Installation and operating instructions for the KB-series
Contents
1. Check the capacitor at every maintenance If the capacitance deviates by more than 5 smaller 2 85 uF then the capacitor has to be replaced Otherwise it may cause the motor to overheat whereby its bearings may be destroyed check the capacitor remove protective cap discharge the contacts by short circuiting check the capacitance with the capacitor measuring instrument no capacitor OK defective capacitor replace the capacitor 6 7 Cleaning of the centrifugal fan Accumulated dust may deteriorate the efficiency and smooth running of the centrifugal fan The fan should be therefore cleaned after a few years of operation 1 Disassemble the fan 2 Clean the blades with compressed air 3 Reassemble the fan www scheer heizsysteme de 28 p T Gast JEE Kabola Blue KB Series 6 8 Measure and adjust emission levels 1 Turn the burner on at the main switch of the control panel 2 After a preheating time of the oil preheater the burner goes into operation 3 Turn the burner on and off 3 times in a row Always include the post purge period of 120 s By switching ON and OFF any air is removed from the nozzle head The air can lead to fluctuations in throughput and thus distort the measurement result 4 Wait until the boiler has reached a minimum temperature of 60 C 140 F The boiler is then in steady condition 5 Connect the flue gas analyser to the measurement port in the ex2. The default fan pressure is only an initial setting e The CO level is critical You can find the required CO value on the burner Turn the burner on at the main switch of the control panel After a preheating time of the oil preheater the burner goes into operation Turn the burner on and off 3 times in a row Always include the post purge period of 120 s By switching ON and OFF any air is removed from the nozzle head The air can lead to fluctuations in throughput and thus distort the measurement result 4 Wait until the boiler has reached a minimum temperature of 60 C 140 F The boiler is then in steady condition 5 Connect the flue gas analyser to the measurement port in the exhaust system behind the boiler 6 Adjust the fan speed using the fan controller board Hold down the and S buttons for approximately 5 s Indicator flashes and indicator S illuminates Adjustment mode can be now accessed ang Adjust the fan speed by pressing or Pay attention to the measured CO value The required CO level is indicated on the burner e Indicator S flashes fast until the speed adjustment is completed f Save the set value by pressing the S key g Indicator illuminates operating setting completed 7 Close carefully the measurement port after the analysis The adjustment of the fan speed and thereby the adjustment of the CO value is also described on the controller board Controller board with the descri
3. 190 F 338 428 302 392 293 401 293 392 284 374 Exhaust pipe connections mm 80 Exhaust pipe mm 50 80 www scheer heizsysteme de A ege Gast JEE Kabola Blue KB Series 2 2 Construction of the KB Series shown is a KB 20 7 kW with storage tank connection 7 pole control panel air pressure ignition oil filter blee burner connection switch unit der combination A three way valve power ON delay timer circulating pump 1 controller board for the fan speed burner controller Ar te ES mixing Rech JEE connection forthe J SS MT RENS filling and emptying of the boiler oil pump motor oil pump flame detector two stage fan Pipe connection mountable on the connection for the filling and emptying of the boiler www scheer heizsysteme de 5 SCHEEN Kabola Blue KB Series 3 Components of the KB Series This chapter presents the components of KB series and their functionality An exploded drawing and spare parts list can be found on pages 35 and 36 3 1 Oil filter bleeder combination The oil filter bleeder combination cleans the oil and keeps it air free The trouble free operation of the burner is only achieved with clean air free oil Use only oil filter and bleeder made of metal Plastic parts are not permitted for fire safety reasons The KB Series are delivered with the oil filter bleeder combination made of metal as shown in the figure T
4. before you start connecting the KB series Check the following prerequisites for the operation of the KB series on the on board power supply e The 230 V power must have the same quality as the normal onshore mains power e The power outlet used must be grounded Once these prerequisites are fulfilled you can connect the KB series 1 Insert the power plug of the control panel into the grounded power outlet 2 Check with the service plug connector the correct phase polarity of the voltage see section 5 1 Correct pha se polarity is indicated by an illuminated indicator light 3 If the indicator light of the service plug connector does not illuminate turn the power plug around Check that the indicator light is illuminated www scheer heizsysteme de 18 UM Gast JEE Kabola Blue KB Series Explosions in the burner may result in serious injury of persons standing nearby e Make sure that the burner is fixed to the boiler in order to prevent the inflow of air into the combustion chamber and thereby to hinter explosions e Make sure that the oil bleeder is mounted on the side of the boiler in the provided holder 1 Once you connect the service plug connector for the fan and controller board to the burner plug the indicator light illuminates when the voltage in phase is If the indicator light does not illuminate turn the power plug by 180 If the oil supply is disrupted e g tank is empty you can fix this
5. circulating pump is receiving power and turned on 2 Check that the rotor of the circulating pump is free to rotate to do this turn the rotor by hand 3 Loosen the screw on the front of the circulating pump with a slotted screwdriver by 1 2 to 1 turn Jx Wait until only water comes out of the screw opening 5 Tighten the screw again The circulating pump is now air free Venting the circulating pump www scheer heizsysteme de 16 p ee Gast JEE Kabola Blue KB Series With improper installation of the oil bleeders it is possible that the explosions in the burner may result in serious injury of persons standing nearby e Attach the oil bleeder to the designated holder on the right side of the boiler see illustration below If this is not possible due to space limitations mount the oil bleeder at least 30 cm higher than the oil pump e Install at least 50 of the oil line length ascending towards the oil bleeder pe Xecc o jj 0 n v n n n ttt The fault free operation of the burner can only be guaranteed with clean air free oil e Pay attention to the flow and return direction when connecting the oil pipes The flow directions are indicated by arrows on the oil pump and the oil bleeder e Use oil filter and oil bleeder made of metal only Plastic parts are not permitted for fire safety reasons The KB Series are delivered with an oil filter bleeder combination made of metal in order to fulfil the fire
6. external air supply through an air ventilation shaft when large air consuming devices eg main engine generators are installed in the same room as the KB Series o air supply dependent on ambient air when there are no other air consuming devices in the installation room For ambient air dependent air supply select a diameter for the room ventilation of about 2 5 times the diameter of the exhaust pipe KB 20 to KB 45 KB 50 and KB 75 50 mm exhaust pipe diameter 80 mm exhaust pipe diameter 125 mm room ventilation diameter 200 mm room ventilation diameter Note that other air consuming devices in the installation room may require a larger diameter for the room ventilation SCHEER recommends an external air supply in order to achieve sufficient air supply to the burner at all times Only with sufficient combustion air does the burner reach the best exhaust emissions soot free combustion and highest efficiency The components of the external air supply from the air ventilation shaft are in the following order 1 Connector for pipe at the air ventilation shaft 2 Pipe rigid or flexible minimum diameter 50 mm 3 Transition piece for any diameter compensation from flexible pipe to inlet manifold 4 Inlet manifold connected with the centrifugal fan with a 50 mm diameter for the pipe connection Connect the individual components with matching hose clamps www scheer heizsysteme de 14 ee Gast JEE Kabola Blue KB Series e Ri
7. the provided holder on the boiler If this is not pos sible due to space limitations mount the oil bleeder at least 30 cm higher than the oil pump If the oil bleeder is not mounted higher than the oil pump the oil can not bled and this can result in explosions ATTENTION Maa a a a The fault free operation of the burner can only be guaranteed with clean air free oil 1 Open the stop valve of the oil tank 2 Open the stop valve of the oil filter 3 Connect the service plug connector to the oil pump motor see section 5 1 4 Let the oil pump run for about 5 minutes The oil is bled through the oil bleeder without the burner running 5 Checkthe underpressure between the oil bleeder and the oil pump with the built in underpressure manometer The system is running optimally in the underpressure range of 0 to 0 3 bar SCHEER recommends a filter change for values between 0 3 and 0 5 bar Even greater underpressure may cause malfunctions and an increased pump wear should be expected 6 Theoil pressure of the oil pump has already been set by SCHEER It is not required to check for the oil pressure of the oil pump 7 Remove the service plug connector from the oil pump motor Re connect the genuine oil pump connector www scheer heizsysteme de 22 p ee Gast JEE Kabola Blue KB Series 5 4 Abgaswerte messen und einstellen ATTENTION SEES e tis essential to adjust the fan pressure during the initial commissioning
8. 3 12 Three way valve for the version with storage tank loading 11 3 13 OPTIONAL water heating via plate heat exchanger 11 4 Installation i ttt 12 4 1 KB Series set up 13 4 2 Airsupply 14 4 3 Exhaust gas routing 15 4 4 Water supply 16 4 5 Oil supply 17 4 6 Power connection 18 5 Commissioning aaa EEEE EEE EEE E E E E EEEIEE EE EE EE EEEE EEEE n 19 5 OPTIONAL Service plug connector for the testing and setup of the KB s 19 5 2 Boiler temperature adjustment 21 5 3 Oil supply verification 22 5 4 Measure and adjust emission levels 23 nri it een a ee ee ee 24 6 1 Control the Condensate collector 25 6 2 Boiler cleaning 25 6 3 Oilfilter replacement 25 6 4 Control the mixing cartridge 26 6 5 Replacement of the oil nozzle 27 6 6 Check the capacitor of the oil pump motor 28 6 7 Centrifugal fan cleaning 28 6 8 Control the exhaust emissions 29 7 Error diagnostics esee 30 8 Decommissioning amp Storage o o o o ee esses esses 31 8 1 Prolonged Inactivity 32 9 Transport 32 10 Disposal 32 11 Circuit diagram of the control panel 33 12 Electrical circuit diagram of the burner icc LL LL LL v s sss 34 13 Exploded view amp parts list 35 www scheer heizsysteme de 2 UM Gast JEE Kabola Blue KB Series 1 Warning and safety information 1 Meaning of the warning and caution signs Suel Possible material damage if ignored N CAUTION possible light and medium injury if ignored severe or life threaten
9. 4 4 2011 IEC 61000 4 5 2005 IEC 61000 4 6 2008 CISPR 16 2 1 2008 CISPR 16 2 3 2006 SCHEER Electrical installations in ships Special features Control and instrumentation Testing and measurement techniques Electrostatic discharge immunity test Testing and measurement techniques Radiated radio frequency electromagnetic field immunity test Testing and measurement techniques Electrical fast transient burst immunity test Testing and measurement techniques Surge immunity test Testing and measurement techniques Immunity to conducted disturbances induced by radio frequency fields Specification for radio disturbance and immunity measuring apparatus and methods Part 2 1 Methods of measurement of disturbances and immunity Conducted disturbance measurements Specification for radio disturbance and immunity measuring apparatus and methods Part 2 3 Methods of measurement of disturbances and immunity Radiated disturbance measurements Heating Systems amp Production Technologies Lineker Dipl Kffr Nicole Schroeter manageress BS Tr bi Ke EG Baumusterpr fbescheinigung ee Spshammg cancan ol new Hd meer Fret Bam of te amuna n berwachung ares rin m Am F Kabola Heating Systems BN Placottweg 1 NL 4131 Vianen Utr Typandisbe s Sete 2 DIN EN 267 0818 T V NORD Systema GmbH A Co KG j Pr fung der Kantormit t mit der zugelassenen Bauart nach Modul A An
10. Adjust correctly 55 90 C Room thermostat battery is empty Replace the battery Pump coupling is closed Open the pump coupling Water does not circulate i Pump electrically disconnected Electrically connect the pump pumped The rotor of the pump is stuck Move the rotor by hand The reset button must be pressed only 1 time If the burner goes again to fault after pressing the reset button there is a permanent fault on the burner SCHEER recommends a maintenance as specified in chapter 6 In this manner you can quickly identify and fix the problems mentioned in the table www scheer heizsysteme de 30 Gast JEE Kabola Blue KB Series 8 Decommissioning amp Storage e e e e e e e e 90 e e e e 909 09 e e e e 00 e e 09 e e e e e e e 09 09 e e 09 09 e e e e e e e e e e 0 09 e e e e e 09 e e 09 09 e e 09 e e 0 e e e e e e e e e e Risk of slipping due to leaking or dripping oil Wipe or collect the oil i e Possible skin irritation from contact with oil When working with oil wear safety gloves e Possible respiratory irritation when working with soot Ensure sufficient ventilation ATTENTION Store this manual near the KB Series in order to enable a secure recommissioning Clean the burner and the boiler thoroughly for the decommissioning In case of insufficient cleaning the boiler and burner will corrode Dispose of the oil filter in an environmentally friendly manner The ultra fine filter clogs w
11. After you have removed the burner from the boiler follow the steps for the cleaning of the boiler Pay attention to an adequate ventilation 1 Remove the insulation on the front side of the boiler 2 Brush the tubes with the plastic brush Do not use a metal brush because you will produce steel fragments that will create corrosion in the exhaust system Sweep the combustion chamber with the cleaning brush 4 Sweep the front side of the boiler with the cleaning brush or a hand brush Vacuum any loose dust with a vacuum cleaner Reattach the insulation 7 Mount the burner to the boiler o eM Cleaning kit plastic brush cleaning brush 6 3 Oil filter replacement Change the oil filter and the filter cartridge only when the underpressure is too high If the underpressure displayed on the underpressure manometer is greater than 0 3 bar this means that the oil filter is clogged and needs to be renewed e The system is running optimally in the underpressure range of 0 to 0 3 bar e SCHEER recommends a filter change for values between 0 3 and 0 5 bar e Even greater underpressure may cause malfunctions and an increased pump wear should be expected Change the oil filter change as described in the manufacturer s manual The oil filter should be made of metal in order to meet applicable fire safety regulations Dispose of the oil filter and the filter cartridge in an environmentally friendly manner www scheer he
12. F 420 V AC Check the capacitor at every maintenance If the capacitance deviates by more than 5 96 smaller 2 85 uF then the capacitor has to be replaced The maintenance procedure for the capacitor is described in section 6 4 Under no circumstances should you replace the oil pump by another oil pump type The oil pump is specially configured for use in the BE KB burner Use only the genuine oil pump from SCHEER Oil pump Oil pump Art No 011236 Pressure range 4 to 25 bar Viscosity range 2 to 12 mm s Forward return flow pressure respectively max 2 bar EH You can find the model depen SPEEN EEN Operating temperature 0 to 60 C dent oil pressure directly on the 32 to 140 F label on the burner 32 to www scheer heizsysteme de 7 am SCHEER Kabola Blue KB Series 3 4 SCHEER oil nozzles Use only genuine SCHEER oil nozzles A trouble free operation can only be ensured through the use of genuine SCHEER nozzles They are specially configured and tested in a flow range with only 5 toleran e Ce The nozzle replacement is described in section 6 2 P SCHEER oil nozzles Art No KB 20 0 18 80 SC 022276 SCHEER oil nozzles KB 40 0 25 80 SC 022277 KB 45 0 40 60 SC 022368 KB 50 0 50 60 SC 022370 KB 75 0 65 60 SC 022373 3 5 Centrifugal fan amp Controller board The centrifugal SCHEER 2 stage fan is a powerful fan that is used in all models of the KB series The fan thro
13. LED is lit Safety testing is conducted flame detector active flame detected No adjustments are required for the SCHEER flame detector at initial commissioning or maintenance The burner controller takes over the operation start up and supervision of the burner If a fault occurs during the start or burning process the burner controller goes to a fault shutdown Fault Response Power failure Restart Loss of flame during operation Restart External light on burner startup Fault shutdown burner controller No flame after the safety period Fault shutdown Art No 020100 Control program by fault shutdown 1 Triggers the fault shutdown in the burner controller 2 Immediate shutdown 1 s of all relevant for the oil supply components solenoid valve oil pump motor oil preheater igniter 3 Interruption of the oil supply and termination of the burning process 4 Fault indicator in shutdown reset button lights up red Under Troubleshooting on page 30 possible causes of fault shutdown and solutions are listed Low voltage detection A separate circuit in the burner controller ensures that at voltages below 165 V AC the burner start up is prevented or without the release of oil a fault shutdown is triggered www scheer heizsysteme de 10 p T Gast JEE Kabola Blue KB Series 3 11 Circulating pump The three stage circulating pump is responsible for the cir culation of the boiler water and is mounted in the return flow o
14. TI Gast HE I7 Installation and operating instructions for the KB series Ecoline KB 20 7kW KB 40 13 kW KB 45 24kW KB 50 28 kW KB 75 38 kW Innovative Heating systems SCHEER C Heizsysteme amp Produktionstechnik GmbH Chausseestra e 12 16 D 25797 W hrden Deutschland Tel 49 0 48 39 90 50 fancdideridesn Fax 49 0 48 39 45 3 692009522 info scheer heizsysteme de Ausgew hlter Ort 201 www scheer heizsysteme de Technical changes reserved 09 2013 a e Gast JEE Kabola Blue KB Series Table of Contents 1 Warning and safety information 6 6 6 0 6 0 06 9 0 0 0 5 0 0 6 9 0 O 9 06 0 0 6 O 0 0 0 O0 0 0 0 0 9 eee eee 0 9 0 O0 0 0 0 0 9 0 O 0 9 0 O 0 9 0 O 0 0 0 O 0 0 O0 0 0 0 O 9 6 0 O 0 6 0 O 0 0 O0 O 0 6 GO 0 9 0 O 9 0 O 06 O0 0 0 0 O0 O 0 O 0 9 0 O0 O 0 0 0 O 9 06 O0 0 0 0 0 9 0 0 9 6 0 O 0 9 0 O0 0 9 6 O 0 0 O0 0 9 0 GO 9 9 0 O 0 9 0 O 0 6 0 O 0 0 O0 0 9 0 GO 9 9 06 0 9 6 0 9 6 2 Operating principle of the KB Series 4 wg EEN e 2 2 Construction of the KB Series 5 3 Components of the KB Series 222022 6 3 1 Oil filter bleeder combination amp Manometer 6 3 2 Oil pump motor 70W with operation capacitor 7 3 3 Oil pump AL 35 C 9553 6 7 3 4 SCHEER Oil nozzles 8 3 5 Fanand controller board 8 3 6 Power on amp power off delay timers 9 3 7 Air pressure switch 9 3 8 lgnition unit 9 3 9 Flame detector 10 3 10 Burner controller 10 3 11 Circulating pump 11
15. ecommends a silencer e Exhaust pipe flexible or rigid note the in the table specified exhaust pipe diameter e Through hull and deck path depending on the outlet direction of the exhaust gases e for vertical outlet double walled chimney The outlet of the exhaust gases can be passed vertically through a chimney or horizontally via a through hull Rtting e Use the vertical outlet for sailing vessels and high seas ships as large heeling and water overflow may occur e Connect the exhaust pipe on the deck pass with the inner tube of the double walled chimney e Install a rain protection cap at the end of the chimney to prevent the entry of water into the exhaust system e Use the horizontal outlet for motor vehicles and vessels in inland waterways The heeling occurring here is much smaller than in the above situations Connect the exhaust pipe to a double walled through hull at a sufficient height above the water line Install a gooseneck in front of the through hull of the exhaust system In doing so you prevent the penetration of water into the exhaust system www scheer heizsysteme de 15 p Gast JEE Kabola Blue KB Series 4 4 Water supply ATTENTION idR e The operating pressure must not be lower than 0 5 bar when cold or higher than 2 5 bar when warm e You can also fill the heating system with a suitable cooling fluid pH 8 5 specifically designed for heating systems Pay attention to the following when installing the flo
16. er heizsysteme de 33 ee g CHEER Kabola Blue KB Series 12 Electrical circuit diagram of the Burner blue Or blower control board grey blue board edge brown connector black rz Co FEO EX ser valve TTT deflation alarm HS max 10A pus phase protective earth neutral entrance boiler thermostat exit boiler thermostat disorder lamp operating hours meter www scheer heizsysteme de 34 P e Gast JEE Kabola Blue KB Series 13 Exploaded view amp parts list t d lr _ Ch Va E i d ie eg e A i m T Sr Ss Cl et i ot UA AY Sc www scheer heizsysteme de 35 g CHEER Kabola Blue KB Series No Description KB 20 KB 40 KB 45 KB 50 KB 75 Boiler KB complete 077980 077984 077987 077990 077993 Control panel 51 001 Combustion chamber insert Boiler insulation 44 004 46 005 47 005 49 005 Door gasket cord 13 M084 Door insulation for the boiler door gasket 44 003 46 004 47 004 49 004 Flame tube 015110 015114 O INIAJAJ AIW INJ 9 Adapter pipe 80 x 1 5 x 109 mm 015179 10 Ring adaptor 015967 11 Fixing screws for the burner including washers 015365 12 Support plate for burner components 015958 13 Supporting plates for components for 17 18 34 015367 14 010276 15 Burner controller 020100 16 Power on delay timer yellow 070555 17 Power off delay timer blue 070553 18 Controller board 015379 19 Air press
17. f oil line from the oil tank Flow indicated by a red tape 22mm Power connection to power plug 230 V www scheer heizsysteme de 12 pepe g CHEER Kabola Blue KB Series 4 1 KB Series set up Do not store any flammable and or gaseous substances in the installation of the KB series That could lead to explosions through the flame in the burner As a result persons in the vicinity may be seriously injured e Place the KB series in a dry room e Watch out for a horizontal and stable surface e Ensure the proper ventilation of the room and burner see section 4 2 e Secure the KB series against slippage for example with bolted angle profiles e Keepaminimum distance of 250 mm from the back wall for the exhaust system e Use a grounded 230 V outlet for connecting the KB series to the on board power supply Use a grounded 230 V outlet for connecting the KB series to the on board power supply The KB series should be fixed on the base with four M5 screws The spacing x is given depending on the model KB20 KB40 KB45 KB50 KB75 KB Serie x mm 147 264 285 nv 345 O Spacing x of the fastening holes www scheer heizsysteme de 13 P LU Gast JEE Kabola Blue KB Series ATTENTION e e e 900 09 0o e 0o e e e e e o e e The burner achieves soot free combustion only with sufficient combustion air Ensure adequate air supply There are two possibilities for the supply of combustion air o
18. f the boiler water The venting of the water system of the circulating pump is described in Section 4 4 circulating pump Art No 9 1053 3 12 Three way valve for the version with storage tank loading The three way valve is provided with an electric drive It is used for the two point control as a mixer or distribution in the hot water system The three way valve is controlled either by the boiler thermostat or by a room thermostat You can switch via a lever between automatic and manual mode AUTO MAN Switch the lever to MAN when filling venting and draining Through the MAN position the valve tappet is in the centre position The water can then flow out to both outlets three way valve Art No 10 7004 3 13 OPTIONAL water heating via plate heat exchanger Via the plate heat exchanger the water in the boiler heats the cold fresh water which is then available as heated water Water heating via a plate heat exchanger can be offered as an option for models KB 40 KB 45 KB 50 and KB 75 These models have the additional Combi e g KB 40 Combi www scheer heizsysteme de 11 P ees Gast JEE Kabola Blue KB Series 4 Installation This chapter describes the steps required for the installation The commissioning is described in Chapter 5 The connections of the KB series are labelled in the following figure Exhaust connection Return 80 mm indicated by a blue tape 22 mm Connection o
19. hang lll der RichiSinie 92 42 EWU VINE en HR C TUN MORE Bye Grimi k Cn a aa EIN mm rer Agen ur ae Installation and operating instructions for the KB series Prost i n 11 00 2011 LEI LO e Gen P re Helps EL inch De Pr fergebnitsa sind in den Berichten KD 2350 C1 CB vom 11032011 zu amp ammengetal TUM NOR byera Oanh amp Cu ef Ol Gne Haswwirafia 11 D 22479 Harbury mer 1 mm a ms mat En AAR ee Ces cy ue mum o ames am com ted ed I4 TT Installation and operating instructions for the KB series
20. haust system behind the boiler 6 The measured CO2 value must correspond with what is stated on the burner 7 If the measured CO2 value deviates from the default value set the emissions levels as described in Section 5 4 under point 6 8 Close carefully the measurement port after the analysis www scheer heizsysteme de 29 Gast JEE Kabola Blue KB Series 7 Error diagnostics In the table below you will find a list of problems their possible causes and solutions If you are confronted with faults that are not listed in the table please contact us Fault Possible cause Possible remedy Bleed the oil filter Replace the clogged oil filter Fill the oil tank d geg Check the fuses isrupted power su 3 St Check the power supply Press the shutdown reset button on Burner has gone into fault mode x the burner Paner top ne ae Clean the light detector tube Replace the flame detector Check the opening of the chimney Burner pulsates at the start Clean the boiler Disrupted oil supply Burner does not start of operation Disrupted oil supply see above Defective oil nozzle Replacement of the oil nozzle Press the shutdown reset button on the burner Burner goes into fault mode J Low Voltage Spannung kontrollieren Check the voltage see above Bridge connected in the terminal box CAR ERE pete T amd T2 Boiler not responding to of the room thermostat thermostat Boiler thermostat incorrectly adjusted
21. he oil filter contains an ultra fine filter insert The oil bleeder vents the oil automatically Oil filter bleeder If you use any other oil filter or bleeder please note the following combination made minimum requirements of metal Art No 040513 1 Oil filter 2 Oil bleeder e completely made of metal e completely made of metal e suitable for single pipe systems automatic bleeder e anultra fine filter insert The installation of the oil filter bleeder combination is presented in Section 4 5 The underpressure manometer shows the underpressure in the supply flow to the oil pump Underpressure The system is running optimally in the underpressure manometer range from 0 0 to 0 3 bar A filter change is recommended for va Art No 040126 lues between 0 3 and 0 5 bar while even greater underpressure may cause malfunctions and an increased pump wear should be expected www scheer heizsysteme de 6 Gast JEE Kabola Blue KB Series Replace the oil pump motor only with a genuine spare part This oil pump motor has a stator with a double l enamelled wire especially suitable for the marine sector Voltages below 200 V may lead to stoppage of the oil pump motor oil pump motor Supply voltage 220 to 250 V AC 50 60 Hz Current consumption 0 54 A Power 70 W Oil pump motor Speed 2810 min at 50 Hz Art No 015138 3200 min at 60 Hz Operation capacitor temperature resistant up to 100 C 212 F 3 u
22. ing injury or possible death if ignored probable life threatening injury or death if ignored 2 Read and store the installation and operating instructions Read these installation and operating instructions carefully and follow the instructions These instructions guide contains the complete information about safety installation and setup and maintenance of the KB series Failure to follow these instructions can result in personal injury fire or property damage These instruction guide is part of the KB series Store this manual near the KB Series so that in the future you may quickly consult it 3 Qualified personel The installation commissioning and maintenance may only be performed by qualified persons Otherwise damage may occur to persons or product As part of training for you free in home SCHEER you obtain the necessary qualifications for working on the BE KB burner and the Handling of heating systems on ships 4 Electrical work All electrical work must be performed by qualified personnel Switch the system power supply OFF before wor king on the KB series Check the wiring when replacing components 5 Prescribed use of the KB series The KB series will be used to produce hot water for space heating and optionally for heating fresh water The model selection is based on a heat load calculation The KB series is not designed to heat the boiler room Boiler and burner of the respective KB series are perfectly matched for optimal pe
23. ith resinified oil and is then no longer functional You can continue to use the oil bleeder Dispose of the boiler water in an environmentally friendly manner The boiler water is contaminated with heavy metals and chemical additives and thus consists a chemical waste Perform the following work steps for decommissioning including storage of the KB series pL o o e e E 10 11 12 13 Disconnect the KB Series from power Close the valves for the oil supply on the oil filter Disassemble the oil pipes Disassemble the oil filter and the oil bleeder Dispose of the oil filter in an environmentally friendly manner Seal the oil pump of the burner with sealing caps Disassemble the burner from the boiler Store the burner with the flame tube facing downwards In this manner leaking oil can not enter the electrical system of the burner Clean the boiler see cleaning the boiler Drain the boiler water Collect the boiler water in a suitable container Dispose of the boiler water in an envi ronmentally friendly manner Rinse the boiler with fresh water Fill the boiler with antifreeze The antifreeze remains in the boiler Seal the water connections of the boiler Store the boiler standing upright on a horizontal and stable surface Store the boiler and the burner in a dry and dust protected location www scheer heizsysteme de 31 p Gast JEE Kabola Blue KB Series 8 1 Prolonged Inactivity When unused for lo
24. izsysteme de 25 ee Gast JEE Kabola Blue KB Series Remove the mixing cartridge 1 Remove the plug from the flame detector and remove the ignition cable from the ignition unit The mixing cartridge is no longer connected to the rest of the burner 2 Loosen the mounting screws of the mixing cartridge Since this is a bayonet mount you do not need to completely remove the screws 2 Turn the mixing cartridge slightly to the left 4 Drag the mixing cartridge towards you and out from the burner Ignition electrodes Mixing head with screw N Ignition cable Electrode distance of 5mm T E out hea V L e mdi e an X Light detector tube Oil preheater Mixing cartridge Art No KB 20 015380 KB 40 015382 KB 45 015383 KB 50 015384 KB 75 015385 Control the mixing cartridge 1 Control the light detector tube The flame detector monitors the flame through the light detector tube Clean the glass surface of light detector tube optionally with burner cleaner and a soft cloth Control the ignition electrodes If these are burned or not properly placed in the holder they should be replaced with genuine SCHEER ignition electrodes Check the distance of the ignition electrodes The distance between the ignition electrodes must be 5 mm If the distance is greater or smaller than the specified they should be replaced with genuine SCHEER ignition electrodes Do not turn the ignitio
25. ld the oil nozzles only at the sides of the hexagon so that they are not damaged 4 Turn the new nozzle hand tight with a box end wrench If necessary secure the nozzle holder with a se cond box end wrench If the nozzle is tightened too hard it may jam tilt in the nozzle holder during the burner operation and may no longer be released without damage In that case a new mixing cartridge is required 5 Mount the mixing head on the nozzle holder The oil nozzles and the air bush must be in the same level Do not use metal for placing The metal may damage the nozzle The oil nozzles must not extend from the air bush 6 Make sure that the light detector tube and the flame detector are in a line In case of an axial rotation there can be no flame detection and this results in a malfunction shut down 7 Turn the screws of the the mixing head hand tight If you tighten the screws too tight the nozzle holder deforms and the exact positioning of the mixing head is no longer possible 8 Mount the mixing cartridge in the reverse order as the one described in the section Cleaning the boiler Air bush and oil nozzle in the same level Electrode distance of 5mm No axial rotation Flame detector www scheer heizsysteme de 27 ee Ee g CHEER Kabola Blue KB Series 6 6 Check the capacitor of the oil pump motor ATENTON Corer TTP eee Tere o oe e ee e e Terre SAC aos OSS ER CR EA RU EK ORES OE EO ESS OO
26. n electrodes The electrodes could break Control the oil nozzle If the nozzle is damaged or if deposits are present it must be replaced The nozzle replacement is described in the next section Proceed with the installation of the mixing cartridge in the reverse order of its removal www scheer heizsysteme de 26 a Gast JEE Kabola Blue KB Series Suid Onlyusegenuine spare parts The oil nozzles are specially designed for the KB burner Therefore only SCHEER oil nozzles are allowed You can recognize the SCHEER oil nozzles from the designation SC If you use other nozzles it may result burner malfunction or burner failure For the right oil nozzle please refer to the opposite table ue SCHEER oil nozzles Art No Take the oil nozzle from the packaging only directly KB 20 0 18 80 SC 022276 before the insertion The nozzle may otherwise be KB 40 0 25 80 SC 022277 damaged KB 45 0 40 60 SC 022368 KB 50 0 50 60 SC 022370 KB 75 0 65 60 SC 022373 Replace the oil nozzles in the following steps 1 Loosen the screw of the mixing head Pull the mixing head from the nozzle holder The nozzle is now ex posed 2 Unscrew the old oil nozzles with a box end wrench If necessary use a second box end wrench to stabilise the nozzle holder Do not use a open end wrench or similar as the oil nozzles or the nozzle holder could be damaged by the unequal stress 3 Take the new nozzle from the packaging Ho
27. ng periods summer winter the KB Series may be corroded by salt laden air and flue gas residues e Clean thoroughly all parts that come in contact with exhaust gas see Maintenance By annually recurring prolonged Inactivity the life expectancy of the KB series is significantly reduced because during every prolonged Inactivity the material corrodes SCHEER strongly recommends to keep the KB Series standing upright all the year round Only so can the long term operation of the KB Series be guaranteed 9 Transport For the preparation of transport and the transport of the KB Series please follow the following steps 1 Disconnect the KB Series from power 2 Disconnect the oil supply 3 Collect any leaking oil and wipe it off Dispose of the oil and oil contaminated material in an environmentally friendly manner Disassemble the burner from the boiler da Clean the burner and boiler see see Maintenance gt Drain the boiler water Collect the boiler water in a suitable container Dispose of the boiler water in an envi ronmentally friendly manner N Wrap the boiler and the burner with blankets or the like to prevent damage ad Transport the burner with the flame tube facing downwards so Transport the boiler standing upright on a horizontal and stable surface If an upright standing transport is not possible you may also transport the boiler placed on its back 10 Secure the burner and the b
28. oiler against slipping and overturning 10 Disposal Note the following points when disposing of the KB Series e Dispose of the parts of the combustion system in an environmentally friendly manner All parts of the com bustion system oil filter oil bleeder oil pipes and residual oil are chemical waste e Dispose of the boiler water in an environmentally friendly manner e Separate metal and plastic parts and dispose of them separately e This instruction guide should be disposed as waste paper The recycling centre in your area can assist you with the environmentally friendly disposal of all material www scheer heizsysteme de 32 P T Gast JEE Kabola Blue KB Series 11 Circuit diagram of the control panel SAS WW A 90987654321 KABOLA we HEATING SYSTEMS C 12345678 B 12345 6 7 6 91011121314 Connection A Connection B Connection C 10987654321 123456 7 89 1011121314 12345678 Maximal Thermostat C 2 Fuse 250V BA 1 A LA Lj On off switch dashboard 2 5 zZ 3 L1 H T1 T2 83 BA LO iN rd Teal dl a L1 Hm 53 B4 Burner plug Plug male Plug female Plug female Plug male LIA UN ATITAT2 83 B4 LIH EJN LTTLT2 83 Bai c mo d c E GMITOPEPYP WI Ki A A p UER ERE LEE 33 amp EB lt lt lt E a ata 2 EC S Z ss s 38888 X 3 Sasse i 333 3 E Erna g iile gt 3 323333 e SEESE S A oaadgddag Mi 477 a noo 8 Quos KEE 8 8 RBB KEE L EE Aa BS i g m g www sche
29. or to the burner The power supply of the burner is now inter rupted Disconnect the plug of the control panel from the power outlet The power supply of the boiler is now inter rupted Dismantle the burner including the burner door from the boiler To do this you should unscrew the door knobs The steps for cleaning the boiler and for the burner maintenance are shown in the following sections After the cleaning mount again the burner to the boiler Proceed with the recommissioning as described www scheer heizsysteme de 24 a e g CHEER Kabola Blue KB Series 6 1 Control the Condensate collector Check occasionally during the heating operation the condensate collector e Existing condensate indicates a faulty or inappropriate exhaust system long ways many turns or inadequa te insulation e Check the exhaust gas routing and its insulation when condensate is present in the condensate collector Dispose of the condensate in an environmentally friendly manner 6 2 Boiler cleaning Do not use for cleaning any aggressive liquids such as thinner or gasoline These attack the material and can lead to corrosion A well adjusted burner has a soot free combustion Because of that the effort of cleaning the boiler is low A thin clear layer can be formed in the combustion chamber This is a sign of a good combustion Do not remove this layer mechanically because it acts as a preservative for the combustion chamber
30. ply to the burner the circulating pump and the 3 way valve Furthermore a temperature sensor is also connected to the control panel and extends into the boiler thereby measuring the boiler water temperature Control panel Art No 51 001 Description of the elements on the control panel o Fuse holder with glass fuse 8A 230V Q Main switch Display for the status and temperature of boiler Adjustment knob for the boiler temperature Reset button for the limit thermostat The maximum boiler temperature is set using the adjustment knob D 1 Press the adjustment knob 9 and turn it until the desired temperature is displayed on the display 9 2 When released the set temperature is stored and the display returns to the current boiler temperature The reset button resets the limit thermostat The display shows the status of the boiler next to the boiler temperature Status Description 1 Heat demand present 3 Post running of the circulation pump is active 4 Boiler is kept warm hot water comfort at your disposal A Low voltage www scheer heizsysteme de 21 p T Gast JEE Kabola Blue KB Series 5 3 lversorgung berpr fen Explosions in the burner may result in serious injury of persons standing nearby e Make sure that the burner is fixed to the boiler in order to prevent the inflow of air into the combustion chamber and thereby to hinter explosions e Make sure that the oil bleeder is stably mounted in
31. ption of the fan speed adjustment www scheer heizsysteme de 23 a Gast JEE Kabola Blue KB Series Risk of slipping due to leaking or dripping oil Wipe or collect the oil Possible skin irritation from contact with oil When working with oil wear safety gloves Possible respiratory irritation due to dust inhalation while cleaning boiler Ensure sufficient ventilation Use only genuine spare parts These are specially designed for the KB series With the use of other replace ment parts no warranty statutory liabilities and rights can be given and the guarantee expires When placing an order please indicate the model and serial number of your KB Series These can be found on the right side of the boiler and the burner In Chapter 13 you can find an exploded view of the KB series and the spare parts list Maintenance interval Condensate collector occasionally Boiler cleaning every two years Burner maintenance every two years Control the exhaust emissions every two years Oil filter replacement recommended when the underpressure manometer indicates underpressu re greater than 0 3 bar Fan cleaning after some years of operation Prepare the KB Series for the maintenance as follows n MI 9 N If the burner is in operation cancel the heat demand Wait for the post purge period with a 120 s duration Turn off the KB Series with the main switch on the control panel Disconnect the plug from the 7 pin connect
32. ressure so that the combustion process can start When the air pressure is insufficient the air pressure switch prevents the leakage of oil into the combustion chamber Thus avoiding the contamination of the combustion chamber from air pressure switch oil and the possibility of explosions at the next start up of the bur Art No 015180 ner 3 8 Ignition unit The SCHEER ignition unit is an electronic ignition unit for intermittent igni tion between 2 electrodes Low weight and small dimensions due to the high operating frequency makes the SCHEER ignition unit very suitable for modern compact burners Connections with a plug on the primary side and secondary side make installation and service quick and simple ignition Unit Art No 010276 www scheer heizsysteme de 9 Pom Gast JEE Kabola Blue KB Series The flame detector evaluates the flames based on their fli cker frequency The SCHEER flame detector is more efficient than a simple light flame detector te 2008 Ce Through the integrated frequency interference suppression neither Light resembling radiation e g glowing surround ings nor constant frequencies e g fluorescent lamps are recognized as a flame flame detector Art No 020064 Unwanted influences of flame detection are thus avoided Operating status display LED off Flame detector inactive LED flashes Safety testing is conducted flame detector is active no flame detected
33. rformance and may not be modified Example Burner BE KB 40 is matched and should only be installed to boiler KB 40 6 Diesel fuel or fuel oil EL The KB series may only be operated with diesel or fuel oil EL standard and low sulfur according to DIN EN 590 It is designed solely for operation with these fuels With other fuels there may be injuries of persons or property due to explosions or malfunctions of the burner 7 Use genuine spare parts Replace components of the KB series only with genuine spare parts from SCHEER The components are specially adapted to the requirements of the KB series Should you use parts from other manufacturers the proper func tion can not be assured and the guarantee expires When placing an order please indicate the type designation and serial number Both can be found on the type plate of the boiler and the burner This will allow us to supply you with the suitable replacement parts 8 Annual Maintenance Have the KB series annually cleaned and maintained by qualified staff in order to enable trouble free and energy efficient operation of the KB series The maintenance procedure is described in Chapter 5 www scheer heizsysteme de 3 SCHEER Kabola Blue KB Series 2 Operating principle the KB series post purge period 120s by the turn off delay relay heat the water in the boiler until T_boiler T_max or until the heat demand is terminated green indicator lamp at the b
34. safety regulations of the maritime sector The allocated holder for the combination is located on the right side of the boiler If because of space issues you can not attach the combination to the holder you can also position the combina tion otherwise However you should mount the combination at least 20 cm higher than the oil pump Otherwise the auto matic bleeder will not work properly the oil will not be air free and this will result to a burner malfunction Use for the oil line between the oil tank and the oil filter only the following lines The oil filter bleeder combina tion mounted on the allocated e Steel pipe or pre oxidised copper pipe SCHEER recommends a pre holder on the side of the boiler cision steel pipe Ermeto type fitting For copper pipes a support sleeve made of brass is mandatory a Inner diameter 6mm o Outer diameter 8mm If you use a longer line it may result in accumulation of air in the oil line which can hinder the flow of oil or lead to burner malfunctions A smaller line can be quickly damaged by external influences You should not use smaller line than the above mentioned The oil filter bleeder combination mounted on the allocated holder on the side of the boiler www scheer heizsysteme de 17 p g CHE EMR Kabola Blue KB Series 4 6 Power connection e Electrical work on 230 V systems shall be performed only by qualified personnel e Make sure that the system is not live
35. sk of burns The exhaust gas and accordingly the exhaust system is heated up to 220 C 428 F Con tact with skin can cause severe burns Insulate throughout the exhaust system with heat resistant material in areas reachable by body parts e Danger of explosion If you include an blocking device in the exhaust system it is then necessary to use a contact switch that is connected to the burner e The entire exhaust system must be made of stainless steel in order to withstand the high exhaust gas temperatures of up to 220 C 428 F and corrosive ingredients of the exhaust gas e Outdoors the exhaust gas routing must be double walled Otherwise condensate may form due to the rapid cooling HINT Condensate may accumulate in the exhaust system when the exhaust gas temperature is low Emission related information for Exhaust temperature C 170 220 150 210 145 205 145 200 140 190 ale 338 428 302 410 293 401 295 7592 284 374 Exhaust pipe connection at the boiler mm 80 Exhaust pipe mm 50 80 Muffler recommended no yes You can also use an existing exhaust gas routing Should this have a larger exhaust pipe diameter than the requi red drag a flexible exhaust pipe with the diameter required in the existing exhaust gas routing e The components of the exhaust gas routing are starting from the boiler e Condensate collector the lowest point of the exhaust system e Tor 50 KB and 75 KB SCHEER r
36. through the direct access to the oil pump motor and put it back into service Only allowed for small oil line lengths With a direct connection to the oil pump motor or fan motor you can check the function of the oil pump motor and the oil pump and listen for sounds that indicate faulty bearings Service plug connector for the fan and controller board Art Nr 73010 www scheer heizsysteme de 19 p E SCHEEN Kabola Blue KB Series 4 In case the fan controller does not allow a burner start up because of a defect or excessive deviations in fan speed see performance data on the burner please connect the service plug connector for the fan and controller board on the fan and the controller board You can now correctthe fan speed on the control board and can also preset a new control board F ATTENTION The pug of the service plug connector connected on the fan should ONLY be upwards connec ted The plug will also fit otherwise but the setup will not work and the fan and possibly other parts may be damaged 5 Through the direct control of the ignition unit you can make the function of the transformer audible If you remove the mixing cartridge and connect di rectly the ignition cable to the transformer you can make the ignition spark visible www scheer heizsysteme de 20 a Gast JEE Kabola Blue KB Series Set the boiler temperature through the control panel The control panel ensures the power sup
37. ugh its centrifugal operation is essentially prohibiting dust and dirt particles to enter the airway The fan is in constant communication with the controller board Through simple use of the controller board the speed of the fan and thus an optimum combustion quality can be adjusted The operation is described in Chapter 5 Centrifugal fan Supply voltage 230 V AC 50 Hz Power input 135 W depending on the air flow Speed max 8500 min depending on the air flow Air flow max 190 m h Back pressure max 3200 Pa and respectively 32 mbar Controller board Centrifuaal f KB 20 015374 entrifugal fan Art No 015112 KB 40 015376 KB 45 015377 KB 50 015378 KB 75 015379 www scheer heizsysteme de 8 p g CHEER Kabola Blue KB Series 3 6 Power on amp power off delay timers power on delay timer power off delay timer 120 seconds 120 seconds Art No 070555 yellow Art No 070553 blue EN e N il The power on delay marked by a yellow dot The power off delay marked by a blue dot ena delays the burner start up for 120 seconds after a bles at the end of the heat demand a post purge power interruption switching over from on board period of the fan for 120 seconds power to mains power 3 7 Air pressure switch The air pressure switch controls the burner fan pressure and is con nected to the solenoid valve of the oil pump The solenoid valve opens only when there is sufficient air p
38. ure switch 015180 20 Ring seal for the air pressure switch 015181 21 Burner block module including 16 22 015966 22 Seal for nozzle holder holding plate 015172 23 Dosagering 015413 24 Ignition electrode set with holder 015358 Nozzle holder complete set 015474 26 Flame detector 020064 27 Mixing device including 23 24 015385 28 SCHEER Oil nozzles 022373 N LI 29 Centrifugal fan two stage 015112 30 Ring seal for the adapter pipe 015170 31 Cil line 2 pieces 041411 92 011236 33 Motor clutch 010292 34 Capacitor 3pF 100 C 010294 35 Oil pump motor 70 Watt 015138 36 Support plate for the oil pump motor 015366 37 Distribution board Kabola single stage 015968 38 Burner flange seal 031430 39 Door rotary knob KB Series 40 41 Circulating pump 9 1053 42 Three way valve 10 J004 www scheer heizsysteme de 36 zs Gast Heer Declaration of Conformity We state in one own responsibility that the product Blautherm DUO BE KB Serie is in conformity with the E C directive 89 336 E E C relating to the Electromagnetic Compatibility This declaration is valid for all products which are produced in accordance with the technical documen tation which is a part of this declaration For verification of conformity with regard to Electromagnetic Compatibility the following harmonized Standards are applied IEC 60092 504 2002 IEC 61000 4 2 2008 IEC 61000 4 3 2010 IEC 61000
39. urner flame detector LED signal to the burner connection flashes up illirminaites controller oil preheater ON preheating time to about 65 C burning process yes oil supply ON flame detector LED flickers ignition unit turned ON AN Pre ignition time possibility that gt i combustible Ate minimal N oil pump fan ON residues ignite and N p solenoid a d valve open p the thermostat of the oil preheater outputs signal to the burner controller pre purge blow out period air pressure switch turned ON oil pump motor concentration and turned ON venting of the oil At initial startup or in case of voltage drop or voltage interruption the power on delay delays the burner start up by 120 s In case of interruption during the operation the power on delay and the post puge period of the fan occur in parallel ee ae _ KB40 KB45 KB50 KB75 7 13 24 28 38 Operating performance kW Dimensions H W D cm 40 38 52 42 38 62 44 38 64 52 43 70 52 43 70 Weight standard combi kg 65 75 80 80 85 90 95 115 120 Efficiency 96 92 93 93 94 94 Medi plate heat Otten teile Water capacity of the boiler Liters 8 5 17 5 20 0 23 0 37 0 Fuel Diesel Heating oil according to DIN EN 590 Cil flow L h 0 69 1 27 2 35 2 75 3 73 Oil nozzles 0 18 80 SC 0 25 80 SC 0 40 60 SC 0 50 60 SC 0 65 60 SC Exhaust temperature C 170 220 150 200 145 205 145 200 140
40. w and return line e The flow is marked with red tape and is under the return line see the figure on page 12 e Thereturn is marked with blue tape and is located above the flow see the figure page 12 e Lay the lines so that the KB series remains accessible for maintenance e Ensure adequate ventilation of the boiler Pay particular attention to areas where air can collect e Install a venting facility if the lines of the boiler do not go straight upwards e For the connection to the optional plate heat exchanger please refer to the manufacturer s instructions For the filling and venting of the heating system through the pipe connec tion proceed as follows Make sure that the KB series is turned off Remove the cover Q Connect the water hose with the supplied grommet Components of the pipe connection Loosen the connecting nut Open the pipe valve O Fill the system slowly with water until the system s pressure manome ter indicates a pressure of 2 bar Tighten the connecting nut ee E s o N Vent the heating system 9 Ifthe water pressure has dropped top up with water until 2 bar are reached again 10 Let the circulating pump run for about 5 minutes 11 Turn off the circulating pump 12 Check the water pressure If the pressure has dropped repeat the steps from step 6 13 Disconnect again the water hose The system is now filled Bleed the circulating pump as follows 1 Make sure that the
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