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How to install a solid fuel boiler with your own hands

This WordPress post provides indispensable and easy-to-follow instructions for those looking to install a solid fuel boiler in their home. The post covers every step of the installation process, including positioning the boiler in-situ, making the necessary electrical connections, and pressure testing the boiler. Moreover, through accurate diagrams and illustrations, it provides readers with a better understanding of each step. This comprehensive guide is designed to teach readers how to install and maintain their own boilers, helping to save time and money. Ultimately, this post is perfect for anyone interested in taking control of their boiler maintenance and installation needs.

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How to install a solid fuel boiler yourself? What do you need to know at each stage of commissioning? What tools and supplies are needed? Is there an alternative heating system without electricity and gas? You can find answers to these questions in our article..

Features of installing a double-circuit solid fuel boiler

A solid fuel heating boiler is a popular solution not only for wooded or “coal” rural areas, but also for the private sector of any city. We wrote about the advantages and features of its installation in the previous article. Now we will consider the step-by-step instructions for the installation and the first start-up of this device with a closed (radiator) heating system.

Note.As an example, a boiler of the “Prometheus” brand was selected. There is only one selection criterion: compliance of the design with modern standards and requirements. This instruction, with minor amendments, can be applied to any of the structurally similar solid fuel boilers (TK).

So, our boiler has the following initial data:

  1. Possibility to work on two circuits – heating and hot water supply.
  2. Power from 6 to 12 kW.
  3. Fuel consumption 3.2 kg / h (coal 20-40 grade DO).
  4. Heating area – up to 100 sq. m.
  5. The volume of water in the tank – 48 l.
  6. Efficiency – 84%.
  7. Weight (dry) 160 kg.
  8. Price RUB 30,000.

The TC design provides the following factory features:

  1. Pressure gauge and thermometer integrated in the housing.
  2. Possibility of installing an electric heating element and a regulator for it.
  3. Three-stage air supply.
  4. Combustion regulator.
  5. Outlets of the supply and return line, chimney.
  6. Tank fill and drain outlet (1/2 in.).
  7. Grate shaking lever.
  8. The kit usually includes: damper regulator, emergency relief valve, air valve, ball valves.

In addition to the listed items of equipment, the factory set may contain auxiliary devices: an ash plate, a skimmer (poker), a hook, a sweeper, a scraper, a hopper.

Note.This master class assumes that the wiring of the heating system is completed, the chimney is arranged and it is possible to connect water under pressure.

Despite the fact that modern TC have good protection against exhaust gas leakage and accidental fires, SNiP standards require their installation in a separate room – a boiler room. It can be located both inside the building and be attached.

Training

This stage includes the removal of the supply and return pipes of the already finished heating system into the boiler room, its installation and pressure testing.

Features of installing a double-circuit solid fuel boiler

Components to be mounted on the wall near which the boiler will be installed (with the back wall):

1. Distribution “comb” – a collector through which heated water is distributed. Calculated, manufactured and installed together with the system. Heating and hot water supply circuits are removed from it.

Features of installing a double-circuit solid fuel boiler

2. All shut-off valves, check valves, three-way mixers, circulation pumps must be installed and ready for operation..

Features of installing a double-circuit solid fuel boiler

3. Control unit for pumps and heating elements (if there are heating elements).

Features of installing a double-circuit solid fuel boiler

4. Expansion tank with supply (with closed pressure system). If an open (gravity) system is used, then only the connection to the tank with a coarse filter.

Features of installing a double-circuit solid fuel boiler

5. The path for the chimney in the wall, or the outlet to the outside with an internal chimney must have a heat-resistant design – an asbestos frame or a factory duct (to avoid overheating of the wall).

Requirements of SNiP, which are obligatory for fulfillment, which the commission will check:

  1. Boiler room area – not less than 7 sq. m.
  2. Availability of ventilation.
  3. Non-combustible base (foundation) for the boiler. The simplest, cheapest and fastest option is to lay the platform out of bricks with mortar or “on dry” and cover it with a “box” made of galvanized sheet. Suitable for any gender.
  4. The distance from the wall to the rear and side walls of the boiler is at least 700 mm. From wall to front wall – not less than 1200 mm.
  5. The first meter of the pipe connected to the boiler (supply and return) must be made of a steel pipe.
  6. When installing an electric heating element – mandatory grounding.

The law allows you to install and operate the TC yourself, no permission is required. The commission only checks the correctness of the gas connection and compliance with fire regulations.

What is needed

The assembly of the heating system piping to the TK implies the manufacture of elements by size, with individual angles and segments. This implies the performance of welding and locksmith works:

  1. Welding machine (3 electrodes).
  2. Grinder with a disc for metal.
  3. Level 600 mm.
  4. Set of adjustable and open-end wrenches.
  5. Screwdriwer set.
  6. Roulette, marker, sealant gun, square.

Features of installing a double-circuit solid fuel boiler

In addition to complete items, you need to purchase the following consumables:

  1. Ball valve with squeegee DU-50 (with internal and external threads) – 2 pcs.
  2. Security group (can be included):
    • pressure gauge – 1 piece.
    • safety valve – 1 piece.
    • automatic air vent – 1 piece.
    • ball valve DU-15 – 2 pieces.
  3. Steel coupling 50 mm – 3 pieces.
  4. Pipes with and without threads 50mm.
  5. Transition steel 57-32.
  6. Steel bend DU-50.
  7. Teng (may be included).
  8. Sanitary winding – fumlenta, tow, flax.
  9. Heat resistant sealant.
  10. Chimney with damper.

Features of installing a double-circuit solid fuel boiler

Features of installing a double-circuit solid fuel boiler

Question.Why do you need an electric heating element in a solid fuel boiler?

Answer.With a high consumption of hot water, the boiler will not be able to quickly bring it to the set temperature (55–60 ° С). Teng is needed for quick heating. Thus, in one boiler two devices are assembled at once – a heating Hub and a boiler. With this combination, electricity costs are reduced by 2.5-3 times (compared to a conventional boiler).

We recommend that you fulfill all the points of the preparation requirements before starting the installation. Remember that violations in pressure systems using open fire can lead to failure of the heating of the house, which is fraught with problems during the frosty period..

Operating procedure

“Zero point” – checking the completeness of the boiler itself, inspection for defects.

Pre-assembly of control elements and power supply

1. Install the standard combustion regulator (threaded connection). Often it is a swing handle with a chain attached through a lever that holds the damper door. By turning the regulator knob, we open the vertical damper door to the required size, thereby controlling the flow of combustion air..

Features of installing a double-circuit solid fuel boiler

2. We mount (prefabricated threaded fastener) and connect (copper wires 3×1.5 in the corrugation) the thermostat. If not, put the plug from the kit. We bring out the wires to the voltage regulator.

Features of installing a double-circuit solid fuel boiler

3. Install the heating element in the seat at the bottom of the boiler (threaded connection). If not, put a plug (included).

Features of installing a double-circuit solid fuel boiler

4. We connect the power supply of the heating element (wires 3×2.5).

Features of installing a double-circuit solid fuel boiler

Attention! Use the advice of an electrician when connecting the heating element. Be sure to use grounding.

Installation of a sealed hydraulic system for the agent (water)

1. Install the ball valve DU-50 on the “return” at the bottom of the rear wall of the TC.

Features of installing a double-circuit solid fuel boiler

2. Locksmith welding works. We measure and manufacture individual elements for connecting the boiler outlets and pipes.

Features of installing a double-circuit solid fuel boiler

3. We mount the “return” to thread or welding (whichever is more convenient under the circumstances, but better for welding). We connect the DU-50 to the tap using an American union nut. The expansion tank must be connected before the “return” inlet to the boiler.

Features of installing a double-circuit solid fuel boiler

4. We make a block of the security group. Weld a section of a profile pipe 60×40 25 cm long on both sides to get a sealed tank. On one side of 40 mm, make (burn through) three 25 mm holes and weld on them 25 mm pipe lengths 50 mm long with threads. On the opposite side 40 mm in the center, make one hole 25 mm and weld the DU-25 coupling.

Features of installing a double-circuit solid fuel boiler

5. We make a tap of the security group. In a 50 mm pipe section with a mutual thread, we make (burn through) a 25 mm hole and weld on a 25 mm pipe (10-15 cm) with a thread. We mount the outlet on the “feed” in the upper part of the rear wall of the boiler through the DU-50 coupling.

Features of installing a double-circuit solid fuel boiler

6. Install a pressure gauge, an automatic air valve and an emergency relief valve (safety valve) in the safety unit. We install the unit itself on the outlet of the security group.

Features of installing a double-circuit solid fuel boiler

7. We install a branch pipe (elbow) into the safety valve to collect water in case of activation (discharge). Put a hose on the branch pipe and fix it on the container (canister, bottle, bucket).

Features of installing a double-circuit solid fuel boiler

Attention! The security group must be installed before the locking devices.

8. Connect the supply to the tap

Chimney installation

1. Apply heat-resistant sealant to the chimney outlet at the rear of the boiler.

2. Install the chimney gate.

3. Apply sealant to the pipe seat on the gate and attach the pipe itself.

Features of installing a double-circuit solid fuel boiler

Attention! Good draft in the chimney is the main condition for the correct operation of the boiler. The pipe must correspond in height and cross-section to the dimensions of the chimney given in the passport of the TC.

Water connection and hydraulic test

1. Connect the water (temporarily or permanently) to the water supply at the bottom of the boiler through the ball valve.

Features of installing a double-circuit solid fuel boiler

2. Open all taps and valves.

3. Bring the pressure in the system to 1.3 atmospheres using a pressure testing device or simply an adjustment valve.

4. Thoroughly check the entire system for leaks, especially threaded and welded joints. There should be no leaks.

Note.SNiP requires holding under pressure for 24 hours.

If everything is done correctly, then there should be no water leaks and pressure losses and you can proceed to the next stage.

Boiler status audit

1. We check the correctness of the installation of cast iron grates and fireclay stones (they could move during transportation). They should be stably located in the seats.

Features of installing a double-circuit solid fuel boiler

2. The ignition flap must be pushed in. This is how it provides the best traction..

3. Check that the cleaning plug is properly seated with a punch hole. It must completely cover the slot.

4. Do not forget to re-install the dampers removed for revision.

5. Test the coal tedding and ash dumping system with the cleaning hatch open and remember how it works. Choose the optimal operating mode of this device for yourself.

Features of installing a double-circuit solid fuel boiler

Attention! This procedure must be practiced as it is repeated frequently. Tedding in jerks can lead to skewing of the grate, device wedge. This is an extremely undesirable action during boiler operation..

6. Try to theoretically clean the ash pan with a plate before switching on and carry out preventive measures.

After such a check, you can proceed to the first launch..

Boiler start

1. Before kindling, it is necessary to release the pressure in the system to the working pressure – 1 atm..

2. Check and close the ignition flap.

3. Fully open the chimney damper.

Features of installing a double-circuit solid fuel boiler

4. Place the starting material (paper, wood chips, sticks) on the grate and pour coal into the boiler hopper.

Features of installing a double-circuit solid fuel boiler

5. Start a fire.

6. After 10-15 minutes, close the ignition flap.

7. When the temperature reaches 85 ° C, adjust the combustion regulator. To do this, set it to 85 degrees and adjust the chain (or other damper drive). The gap between the primary air flap and the door must be at least 5 mm.

Features of installing a double-circuit solid fuel boiler

8. Using the dampers, you can adjust the amount of secondary and tertiary air and increase the efficiency of the boiler..

Attention! If a yellow or red glow is visible through the inspection holes of the tertiary air supply, then the amount of tertiary air is correct.

Maintenance of a solid fuel boiler

The interior of the combustion chamber hopper should be cleaned weekly. To do this, use a standard scraper and other tools..

Attention! 1 millimeter of soot on the wall surface reduces power by 3%.

The procedure for regular prevention:

  1. Open the hole for cleaning with a sanding hole.
  2. Clean the surfaces of the furnace and the loading chamber with a scraper.
  3. Open the ignition flap and clean the rear wall.
  4. Clean the front grill with an ash plate.

Features of installing a double-circuit solid fuel boiler

For greater efficiency, it is recommended to use solid fuel boilers together with heat accumulators. This allows you to stabilize the heat supply to the room and reduce energy costs to a minimum..

Open (gravitational) heating system

This system is considered primitive and outdated, but in many cases it may be required. Modern boilers and radiator heating systems are on guard for saving money for citizens and resources of the planet, while the gravitational system guarantees them life in case of force majeure.

It has a lot of disadvantages:

  1. High fuel consumption.
  2. An inconvenient and ugly register system in which a solid pipe with a diameter of 75 mm serves as a radiator.
  3. Long warm-up (however, long cooling) due to the large amount of agent – up to 250 liters.
  4. Works only for heating.

The advantage of this system is one – it works without electricity. First, the water rises due to expansion when heated. The pipes are located at an angle to the horizon, and water flows by gravity to the “return” at the bottom of the boiler. There is nothing more reliable than this system, since there are no mechanical parts in it – only the forces of nature (the force of gravity, gravity). As an upgrade, one circulation pump can be included in it, which will increase efficiency (save fuel) by 2-3 times.

When integrating the TK into an open system, of the above steps for installing hydraulics, you only need to complete items 1–3 and 8 from the section “Installation of a sealed hydraulic system for the agent (water)”.

Another difference is that the expansion tank must be open in the literal sense and have a supply of free space for expanded water heating (for 100 liters of the system – 5 liters of the tank).

Improving your heating system can be a lifelong endeavor. Numerous sensors and controls allow making obedient and efficient home robots integrated into the “smart home” system even from coal boilers. Whatever your boiler is, careful operation and regular maintenance will help it keep your home warm.

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Comments: 3
  1. Marlowe

    Are there any specific guidelines or step-by-step instructions available for a DIY installation of a solid fuel boiler?

    Reply
    1. Mason Johnson

      Yes, there are specific guidelines and step-by-step instructions available for a DIY installation of a solid fuel boiler. It is important to first consult the manufacturer’s installation manual to understand the specific requirements for your particular boiler model. Additionally, it is recommended to have a qualified professional conduct a site survey to ensure that the installation location is suitable and meets all safety regulations. Following the manufacturer’s guidelines, the general steps for installing a solid fuel boiler include preparing the installation area, connecting the boiler to the flue system, connecting the water pipes and electrical supply, and testing the system for proper functionality. It is essential to follow all safety precautions and building codes during the installation process to ensure a safe and effective outcome. If you are unsure about any step of the installation process, it is advisable to seek professional assistance to avoid potential hazards.

      Reply
  2. Levi Turner

    Can anyone provide step-by-step instructions on how to install a solid fuel boiler without professional help? I’m curious to know if it’s feasible and what potential challenges or safety considerations I should be aware of. Any personal experiences or tips would be greatly appreciated!

    Reply
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