kalvis-5
Contents
1. CENTRAL HEATING SOLID FUEL BOILER KALVIS 5 16 10 5 20 5 30 KALVIS 5 16 10 W 5 20W 5 30W USER S INSTALLATION AND OPERATION MANULA SG 71 LST EN 303 5 9817 95 IST 144948958 13 2004 ATTENTION Get acquainted with this technical certificate before installing the boiler It shall help you to mount and operate the boiler as efficiently as possible 1 Basic engineering data Central heating solid fuel boiler Kalvis 5 Kalvis 5 W hereinafter referred to as the boiler is used for heating various premises where central heating system with natural or forced circulation 15 arranged Boiler has a socket for mounting 3x1 5 3x2 kW electric heating devices with 2 thread with temperature control and emergency thermostats or without them devices not included 25 24 26 1 Ash tray 2 Cast iron door 3 Exhaust damper 4 Servicing covers 5 Hot water pipe 6 Insulating shields 7 Draught adjuster amp Thermomanometer 9 Draught damper 10 Ignition damper 11 Fuel loading door 12 Refractory bricks 13 Secondary air pipe 14 Secondary air damper 15 Fire grate 16 Return water pipe 17 Drainage pipe 18 Air supply damper 19 Servicing door 20 Electric heating 21 Exhaust damper s handle 22 Ignition damper s handle 23 Removable_ refractory brick only for 5 16 10 and 5 16 10 types 24 temperature sensor 25 Cooling water suppl2. ANTWA TUAYAAO SNILVSH YALVM AYVLINYVS TOYNLNOD IVLSOWYAHL LOVLNOD AYVLINVS WALSAS OL J 100 137 Q YUD ADM DUAYIS Wajsds 1920 BY Ip WOU gt lt gt A JAVA 148 9 09 WALSAS OLNV 1 AWM 33 OL OLLWLSOWYSHL WALSAS 1 21519913 T4340 6 4 TOYLNOD o TOULNOD X04 LIVLSOWYSAHL IVLSOWYSHL LOVWLNOOD LOVLNOD 5 WALSAS OL V v 2 A LA yalsnrav _____ Be ee YALVM AYVLINVS 102 ANY IONLNOD gt lt gt noose WALSAS ONILVSH AYVLINVS LNO 137 KALVIS 5 W 2009 05 18 ad KALVIS 5
3. V2 Pipe location dimensions mm G Weight K 5 K 5 W not greater than kg 18 20 moist content birch wood 226 249 245 242 180 178 176 230 x 2 92 1160 1370 1370 530 530 640 980 980 1000 G1 4 B G2 B 0158 178 x 178 G 4 B 243 248 283 288 400 405 Firing boiler with wood that has more than 30moist content is not recommended x With refractory brick p 23 1 fig in combustion chamber For the boilers with installed emergency cooling KALVIS 5 KALVIS 5 W EN 2009 05 18 2 Design description Due to constant development of design minor inconsistencies with the manual are possible Boiler frame is welded from special sheet steel has water cavities where water is heated see 1 fig Internal boiler frame is made of 6 mm thick steel external 3 mm Exterior of the boiler 15 covered with insulating shoelds p 6 On the front side of the boiler there is a draught adjuster p 7 that controls the air supply damper p 18 thermomanometer p 8 door p 19 beyond which there are cast iron doors p 2 and an ash tray p 1 Loading chamber is closed by the door p 11 Inside the frame there is an exhaust damper p 3 and ignition damper p 10 that open up the flue way directly into the chimney and that are used when fuel is ignited or adding more fuel intot he boiler also there is a fire grate p 15 and a secondary air pipe p 13
4. Address Phone Foreman name last name signature Company Address Phone Manufacturer UAB Siauliy tauro kalvis Pramones 15 LT 78137 Siauliai Lithuania Phone 370 41 540556 E mail prekyba kalvis It Basic engineering data Boiler type Fuel used Fuel combustion duration val at nominal output at minimm output Efficiency at nominal output not less than Boiler grade according to EN 303 5 W K 5 16 10 K 5 20 K 5 30 K 5 16 10 W K 5 20W K 5 30W Area heated when the thermal resistance of 60 120 100 200 120 280 200 400 the building is 2 5 m Fire wood waste wood saw dust and peat briquettes coal Wood size L x iki cm 37 x 10 40 x 10 Combustion chamber volume dm 1 pS 8 2 5 2 8 2 8 4 8 4 0 4 8 4 8 Fuel used per heating season 10 16 15 20 20 25 3 ater volume in the boiler Water pressure in the boiler not greater than MPa kgf cm Maximum permitted water temperature in the boiler C Minimal return water temperature during operation C Temperature adjuster control range C Parameters for the cooling water used to remove excessive heat pressure bar temperat C 0 15 1 5 Minimum chimney draught Pa Exhaust at nominal output at minimum output H Overall dimensions mm B L M G Connection pipe s dimensions Cooling pipe s dimensions D
5. C and the temperature of the water supplied into the cooling loop at 2 21 min is 15 C water in the cooling loop upon exit warms up to 42 C But when the water flow is increased up to 5 l min temperature upon exit reaches only 32 C In order to use the cooling loop for whot sanitary water preparation it is necessary to know that the temperature upon exit depends on Boiler water temperature Temperature of water upon entrance into the cooling loop and the amount of hot water used 1 the water flow through the cooling loop 4 5 Requirements for electric connection If electric heating devices are installed e Electric heating devices may be installed into the boiler when boiler was connected to the system according to fig 4a e Only a qualified and licenced electrician may install the heating devices e Installation works should be performed according to the prepared project assuming the total output of the main Recommended electric heating device connection schema 15 shown on fig 5 Heating device fixing thread G2B L 400 Recommended electric heating device connection schema 0 Protection valve Other symbols o 5 SANITARY WATER WATER HEATER AIR LET OUT KALVIS 5 KALVIS 5 W EN 2009 05 18 Auto air let out Thermostatic valves may Return damper gt lt Closing damper
6. In the secondary combustion chamber there are refractory bricks p 12 that maintaint he high temperature of combustion Below the shields p 6 there is a servicing cover p 4 which allows access for cleaning of boiler internal surfaces On the side walls of the boier there are secondary air control dampers 14 On the backside of the boiler there is a drainage pipe p 17 return p 16 and hot p 5 water pipes smoke outlet with a draught damper p 9 On the side wall of K 5 W there are pipes for the emergency cooling In the hole p 24 4 B a bushing with the temperature sensor is mounted Water from the main is connected into pipe p 25 pressure 4 2 bar p 26 is for removanl of heated water Electric heating device automatically turns electric heating on when fuel runs out and temperature fall to the preset stand by mode temperature In the combustions chambers of boilers 5 16 10 and K 5 16 10 W there is a removable refractory brick p 23 When it is set into the boiler boiler output may be decreased from 16 to 10 kW prolonging the combustion duration It is prohibited to alter the design of the boiler 3 Transportation and storage Transport boilers only in the vertical position by all types of covered transport Transporting by not covered transport is possible only when the weather is dry Use additional protection means to protect boilers against fall downing and scratching Striking turning over or throw
7. No other connections through that hole are allowed If chimney is connected with additional elbow it s cross section has to be not less than that of the boiler smoke pipe and bending radii not less than 100mm e Pipe from the smoke pipe to chimney may not be longer than 1 5 m and lean upwards toward chimney KALVIS 5 KALVIS 5 W 2009 05 18 6 15 B Malfunction Insulatio Sealed Close air supply dampers monitor boiler gi iE Too intensive combustion Extra insulation A 1 Boiler overheats Power outage for systems H 7 en temperature falls return to the regular 160 lt with forced circulation firing Call the electrician During winter when the power is out for eee ee eer _ 5 prolonged period of time when there is a risk a of system freezing down drain the system A Boiler does not reach Bad humid fuel Use dry fuel open up ignition damper A B B nominal output Poor draught Check chimney draught A Bad fuel A y Boiler tears Return watrer temperature Use dry fuel 4 is too low gt 57 Adjust the mixing valve Poor draught Close air supply dampers monitor boiler A y Overpressure in the temperature Connection y malfunctions 2 17 boiler Check and replace in case of necessity F Expansion tank a protection valve an
8. gt lt RECIRCULATIONARY AND COLD WATER SANITARY WATER RECIRCULATION control only 75 percent of heating devices radiators gt lt gt lt TO SYSTEM THREE WAY Contact thermostat for pump control MIXING OVERFILL VALVE VALVE BALANCING VALVE THERMOSTATIC THREE WAY TEMPERATURE ADJUSTER 60 C AUTO SYSTEM REFIL VALVE EXPANSION t e FROM SEWER FROM SYSTEM Y TO DRAIN 4 fig Recommended local heating system schema with the 3 way valve sff 10 YUV 4 OY wajsas 1920 6 My sesiwed 10 indino HO M Ul NO s noy Ul 8 gt lt 72 NOISNWdX4 yue SA X AATWA 1434 WALSAS OLNV Q PS s N ds 1 mn 0 1 9 A AVM 33HHL OL OILVLSOWNYSHL 2 yug MNVL NOILVINWNDDV 54 19373 IWALSAS NOILLV1NOYIDAY AYVLINVS 5
9. supply that is why ash needs removal Keep the loading doors p 11 shut when firing the boiler SANITARY WATER SANITARY WATER RECIRCULATION 4a fig Recommended local heating system schema with the four way valve WATER HEATER AUTO SYSTEM REFIL VALVE RECIRCULATIONARY AND COLD WATER MIXING OF EXPANSION AIR LET OUT Contact thermost for pump control TO DRAIN FROM SEWER Y KALVIS 5 KALVIS 5 W EN 2009 05 18 12 4 4 Boiler cooling system connection A cooling loop is installed into the boiler Kalvis 5 W which serves as a protection against overheating When water in the boiler heats up to 95 C valve is opened and cold water from the main flowing through the cooling loop cools the water in the boiler Water after the boiler is directed into the sewer via pipes that are not smaller than pipes shown in 1 fig p 26 water has to flow freely into the sewer Honeywell TS 130 tmeperature valve is included In case of a power failure in the house where the water supply is local water is supplied by a pump boiler may overheat water circulation pumps stopped It is necessary to have an additional water supply into the cooling system f e an extra tank Recommended cooling schemas are shown in 4a 4d figures Cooling loop may also be used for preparation of a small quanity of hot sanitary water Tests show that when the water temperature in the boiler is 75
10. why it 1s recommended to use boiler connection schemas with accumulation tanks fig 4c 4d Minimum volume of the accumulation tank has to be calculated according to the formula given by the fig 4d KALVIS 5 KALVIS 5 W EN 2009 05 18 8 13 Uzdaromoji sklend gz cs 55 EES SS 5 Servicing of the boiler ex Zt 365 52 222 525 OQ qa Only adults that are well acquainted with the design and users manual may service 298 the boiler 5 2 eg ese gt gt ef 5525 9 2 se 8 Attention When firing the boiler with humid fuel or sawdust condensate and lt 9 or combustible gases form acids that significantly decrease the lifespan of the boiler 5 Firing boiler with fine fuels is prohibited due to a danger of explosion and draughting out of the burning particles through the chimney P lt gt lt 5 1 System preparation for heating Fill system with water and let the air out Check if valves disconnecting boiler from the heating system are fully opened and remove their handles VS 5 2 Firing the boiler fig 1 Open exhaust damper p 9 and ignition damper p 10 before firing the boiler Place some chopped wood on the fire grate through the door p 2 and ignite it Secondary air pipe s p 13 dampers have to be closed
11. wood of 20 humidity Fir Average coal caloric value 6500 kcal kg 7 56 kWh kg 9 Certificate of acceptance Central heating solid fuel boiler Kalvis 5 factory Nr conforms to manufacturing drawings provisions and regulations of IST144948958 13 2004 and LST EN 303 5 and 15 suitable for comissioning Boiler tested at 0 4 MPa pressure Hydraulic pressure test date Date of manufacturing Quality assurance manager f f 4 2 722 Notice 1 eft sided boiler shown fig Nr 2 For a right sided boiler change measures and b 2 fig Recommended distance from the non flammable partitions 4 1 Fire precautions Boiler should be placed on the incombustible material If boiler is connected to the chimney by metal pipes pipes should be not thinner than 1 5mm and they have to be covered by thermal insulation Attention When chimney s draught is too great and sawdust is used for fuel sparks may fly out through the chimney It is prohibited to use sawdust for fuel if the distance between chimney and flammable roof or other flammable structures is less than 20 m 4 2 Requirements for chimney Chimney design and boiler connections into it are shown on the fig 2 and 3 e Chimney draught is not less than specified in main technical data table e Chimney hole s cross section should not less than 120x270 mm e Boiler needs a separate hole for the chimney connection
12. Dampers p 14 are adjusted reguliuojamos when water temperature in the boiler rises up to 60 C When fuel 15 well ignited combustion chamber may be loaded with fire wood coal Ignition damper p 10 is closed Finer wood increases boiler output Chimney draught 15 adjusted by damper p 9 Wood should be loaded freely so that it 1s able to fall down during combustion Coal is addwed in layers depending on quality and required heat amount 10cm thick layer of coal should be added for about 5 10kg of fire wood When adding more fuel Open exhaust damper p 3 Open ignition damper p 10 Open door p 19 and check if the ash does not block the air passages in the fire grate Stir the bottom layer of fuel 11 necessary Remove the chain of the draught adjuster p 7 from the damper p 18 so that the damper 1s tightly closed Open up the loading door p 11 slightly in 5 10 seconds open it fully and add more fuel Close loading door and dampers tightly Attach the draught adjuster s chain to the damper Check the smoke color flowing out of chimney Smoke should be thin of a light grey color If smoke is thick and black it means incomplete combustion not enough secondary air Open secondary air supply dampers As a part of combustion process ash is formed it blocks the openings in fire grate boiler output and combuistion intensity drops Stir the fuel and ash Excessive ash in an ash tray blocks primary air
13. d an expansion tank j malfunctions j BOILER f gt gp Cleaning 6 Safety precautions ETTA A It is prohibited to e Disassemble boiler or electric installation Boil oe ie Connect boiler to the system without protection valve that keeps pressure in the oller to chimney connection insert installation system below 0 15MPa 1 5 kgf cm not less than 60 A incorrect B correct Close hot return water valves when boiler is operated Store dry fuels or other combustible materials close to or on top of the boiler Store fuel closer than 500 mm to boiler Ignition fuel with combustible liquids petroleum kerosene etc Operate boiler with doors and covers open Allow children into the boiler room without adult supervision Operate boiler with electric heating devices without having it grounded Rapidly open loading doors during combustion open a little wait then slowly open wide 6 8m 3c fig Necessary to e Joints have to be well sealed e Monitor grounding efficiency e Chimney hole has to be cleaned periodically It is necessary to know that 7 Consumables e Smoke continues to cool in the chimney vapor condenses on the chimney walls Glazing gaskets secondary air pipe fire grate and cast iron doors refractory bricks especially in the unheated loft and on the outside of the building may all fail during
14. iler design e Boiler should be connected by hot and return water pipes not smaller than 1 5 in diameter e Boiler may be connected to the heating system with the expansion tank where operating pressure does not exceed 0 15 MPa 1 5 kgf cm2 e If system pipes have valves that disconnect boiler from the system mounted they have to be fully opened To avoid break down due to inadvertence valve handles should be removed e It 15 necessary to mount the protection valve that keeps the operating pressure in the system not greater than 0 15 MPa 1 5 kgf cm2 Valve s operation should be checked upon ignition by turning it s handle e In order to avoid forming of the condensate which may significantly reduce the lifespan of the boiler it is necessary to install the four way mixing or thermostatic valves intot he system see recommended connection schemas These valves allow to maintain the return water temperature not lower than 57 C e it is recommended that boiler is inspected at least once a year by a qualified boiler supervisor e Drainage pipe is used to remove water from the boiler and the system when there is a risk that the system will freeze Recommended boiler connection schemans are shown in fugures 4a 4d e When boiler is operated at lower than nominal output efficiency drops environmental indicators are getting worse as well In case of an emergency when the circulation pump is not working boiler may overheat That is
15. ing boilers during loading unloading or transportation time is strictly prohibited The boilers are to be stored in the dry rooms where is no vapour of chemicaly active materials 4 Boiler installation Boiler has to be installed in the premises that meet RSN 159 95 and RPST 01 97 requirements It 15 recommended to have mounted a smoke collecting cobver above boiler Boiler should be mounted vertically or with forward inclination which would not exceed 1 degree When boileri s installed outside of Lithuania it is necessary to meet the national requirements for installation of such equipment 17 10 Complement 1 Boiler Kalvis 5 1 unit 2 Poker unit 3 Grinder 1 unit 4 Ash scoop unit 5 Draught adjuster C20 25 1 unit 6 User s manual 1 unit Electric heating device and temperature valve are not included 11 Guarantee e Manufacturer guarantees that boiler conforms to conforms to manufacturing drawings provisions and regulations of JST144948958 13 2004 and LST EN 303 5 e Manufacturer applies the following guarantee servicing terms from the date of sales Boiler frame 24 months Complement 12 months Consumables para7 6 months Manufacturer will repair any malfunctions in the product that appear due to manufacturers fault e Manufacturer will not acknowledge any quality claims for boiler operation and consequences if the product has been wrongly chosen mounted installed o
16. n from boiler overheating or without it are used Adjuster is turned into a socket scotch tape is used for sealing Attach chain to air supply damper When boiler heats up to 70 C adjust adjusters handle to position 4 and shorten the chain so that air supply damper is closed Turning adjuster to the correspondent position sets desired temperature Position 6 corresponds to 90 C Temperature increment between positions is 10 C 5 4 Katilo valymas Ash that settles down beneath the fire grate may restrict air acces to the combustion chamber Ash tray and ash pit has to be emptied once every 2 days In order to ensure efficient boiler operation sooth from the internal boiler frame walls has to be periodically Cleaning intervals depend on fuel quality especially moisture content and chimney draught Cleaning should be performed when the layer of sooth reaches 3mm but not less frequently than 2 3 times per month Remove covers p4 and dampers 3 10 before cleaning the internal boiler surfaces Hard solids may be removed by chemical cleaners Swedish Fauch 300 cleaner or cleaners used for fireplaces glass may be used Chimney should be cleaned at least once a year before the heating season Notice During the first ignition or after not having fired the boiler for a long time smoke may be blocked in the chimney In such an event during ignition open up the chimney connection or cleaning hole and stick a burning piece of paper thr
17. operation e Condensate acids and erosion may destroy the chimney in few years Consumables may be purchase from authorized distributors or the manufacturer of Not cleaned soot in the chimney may self combust and become the cause of fire the boiler KALVIS 5 KALVIS 5 W 2009 05 18 14 Firing the boiler requires a lot of air so it is important that the sufficient amount is supplied into the boiler room Recommended fuel moisture content is not greater than 15 22 Notice Upon ignition of fuel when there is still no sooth on the boiler internal walls water condensate forms that gives the impression that the boiler 15 not water tight Water vapour condensate disappears when the temperature in the boiler reaches 70 80 C degrees It is recommended to keep the water temperature in the boiler as high as possible When the return water temperature is lower than 57 C water vapours condense on the internal boiler walls and condensate together with products of combustion forms aggressive acids that may significantly decrease the lifespan of the boiler To make sure that the boiler is water tight it has to be fired intensively for several hours The firing has to be stopped and the amount of condensate forming has to be monitored If the amount of condensate does not increase boiler is water tight 5 3 Installing and adjusting the draught adjuster Draught adjusters manufactured by Swedish ESBE C20 25 with protectio
18. ough it Close the door when it burns down Draught should improve 5 5 Possible dangers and means of their removal Boiler is protected against the overpressure by the protection valve and the expansion tank ey It is recommended e Install a stainless steeel insert in the chimney Well installed insert protects chimney from the effects of condensate and moisture Insert should not significantly decrease chimney hole s cross section Connected parts of the insert should be well sealed not by soldering Condensate collector should be mounted in the bottom The gap between the chimney and an insert should be filled with non flammable material at least at the top of the chimney The gap on top should be sealed and covered with steel sheet with a lean towards the edge of the chimney e Chimney in the cold loft should be insulated by a non flammable insulation e If residue in the chimney catches fire close the air supply into the boiler and call the firefighters e Arrange holes in the chimney connection for periodic sooth cleaning once in a month e It is recommended that chimney is inspected at least once a year by a qualified chimney supervisor 4 3 Requirements for the connection to the heating system e Boiler may be connected to the heating system according to the project prepared by heating equipment specialists or works may be performed by a well qualified plumbing welder who is well acquainted with this manual and bo
19. r serviced acquainted with rules of installation and servicing and guarantee policy Purchaser name last name signature KALVIS 5 KALVIS 5 W EN 2009 05 18 HIG Use only boiler manufacturer s consumables and spare parts 8 Fuel types and properties Heat resistant ceiling Fireproof CENTRAL HEATING BOILERS Combustion heat of absolutely dry wood does not depend on the wood type and equals 4510 kcal kg So in order to compare different kinds of wood we need to assume their relative weight weighs h1 oak wood 500 kg Boiler type n mm mm 1 birch wood 450 kg Kanis 5 16010 1250 550 200 21000 fir wood 330 kg Kehiss 20 1250 200 5 30 __ 1280 20 21250 asp wood 330 kg The higher wood humidity 18 the smaller calorific value Decrease in calorific value of humid wood in comparison to 20 humidity wood 30 humidity 10 15 50 humidity 35 40 Fresh cut tree has about 35 60 maist content Wood cut in the beginning of winter or hard wood has the least amount of moist Peat and wood calorific value is similar 1 kg of coal gives 2 3 times more heat than kg of wood Combustion of 1 kg of wood requires 4 5 m3 of air coal around 10 m3 The more ash 15 left the worse fuel 15 Energy radiation from combustion of 1 dm3 of
20. y 26 Cooling water exit pipe Letters mark dimensions provided in the basic engineering data table Boiler cooling is only installed in Kalvis 5 W types of boilers KALVI meee See _ ________________ ___ ___ _ _ ee _ Mm Mm em em em em mm F 02 IN 04 5 Guarantee servicing request KALVIS 5 W EN 2009 05 18 and having installed it as gt 5 manual Products No Having acquainted with fireplace s Kalvis required I have following claims I consider it a manufacturing error and I ask you to send your representatives to inspect the fireplace determine the defects and remove them If the aforementioned defects are due to wrong installation and operation of the fireplace I shall cover the arrival costs of your representatives and the time spent for travel and on site at driver hour for each representative including the My address Phone number Signature Surname Name Notice Request should be sent by a registered mail to the address specified in this passport in case of emergency call specified phone number Boiler sold by Boiler installed by In case of a breakdown contact 18 Sales date Address Phone Company
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