Centrometal EKO-CKS 500 Owner's manual

TECHNICAL INSTRUCTIONS
for assembling, use and maintenance
of solid fuel firing boiler and its
additional equipment
TUBCKPM-05-2014-eng
EKO-CKS 500
HEATING TECHNIQUE
Centrometal d.o.o. - Glavna 12, 40306 Macinec, Croatia, tel: [phone], fax: [phone]

2Technical instructions EKO-CKS 500
Technical data
TECHNICAL DATA
of the boiler
body
Total boiler
dimensions
connections
Dimensions
Boiler
Width (B)
Total width (B1)
Depth (L)
Total depth (L1)
Main / return flow
Safety line
Filling / drainage
Safety line dimensions
Safety pump
suggestions
Rated thermal output kW
mm
mm
mm
mm
mm
mm
kg
l
bar
DN
DN
G
G
mm
mm
kg 2920
Height (H)
Total height (H1)
Boiler body mass
Total boiler mas (firing boiler body
with insulation & regulation)
Boiler water content
Max. operating pressure
Flue gas connection (on boiler)
Flue gas connection (on fan)
TYPE
380-500
2665
1245
2540
2665
1391
2540
2850
1700
4
100
50
5/4"
2"
430 x 170
202
EKO-CKS 500
TIP like Grundfos
TYPE UPS-32-80
Dimensions
H2
H3
H4
H5
DL
SV
VV
mm
mm
mm
mm
mm
mm
mm
Type
670
920
2080
600
1613
782
654
EKO - CKS 500
mm
mm
mm
mm
Type
3510
2560
2505
2355
EKO - CKS 500
Total boiler lenght with cyclone L2
Total height of the cyclone with the fan K
Height of the flue gas exh. conn. of the fan J
Height of the cyclone I

3
Technical instructions EKO-CKS 500
Dimensions of the boiler
Legend:
DPK
DPV
OC
OSZ
PLV
PP
PVV
SPLV
VC
V
K
Boiler flue gas exhaust
(boiler to cyclone)
Fan flue gas exhaust
(fan to the chimney)
Opening for cleaning
Secondary air door
Inlet
Filling/Draining
Outlet
Outlet
Door for cleaning
Fan
Hot water boiler EKO-CKS 500
-
-
-
-
-
-
-
-
-
-
-
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
Opening for under pressure regulator
Side opening for the primary air
Cyclone
SPVV
STO
T
OK
DV
GV
OG
VPZ
ZP
BOZ
CC
-
-
-
-
-
-
-
-
-
-
-
B1
DL
SPVV
DPK
PVV
ZP
DPV
V
CC
I
J
K
B
VPZ
OSZ
DV
OK
T
GV
OG
SV
VV
VC
STO PLV SPLV
BOZ
L=L1
L2
OC
PP
H5
H2
H3
H4
H=H1
DPK
DPV
KA
A
Section A-A
f260
f230
f202
f11
Flue gas connection
DPV-dimensions

4
Dimensions of cyclone CC
H
H1
H2
D
D1
D2
D3
D3
L
L2
L1
L3
L4
L5
L6
Draining / cleaning
door
Connection to the fan
and flue gas exhaust
installation
Connection to the boiler
CYCLONE CC 500 - Technical data
Cyclone type
Boiler type
CC 500
EKO-CKS 500
Total height of the cyclone H
Boiler connection height H1
Height opening for draining H2
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 DO
Pening 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)
(mm)
(kg)
2360
2080
730
845
790
232
526
266
430
170
226
243
fi 650
fi 203
fi 260
fi 14
158
L7
L8L8
Technical instructions EKO-CKS 500

5
Description of the boiler
1.0. DESCRIPTION OF THE BOILER
Boiler EKO-CKS 500 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. 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 to the cyclone. In the cyclone the rigid particles are outshine from the flue
gases, passages through the fan and went to the chimney. The firing procedure is manual
through the spacious door. The temperature , i.e. fire intensity is regulated by a before fixed
flue gas damper which is situated in the flue gas exhaust and the regulator which steers
the fan installed on the cyclone. Additional regulation of the fire intensity can be also
perform with the opening for the secondary air which is situated on the lower boiler door.
The upper boiler door enables the access to the first and second bundle of the boiler flue
exhaust tubes and their cleaning. 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 and separately cyclone and fan
which enables easier transportation and assemblage without unnecessary risks of casing
damage.
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.
Technical instructions EKO-CKS 500

6
Delivery package, assemblage of the boiler
1.1. DELIVERY PACKAGE
- Boiler's body with the door
- Casing with thermal insulation
- Thermometer, draught regulator, cleaning set (cleaning brush, poker, shovel)
- Cyclone is used to expell the dust particle
- Fan for the flue gases
- Boiler regulation CK/CKB
2.0. ASSEMBLAGE OF THE BOILER
The boiler and cyclone has to be put 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 and the cyclone
has to be situated in order its connection to the chimney can be performed correctly (Image
1.) its cleaning and handling should be convenient, the boiler, cyclone and fan has to be
situated to have all its parts easily accessible. The casing has to be assembled after the
boiler has been connected to the cyclone, chimney and to the central heating system,
according to the instructions attached with the casing (Image 5.). Before the mounting of
the casing to the boiler it is necessary to attach the boiler regulation to the casing of the
boiler (see point 9.3) Before any kind of connecting the boiler and cyclone to the installation
the boiler and the cyclone has to be in level ( has to be put exactly in the horizontal
position)
Opening of upper
boiler door on left
side
Opening of upper
boiler door on right
side
Chimney
min. 100 mm
min. 300 mm
min. 1600
Figure 1. Minimal distances from the boiler room walls
Cyclone CC
with fan
Technical instructions EKO-CKS 500

7
Connection to the chimney
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 temperature of their condensation point.
The choice and the construction of the chimney have to be performed by the authorized
person.
Damper for the fan balancing
(Flue gases temper. behind the fan drive has to be
min. 160°C-180°C)
Klingerit joint (included)
Note:
- Cyclone and boiler connection with screw joint
M12- 6 pieces
- Cyclone to be connected to the fundament by
screws
- Connection of cyclone to the fan by screw joint
M10 - 8 pieces
Flue gas exhaust
fan with electro
motor
Cyclone CC
Compensating
set (included)
- Connection of the fan to the flue gas installation has to be
performed using the compensating set to reduce vibrations
- Connections of the boiler to the cyclone and fan to the flue gas
installation have to be gas-proof.- Flue gas installation has to be
absolutely gas-proof.
- Flue gas installation and the cyclone have to have a thermal
insulation
Temperature at rated thermal output
has to be min. 160°C - 180°C
Chimney
Vessel for cyclone
cleaning (clean when
necessary)
Figure 2. Connection mode of the boiler EKO-CKS with the cyclone and fan to the chimney
Thermal insulation
necessary
Thermal insulation
necessary
Boiler regulation
10mm
TEHNIKA GRIJANJA
!
Technical instructions EKO-CKS 500

EKO-CKS 500
TYPE
INTERSECT
HEIGHT *
CHIMNEY
DIAMETER **
10 metara minimalno fi 500 mm
* Intersect height
- chimney height from intersect flue gas tube with chimney to top of the chimney
** Promjer dimnjaka
- interior chimney diameter.
NOTE:
Flue gas box (connection fan with chimney) must be straight and maximal lenght of
1 m (elbow must not be used)!
4.0. PRIMARY AIR SUPPLY OPENING
Every heating room has to have an fresh air opening dimensioned according to the boiler's
capacity. The opening has to be protected by a net.
A=6,02 × Q
2
A - opening surface in
Q - rated thermal output in kW
The cyclone and connecting tubes has to have a thermal insulation made out of 30-50mm thick
stone wool. In order to unable condensate fwlrom the chimney to the fan, the flue exhaust tube
has to be situated 10mm deeper inside the chimney. If for any reason the boiler and the cyclone
have to be connected to the chimney dimensioned for higher capacity boilers, the possibility of
condensation inside the chimney shall be highly increased. The boiler's function shall not be
affected, but the damper on the flue exhaust has to be positioned according to the chimney
underpressure.
8
Connection to the chimney, opening for fresh air
Technical instructions EKO-CKS 500

The boiler has to be connected to the open system according to the scheme on the
image 3. 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.
5.0. CONNECTION OF THE BOILER TO THE CENTRAL HEATING INSTALL.
5.1. CONNECTION OF THE BOILER TO THE OPEN EXPANSION VESSEL
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 4.). 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 have
to be cover by thermal insulation, min. 40mm stone wool or equivalent insulating material.
5.3. CONNECTION OF THE BOILER TO THE CENTRAL HEATING SYSTEM
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 dis activated by
means of the pipe thermostat 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 4.
9
Connection to the installation, boiler safety pump
Technical instructions EKO-CKS 500

Figure 3. General connection plan of the EKO-CKS boiler with the open expansion vessel
(open system)
A
B
C
D
E
F
H
A - Safety inlet NO 40
B - Safety outlet NO 32
C - Overflow line NO 40
(has to lead to the boiler
room)
D - Air vent
E - Throttle valve
F - Open expansion vessel OPC
G - Main flow
H - Return flow
I - Thermal insulation
OPC
To the boiler
room
G
LEGEND:
I
TEHNIKA GRIJANJA
!
10
Connection scheme
Technical instructions EKO-CKS 500

11
Connection scheme
Figure 4. General connection plan of the EKO-CKS boiler to the heating system
B
E
F
A
C
D
J
H
G
cca. 300mm
I
KT
T
T
L
TEHNIKA GRIJANJA
!
....
Probe
position
Boiler
regulation
A - Main flow
B - Return flow
C - Safety line
D - Safety pump
E - Pipe thermostat
(operat. temp. 0-60°C)
F - 4-way manual mixing valve
G - Circulation pump – according.to the system
H - Safety main flow (to open expansion v.)
I - Safety return flow (from open expansion v.)
J - Stop valve
K - Thermal insulation of the safety boiler circuit
L - Thermal insulation of the safety boiler circuit
T - Thermometer
LEGEND:
NOTE: Closing valves are not displayed on this plan.
Technical instructions EKO-CKS 500

12
Filling the system, casing assemblage, condensate output connection
6.0. FILLING THE SYSTEM
The boiler and the entire central heating system have to be filled with water
according to the HRN M.E2011 norm – table 4.
The system has to be air vented in order the water can circulate normally.
Assamblage of the thermal insulation and plastificied metal sheet coating can be
started after the all works with connection to the chimney and to the central heating
installation. Before assembling the boiler casing, the regulation has to be fixed. The order
of assembling is described on image 5 and with picture 7 and 9 and in the scheme which is
attached to the casing packed in the cardboard box.
7.0. CASING ASSEMBLAGE
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 image 3) there is an
output. It is connected by an ½“ outer 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.
Technical instructions EKO-CKS 500

13
Assebling the boiler regulation
Figure 5. Figure 6.
9.0. ASSEMBLING THE BOILER REGULATION
TEHNIKA GRIJANJA
!
Regulation
box
Cover of
regulation box
3
Drill the
holes
Right upper front side
(option: left upper front
side) od casing cover
Upper side of casing cover
Technical instructions EKO-CKS 500
Before assemblage of the boiler cover is neccesary on the right upper fron side of the cover drill
two holes (fi 3,2 mm) for screws and one bigger hole (fi 23 mm) for sensors of regulation.
Positions for holes are shown on figure 5.
After drilling holes is neccesary to put out regulation box cover (Figure 6.).

14
Assembling the boiler regulation
Figure 7. Assemblage of regulation to boiler
To make the sensors because of their limited length could pull up the socket on the
upper front side of the boiler, boiler regulation must be mounted to upper part of right upper
front side of the boiler (option: left). Other dimnesions is like on Figure 5.
TEHNIKA GRIJANJA
!
Tube for temperature
sensors
Safety
thermostat
sensor
Boiler EKO-CKS 500
3
Right upper front side
(option: left upper front
side) casing cover of the
boiler EKO-CKS
Regulation
thermostat
sensor
Thermometar
sensor
Thermosta of heating pump
sensor (turning on pump
on 75°C)
Technical instructions EKO-CKS 500
Fasten regulation box to right upper front side of casing cover with two screws 3,9x19
(Figure 7.) to previously drilled holes fi 3,2 (Figure 5.). Pull sensors of safety thermostat and
regulation thermostat throught previously drilled hole fi 23 (Figure 5). Fasten again regulation
box cover (Figure 8.).

15
Assemling the boiler regulation
Figure 8.
TEHNIKA GRIJANJA
!
Regulation
box
Regulation box
cover
Technical instructions EKO-CKS 500

B
A
A
A
A
C
C
C
C
C
C
C
D
D
B
Insert the lower lateral part of the insulation (1) and ( 2 )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 (3) and ( 4 )on to 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, operating and safety thermostat has to be inserted into the
probe on the upper side of the boiler and the upper front cover (5) has to be hanged over
the hooks A and fixed by screws B for the sides (3) on the casing. The same has to be
done with the upper back cover (6).
The stone wool has to be placed on the upper side of the boiler, then with the screw C fix
the U-profile (7), after that put the cover (8)on to the plate(3)and U-profile (7), then cover
(9)put into the slid of the cover (8) – detail X and recline on to U – profile (7).
The back side plates (11) and (12), and back upper plates (7) and (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 (2) and (4).
Before assembling the front plate the lower door has to be opened and the front plate (10)
has to be pulled over the door. After that the front plate has to be hanged over the hooks
(A) on the left and on the right side of the plate (1).
Slika 10. Assembling order for the casing of EKO-CKS 500 boiler
(4.2x16)
(fi 12x4.2) factory installed
A
(4.2x32)
B
(3.9x9.5)
C
B
D
detail X
D
D
Nosač
oplate
donji
Nosač
oplate
gornji
detail Z
detail Y
1
3
1
3
B
2
1
2
34
3
4
5
6
7
8
9
13
12
11
14
CC
CC
C
C
9
10
TEHNIKA GRIJANJA
!
16
Assembling order for the casing
Technical instructions EKO-CKS 500

17
Boiler regulation
10.0. BOILER REGULATION
In order to obtain a regular and safe operation of the EKO-CKS 500 boiler connected with the
Cyclone CC and the exhaust fan there is a need to install the EKO-CK/CKB boiler regulation.
The regulation steer the start ups and stops of the fan, according to the set boiler temperature.
10.1. DESCRIPTION OF THE BOILER REGULATION
Technical instructions EKO-CKS 500
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.
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.

18
Assembling of the boiler regulation
10.2. 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 12. – scheme of
the connection the fan to the boiler regulation EKO-CK/CKB and to the electrical power net.
Slika 11. Control panel of the boiler regulation
TEHNIKA GRIJANJA
!
1
2
4
56 7
89
3
11.0. CYCLONE CC
The Cyclone produced by Centrometal d.o.o. is used to filter hard particle from the flue gases.
The cylone has to be connected to the flue gas exhaust behind the boiler. A general connection
scheme is shown on the image 2. Between the boiler and the cyclone, 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 gas
installation have to be coated by thermal insulation made out of 40mm thick stone wool or
equivalent material.
11.2. CONNECTING THE CYCLONE
11.1. CONNECTING THE CYCLONE
The cyclone 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.
Technical instructions EKO-CKS 500

19
Fan
12.2. FAN CONNECTIONS
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 airproof closed.
12.3. CONNECTION 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 drive is indicated on its casing and has to be considered.
The cable has to be protected from mechanical 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
12.
12.4. STARTING THE FAN
First to be checked if the fan drive is properly fasten to the cyclone. Revolve the fan
manually 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 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 noice 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 gas exhaust of the boiler and
should be put in the position which enables the flue gases temperature to reach minimum
160°C-180°C at nominal thermal output.
12.0. FAN
The fan takes out exhaust gases out of the boiler and pushes them to the chimney.
12.1. INSTALLING THE FAN
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 to the image 1 to the cyclone outlet. After
assembling the fan drive has to be leveled.
Technical instructions EKO-CKS 500

20
Fan
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 and solve it.
12.5. TEMPERATURE OF THE FAN BEARINGS
12.6. 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 steering (tightness, wear and
tear). In case the spare parts are needed, they have to be cleaned previously.
12.7. THE ROTOR AND THE FAN'S HOUSING
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 pay 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.
Technical instructions EKO-CKS 500