameter of the flue gas outlet on the boiler see also technical specifications Use double walled chimney pipe outside to prevent a rapid cooling of the flue gasses which might result in condensation in the chimney Hint When using a existing chimney of a larger diameter than the diameter on the boiler you can install flexible piping of the correct diameter inside the existing chimney The flue can be installed in several different ways You must carefully consider under which circumstances the boiler will be used For sea going boats and sail boats we advise the installation of a vertical flue where the angles of the boat may be larger The following installation examples are most common Horizontal flue gas outlet It is possible to fit a horizontal flue gas outlet to the boiler The following points need to be observed When a burner with an after purge cycle is used the
13. e power supply the earthed outlet for the 230V version and the battery for the 24 V DC version 2 Switch the boiler on with the on off switch on the dashboard The lamp in the switch will indicate that the system is active This lamp is not present in the 24 V DC version Set the required boiler temperature between 55 and 90 C using the boiler thermostat Set the room thermostat so that it is switched on See manual of the room thermostat Start the oil burner figure 11 5 1 Open the valve of the fuel tank 5 5 2 Open the valve on the oil filter 5A 5 3 Install the bleeding hose 3C on the bleeding opening of the filter 5 4 Start the oil burner 5 5 The burner switches on when the burner is fitted with a pre heating element this will take 1 5 minutes 5 6 Open the bleeding valve on the oil filter 5 7 Check if oil is coming out of the hose 5 8 Check all oil connections for leakage s 5 8 1 When the burner won t start the control light 8 will light 5 8 2 close the bleeding valve on the filter 5 8 3 Wait approximately 3 minutes 5 8 4 reset the burner by pushing button 8 and return to 5 4 repeat if necessary 5 9 Close the bleeding 3B when only oil and no bubbles come out of the hose Attention The oil burner is tested by the manufacturer adjusted The adjustment of the burner has to be done by an experienced installer because this requires expert knowledge To be eligible for warranty the boiler
14. has to be adjusted by an approved installer Contact Kabola Heating Systems or your importer to make an appointment Never adjust the burner using your own initiative A correctly adjusted burner shows a clear white flame which is visible through the inspection opening 6 5 Operating the boiler When the boiler has been started and adjusted according to 4 2 operation of the boiler is very simple The required temperature is set with the room thermostat which regulates the boiler The operation of the thermostat is explained in the manual of the room thermostat If problems arise with the operation of the boiler you will find a list of possible problems and solutions in Appendix D 6 Cleaning and maintenance 6 1 Points of attention Spare parts must be ordered through your importer dealer or from Kabola Heating Systems For warranty purposes only original spare parts may be used When ordering spare parts mention the type of the boiler and its serialnumber Kabola Heating Systems will then be able to deliver the correct parts In Appendix B the main spare parts are listed User manual Kabola B serie oktober 2009 12 6 2 Cleaning and maintenance Warning Maintenance and repairs should only take place when the boiler is switched off this is because the boiler might start unexpectedly Take the plug from the wall socket Disconnect the power supply for the 24 Volt version Warning Maintenance and repairs may only be performed
15. ith possible problems their reasons and solutions When you encounter problems not listed you should contact your dealer Never try solve problems on your own Problem Possible reason Possible solution Burner won t start Oil supply interrupted Bleed the oil filter Change contaminated filter element Fill the oil tank Power supply interrupted Check the fuses Check the power supply Burner stops Reset burner Flame protection dirty photo cell Clean glass of flame protection Flame protection defect photo cell Replace flame protection Burner starts pulsing Flue glass flow interrupted Clear chimney opening Boiler dirty Clean boiler Oil supply interrupted See above Nozzle defect Replace nozzle Burner shows error Reset burner Low voltage Check voltage level Oil supply interrupted See above Boiler does not react to Wire in main connector has not Remove wire from main thermostat been removed room thermostat connector Boiler thermostat incorrect adjusted Adjust boiler thermostat Battery of room thermostat empty Replace battery Water is not pumped Pump couplings are closed Open pump couplings Pump not connected to power supply Connect pump Rotor of pump is stuck Turn pump with your hand see manual pump User manual Kabola B serie oktober 2009 19 Appendix G CE dec
16. laration Kabola Heating Systems Populierenweg 41 3421 TX Oudewater Nederland KABOLA heating systems EC declaration of conformity Kabola Heating Systems Populierenweg 41 3421 TX Oudewater Nederland declare under our own responsability that the product Branderketel Kabola B8 12 17 25 35 45 55 70 to which this declaration relates complies with the following standards EN 303 1 EN 303 2 EN 304 EN 50081 1 EN 50082 1 EN 61010 following the provisions of the following EC directives 73 23 EEG 89 336 EEG 92 42 EEG amended by 93 68 EEG Nederland Oudewater 1 4 2005 ee Alles Directeur User manual Kabola B serie oktober 2009 20
17. n pump to points 3 and 4 of the main connector 3 The core diameter of the wires to points 5 and 6 of the connector should conform to the values in table 1 Table 1 Distance to the batte en 4 1 5 Filling the central heating system The pressure in the system should e Never be lower than 0 5 bar cold Never be higher than 2 5 bar hot Follow the procedure listed below for filling the CH system see figure 7 1 Switch off the boiler 2 Turn the coupling nut below the pressure indicator to loosen it 3 Pull the hose connection a little downwards 4 Connect the hose with a hose clamp to the connection 5 Fill the system slowly with water until the pressure indicator indicates a pressure of 2 bar 6 Fasten the coupling nut T Bleed the CH system 8 If necessary fill with water again up to 2 bar of pressure 9 Switch on the boiler and let the pump run for about 5 minutes 10 Switch off the boiler 11 Check the water pressure if it is too low repeat steps 5 through to 10 12 Remove the hose Hint The CH system can be filled with cooling fluid suited for CH systems pH value 8 5 Bleeding the circulation pump Figure 8 User manual Kabola B serie oktober 2009 9 The circulation pump can only be bled when the electrical circuit is connected because this has to be done with a running pump Follow the points listed below to bleed the pump see figure 8 1 Check if the rotor can r
18. otate without problems by turning the pump by hand see manual pump 2 Loosen the screw on front of the pump to 1 turn with a screw driver 3 Fasten the screw when water comes out ofthe opening 4 The pump is bled Attention when locking pump couplings which are supplied with the boiler the adjusting grooves must point towards the pump see figure 9 4 1 6 Mounting the burner Hint Check if the inspection opening on the mounting plate can be reached If this is not the case the mounting plate can be turned 180 to reach the opening easier Fora B12 you need to saw an extra piece off the flange The mounting of the burner is done in the following way 1 Place the nut for the flange bolt in the dedicated position and place the gasket 2 Mount the flange with the 4 supplied M8 bolts hand tighten on the mounting plate The arrow on the flange should point upward Hint Smear some sealant in the crack in the flange to seal 3 3 1 Measure and set the distance from the back of the gasket mounted behind the mounting plate to the J front of the flange using the table below and figure 10 ZN Boiler type B25 B35 B45 155 155 sd B55 B70 B80 B100 3 2 Scribe the distance on the pipe 3 3 Push the burnerpipe gently in place up to the scribed Figure 10 position see figure 10 4 Lift the burner a little figure 11 according to 7A 5 Fasten bolt 7 figure 11 on the flange to clamp the burner 6 F
19. ow Process the oil filter and the oil hoses as chemical waste Separate the metal from the plastic parts and dispose them separately Process any excess oil in an environmentally friendly way Transport the boiler according to the instructions in chapter 3 Recycle this manual User manual Kabola B serie oktober 2009 13 Appendix A Technical specifications 4 ype IOTMOOU gt Flue gas Fluegas temp C C H connection IP value Burner 230 V 24V Nozzle 60 Nom Capacity KW min max Max oil consumption kg h Testpressure in bar Operating pressure in bar Weight in kg Water volume in Temperature control range Isolation thickness in mm Fuel Burning efficiency in 96 Waterside efficiency 96 Standby loss CF B 25 970 455 115 466 283 388 385 396 753 100 180 220 5 4 2 B012 3 C015 0 85 19 7 3 3 118 35 90 50 92 B 35 970 455 115 468 284 491 70 385 503 754 125 180 230 1 2 B013 3 C016 1 00 29 40 7 3 7 5 3 140 23 35 90 50 92 89 B 45 B 55 B 70 970 970 1165 445 485 487 125 125 488 498 508 284 384 314 580 697 699 70 70 70 385 385 385 593 708 708 754 759 961 150 150 180 180 230 180 240 180 240 1 2 2 50 11 2 B014 2 B014 2 B016 3 C017 1 25 1 50 1 75 40 7 51 1 63 9 52 3 63 9 81 4 5 2 6 5 75 5 5 5 3 3 3 155 178 270 26 36 55
20. s manual are not complied with The user must Have read and understood the chapter safety Avoid any actions which may lead to hazards to his health or others Avoid any actions which may lead to damage to the boiler Ensure that the boiler is only used when the boiler is in sound technical condition Ensure that the safety regulations are observed whilst operating the boiler Attention No alterations to the boilers may be done without the explicit written consent of Kabola Heating Systems 2 2 Safety instructions The safety instructions listed below must be complied with when operating the B Series boilers Measures for a safe installation Don t store any flammable and or gaseous products in the room where the boiler is installed to avoid explosions and fires Install the boiler in a non humid environment on a firm horizontal base Ensure that there is sufficient ventilation in the room where the boiler is installed See also 4 1 1 Make sure before you start connecting the boiler that the system is disconnected from the power supply Only use multiple stranded wire for electrical connections Don t change the pole with the pole of the battery for the 24 Volt DC version Measures for a safe operation Never change the settings of the burner Don t use any aggressive solvents which may affect the boiler like gas or turpentine Don t damage the fire bricks E Make sure that the boiler
21. s or fires can occur Geif 4 1 Installation 4 1 1 Fitting the boiler Install the boiler in a dry place Install the boiler on a firm horizontal base Make sure there is sufficient supply of fresh air in the room where the boiler is installed see hint below Hint As a rule of thumb for the ventilation openings take 2 5 times the diameter of the flue gas outlet GE E To avoid movement secure the base of the boiler by Figure 1 means of spotwelds or with nuts and bolts Keep a minimum distance of 250mm behind the boiler for the flue gas outlet see figure 1 Use a earthed plug socket for connecting the 230 V AC versions to the power supply User manual Kabola B serie oktober 2009 6 4 1 2 Connection of the Central heating system Piping Take note of the following points when installing the piping Install the piping in such a way that the boiler cover and dashboard remains accessible Provide enough bleeding points in places where air might collect Attention Install a automated bleeding valve near the boiler Connect the piping to the boiler as follows see figure 2 1 Install the feeding to CH at point A 2 Install the return of the CH on point C Hint Install a shunt with pressure equaliser when thermostatic radiator valves are applied 4 1 3 Flue gas outlet General Figure 2 The flue gas outlet is an essential part of your heating installation An incorrect flu
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