Opop ECOMAX 25kW, ECOMAX 42kW, ECOMAX 35kW User Manual

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HOT WATER WOOD BOILER

ECOMAX 25, 35, 42kW

USER MANUAL

2012

Manufacturer:

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Contents

1. Safety instructions 3

1.1 Basic safety precautions 3

1.2 Fire protection in installing and using heating appliances 3

1.3 Operators and supervisors 4

2. Use 4

3. Technical description of the boiler 4

4. Technical parameters 6

5. Fuel material 6

6. Accessories 7

7. Preparing the boiler for commissioning 7

7.1 Binding standards for designing and installing the boilers 7

7.2 Boiler connection to the hot water system 7

7.3 Boiler connection to the smoke duct and chimney 9

7.4 Boiler connection to the power grid 9

8. Operating and maintaining the boiler 10

8.1 General principles 10

8.2 Operating modes 10

8.3 Adding fuel material 11

8.4 Control principle 11

8.5 Operation adjustment 13

8.6 Boiler cleaning and maintenance 13

8.7. Overview of possible defects 14

9. Controller configuration 16

9.1 Commissioning 16

10. Electric wiring 17

10.1 Conducting the patching cables 17

10.2. Description of the connection 17

10.3 Controller parameters 19

11. Disposal 19

12. Warranty Certificate 20

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1. Safety instructions

1.1 Basic safety precautions

1. Read carefully through the present boiler operating and maintenance manual and request adequate training from the
installer

2. The boiler connection must comply with the applicable regulations

3. Keep the boiler room tidy

4. Do not leave combustible articles in the vicinity of the boiler

5. The boiler may only be operated by persons above the age of eighteen

6. Do not allow children in the vicinity of the boiler

7. Use personal protective equipment – gloves, goggles and a cap

8. Use appropriate work attire avoiding easily combustible materials

9. Remain cautions while handling the stoking and ash pan door

10. Do not try to stoke with you long hair loose

11. Do not attach multiple appliances into one and the same chimney flue

12. Before leaving the boiler room, always make sure the chimney damper and the two doors are shut down

13. Regularly check water quantity in the system as well as the functioning of the safety equipment

14. Make sure the water in the system and the open expansion vessel has not frozen

15. Use specified fuel only

16. Do not leave the boiler unattended, ensure the heat power is consumed in the event the circulation pump stops
to work

17. In the event of boiler overheating, remove the hot firewood from the chute and allow the boiler to cool down

18. Any repairs and interventions with the electric wiring may reserved to an authorised person with a certificate in electric
engineering as provided for in Decree 50/75 Coll.

19. When handling the side covers, disconnect the boiler from the grid by pulling out the plug from the socket

20.

Follow the warning signs

1.2 Fire protection during installation and use of heating appliances

(Excerpts from ČSN 06 1008-Fire safety of local heating appliances a heat sources)

When installing the appliances, the safe distance of at least 200 mm from any construction material must be adhered to.
The distance applies to boilers and smoke ducts located in the vicinity of degree B, C1 and C2 combustibility materials
(for the degrees of combustibility, see the Table)
The safe distance (of 200 mm) must be doubled for any boiler and smoke flues located in the vicinity of C3 degree
of combustibility material.
The safe distance must also be doubled in the event no degree of combustibility of the combustible material is identified.
The safe distance shall be halved (100 mm) in the event of use of a heat insulating non-combustible board of the thickness
of at least 5 mm located 25 mm away from the combustible material (air insulation). A screening board or a protective screen
(over the protected article) must transcend the contours of the boiler including the smoke ducts by at least 150 mm on each side
and project at least 300 mm above the top surface of the boiler. A screening board or a protective surface must also be provided
to any fixtures made of combustible materials unless the safe distance can be adhered to (such as in mobile vehicles, weekend
houses, etc., for details see ČSN 06 1008).
The safe distance must also be adhered to when placing fixtures in the vicinity of the boilers.
If the boilers are located on the floors made of combustible materials, the same must be fitted with a non-combustible heat
insulating pad reaching at least 300 mm beyond the contours of the boiler on the side of the stoking and ash pan openings and
at least 100 mm on the other sides. All materials that display A degree of combustibility may be used as non-combustible heat
insulating pads.

Degree of combustibility of construction
materials and products

Construction materials and products classed into degree of
combustibility
(excerpt from ČSN 73 0823)

A - non-combustible

Granite, sandstone, concrete, bricks, ceramic tiles, mortar

Fireproof plasters, etc.

B - difficult to ignite

Acumin, isomin, heraclit, lignos, basalt felt boards, fibreglass
boards, "novodur", etc.

C1 – hardly ignited

Hardwood (oak, beech) hardboards, plywood,”sirkolit”, “werzalit“,

hardened paper

(“umakart

”)

C2 – normal combustibility

Coniferous wood (pine, larch, spruce),particle boards, cork boards,
rubber flooring (“Industiál”, “Super”)

C3 – easily ignited

Fibreboard (hardboard, sololaquers, etc.), cellulose materials,
polyurethane, polystyrene, polyethylene

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1.3. Operators and supervisors

Boiler operators must follow the operation and maintenance manual. Any interventions with the boilers that could endanger
the health of the operators or those sharing the household are inadmissible!
The boilers may only be operated by persons above the age of 18 familiar with the manual and operation of the boiler.
It is inadmissible to leave children unattended near the boilers in operation.
When operating solid fuel boilers, it is prohibited to use combustible liquids to fire up as well as to increase the nominal power
while the boiler is in operation (overheating).
No combustible articles may be cast towards the stoking and ash pan openings and the ashes must be put away
in non-combustible vessels with lids.
The boilers in operation must be under frequent supervision of the operators.
The user may only carry out such repairs that consisting in the plain replacement of a spare part supplied (such as shaped fireclay
bricks, sealing cords, etc.).
While operating the boiler, caution must be exercised to ensure tightness of the doors and cleaning holes. These must at all times
be closed with care!
The user must not interfere with the structure and electric wiring of the boilers!

The boiler operators must regularly check the water filling level of the heating system and check the pressure meter function.

In the event of overheating, the operator must shut off primary air supply and collect the fire wood including the hot
charcoal into a non-combustible vessel. If the water has boiled out of the heating system, it must not be filled into
the boiler until after the latter has cooled down! Otherwise the boiler and the heating system will be damaged!
An overheated boiler and heating system may only be recommissioned after all boiler and heating systems have been
thoroughly checked (this particularly applies to all safety systems).

1.4 Type of environment

The boilers may only be used in the basic “regular environments" as specified by ČSN 33 0300. The boilers must be installed
in a boiler room where access of air required for the combustion process is ensured; the boilers must be based on a non­combustible pad.

It is prohibited to position the boilers in residential spaces (including corridors)!

Warning:
In circumstances resulting in the risk of temporary ingress of combustible gases or vapours and while performing works
that might imply a temporary risk of fire or explosion (e.g. when gluing the lino, PVC, etc.), the boilers must be put out
of use in time and well in advance. No articles made of combustible materials may be placed on the boilers and within
smaller than the safe distance away from them!

2.

Use

The ECOMAX series hot water boilers are intended for heating villas or adequate production departments. The boilers must be
installed in specified working environments only.
The boilers are supplied in basic design controlled by an operating thermostat only and with electronic control which ensures
boiler power, control of the circulation pumps and, where relevant, control of the mixing valve.
The boiler must be operated in line with the requirements for the parameters of the chimney and the heating system.
The temperature of water returning to the boiler must not be less than 65°C. We recommend using a mixing valve and a water
storage tank.

3.

Technical description of the boiler

The core of the boiler is the body welded together out of steel plates. In the upper part of the body, a chute is fitted, equipped
with a closing stoke door. The lower part of the body is fitted with a circular combustion chamber with a closing ash-pan door. The
two spaces are mutually separated by a ceramic nozzle.
An air duct is provided in the frontal part of the body, which divides primary and secondary air. In the back part, there is
an exchange, a flue gas duct, a flue gas removal branch and cleaning holes. At the very bottom of the boiler body, there is a hole
of the filling and discharge valves.
Scanning sensor (pressure sensor, temperature sensor and safety sensor) beds and the hot water branch pipe issuing
into the heating system are welded on the top of the boiler body.
The boiler body is insulated with mineral felt and clad with protective covers. A discharge fan is connected to the smoke duct
outlet, where the purpose is to remove the flue gases towards the chimney. In the upper part of the boiler body there is a cooling
loop.
In the upper part of the flue gas duct, there is a chimney dumper controlled from the frontal part of the boiler.
Control and display elements contributing to the proper functioning of the boiler are installed on the boiler casing.

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Description and drawing of the boiler

18 7
10 11

16

1 5
6

9 3

17

2 4

8

1 – Filling door
2 – Cleaning door
3 – Chute
12 4 – Combustion chamber
5 – Chimney dumper
14 15 6 – Door screen
7 – Hot water branch
8 – Cold water branch
9 – Door closing
10 – Control unit
11 – Main switch
12 – Safety valve branches
13 – Cleaning cap
14 – Smoke duct outlet
15 – Stack valve draw bar
16 – Pressure meter
17 – Primary air valve
18 – Upper cleaning lid

13

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4.

Technical parameters

Boiler type

ECOMAX 25

ECOMAX 35 ECOMAX 42

Nominal power kW 25 35 42
Chute volume Dm

3

120 170 200
Water volume Dm3 60 68 78
Outlet branch diameter mm 160 160 160
Maximum boiler width mm 612 612 712
Maximum boiler depth mm 850 1000 1120
Maximum boiler height mm 1200 1200 1475
Chute depth mm 500 500 650
Maximum log diameter mm 220 220 220
Maximum log length mm

300 500 500

Operating chimney draught Pa 20-25 20-25 20-25
Maximum working overpressure kPa 200 200 200
Maximum noise level dB 65 65 65
Efficiency % 83 81 79
Mass kg 270 360 454
Operating voltage V/Hz 230/50 230/50 230/50
Electric power requirement W 21 21 41
Electric power requirement with electronic
control

W 30 30 50
Protection IP 20 IP 20 IP 20
Nominal power and efficiency were measured at 11% firewood humidity

5. Fuel material

The fuel material specified is lump wood. No wood quality is specified. It is recommended to burn lump wood cut in maximum
lengths as per the table of technical parameters. The wood must be combusted as dry as possible, with at least 15% humidity
max. Damp wood releases water when combusted, which then condensates on the walls of the boiler body and the chimney. This
results in the emergence of aggressive substances which markedly reduce the boiler and chimney life. Burning damp wood also
results in a marked boiler power reduction.

Indicative table of the calorific value of wood mass depending on the water content

Humidity

Calorific value

( kWh/kg)

(%) Coniferous Deciduous

15 4.329 4.057
20 4.035 3.779
25 3.740 3.500
30 3.446 3.222
35 3.151 2.943
40 2.856 2.664
45 2.562 2.386
50 2.267 2.107
55 1.973 1.829
60 1.678 1.550

6. Accessories

The following accessories are supplied along with the boiler:
Steel brush 1 unit Screw M8 x 25 8 units Filling valve 1 unit

Scraper 1 unit Nut M8 8 units Gasket 2 units
Discharge fan 1 unit Washer 8.2 8 units Warranty Certificate 1 item
Counterflanges 2 units Operating Manual 1 item

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7. Preparing the boiler for commissioning

Prior to putting the boiler into operation, the conditions stipulated under the relevant ČSN must be adhered to (such as chimney
inspection and approval of fitness for purpose by the Chimney Authorities, a heating system designed calculated for this type
of boiler, completion of a heating test, etc.).
Installation of the boiler is conditioned by the connection of the controlled mixing valve in the primarily heating water circuit and
connection of a safety discharge valve, TS 130. The connection of the safety discharge value is mainly necessary in the event
of a use of an uncontrolled mixing valve in the primary heating water circuit. In the event that the specified safety discharge valve
is not used, emergency removal of the residual heat in the event of power failure needs to be ensured while designing
the heating system and installing the boiler, where the pumps and the servo-drives of the mixing valves are blocked.

At the beginning of the heating season, it is always necessary to check the filling and de-aeration of the heating system!

7.1 Binding standards in designing and installing the boilers

ČSN 06 0310 - Heating systems in buildings – Design and installation
ČSN 06 0830 - Heating systems in buildings – Safety equipment
ČSN 73 4201 - Chimneys and smoke ducts – Designing, executing and connecting fuel material consuming appliances
ČSN 06 1008 - Fire safety of local heating appliances and heat sources
ČSN 07 0240 - Hot water and low pressure steam boilers
ČSN 07 0245 - Hot water boilers with power up to 50kW
ČSN EN 13501-1 - Fire classification of construction products and building constructions – Part 1:

Classification based on response to fire test results

7.2 Boiler connection to the hot water system

The boiler shall be connected to the heating system using flanges to be welded onto the pipes of the heating system. A
gasket must be inserted between the flanges and bolted together using M8x25 bolts. A TS 130 safety discharge valve shall be
fitted. The fixture must be bolted to one of the lateral 3/4“ outlets and a measuring probe shall be inserted into the sink between
the outlets. Connect the cold water branch of the water mains to the TS 130 fixture. Connect the sanitation outlet to the other 3/4“
outlet. In the event of boiler overheating, the thermostatic valve integrated in the fixture shall open the cold water supply into
the cooling loop. After passing through the cooling loop, the cooling water flows spontaneously away into the sewerage system.
Once the boiler has cooled down, the water flow rate is automatically stopped.

Connection of the safety outlet fixture is a pre-condition to safe boiler running. The boiler may only be connected
up by an expert company or a professional heating engineer.

Safety valve connection chart

The boilers are partially protected against overheating by a safety thermostat. The thermostat switches off the fan once the water
temperature in the boiler exceeds 95oC (the condition being moreover indicated by the failure indicator LED). This will result
in the boiler passing into the steady heating mode and gradually reducing its power. Once the boiler water temperature drops
by approx. 15oC, the safety thermostat will switch the fan back on and the boiler will ramp up to the required power.

The present system of boiler protection only works reliably under the condition of steady supply of pressurised cold water
from the water mains (pay attention to domestic water plants in the event of power failures). Please also note that the safety
systems described above are only fully and reliably functional under the condition of electric power supply. Therefore, the very
issue must be addressed, for hot water systems with forced circulation, by connecting a part of the heating system to a gravity
circulation circuit with the minimum power consumed being at the level of 20% of the nominal boiler power, as a minimum
requirement.