Centrometal EKO-CKS Boiler Technical Manual

Technical Manual

For assembling, use and maintenance of solid fuel firing boiler and its additional equipment.

Model: EKO-CKS

CE Marked

1.0. Description of the Boiler

The EKO-CKS is a special steel boiler for central heating systems, engineered for solid fuel firing. It is constructed using modern technology with high-quality materials, tested in compliance with EN-303-5 norm. The boiler boasts an efficiency rate over 75% and a maximum operating pressure of 4.0 bar. It features a three-passage system for flue gas streaming: combustion chamber, first bundle of boiler flue exhaust, and the second bundle of boiler flue exhaust tubes. Manual firing is done through a spacious door, with temperature regulation via an underpressure lid in the boiler flue exhaust and a sized fan. Secondary air regulation is available through a door on the lower boiler. The upper boiler door provides access for cleaning the flue exhaust tubes. The boiler is delivered separately from its casing and thermal insulation for easier transportation and assembly.

WARNING: Connection to the chimney and central heating system, as well as start-up, must be performed by an authorized person licensed by Centrometal d.o.o.

Technical Data

Dimensions

3.0. Connection to the Chimney

A properly dimensioned and built chimney is crucial for safe and economical boiler functioning. The chimney must be well-insulated, gas-proof, and smooth, with a lower opening for cleaning. Brick-layed chimneys require three layers with 30mm insulation in heated areas or 50mm in unheated areas. Flue gas temperature should be at least 30°C higher than the condensation point. Chimney construction must be performed by an authorized person.

3.1. Direct Connection to the Chimney

Chimney intersection dimensions depend on height and boiler capacity. The maximum distance between the boiler and chimney is 700mm, minimum 300mm. The flue exhaust pipe angle should be 30° to 45°. To prevent condensate entry, the flue exhaust pipe must be situated 10mm deeper inside the chimney. The connecting pipe requires 30-50mm thick stone wool insulation. Connecting to a chimney designed for higher capacity boilers increases condensation risk. The damper on the flue exhaust should be positioned according to chimney underpressure.

3.2. Connection Through the Cyclone and Fan Drive

Using a flue gas fan can reduce chimney height by 50%. The cyclone connects directly to the boiler. The distance between the fan and chimney should allow for easy maintenance of the cyclone, fan, boiler, and chimney. The cyclone and connecting tubes require 30-50mm stone wool thermal insulation.

4.0. Primary Air Supply Opening

The heating room requires a primary air opening dimensioned according to the boiler's capacity, protected by a net.

14.0. Boiler Regulation

The boiler regulation is essential for regular and safe operation of the EKO-CKS boiler with the cyclone CC and fan. It controls fan start-ups and stops based on the set boiler temperature.

14.1. Description of the Boiler Regulation

• 1. Main Switch: Starts and stops the control unit with a signal light.
• 2. Fan: Starts and stops the fan with a signal light (on when active).
• 3. Control Light of the Fan: Indicates when the fan is working.
• 4. Circulation Pump: Starts and stops the circulation pump with a signal light (on when active).
• 5. Control Light of the Circulation Pump: Indicates when the circulation pump is working.
• 6. Regulation Thermostate of the Boiler: Regulates boiler operating temperature between 30-90°C.
• 7. Safety Thermostat: Switches off the fan if boiler temperature exceeds 110°C ± 9°C to prevent system breakdown. To restart, wait for temperature below 70°C, open the safety thermostat lid, and press the red button. If issues persist, contact an authorized person.
• 8. Control Light of the Fan: Illuminates if the fan operation is disturbed.
• 9. Control Light of the Safety Pump: Illuminates if the safety pump is working.

1.1. Delivery Package

• Boiler's body with the door
• Casing with thermal insulation
• Thermometer, draught regulator, cleaning set (cleaning brush, poker, shovel)

1.2. Additional Equipment

• Cyclone CC for dust cleaning
• Fan for flue gases
• Boiler regulation
• CAS water accumulator

2.0. Assemblage of the Boiler

The boiler should be placed on a prepared concrete fundament (minimum height 200-300 mm), ensuring the surface is smooth and horizontal. The room must be frost-proof and adequately ventilated. The boiler's position should facilitate chimney connection, cleaning, and handling. If a cyclone and fan are used, ensure all parts are accessible. Casing assembly follows boiler connection to the chimney and central heating system. Boiler regulation should be connected to the casing prior to installation. Ensure the boiler is positioned horizontally.

13.3. Connection of the Fan to the Electrical Power Net

This connection must be performed by an authorized person. Ensure the fan's rotation sense is correct and that the cable is protected. Refer to Image 7 for the connection plan.

13.4. Starting the Fan

Verify the fan is securely fastened to the cyclone and rotates freely. During the first start-up, close the draught regulator to allow the motor to reach speed. Check fan rotation sense, listen for unusual noises, and check for vibrations. Set the fan damper to achieve a flue gas temperature of at least 160°C-180°C at nominal thermal output.

13.5. Temperature of the Fan Bearings

Monitor motor and bearing temperature; it should not exceed 70°C during operation. Stop the fan if bearings overheat.

13.6. Maintaining the Fan

Every 6000 working hours or annually, check the fan's general condition, screw joints, welding points (especially on the rotor), wear on the motor housing and rotor, and the compensator and steering condition. Clean or replace spare parts as needed.

5.0. Connection of the Boiler to the Central Heating Installation

5.1. Connection of the Boiler to the Open Expansion Vessel

Connect the boiler to the open system as per Image 4. All connections must have a minimum 40mm thermal insulation. The open expansion vessel size depends on the installation's water quantity (approx. 7% of total).

5.2. Boiler Safety Pump

A safety line with a safety pump minimizes condensation inside the boiler (Image 5). The safety pump is activated/deactivated by a pipe valve. Safety line suggestions are in the "TECHNICAL DATA" table. The safety line requires minimum 40mm thermal insulation.

5.3. Connection of the Boiler to the Central Heating System

Connect the central heating system according to professional and security standards. Ensure the outlet water operating temperature does not fall below 60°C. A 4-pass manual valve is recommended. To minimize flue gas condensation, the circulating pump should be activated/deactivated by a pipe thermostat set to a minimum of 75°C. The pipe thermostat should be located on the boiler's inlet.

6.0. Filling the System

Fill the boiler and central heating system with water according to EN norms and ensure proper air venting for circulation.

7.0. Casing Assemblage

Thermal insulation and casing assembly can begin after the boiler is connected to the chimney and central heating installation. If the boiler regulation with a fan is planned, fix the regulation before assembling the casing. Refer to Image 6 and the package plan for assembly order.

8.0. Connection of the Condensate Output

During the initial heating process, condensate may form on the boiler's cold walls when temperatures are below 65°C. An output in the lower left corner of the upper boiler door (see page 3) allows condensate to drain via a 1/2" thread connection to a plastic pot or outside the boiler.

9.0. Start Up of the Boiler

Start-up must be performed by an authorized person. Verify correct assembly, water filling and air venting, functioning of security elements, proper flue connection, correct flue gas lid setting, removal of any objects from the boiler, proper sealing of doors, and correct position of the draught regulator. Ensure proper air circulation in the heating room. Set the boiler's security pump thermostat to 65°C and the heating circuit pump thermostat to 75°C.

Start-up procedure includes:

• Conducting at least one heating process to set the draught regulator for optimal temperature (75°C-90°C) and minimize condensation.
• Checking outlet water temperature (should not be below 60°C).
• Setting secondary air flow.
• Training the person in charge of the boiler room and signing a training protocol.

10.0. Firing the Boiler

The boiler is designed for manual firing with solid fuel (calorific value Hd>15000 kJ/kg). After initial firing, supply fuel to reach 70°C quickly to minimize condensation. Set the draught regulator to maintain boiler temperature between 75°C and 90°C. Ensure outlet water temperature does not fall below 60°C. Secondary air opening can be adjusted for combustion quality. Periodically pass a poker through the glow for balanced air supply. Use dry fuel with less than 30% humidity.

11.0. Cleaning and Maintaining

Clean the space under the grate and the combustion chamber daily. Clean flue exhaust tubes weekly or as needed using the brush. An opening on the back of the boiler allows removal of collected material. If freezing is possible, keep the boiler firing constantly. Draining the system is not recommended due to corrosion risks.

12.0. Cyclone CC

The Cyclone CC, produced by Centrometal, filters flue gases. It connects to the chimney behind the boiler. A connecting part may be needed if diameters differ. Ensure hermetic sealing and use the provided klingerit-joint. The cyclone and flue exhaust installation require thermal insulation.

12.1. Assembling the Cyclone

The cyclone has no moving parts. It has a cleaning opening at the lowest point, which should be opened and cleaned as needed.

13.0. Fan

The fan expels flue gases from the boiler to the chimney.

13.1. Installing the Fan

Do not touch the fan's inlet, outlet, or axle during installation. Ensure adequate space for assembly and maintenance. Install according to Image 2 and level the fan.

13.2. Fan Connections

Connections to the pressure tubing system must not be forced. Use elastic compensators to prevent vibration transfer. Ensure all tube connections are hermetically sealed.

13.7. The Rotor and the Fan's Housing

Both parts are subject to wear due to dust and acidic substances. Check the rotor and housing monthly. Monitor for smooth operation and vibrations. Rotor cleaning depends on dust quantity. Adjust control frequency based on wear and dust stickiness.

Image 3. Dimensioning the chimney for EKO-CKS boilers

Diagram showing chimney dimensions based on rated thermal output (kW) for wood and coal firing, with and without cyclone and fan drive.

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

Diagram illustrating the connection of the EKO-CKS boiler to an open expansion vessel system, including safety inlet, safety outlet, overflow line, air vent, throttle valve, and circulation pump.

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

Diagram showing the general connection of the EKO-CKS boiler to the heating system, including circulation pump, pipe thermostats, safety inlet, safety outlet, stop valve, and thermometer.

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

Step-by-step diagram illustrating the assembly order of the boiler casing, including insulation parts, covers, and fixing screws.

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

Wiring diagram showing the connections between the boiler regulation, fan, safety pump, and the electrical power net.

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

Diagram showing the direct connection of the EKO-CKS boiler to the chimney, including recommended distances and thermal insulation.

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

Diagram illustrating the connection of the EKO-CKS boiler to the chimney via a cyclone CC and fan drive, including notes on temperature, insulation, and connections.

Image 8. Control panel of the boiler regulation

Diagram of the boiler regulation control panel with numbered components.

Image 9. and 10. Assembling the boiler regulation

Diagrams showing where to drill holes for the boiler regulation and how to insert the tap for sensors and wires.

Legend for Diagrams

Image 4 Legend: A - Safety inlet NO 40, B - Safety outlet NO 32, C - Overflow line NO 40, D - Air vent, E - Throttle valve, F - Open expansion vessel OPC, G - Inlet (heating), H - Outlet (heating)

Image 5 Legend: A - Inlet, B - Outlet, C - Safety line, D - Safety pump, E - Pipe thermostat (operat. temp. 0-60°C), F - 4-way manual mixing valve, G - Circulation pump accord. to the system, H - Pipe thermostat (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

Image 2 Notes: Connection of the fan drive to the chimney requires specific screw joints and compensating sets. Cyclone to fundament connection is by screws. Cyclone to fan drive connection uses screw joints. All connections must be gas-proof. Flue gas installation and cyclone require thermal insulation.

Diagram Notes: Rectangular boiler flue exhaust is recommended when the boiler is connected to the chimney through the fan and fan drive (cyclone).