Centrometal EKO-CKS Technical Manual

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HEATING TECHNIQUE Centrometal d.o.o. - Glavna 12, 40306 Macinec, CROATIA, tel: +385 40 372 600, fax: +385 40 372 611

TECHNICAL MANUAL for assembling, use and maintenance of solid fuel firing boiler and its additional equipment

Centrometal d.o.o. Glavna 12, 40306 Macinec, CROATIA sales department tel: +385 40 372 640 central tel: +385 40 372 600, fax: +385 40 372 611

EKO-CKS

www.centrometal.hr e-mail: [email protected] .hr HEATING TECHNIQUE TUCKS-11/2015



Technical data

Notes

TECHNICAL DATA

TYPE kW mm mm mm mm mm mm kg

Rated thermal output Depth (L) Dimensions Width (B) of the boiler Height (H) Total depth (L1) Total Total width (B1) dimensions Total height (H1) Total boiler body mass

EKO-CKS 150

EKO-CKS 200

EKO-CKS 250

EKO-CKS 300

EKO-CKS 380

110 - 150 1600 750 1600 1600 900 1600 700

150 - 200 2000 750 1600 2000 900 1600 900

200-250 2000 850 2100 2000 1000 2100 1300

250-300 2350 850 2100 2350 1000 2100 1500

300-380 2350 1000 2100 2350 1150 2100 1750

Total boiler mass (firing boiler body with insulation and regulation) Boiler water content Max. operat. pressure Inlet/Outlet Safety line Boiler connections

Filling/Draining Safety line dimens. Safety pump -

Boiler flue exhaust outer diameter Boiler flue exhaust (cyclone)

Chimney underpressure

800

1050

1405

1625

1885

l bar R/DN R/DN G G

380 4 2" 6/4" 1" 6/4"

520 4 2" 6/4" 1" 6/4"

790 4 80 40 1" 6/4"

963 4 80 40 1" 6/4"

1155 4 80 40 1" 6/4"

as Grundfos

as Grundfos

as Grundfos

as Grundfos

as Grundfos

250 250x90 18 0,18 34 0,34

300 250x90 20 0,20 38 0,38

300 300x100 23 0,23 42 0,42

300 350x100 25 0,25 45 0,45

300 350x100 27 0,27 50 0,50

TIP type UPS-32-60 type UPS-32-55 type UPS-32-55 type UPS-32-80 type UPS-32-80

suggestions

Combustion chamber resistance

kg

mm mm Pa mbar Pa mbar

Dimensions TYPE B B1 H1 H2 H3 H4 H5 L DL SV VV

mm mm mm mm mm mm mm mm mm mm mm

EKO - CKS 150

EKO - CKS 200

EKO - CKS 250

EKO - CKS 300

EKO - CKS 380

750 900 1600 290 500 1280 155 1965 606 532 424

750 900 1600 290 500 1280 155 2000 1006 532 424

850 1000 2100 290 500 1705 155 2000 1006 582 630

850 1000 2100 290 500 1705 155 2350 1356 582 630

1000 1150 2100 290 500 1705 155 2350 1356 682 625

2



Technical manual EKO-CKS

Technical manual EKO-CKS

27

Aditional equpiment-Assembling and connecting the boiler regulation While assembling the boiler casing the regulation sensors have to be inserted in the probe situated on the upper front side of the boiler, the fan connection and supply cables have to be pulled through. Screws 4,2x16 mm screw to half into allredy drilled holes in lower side of the casing (Image 9 and 10). Put regulation on screws and screw the screws completely. At the end put the regulation lid on regulation and screw 2 screws M4x10 mm on (Image 11.)

Dimensions of the boiler STO

T

PLV

SPLV DPO

GV

RP ZP

OK

DV

OG SV

SPVV PVV

VV OSZ

Image 11.

EKO-CKS boiler

or

r tu

Regulation thermostate sensor

e

BOZ

ns se

VPZ

ra pe m e Te rob p

DL

B

L = L1

B1

DPO

Thermometer

DPK*

OC Lower right (option: lower left) side of the boiler casing EKO-CKS

Sensor of the termometer

H4

A

!

Boiler regulation lid

H2

Screw M4x10 mm

H5

H3

TEHNIKA

GRIJANJ

PP



H = H1

Safety thermostate sensor

* Rectangular

Boiler regulation EKO-CKS Tapping screw 4,2x16 mm

26



Technical manual EKO-CKS

Legend: DPO - Boiler flue exhaust (direct connection to the chimney) *DPK - Boiler flue exhaust (connection through the cyclone and fan drive) OC - Opening for cleaning OSZ - Secondary air door PLV - Inlet PP - Filling/Draining PVV - Outlet RP - Opening for draught regulator (with cyclone - watertight sealed) SPLV - Safety inlet line

Technical manual EKO-CKS

boiler flue exhaust is recommended when the boiler is connected to the chimney through the fire fan and fan drive (cyclone).

SPVV STO TOK DV GV OG VPZ -

Safety outlet line Temperature sensor probe Thermometer Condensate exhaust connection Lower boiler door Upper boiler door Visual control opening Primary air door/opening for cleaning ZP - Underpressure regulator lid BOZ - Side air opening

3

Aditional equpiment-Assembling of the boiler regulation

Description of the boiler

Image 8. Control panel of the boiler regulation

1.0. DESCRIPTION OF THE BOILER

5

WARNING: Connection of the boiler to the chimney and to the central heating system as well as the start-up has to be performed by the authorized person licensed on behalf of Centrometal d.o.o. company.

6

7

4 3 2 1

TEHNIKA GRIJANJA

!

9

14.2.

8

CONNECTION THE BOILER REGULATION WITH THE FAN TO THE EL. POWER NET

The boiler regulation should be connected to the fan according to the image 7. plan of the connection to the boiler regulation and to the electrical power net on page 22. 14.3. ASSEMBLING THE BOILER REGULATION Before assemblage of the boiler cover, 3 holes should be made on the lower side of the cover: on the right lateral (or left lateral side), which depends upon the position of the boiler in the heating room - (see plan for the boiler casing EKO-CKS on the page 13). The 2 holes should have diameter of Ř3,5 mm for screws and also one bigger hole (Ř22,3 mm) should be made for sensors, supply and connection to the fan. The Image 9. shows places where the holes are to be made. Lower right side (option lower left side) of EKO-CKS boiler cover

200

0 20

Hole for the sensor (included)

1

f3 ,5 f2 2, 3

45

EKO-CKS is a special steel boiler for central heating systems. It has been constructed on the basis of a long term experience. The boiler is engineered for solid fuel firing. Its nominal thermal output is achieved through solid fuel (Hd>15000 kJ/kg). The steel body of the boiler is welded according to modern technology, produced out of high quality material and tested in compliance with EN-303-5 norm. Boiler`s efficiency rate reaches over 75%. It is constructed for a maximum operating pressure of 4,0 bar. The entire surface inside the boiler which comes in touch with fire or with smoke is in contact with water and its tubing net has water cooling. Flue gases are streaming through three passages of exchanging surfaces: combustion chamber, first bundle of boiler flue exhaust and the second bundle of boiler flue exhaust tubes. After that they are coming out through the smoke chamber and through the chimney connection. The firing procedure is manual through the spacious door. The temperature , i.e. fire intensity is regulated by the underperssure lid in boiler flue exhaust and properly sized fan. Additional firing regulation can be achieved through the secondary air door which is situated on the lower boiler's door. The upper boiler door enables the access to the first and second bundle of the boiler flue exhaust tubes and their cleening. There is also free access to all other doors and openings when the boiler has to be cleaned. The boiler is equipped with all necessary connections for the connection to the central heating system. The body of the boiler is delivered separately from the casing and the thermal insulation which enables easier transportation and assemblage without unnecessary risks.

0

Drill the holes

1

36 00

1

Lower right side (option lower left side) of EKO-CKS boiler cover

Image 9.

Image 10.

After the holes have been perforated, through the bigger hole the tap should be inserted (included in delivery package) and pulled through the sensors, supply and the wires for the connection with the fan (Image 10). 4



Technical manual EKO-CKS

Technical manual EKO-CKS

25

Delivery package, additional equipment and assemblage of the boiler

Additional equipment-boiler regulation 14.0. BOILER REGULATION In order to obtain a regular and safe operation of the EKO-CKS boiler connected with the cyclone CC and the fan there is a need to install the boiler regulation. The regulation steeres the start ups and stops of the fan, according to the set boiler temperature.

1.1. DELIVERY PACKAGE - Boiler's body with the door - Casing with thermal insulation - Thermometer, draught regulator, cleaning set (cleaning brush, poker, shovel)

14.1. DESCRIPTION OF THE BOILER REGULATION 1. MAIN SWITCH Switch with the signal light for starting and stopping the control unit. 2. FAN Switch with the signal light for starting and stopping the fan (light if the switch is on). 3. CONTROL LIGHT OF THE FAN If switch is on (position 2), light is on when the fan is working. 4. CIRCULATION PUMP Switch with the signal light for starting and stopping the circulation pump (light if the switch is on). 5. CONTROL LIGHT OF THE CIRCULATION PUMP If switch is on (position 4), light is on when pump is working. 6. REGULATION THERMOSTATE OF THE BOILER Interval of the boiler operating temperature regulation (30-90°C), is performed by turning the button (position 6). 7. SAFETY THERMOSTAT Switches off the fan if the boiler temperature exceeds 110°C-9°C; which protects the system from break down. In order to restart the fan, following has to be done: - wait until the boiler temperature falls below 70°C. -open the safety thermostat lid (position 7): - press the red button If the system switches off successively, let the authorized person check the system.

1.2. ADDITIONAL EQUIPMENT - Cyclone CC for dust cleaning - Fan for flue gases - Boiler regulation - CAS water accumulator 2.0. ASSEMBLAGE OF THE BOILER It is recommended to put boiler on the previously prepared concrete fundament which minimum height is 200-300 mm. The upper fundament surface has to be smooth and exactly horizontal. The room has to be frost proof and adequately ventilated. The boiler has to be situated in order its connection to the chimney can be performed correctly (Image 1. and 2.); its cleaning and handling should be convenient. If there is planned an cyclone and fan connection, the boiler has to be situated to have all its parts easily accessible (Image 2.). The casing has to be assembled after the boiler has been connected to the chimney and to the central heating system, according to the instructions attached (Image 6.). If the fan regulation is included, the boiler regulation has to be connected previously to the casing (page 23.). Before connecting to the instalation the boiler has to be put exactly in the horizontal position.

8. CONTROL LIGHT OF THE FAN The light shall be switched on if the fan's operation is disturbed. 9. CONTROL LIGHT OF THE SAFETY PUMP Light is on if safety pump of the boiler is working. 24



Technical manual EKO-CKS

Technical manual EKO-CKS

5

Connection to the chimney, fresh air opening

Additional equipment-boiler regulation

3.0. CONNECTION TO THE CHIMNEY Properly dimensioned and built chimney is the main condition for safe and economical functioning of the boiler. The thermal insulation of the chimney has to be done properly, it has to be absolutely gas-proof and smooth. On its lower part there has to be built in the opening for cleaning with the door. An brick-layed chimney has to have three layers with an insulation of 30 mm in the middle, if the chimney is built inside the house (i.e. inside the heated area), or an insulation of 50 mm if it is built outside the house (i.e. outside the heated area). The flue gas temperature has to be at least 30°C higher then the temprerature of their consdensation point. The choice and the construction of the chimney has to be performed by the authorized person. 3.1. DIRECT CONNECTION TO THE CHIMNEY Inside dimensions of the chimney intersection depend of its height and of the capacity of the boiler (Image 3.). Prescribed maximal distance between boiler and the chimney is 700 mm, minimal distance 300 mm. Boiler flue exhaust angle has to be 30° to 45° (Image 1). In order to unable condensate to enter the boiler, the flue exhaust pipe has to be situated 10mm deaper inside the chimney. The pipe connecting the boiler and the chimney has to have a thermal insulation made out of 30-50mm thick stone wool. If for any reason the boiler has to be connected to the chimney dimensioned for higher capacity boilers, the possibility of condensation inside the chimney shall be highly inreased. The boiler's function shall not be affected, but the damper on the flue exhaust has to be positioned according to the chimney underpressure (see technical data regarding the chimney pressure for each type of the boiler).

TECHNICAL MANUAL for assembling, use and maintenance of the solid fuel firing boiler and the installation of the additional equipment

3.2. CONNECTION THROUGH THE CYCLONE AND FAN DRIVE In case of the connection through the flue gas fan the height of the chimney can be reduced for 50% regarding the read value (see Image 3). The cyclone is directly connected to the boiler and the distance between the fan and the chimney shall be determined by enabling the smooth maintaining of the cyclone, flue gas fan, boiler and the chimney. The cyclone and connecting tubes have to be coated by an 30-50mm stone wool termal insulation. 4.0. PRIMARY AIR SUPPLY OPENING Every heating room has to have an primary air opening dimensioned according to the boiler's capacity. The opening has to be protected by a net. A=6,02 Q

A - opening surface in cm˛

BOILER REGULATION

Q - rated thermal output in kW

6



Technical manual EKO-CKS

Technical manual EKO-CKS

23

Additional equipment-electrical power net connection

Connection to the chimney, connection to the cyclone

CONNECTION OF THE FAN TO THE REGULATION AND TO THE ELECTRICAL POWER NET

Image 1. Connection of the EKO-CKS to the chimney

Image 7. Plan of regulation and fan connections to the electrical power net.

PS2

PS1

10mm

Thermal insulation necessary Opening for cleaning

BOILER EKO-CKS

ST SS RT1

1

3

2

3

1

2

1

2

60

80

70

2

1

min. 300 mm max. 700 mm

Image 2. Connection of the EKO-CKS to the chimney through the cyclone CC and the fan drive

0 L1

0 L1

SAFETY TENSION BOILER 230V PUMP

0 L1 S3 T1 T2

95

FAN

Temperature at rated thermal output has to be min. 160°C-180°C

Ie

Boiler regulation (additional equipment)

A1 C1 Compensating set (included)

Additional equipment

C1

Kingerit-joint (included) Damper for the fan balancing (flue gases temper. behind the fan drive has to be min 160°C-180°C)

96 98

Thermal insulation necessary

Flue gas exhaust fan with electro motor

Ie

L1 L2 L3

TENSION 380 V

AJNAJIRG

AKINHET

!

Cyclone CC

U1 V1 m1 W1

Chimney Thermal insulation necessary

Boiler EKO-CKS

Box for cleaning the cyclone

PS1 - Switch (burner) PS2 - Switch (pump) SS - Signal light ST - Security thermostate RT1 - Working thermostate 1. stage

C1 - Contactor ABB, A16-30-10 le - bimetal protection, 4-6 A m1 - fan motor

22



Technical manual EKO-CKS

- Connection of the fan drive to the chimney has to be performed Note: - Cyclone and boiler connection with screw joint M8 - 6 pieces using the compensating set to reduce vibrations - Connections of the boiler to the cyclone and fan drive to the chimney - Cyclone to be connected to the fundament by screws have to be gas-proof. - Connection of cyclone to the fan drive by screw joint - Flue gas installation has to be absolutely gas-proof. M8 - 8 pieces done in the factory before delivery - Flue gas installation and the cyclone have to have a thermal insulation

Technical manual EKO-CKS

7

Choice of the chimney

Additional equipment-fan

Image 3. Dimensioning the chimney for EKO-CKS boilers (Tdpl=250°C) boiler connection directly to the chimney (without cyclone and fan drive).

Chimney intersection (cm)

Rated thermal output (kW)

Both parts are subjected to the wear and tear. The main reason is dust, i.e. the acid mixed with the medium inside the tubes, steam and gases. The wear and tear grade depends on the kind and quantity of the substance. During the rotation the rotor could slip out of its center, which causes the damage of bearings, of the axle and of the rotor itself. Because of the material wear and tear the solidity of the rotor can be minimized, which leads to its break down as well as to a heavy damage of the fan. The rotor and the housing have to be checked once in the month. During the operation process of the fan, there has to be payed special attention to its smooth moving, i.e. the vibration level has to be checked. The cleaning of the rotor depends of the dust quantity. Depending on general conditions (wear and tear of the rotor, higher dust stickiness) the controls have to be repeated in shorter periods.

50

40

45

35

30

22

25

20

18

16

Coal

Height of the chimney (m) (from the connecting point of the boiler )

Example for the chimney selection for the direct connection with the chimney (wood firing ) without cyclone and fan drive

50

45

40

35

30

25

22

20

18

Wood

Height of the chimney (m) (from the connecting point of the boiler )

Thermal output (300kW) Height of the chimney (13m) Min.chimney intersection 45cm

Rated thermal output (kW)

13.7. THE ROTOR AND THE FAN'S HOUSING

Chimney intersection (cm)

8



Technical manual EKO-CKS

Technical manual EKO-CKS

21

Connection to the installation, safety pump

Additional equipment-fan 13.3. CONNECTION OF THE FAN TO THE ELECTRICAL POWER NET This connection has to be performed only by an authorized person. Technical data concerning the motor are attached in the technical manual and are also written on the motor body. The rotation sense of the fan is indicated on its casing and has to be considered. The cable has to be protected from mecanical or other kind of damages, set in the proper way, in order to avoid any damages. Connection plan to the electrical power net is shown on Image 7., page 22. 13.4. STARTING THE FAN First to be checked if the fan is properly fasten to the cyclone. Revolve the fan manualy and find out if it is rotating without touching any obstacle. The rotor is not allowed to touch its housing! During its first start up it is necessary to start the fan when the draught regulator is closed or otherwise closed air flow, in order to enable the motor to reach the speed easier. During the first short start up it is necessary to control the fan rotation sense (sense of the arrow). It has also to be checked if during the start up some kind of strange noices are appearing. Check the vibrations and find out if they are exceeding the normal range. The damper for the balancing of the fan which is situated on the flue exhaust of the boiler and should be put in the position which enables the flue exhaust gases temperature to reach minimum 160°C - 180°C at nominal thermal output.

While the motor is running it is necessary to control the temperature of the motor and its bearings. The motor housing temperature should not exceed 70°C (constant operation). If the bearings are getting warmer the fan has to be stopped and the reason for the exceed temperature has to be found out. 13.6. MAINTAINING THE FAN After each 6000 working hours, i.e. once in the year it is necessary to: check the general condition of the fan; check all elements and screw joints; check all welding points, especially those on the rotor; check the wear and tear of the motor housing and of the rotor; check the condition of the compensator and belonging steerings (tightness, wear and tear). In case the spare parts are needed, they have to be cleaned previously.



5.1. CONNECTION OF THE BOILER TO THE OPEN EXPANSION VESSEL The boiler has to be connected to the open system according to the Image 4. All connections from the boiler to the open expansion vessel and from the open expansion vessel to the boiler have obligatory to be covered by the thermal insulation of min. 40mm (stone wool or equivalent insulating material). If the expansion vessel is situated outside the heated area, it has to be insulated. The dimension of the open expansion vessel is determined by the quantity of water inside the installation, i.e. approximatly 7% of the total water quantity inside the entire installation. 5.2. BOILER SAFETY PUMP In order to minimize the condensation inside the boiler a safety line with an safety pump has to be build in (Image 5.). Activating and disactivating of the safety pump is steered by the pipe valve situated on the boiler's outlet, approx. 300 mm from the safety line connection point, towards the installation with an functioning field of 0°C to 65°C. Safety line suggestions according to the boilers' capacity is shown by the table „TECHNICAL DATA“. Safety line has to be covered by thermal insulation, min. 40 mm stone wool or equivalent insulating material. 5.3. CONNECTION OF THE BOILER TO THE CENTRAL HEATING SYSTEM

13.5. TEMPERATURE OF THE FAN BEARINGS

20

5.0. CONNECTION OF THE BOILER TO THE CENTRAL HEATING INSTALLATION

Technical manual EKO-CKS

The central heating system to be connected to the boiler has to be performed according all professional and security standards. The regulation of the room temperature can be solved in few ways, but each of solutions has to be worked out in order the outlet water operating temperature does not reach the value below 60°C. It is recommended to build in the 4-passes manual valve. In order to minimize the water steam condensation of the flue gas, it is necessary the circulating pump of the heating circuit/s to be activated and disactivated by means of the pipe thermostate set up to min. 75°C. The system can also be regulated by means of any other appropriate system. The pipe thermostat has to be situated on the boiler's inlet right next to its connection to the boiler. The general connection plan is figured on the Image 5.

Technical manual EKO-CKS

9

Additional equipment-cyclone and fan

Connection scheme

Image 4. General connection plan of the EKO-CKS boiler to the open system

D

OPC

A E

B

The cyclone CC produced by Centrometal is used to filter flue gases. 12.1. CONNECTING THE CYCLONE CC

F

G

12.0. CYCLONE CC

C

The cyclone CC has to be connected to the chimney behind the boiler. A general connection plan is shown on the Image 2, page 7. If the flue exhaust of the boiler and the opening of the cyclone do not have identical diameter, there has to be constructed a connecting part, which has to be hermeticaly fixed between cyclone and the boiler. There also has to be built in the klingerit-joint which is included in our standard delivery. Connect the absorbing part of the cyclone to the upper connection point (flange), if it has not already been connected by the manufacturer. Between the cyclone and the fan there a klingerit-joint has to be inserted (if it has not already been built in by the manufacturer). The cyclone and the entire flue exhaust installation has to be coated by thermal insulation made out of 40mm thick stone wool or equivalent material. 12.2. ASSEMBLING THE CYCLONE The cyclone CC has neither movable nor parts subjected to wear and tear. On its lowest point there is an opening for cleaning. When necessary (depending on the quantity of the exhaust gases particles) it has to be opened and cleaned.

BOILER EKO-CKS

13.0. FAN The fan takes out exhaust gases out of the boiler and pushes them to the chimney. TO THE BOILER ROOM

H

The fan is not allowed to be touched neither on the inlet or outlet opening nor on the fan axle or on the electrical motor. There has to be enough space provided for the assemblage, for the technician and his tools. The installation according the Image 2 to the cyclone outlet. After assembling the fan has to be leveled. 13.2. FAN CONNECTIONS

LEGEND: A - Safety inlet NO 40 B - Safety outlet NO 32 C - Overflow line NO 40 (has to lead to the boiler room)

13.1. INSTALLING THE FAN

D - Air vent E - Throttle valve F - Open expansion vessel OPC G - Inlet (heating) H - Outlet (heating)

10



Technical manual EKO-CKS

The connection to the pressure tubing system only with their connections is not allowed. It is also not allowed to transfer additional burden to the fan through the tubing system. Pressure tube connection of the fan has to be connected to the pressure tubing system by means of elastic joints compensators, which do not transfer vibrations. The tube connections and tubes itself have to be hermeticly closed. Technical manual EKO-CKS

19

Connection scheme

Technical data for cyclone CC Cyclone CC - technical data

Image 5. General connection plan of the EKO-CKS boiler to the heating system

L L2

K

D1 D3

L1

D2

....

L7

D3 L6

D

L3

L5

Connection to the boiler

L8 L8

G

Connection to the cyclone and flue exhaust installation

M

A

L

F

T T

H L4

C

T

B

H1

H

I

BOILER EKO-CKS

Box for cleaning the cyclone

D J

CYCLONE TYPE FOR THE BOILER Total height of the cyclone H Boiler connection height H1 Total depth of the cyclone L Total width of the cyclone L1 Distance L2 Connection height L3 Connection width L4 Height opening L5 Width opening L6 Distance L7 Distance L8 Cyclone diameter D Opening diameter D1 Outer connection diameter D2 Screw hole diameter D3 Cyclone mass

(mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (mm) (kg)

CC 150-200 EKO-CKS 150/200

CC 250 EKO-CKS 250

CC 300-380 EKO-CKS 300/380

1476 1284 566 458 142 340 190 250 90 140 150 fi 380 fi 174 fi 253 fi 11,5 61

1988 1705 612 498 157 390 190 294 94 150 175 fi 426 fi 214 fi 310 fi 10 88

1940 1705 718 607 208 440 190 344 94 150 200 fi 526 fi 203 fi 260 fi 11 114

18



Technical manual EKO-CKS

E cca. 300mm

LEGEND: A - Inlet B - Outlet C - Safety line D - Safety pump E - Pipe thermostate (operat. temp. 0-60°C) F - 4-way manual mixing valve

G - Circulation pump accord.to the system H - Pipe thermostate (operat.temp over 75°C) I - Safety inlet J - Safety outlet K - Stop valve L - Thermal insulation of the safety boiler circuit M - Automatic air vent pot T - Thermometer

NOTE: CLOSING VALVES ARE NOT DISPLAYED ON THIS PLAN Technical manual EKO-CKS

11

Filling the system, casing assemblage, condensate output connection

Additional equipment-cyclone and fan

6.0. FILLING THE SYSTEM The boiler and the entire central heating system have to be filled with water according to the EN norm. The system has to be airvented in order the water can circulate normaly. 7.0. CASING ASSEMBLAGE

TECHNICAL MANUAL

Assamblage of the thermal insulation and plastified metal sheet coating can be started after the boiler has been connected to the chimney and to the central heating installation. If the boiler regulation is planed for the fan, before assembling the boiler casing, the regulation has to be fixed. The order of assembling is described on Image 6. and the plan which is attached to the package.

for assembling, use and maintenance of the additional equipment

8.0. CONNECTION OF THE CONDENSATE OUTPUT During the first heating process, usually by means of solid fuel firing, when the temperature in the boiler is below 65°C, a certain quantity of condensate produced by water steam appears on the cold walls of the boiler. In order to let this condensate get out of the boiler, in the left lower corner of the upper boiler's door (see page 3) there is an output. It is connected by an 1/2“ inside thread to which a flexible plastic/gum pipe can be connected which is draining the condensate into the plastic pot, or simply out of the boiler.

CYCLONE CC AND THE FAN 12



Technical manual EKO-CKS

Technical manual EKO-CKS

13 17

Notes

Assembling order for the casing Image 6. Assembling order for the casing of EKO-CKS boiler B

B 4

A 5

Detail X

6

D

B

B

3

C

A C

2

2

D

D 8

D 1

A

C

99

Detail Y

C C

2

7

D

upper casing porter

1

B

(4.2x16) (fi 12x4.2) factory mounted (4.2x32)

C

(3.9x9.5)

A

A

1

lower casing porter

C

C

2

Detail Z

Insert the lower lateral part of the insulation (1) into the slit D in order it fits into the lower boiler casing porter (see detail Y), in the same time put the lower part of the casing into the lower slit. Fix the upper lateral part of the insulation (2) onto the upper porter of the boiler (see detail Z), while the lower part of the upper lateral insulation plate is fixed on the porter of the boiler according to the detail Y. The sensor of the thermometer has to be inserted into the probe on the upper side of the boiler and the upper front cover (3) has to be hanged over the hooks A and fixed by screws B on the casing (2). The same has to be done with the upper back cover (4). The stone wool has to be placed on the upper side of the boiler. After that the cover (5) hast to be placed on the plate (2) as well as the cover (6) being fixed into the slit (5) (detail X). The back side plate (7) and then (8) has to be fixed on the boiler and fixed together by help of the screw C, successively to the lateral plates of the boiler (1). Before assembling the front insulation plate (9) take off the side air opening, then open the lower door and pull through the front insulation plate over them. After this step we adjust front insulation plate on the pin A on the left and right plate (1), and put back the side air opening. 16 12



Technical manual EKO-CKS

Technical manual EKO-CKS

13

Firing the boiler, cleaning and maintaning

Start up 9.0. START UP OF THE BOILER

10.0. FIRING THE BOILER

The start up has to be done by the person authorized on behalf of Centrometal d.o.o. It is necessary the check if previous assemblage has been performed exactly according to the requirements and description of this manual. Additionaly following has to be checked: - the boiler and the central heating system have to be filled with water and airvented. - the security elements are functioning and if they are correctly connected. - the flue connection tube is well connected, insulated, and sealed. - flue gas lid is properly set according to the chimney underpressure. - all objects, which eventually could have been left inside the boiler are removed (from the combustion chamber, exhaust tubes, etc.). Some objects could have been put inside during the assemblage for any reason and could negatively influence the functioning. - the upper and lower door of the boiler is well set (seal properly). - the primary air/cleaning door properly fits. - the draught regulator is put in the proper position and if it is properly connected with the chain to the primary air/cleaning door (in case of cyclone - opening of draught regulator must be watertight sealed). - the secondary air regulator on the lower boiler door is closed. - the side air opening can freely open/close, when the boiler does not work, side air opening must be closed. - the heating room has proper air circulation. - the tube thermostate of the boiler's security pump is set to 65°C (the pump is functioning from 0°C to 65°C). - the tube thermostate of the heating circuit pump is set up to 75°C (the pump is functioning above 75°C). The start up procedure includes also: - starting of at least one heating process during which the functioning of the draught regulator (in case of cyclone - uderpressure regulator lid and fan regulation) has to be set, so that the temperature inside the boiler during a normal firing process does not exceed 90°C and does not decrease below 75°C. - check the outlet water temperature during functioning, because this temperature should not be under 60°C. If it happens the system should be accordingly set up. - secondary air flow is set (can also be closed) - training the person in charge of the boiler room, training protocol signed by the trained person. 14



Technical manual EKO-CKS

The boiler is constructed to be manualy fired by means of solid fuel. Nominal thermal output is obtained through solid fuel and its lower calorific value Hd>15000 kJ/kg. After the initial firing the fuel has to be supplied in the way the boiler reaches the temperature of 70°C as soon as possible in order to minimize the intensity of the initial condensation. The functioning of the draught regulator (in case of cyclone - uderpressure regulator lid and fan regulation) has to be set in the way the temperature inside the boiler during the normal combustion does not exceed 90°C and does not fall below 75°C. It is also necessary to take care of the outlet water temperature during the operation, because it should not fall under 60°C. Additional regulation of the combustion quality can also be reached by setting the secondary air opening. Between two firing, it is recommended to pass over the glow with the poker in order to obtain a balanced fresh air supply. It is also necessary to take care of all other previously mentioned points of this technical manual. The fuel has to be dry as usualy recommended for this kind of firing, for example, two years long air dried wood, i.e. the wood has to contain less then 30% humidity. 11.0. CLEANING AND MAINTAINING The space under the grate and the combustion chamber has to be cleaned every day. The space under the grate can be cleaned through the primary air/cleaning door, which previously has to be removed without separating the chain of the draught regulator. Clean of the flue exhaust tubes of the second and third passage when necessary or once a week through the upper boiler door with the brush which has to be pushed through the whole length of the tube. On the back side of the boiler there is another opening for cleaning (see page 3.) through which is possible to remove the material which has been collected during firing as well as during the cleaning process. The hole can be approached by removing M8 screws and covers. If there is a possibility of freezing, the boiler has to be fired constantly. Draining the water out of the system is absolutely not the right solution, because this would cause corrosion of the entire central heating system as well of the boiler' interior. Technical manual EKO-CKS

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