Kabola HRE serie
Contents
1. User manual HRE serie version 6 November 2013 Letter HRE300 HRE400 HRE500 A 380 460 505 B 330 330 330 C 354 370 370 D 61 75 185 E 298 298 306 F 360 392 467 G 242 242 242 H 344 344 344 140 140 140 J 75 75 75 Technical specifications HRE300 HRE400 HRE500 Flue gas mm 60 80 80 C H connection mm 22 22 22 Max capacity kW 8 10 10 14 20 Service pressure Bar 2 2 2 Working pressure Bar 3 3 3 Weight Kg 60 70 81 Exhaust gas temp Max 230 230 230 Efficiency 90 90 90 Max length horizontal max mir 5 5 5 Power consumption 230V Power consumption 230V starting load W 740 740 740 Operating load 230V W 230 230 230 Fuel Diesel Diesel Diesel 16 Appendix B Electrical diagram 230 V FRE serie 230V Intercal SLV100B Room Pump 230 VAC demen 230VAC Dimensions wiring Power supply 1 1 5 mm thermostat 1 1 5 mm User manual HRE serie version 6 November 2013 KABOLA HEATING SYSTEMS Plug for burner 230 VAC input Appendix C Troubleshooting Listed below you will find a list with possible problems their reasons and solutions When you encounter problems not listed you should contact your dealer Never try to solve problems on your own Problem Possible reason Possible solution Burner will not start Bleed th2. User manual Kabola HRE 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 HRE 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 Vianen The Netherlands Phone 31 0 347 320030 Fax 31 0 347 355688 Web www kabola nl E mail info kabola nl Vianen November 2013 2013 Kabola Heating Systems Copying of parts of this manual is only allowed with written consent of Kabola Heating Systems User manual HRE serie version 6 November 2013 2 Tab
3. VVVVVVV User manual HRE serie version 6 November 2013 9 4 1 5 Electrical connection Warning Disconnect the power supply from the boiler before you start the installation The quality of 230 VAC power supply to the boiler should be as good as the power supply from a land line Figure 5 Connecting the room thermostat Figure 5a amp 6 For connecting the room thermostat you must use a wire with 2 cores 0 75 mm isolated hose The room thermostat you need to connect at the following way gt Remove the lid from the connector A figure 5a what is mounted at the back of the dashboard gt Connect the wires from the room thermostat as pointed at the sticker in the connector Figure 5a Connecting the circulation pump figure 5 amp 5a and vane appendix C 1 Remove the lid from connector A and connect the wires from the circulation pump as pointed at the sticker in the connector 2 Don t forget the earthing 3 Close the lid from the connector O Figure 6 User manual HRE serie version 6 November 2013 10 4 1 6 Filling the central heating system The pressure in the system should gt Never be lower than 0 5 bar cold gt Never be higher than 2 5 bar hot Follow the procedure below for filling the CH system see figure 7 gt Switch off the boiler gt Remove nob 4 gt Screw the adaptor 3 at the thread gt Connect the filling tube at 3 and open 5 by t
4. 1 Transport Take following precautions before transporting the boiler gt Drain the water from the boiler gt Uncouple the fuel system gt Remove the burner see 4 1 5 replacing the burner While transporting the boiler take following precautions gt Don t damage the boiler use a blanket to cover the boiler gt Transport the boiler standing up 3 2 Storage Take the following precautions when the boiler is stored for a longer period of time gt Store the boiler and accompanying parts in a dry place gt Dismount the burner see 4 1 7 gt Store the boiler standing up gt Store the boiler on a firm horizontal base User manual HRE serie version 6 November 2013 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 H Warning Do not store any flammable or N i gaseous substances in the room where the boiler installed This is to t t ensure that no explosions or fires can occur lect ms 4 1 Installation 4 1 1 Fitting the boiler gt Install the boiler in a dry place H gt Install the boiler on a firm horizontal base gt Make sure there is sufficient supply of fresh air in the room where the boiler is installed see hint below gt To avoid movement secure the base of the b
5. Appliance type Bay Apeldoorn 28 Febru TSASTE lt Certification M L D an Rij eneral Manager Wimmsor 50 1 FART AT Apeldoorn HINE The Netherlands Ivat m User manual HRE serie version 6 November 2013 Hil VO JE 23
6. ations 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 In this chapter we emphasizes the safety related points for operating the boiler MEASURES FOR A SAFE INSTALLATION Vv VVV Vv 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 multi stranded wire for electrical connections MEASURES FOR A SAFE OPERATION VV VVVVV Never change the settings of the burner Don t use any aggressive solvents which may affect the boiler like petrol or turpentine Insulate the chimney when it can be touched by body parts Make sure that the boiler 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 form 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 HRE serie version 6 November 2013 5 3 Transport and storage 3
7. burner cap a 18 Photo cel 4 D037 19 Motor 20 Motor cable 21 Oil pump 35 015 22 Cable with connector for magnetic valve 4 D093 23 Magnetic coil for oil pump 35 016 23 Filter for oil pump 35 017 24 Pressure cupper pipe 25 Nozzle rod with pre heat 26 Cable for pre heat 5 E015 27 Baffle plate 35 009 28 Ignition pin 35 010 29 Fan 30 Burner cap 31 Oil hoses 35 018 User manual HRE serie version 6 November 2013 21 Appendix F EG declaration EC declaration of conformity Kabola Heating Systems BV Placotiweg 1 E 4131 NL Vianen The Netherlands declare under our own responsibility that the product Kabola HRE300 HRE400 HRE500 230 V to which this declaration relates complies with the fol owing standards EN 303 1 EN 303 2 EN 304 EN 50081 1 EN 50082 1 EN 61010 fol owing the provisions of the fol owing EC directives 73 23 EEG 89 336 EEG 92 42 EEG amended by 93 68 EEG Nederland Vianen 2 9 2010 De ree P Al es Director User manual HRE serie version 6 November 2013 22 Appendix G CE certification Number E 4008 0063 Gastec Certification B V hereby declares that the Heating boiler with forced draught burner type HR 400 made by Kabola Heating Systems B V in Oudewater The Netherlands meets the essential requirements as described in the Directive on efficiency requirements 92 42 EEC PIN 0063803246 Report number 176246
8. der warranty 4 1 8 Mounting the oil filter and oil burner To connect the filter to the burner follow the procedure below see also figure 9 gt Remove the burner cover from the oil burner 1 gt 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 gt Connect the fuel line from the tank to the filter 5A The fuel line must have an outer diameter of 8 mm and must be made from copper or steel The fuel line Figure 10 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 gt 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 The articlenumber 4 D133 figure 11 standard the 4 D131 figure 12 is supplied with the set This prevents unnecessary malfunctioning of the burner In the manual of the burner you will find an overview with the allowed dimensions of the oil supply line Figure 11 User manual HRE serie version 6 November 2013 12 4 2 Starting your system When everything is connected follow the procedure below 1 Connect the boiler to the power supply The 230 VAC will need to be connected for the 230 VAC Switch the boiler on with
9. e 230 VAC versions Warning Maintenance and repairs may only be performed by personnel who have read and understood the information in this manual preferably an expert installer or a service engineer from Kabola Heating Systems Every year 1 Clean the boiler 1 1 Remove the burner see 4 1 5 1 2 Remove the burner from the boiler 1 3 Open the door of the boiler 1 4 Remove the insulation 1 5 Clean the inside of the boiler using a stiff brush Attention Don t use any aggressive solvents like thinner or gasoline 1 6 Clean the boiler with a vacuum cleaner 1 7 Replace the door if necessary use a new isolation 1 8 Replace the burner 2 Clean the chimney 3 Change the oil filter element 4 Clean the burner see manual of the burner Attention The old oil filter element has to be processed as chemical waste 7 End of life of the boiler When the boiler is scrapped take note of the points listed below Process the oil filter and the oil hose as chemical waste Separate the metal from the plastic parts and dispose off 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 HRE serie version 6 November 2013 15 Appendix A Technical specifications Boiler dimensions
10. e oil filter Change contaminated filter element Fill the oil tank Power supply interrupted Check the fuses Check the power supply Check the maximal thermostat Burner stops os ee Resetburner once Flame protection defect Replace flame protection photo cell Burner starts pulsing Burner shows error I Resetburer once Oil supply interrupted Boiler does not react to thermostat Boiler thermostat incorrectly Adjust boiler thermostat adjusted Battery of room thermostat flat Replace batter Water is not circulating Pump couplings are closed Open pump couplings Pump not connected to electricity Connect pump supply User manual HRE serie version 6 November 2013 18 Appendix D Boiler parts ieee y Ee HR SERIE SS n al hes Dan R G u x o a en ed EM 67 3 N rar UEL wr HE SN a i N 17 18 19 20 21 Pos Discription Article number 1 Dashboard HRE serie 230V 9 1138 2 Insulation Rockwoll 25 mm 3 Conversion coupling 1 int x 22mm 17 R161 4 Locking pump coupling 1 9 1023 5 Circulation pump 230V Kabola h 130 mm 9 1129 6 Conversion coupling 1 int x 22mm 9 1023 7 Pipe nipple 1 x 40 mm 18 S481 8 Knee 221 1 18 S482 9 Reducing ring 1 x 1 2 ext x int 18 S297 10 Pipe niple 1 2 x 120 mm 18 S483 11 Fill drain pressure relief valve wivakom 9 1015 12 Stainless steel efici
11. ency tube HRE300 400 14 N219 12 Stainless steel eficiency tube HRE500 14 N225 13 Insulation door 294 x 294 x 20 mm HRE300 9 1081 13 Insulation door 300 x 300 x 20 mm HRE400 9 1082 13 Insulation door 355 x 300 x 20 mm HRE500 9 1096 14 Door gasket cord HRE serie 15 mm per m 9 1083 15 Insulation door 276 x 276 x 15 mm HRE300 9 1084 15 Insulation door 282 x 282 x 15 mm HRE400 9 1085 15 Insulation door 282 x 338 x 15 mm HRE500 9 1097 16 Door HRE300 9 1086 16 Door HRE400 9 1087 16 Door HRE500 9 1120 17 Door mounting knob HR series 9 1089 18 Isolation burner Kabola SLV100B 35 007 19 Burner fixing flange Kabola SLV100B 35 035 20 Mounting clamp HRE series 9 1088 21 Kabola SLV100B burner HRE300 230V 2 B023 21 Kabola SLV100B burner HRE400 230V 2 B024 21 Kabola SLV100B burner HRE500 230V 2 B025 User manual HRE serie version 6 November 2013 19 Appendix E Burner parts User manual HRE serie version 6 November 2013 20 Pos Discription Article number 1 Casing bumer house 2 Air intake 5 3 Air intake casing 4 Flame tube 5 Burner fixing flange 6 Isolation burner 7 Air flap 10 Lid burner casing 11 Burner transformator 12 Ignition cable with connector 35 041 13 Burner automat Siemens LMO24 14 7 Pole connector 4 D164 15 Adjust mutter 16 Fixing mutter 17 Pilar
12. le of contents Preface Table of contents 1 Introduction 1 1 General 1 2 Range of application 1 3 Product description 1 4 Technical specifications 2 Safety 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 4 1 2 Connection to the central heating system 4 1 3 Flue gas outlet 4 1 5 Electrical connection 4 1 6 Filling the central heating system 4 1 7 Mounting the oil burner 4 1 8 Mounting the oil filter and oil burner 4 2 Starting your system 5 Operating the boiler 5 1 Explanation of the dashboard 6 Cleaning and maintenance 6 1 Points for attention 6 2 Cleaning and maintenance 7 End of life of the boiler Appendix A Technical specifications Appendix B Electrical diagram 230 V Appendix C Troubleshooting Appendix D Boiler parts Appendix E Burner parts Appendix F EG declaration Appendix G CE certification User manual HRE serie version 6 November 2013 oo 0 NNNODONAAAN RAA AARON 1 Introduction 1 1 General Congatulations with your purchase of this Kabola boiler This user manual covers the HRE series The HRE boilers cover a wide range of boilers with a broad range of applications 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 Range of application The HRE boilers with are desig
13. ned 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 boilers of the HRE series heats the boiler water by means of a pressure jet burner which is installed at the front of the boiler The boilers are available in 230 VAC For fuel diesel oil has to be used 1 4 Technical specifications The most important technical specifications are listed on the plate at the back of the boiler More technical details are listed in Appendix A User manual HRE serie version 6 November 2013 4 2 Safety In this chapter we emphasizes 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 present themselves which could lead to injuries or damage to the boiler if the safety instructions in this manual are not complied with The user must gt gt gt gt gt Have read and understood the chapter safety Avoid any actions which may lead to dangers 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 regul
14. not possible use a swan neck bend in the pipe as in figure 3 Use the correct hull fittings for installing the flue through a hull side The maximum allowed length is 5 meters Don t use more than 3 elbows of 90 Every elbow of 90 is equivalent to 1 meter straight pipe vvv WV Figure 3 VERTICAL FLUE GAS OUTLET This way if installation is preferable for seagoing boats and sailing boats because these boats encounter large angles of heel through waves and under sail For this kind of flue gas outlet the following points are important gt Install a proper storm cowl on top of the chimney this must stop rain from entering figure 4 Install deck fittings for installing the flue through a deck Install a water trap to drain possible water caused by condensation Keep the chimney as vertical as possible Don t use more than 3 elbows 90 The maximum allowed length is 7 meters Every elbow of 90 counts as 1 meter Use outside double walled chimney pipe VVVVV vv Hint To reduce the noise from flames it is wise to install a silencer in the flue Your Kabola supplier can provide you with all components which may be required for installation such as Figure 4 Cowls Flexible piping Single and double walled chimney pipes Hull and deck fittings Silencers Water traps Insulation
15. oiler by using the holes with M5 threat in the feet from the boiler gt Keep a minimum distance of 250 mm behind the boiler for the flue gas outlet see figure 1 ON ee gt Use an earthed plug socket for connecting the 230 Volt AC versions to the power supply Figure 1 Hint As a rule of thumb for the ventilation openings take 2 5 times the diameter of the flue gas outlet User manual HRE serie version 6 November 2013 7 4 1 2 Connection to the central heating system PIPING Take note of the following points when installing the piping gt Install the piping in such a way that the boiler cover and dashboard remains accessible gt Provide enough bleeding points in places where air may collect especially near the boiler Attention Install a bleeding point near the boiler especially when the piping does not go up Connect the piping to the boiler as follows see figure 2 1 Install the feed from the CH at point 1 2 Install the return of the CH at point 2 Figure 2 Hint Install a shunt with pressure equalizer when thermostatic radiator valves are applied 4 1 3 Flue gas outlet GENERAL The flue gas outlet is an essential part of your heating installation An incorrect flue 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 ins
16. talled Warning Because the flue gas temperature lies between 180 240 C it is advisable to insulate the flue with heat resistant material on those parts where contact with human body parts is possible For a correct flue gas outlet the following points need to be observed gt Use the proper diameter use a diameter equal to the diameter of the flue gas outlet on the boiler see also technical specification gt Use double walled chimney pipe outside to prevent a rapid cooling of the dlue gasses which may result in condensation in the chimney Hint When using an existing chimney of a larger diameter than the diameter on the boiler you can install flexible piping of the correct diameter insides the existing chimney Warning It is necessary that condense water always can flow back to the drain or the boiler avoid water bags User manual HRE serie version 6 November 2013 8 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 heel 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 gt Make sure that the outlet is positioned at a sufficient height above the waterline If this is
17. the on off switch on the dashboard The lamp in the switch will indicate that the system is active 2 Set the required boiler temperature between 65 and 90 C using the boiler thermostat 3 Set the room thermostat so that it is switched on see manual of the room thermostat 4 Starting of the oil burner see figure 10 4 1 Open the valve in fuel line 5 4 2 Install the bleed hose 3C on the bleed opening of the oil filter 4 3 Open the valve on the oil filter 5A 4 4 Start the oil burner 4 5 The burner switches on this will take approximately 1 5 minutes because of the oil pre heating element 4 6 Open the bleed valve on the oil filter 3B 4 7 Check if oil is coming out of the hose 3C 4 8 Check all oil connections for leaks 4 8 1 f the burner does not start the control light will light Figure 12 4 8 2 Close the bleed valve 3B on the oil filter 4 8 3 Wait approximately 3 minutes 4 8 4 Reset the burner by pushing button and return to 5 4 repeat if necessary 4 9 Close the bleed valve 3B when only oil and no bubbles come out of the hose Attention The oil burner is tested by the manufacturer not 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 has to be adjusted by an approved installer Contact your Kabola supplier to make an appointment Never adjust the burner using your own initia
18. tive 5 Operating the boiler When the boiler has been started and adjusted according to 4 2 operation fo the boiler is very simple The required temperature is set with the room thermostat which controls the boiler The calorifier thermostat controls the boiler The operation of the room 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 C User manual HRE serie version 6 November 2013 13 5 1 Explanation of the dashboard Figure 13 Explanation from the number in the figure 13 Fuse holder with a glass fuse 10A 230V On off switch Analogue display for boiler temperature Adjust nob for boiler temperature Reset nob maximal thermostaat MOO W gt User manual HRE serie version 6 November 2013 14 6 Cleaning and maintenance 6 1 Points for attention Spare parts must be ordered through your Kabola supplier For warranty purposes only original spare parts must be used When ordering spare parts state the type of boiler and its serial number Your Kabola supplier will then be able to supply the correct parts In Appendix B the main spare parts are listed 6 2 Cleaning and maintenance Warning Maintenance and repairs should only take place when the boiler is switched off this is because the boiler may start unexpectedly Take the plug form the wall socket for th
19. urning it Figure 7 gt Fill the system slowly with water until the pressure indicator indicates a pressure of 2 bar gt Close the valve 2 gt Bleed the CH system gt If necessary fill with water again up to 2 bar of pressure gt Switch on the boiler and let the pump run for about 5 minutes gt Switch off the boiler gt Check the water pressure if it is too low repeat steps 5 through 10 gt 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 See instruction manual Attention When locking pump couplings are supplied with the boiler the adjusting grooves must point towards the pump Figure 8 User manual HRE serie version 6 November 2013 11 4 1 7 Mounting the oil burner Follow the instruction below for mounting the oil burner gt Passionate the insulation 2 and the burner clamp 3 that they are in one line with the mounting holes in the door gt Assemble the burner clamp with the 4 M8 bolts The arrow at the burner clamp must point to the top Hint Smear some sealant in the crack in the flange to seal gt Slide the burner trough the burner clamp and push it as far as possible gt Fasten the screw from the burner clamp what is clamping the burner Attention Take care that the flame tube is not damaged during installation Repairs to the flame tube are very expensive and don t fall un
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