ALLAN'S Ecomax Auto-Stoker User manual

Auto-Stoker Coal Boiler
By
Ecomax
Installation and Operating Manual
Manufactured by:
Location
Postal
1 Thomas Burns Street
Dunedin 9016, New Zealand
PO Box 49, Dunedin 9054
Phone
Fax
+64 3 477
-
7909
[phone]
www.allans.co.nz
Engineering / Sheetmetal / Long Run Roofing / Scaffolding / Christie Glasshouse and Garden Sheds / Ecomax Boilers

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CAUTION
THIS APPLIANCE MUST BE INSTALLED BY APPROVED
AND COMPETENT PERSONNEL ONLY. FAILURE TO
INSTALL THE APPLIANCE IN ACCORDANCE WITH
THESE INSTRUCTIONS AND LOCAL BUILDING
REGULATIONS AND BY-LAWS WILL INVALIDATE THE
WARRANTY.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
Children should be supervised to ensure that they do not play with the appliance.
If the supply cord is damaged, it must be replaced by the manufacturer, its service
agent or similarly qualified persons in order to avoid a hazard.
This appliance MUST be securely fixed to its support by means of mechanical
fasteners. The use of adhesives is not considered a reliable means of fixing.
Any unauthorised modification to the appliance will invalidate the warranty.

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CONTENTS
CAUTION ............................................................................................1
CONTENTS .........................................................................................4
Introduction .........................................................................................5
Specifications........................................................................................6
Product Overview................................................................................7
Product Dimensions....................................................................................................7
Product Description ....................................................................................................8
Component Description............................................................................................10
Installation..........................................................................................12
Installation Location .................................................................................................12
Floor Protector..........................................................................................................13
Coal Hopper..............................................................................................................13
Installation Clearances..............................................................................................14
Flue ...........................................................................................................................15
Water Connection .....................................................................................................17
Installation Checklist ................................................................................................19
Operating Your Appliance ...............................................................20
General Safety ..........................................................................................................20
Operating for the First Time/Priming.......................................................................20
General Operation.....................................................................................................20
Notes on Fuel Selection............................................................................................21
Optimising Boiler Operation ....................................................................................22
Maintenance.......................................................................................23
Daily Maintenance....................................................................................................23
Monthly Maintenance...............................................................................................24
Yearly Maintenance..................................................................................................25
Dislodging a Stone from the Coal Feed Screw ........................................................25
If the Appliance is to be Shut Down for a Long Period:..........................................26
Starting the Appliance After it has Been Shut Down for a Long Period .................27
Troubleshooting.................................................................................28
No heat from radiators/in house ...............................................................................28
Coal Feed Screw not turning ....................................................................................29
Smoke observed at cowl or issuing from Boiler or Hopper .....................................30
Buildup of clinker in Burn Pot .................................................................................31
Excessive noise or vibration.....................................................................................31
Tension pins regularly breaking ...............................................................................32
Wiring Diagram.................................................................................33
Warranty ............................................................................................34
Owner Details.....................................................................................35

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Introduction
Dear Customer,
Congratulations on choosing an Ecomax appliance to heat your home and hot water.
You have also purchased a New Zealand manufactured appliance with after sales
service and parts readily available, unlike some imported central heating appliances.
The “Ecomax” Auto Stoker is used to supply hot water to central heating systems,
which includes underfloor, radiators, fan convectors and domestic/commercial hot
water all year round. It has the capacity to supply up to 26kW of energy, depending on
coal quality.
Automatic coal stokers are the cleanest coal burning appliances on the market, as the
air to fuel ratio can be set to achieve 95% combustion efficiency and 74% thermal
efficiency with smokeless operation.
The unit uses between 5-7 kg of coal per hour (depending on quality) to produce up to
26kW of energy. The running costs can be less than one eighth of the price of
electricity, and can be cheaper depending on regional coal prices.
The fire is mechanically fed with coal from a 500kg (up to 3000kg if required) hopper.
The automatic stoker will switch on and off automatically by thermostat and can
operate for short periods of time every day without the need to re-light. In fact the
stoker can shut down for up to 24 hours and then automatically re-light itself.
The unit is fully wired ready to plug into the wall, with a water thermostat and a boiler
tube cleaning device with external lever. The boiler is fully insulated and has a
durable powder coated cladding. Our quality controls ensure that with proper
maintenance and care, you can expect years of trouble free operation.
An additional water pump must be supplied by the installer, which is piped to the
water inlet (return) of the appliance. The pump must be sized to suit the overall
system. The pump must be wired to the appliance, via the electrical strip connector
inside the back panel.

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Specifications
Electrical Specification: Single phase 230V 50Hz AC
Weight (Empty): 150kg
Water Capacity of Appliance (not including external pipework): 34 litres
Water Connections: ¾” BSP Female
Fuel Type: Pea sized coal only
Fuel Input (Max): 7kg/hr
Heat Output (Max): 26kW
Efficiency: 74%
Average Particulate Emission Factor: 1.2g/kg
Average Particulate Emission Rate: 57g/MJ
Ambient Operating Temperature Range: 0°C - 60°C
Test Report Number: ARS: 07/1636
Note: Performance may vary from tested values depending on the installation and
quality of the fuel used.

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Product Overview
Product Dimensions

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Product Description
Combustion
Chamber Door
Ash Pan
Scrubber Coils Spanner Flue Spigot
Boiler Hopper Coal Feed Screw GearboxMotor
Ash Valve Lever

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Scrubber Coils Flue Spigot
Combustion Chamber
Insulating Board
Burn Pot Blower
Smoke Back Tube
Heat Exchanger Tubes
Coal Feed Screw timer
Top dial ON (minutes)
Bottom dial OFF (minutes)
Boiler fuse
Coal Feed Screw ON/OFF
Boiler ON/OFF

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Component Description
Burn Pot - The coal is burnt in the burn pot with the air supplied through the air ports
and the coal supplied from the coal screw below.
The burn pot is made of cast iron and can be removed by cutting the three metal tags
that are holding it in place with a cutting disc. Access can be gained through the top of
the boiler
Retort - Area surrounding the Burn Pot that supplies the primary air for combustion
Blower - Supplies air for combustion and the smoke-back tube. The blower can be
choked to properly tune the combustion rate of each batch of fuel.
Coal Feed Screw – This is the screw that feeds the fuel from the bottom of the hopper
to the bottom of the Burn Pot. The helix flight is made of 5mm mild steel plate, and
the shaft is made from Ø20mm bright mild steel.
Ash Pan - Removable pan underneath Combustion Chamber that collects the left over
solid products of combustion.
Coal Hopper – The coal hopper can be supplied with the boiler. Standard capacities
are 150 kg for bagged lots, 500 kg or 1,000 kg for trailer loads and 2,000 kg for truck
loads. The hoppers have sloping sides at angles of no less than 50° so that they will
empty fully. The large hoppers have self-supporting legs which must be secured to a
suitable foundation. The large hoppers are constructed to be weather proof with lids,
and are constructed from 3mm mild steel. Coal hoppers must not be constructed from
combustible materials.
Combustion Chamber - Area where the fuel is burnt and initial heat transfer from the
exhaust gases to the water takes place.
Fully Water Jacketed – The combustion area of the boiler is fully water jacketed
with 6mm thick steel. Because the steel in the boiler is cooled by water, the steel does
not become damaged by severe expansion and contraction, so a long operational life
can be expected.
Heat Exchanger Tubes - Tubes where the secondary heat transfer from the exhaust
gases to the water takes place, featuring scrubber coils to maximise heat transfer to the
water.
Scrubber Coils – The scrubber coils are provided to reduce heat coring and increase
efficiency by removing scale from the heat exchanger tube surfaces.
Waterside Corrosion – Once the water in the system becomes stagnant, little
corrosion occurs but a rust inhibitor should still be used to prolong the life of the
boiler.

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Ash Removal – The ash is removed from the ash pan located in the bottom of the
boiler. Use leather gloves when handling the ash pan. Always allow ashes to cool
properly (a minimum of seven days) in a non-combustible container before
disposing of ashes according to local regulations.
Flue – A stainless steel 150mm nominal diameter flue is recommended.
Insulation – 25mm fiberglass hot water cylinder insulation is used.
Smoke-Back Tube – A smoke-back tube is connected between the outlet of the
blower and the top of the coal pipe. The purpose of the tube is to stop smoke from
traveling back through the coal pipe to the hopper. It is vital this is kept clear of fines
or any material that may block the tube.
Controller - Electronic unit that controls the operations of the appliance

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Installation
Installation is carried out in the following steps:
•Determining the Coal Boiler’s installation location, taking into account flue
position, accessibility for coal delivery to the hopper, accessibility for future
servicing and availability of electrical connections and suitable locations for
water piping and pressure relief
•Applying for consent from the appropriate local consenting authority
•Once consent is granted, installing the appliance in its final location
•Installing the flue
•Installing the sealed water circulating system
•Commissioning
Installation Location
Careful consideration must be made as to the location of the Coal Boiler. Noise
sensitive areas, such as near bedrooms or living areas, should be avoided. Ideally it
would be installed somewhere with ease of access in order to fill the appliance with
fuel and service it easily, but somewhere such that children do not have access to it.
The appliance should never be installed inside a dwelling, except in a purpose
designed and built boiler room or shed.
The Coal Boiler site must be provided with permanent adequate ventilation. An area
of 18,000 mm
2
(or the equivalent to Ø150mm, or a rectangle 180mm x 100mm ) is
required. If the area under doorways is not sufficient, then ducts or louvres must be
installed to maintain ventilation. Never allow the ventilation to be obstructed as this
will adversely affect the performance of the Coal Boiler.
The Coal Boiler must be installed on a non-combustible base, ideally a concrete
foundation. It must be securely fixed to this foundation in the event of an earthquake.
If the Coal Boiler is to be installed on a heat sensitive floor covering, a floor protector
must be installed. The minimum clearances to combustible surfaces around the Coal
Boiler must be maintained for safety.
The Coal Boiler needs to be supplied with a standard electrical wall socket with
isolating switch within 1m of the rear of the appliance.
The Coal Boiler must not be in an area where it will be subject to sustained, direct
sunlight, especially on the controls. The Coal Boiler electronics are sensitive to both
extremes of hot and cold, as well as excessive humidity. Mount the controller on a
wall close to the boiler in a position sheltered from heat and dust.
The Coal Boiler must not be installed in an area where it can be rained upon, or have
water dripping on it. It must not be in an area that may flood. Careful consideration
must be given to the likely weather conditions in the Coal Boiler installation location,

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for instance high wind areas may adversely affect the performance of the appliance
through high back pressure in the flue. Cooling winds can also prevent the evacuation
of fly ash in the flue, leading to restrictions in the flue over time.
Floor Protector
The New Zealand standard AS/NZS 2918:2001 states that if the appliance is to be
installed on or within 500mm of any heat sensitive or combustible materials in the
floor, then a floor protector will be required. The floor protector must extend
underneath the appliance, and finish no less than 300mm in front of the Ash Pan. The
floor protector must not be any less wide than the appliance, and extend at least
200mm from the side of the Ash Pan (unless it comes into direct contact with a wall or
heat shield at a lesser distance).
Coal Hopper
The Hopper should be installed in a location that makes for ease of access for filling
and cleaning. Never construct a Hopper from combustible materials.
It is essential that the Hopper is sealed at the bottom where it joins the Boiler Hopper.
Condensation or rain running down the outside surfaces of the Hopper must not be
allowed to enter the Boiler Hopper, otherwise excessive wear will occur.
Standard hoppers in 150kg, 1000kg and 2000kg are available through Ecomax. Many
other non-standard hopper sizes are also available, including 3000kg double hoppers
(for double boiler installations).

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Installation Clearances
It is essential that the Coal Boiler is installed with AT LEAST the minimum
clearances to combustibles as illustrated below. If possible, it is recommended that
these dimensions are greater, to allow for better access during installation and
servicing. In particular, ensure there is sufficient room to remove the Coal Feed
Screw.
Clearances above the appliance can be any size, as long as they do not interfere with
the opening of any of the doors, or access for servicing.
A flue liner is required if the flue is closer than 600mm to a combustible surface.
Always ensure that there is sufficient provision made to disconnect the flue for the
purposes of servicing.

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Flue
This appliance is designed to be run with Ø150mm stainless steel flue with Ø250mm
galvanised liner. Keep horizontal or inclined flue sections to a minimum, as
accumulation of ash will occur in these sections and access for cleaning needs to be
provided.
As the flues are provided by various manufacturers, the flue must be installed to
AS/NZS 2918:2001. Some councils have their own specific rule on the height of the
flue, but most follow Rule 4.5.6(b) and Schedule 6 and Section 4.9.1 of AS/NZS
2918:2001. Minimum clearances to combustible materials outlined in these and any
local regulations must be maintained.
It is the responsibility of the installer to ensure that the installation is compliant with
AS/NZS 2918 and all other relevant national codes and local body regulations.
Ecomax can supply a compliant flue kit that has been tested to AS/NZS 2918. A
schematic of this flue kit is on the following page.
If the ceiling contains insulation (such as batts) then an insulation barrier will be
required between the insulation and the flue liner.

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Ecomax flue kit schematic:

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Water Connection
The water system for the Coal Boiler must be a sealed, pressurised system. It must be
sized appropriately for the dwelling and the expected heating load it will carry by a
suitably qualified person. The expansion vessel should be at least 10% of the total
volume of the system. The Coal Boiler contains 34 litres of water, not including
external pipework. The flow and return connections on the rear of the appliance are
¾” BSP female threads.
DO NOT use an open vented system with a header tank, as this allows boiling of the
water and a continuous supply of oxygen into the system, which will corrode the
internal surfaces of the Coal Boiler & radiators.
The water system must be fitted with an air vent, or vents, to bleed the system on
filling, as well as a pressure relief valve. The pressure relief valve must be vented to
an area such that, if it was to relieve, could not cause damage to people or property.
Ideally this would be somewhere outside.
The first two metres of pipework to and from the appliance must be in a high
temperature resistant material such as copper. This is to protect the pipework from
possible damage from over-temperature in the unlikely event of a power cut.
For the rest of the water piping, pipe made from material that has an oxygen barrier
must be used, as internal corrosion of the Coal Boiler could otherwise occur. A rust
inhibitor must be used to treat the water and prevent internal corrosion.
A draining valve should be fitted at the lowest point for servicing. The best type of
valve is one in which the handle is removed so the system cannot be drained
accidently. Pipe thermometers should be fitted to both the flow and return pipes so
that the operator can check that the flow and return temperatures are not too low. The
return should not be below 55°C when the pump is running. If the return water is too
low, it is possible that the heating load & heat loss in the pipework has been
underestimated, and the appliance will not be able to heat it.
It is recommended that an isolating valve be fitted on both the flow and return lines at
the boiler connection to make future servicing significantly easier. The pump should
also have isolating valves either side.
The plumbing work must be carried out in a proficient manner and be free of leaks. If
the system needed regular topping up with fresh water due to leaks, oxygen would be
introduced and internal corrosion of the Coal Boiler and radiators would occur.
The Coal Boiler requires a suitable pump to be installed, appropriately sized by the
installer. The pump should be installed as per the pump manufacturer’s instructions. It
must be electrically connected to the Coal Boiler via the connector inside the rear
panel of the appliance. The Coal Boiler will switch the pump on and off depending on

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the temperature of the water in the appliance. This ensures the Coal Boiler will get up
to an ideal temperature operating range before it starts to circulate the water. If the
pump is not connected to the Coal Boiler, the appliance may not be able to heat the
water sufficiently and the warranty on the appliance may be voided. A mixing valve
may also be used to maintain the water temperature in the water jacket.
During the process of filling the system with water, all the air needs to be bled out to
prevent an air lock developing and water flow being inhibited.
Where possible all piping should be lagged. This will ensure the best possible thermal
efficiency of the system, and make it cheaper to run.
A typical schematic for a domestic installation is shown below.

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Note: Schematic depicted is an example only. It is the responsibility of the installer to
design and install a suitable circulation system based on each installation’s unique
conditions.
Installation Checklist
Minimum clearances to combustibles checked
Minimum clearance for removal of Coal Feed Screw checked
Floor protector fitted (if required)
Appliance securely fastened to support
Water system sealed, pressurised, properly bled and leak tested
Flue installed to AS/NZS 2918:2001 and/or any other local regulations
Pressure relief valve installed and piped safely
Water pump wired into appliance
Appliance plugged into suitable wall electrical socket (NOT hard wired)
Controller mounted on wall in accessible position
Water temperature set at 75°C minimum (dependent on system design)
Appliance run up to temperature at least once
Customer shown basic operation of appliance
Warranty card filled out

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Operating Your Appliance
General Safety
The Coal Boiler is fully sealed, but during normal operation some of the panels may
get hot. Do not stack or lean anything against the appliance, and make sure all
combustible materials are at least to the minimum clearances stated in the Installation
Clearances section. The appliance should never be used as a shelf or a bench. Do not
keep bags of fuel leaning against or sitting on top of the appliance.
Never try to operate the Coal Boiler with any of the panels removed or doors open.
This appliance is not intended for use by persons (including children) with reduced
physical, sensory or mental capabilities, or lack of experience and knowledge, unless
they have been given supervision or instruction concerning use of the appliance by a
person responsible for their safety.
When dealing with hot ashes make sure they are stored in a non-combustible container
until completely cold, which should be a minimum of seven days. Dispose of ashes
according to local body regulations.
Operating for the First Time/Priming
With suitable stone-free pea sized coal in the hopper, turn the Coal Feed Screw switch
on and feed fuel right through from the hopper until it fills the burn pot completely.
This may take a few minutes, and the Coal Feed Screw may automatically stop. This
is due to the timer; if you wait it should turn itself on again or turn the switch on and
off to restart the Coal Feed Screw. Fill the Burn Pot until fuel is in a mound just proud
of the top of the Burn Pot.
To light the appliance, pile kindling on top of the coal, along with paper and/or
firelighters. Light the kindling and turn on the boiler switch, starting the blower. Close
the Combustion Chamber Door and allow the flame to establish. Once a solid ring of
fire has been established around the entire outside of the Burn Pot, turn on the Coal
Feed Screw switch.
General Operation
Once lit, the boiler will be able to be left to run on its own. The Timer will turn the
Coal Feed Screw on and off to regulate the fuel input to the appliance. Once the water
temperature in the water jacket gets hot enough, the pump will start up and start
circulating the hot water to the heating system. This may switch on and off a few
times until the entire system is up to temperature.