green ecotherm ELTHERM Series User manual

Instruction manual
for installation and operation of
of hot water electric boiler of series :
ELTHERM, ELTHERM M, ELTHERM MM
www.greenecotherm.eu

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Thank You for buying our product – hot water flow electric boiler of series
„ELTHERM”. This manual will help you to use and maintain the unit properly.
According to Decree No 187/21.09.2000 this product is subject to supervision as
equipment with high hazard and must be entered in the register of technical
supervision of the authorized persons on location by customer’s initiative
ATTENTION!
IN INTEREST OF YOUR PERSONAL SECURITY IT IS
NECESSARY TO READ THOROUGHLY AND CAREFULLY THIS
INSTRUCTION MANUAL BEFORE PROCEEDING WITH ANY ACTIONS
WITH THE BURNER – INSTALLING, CONNECTING, OPERATING,
ETC. IN CASE THAT REQUIREMENTS, DEPICTED IN THIS MANUAL
ARE NOT SATISFIED, FAILURE OF THE UNIT COULD BE EXPECTED,
OR EVEN FATAL CONSEQUENCES, FOR WHICH THE PRODUCTION
COMPANY DOES NOT TAKE RESPONSIBILITY.
Producer ZMM Haskovo Plc.
Address Bulgaria, Haskovo 6300, “Saedinenie” 67 blvd.
Phone [phone]
Fax [phone]
e-mail [email protected]
home page www.greenecotherm.eu
Instruction manual for installation and operation of hot water electric boiler of series “ELTHERM”
(
Version : 13.12.2011 13:07
)

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Table of contents Page
1. Hot water electric boiler of series “ELTHERM” – general description and
advantages................................................................................................................ 5
2. Hot water electric boiler of series “ELTHERM ” – technical data............. 7
3. Description of the construction of hot water electric boiler of series
“ELTHERM”......................................................................................................... 10
3.1. Main properties.........................................................................................10
3.2. Detailed description of the hot water electric boilers of series
“ELTHERM”......................................................................................................14
4. Installation of hot water electric boiler of series “ELTHERM”................ 15
4.1. Some basic requirements for correct installation of electric hot water
boiler of series “ELTHERM” are :...................................................................15
4.2. Basic requirements for the properties of the circulating water of the
heating system:....................................................................................................16
4.3. Installation of the hot water electric boiler............................................17
4.1.1. Installation of the hot water electric boiler of series “ELTHERM”,
considering it’s easy maintenance and servicing: ........................................17
4.1.2. Boiler’s positioning according to the requirements for attachment
to the electric power supply circuit................................................................17
4.2. Procedure for installation of the hot water electric boiler of series
“ELTHERM” of the heating system..............................................................18
4.2.1. Connecting to the heating system.....................................................18
4.2.2. Recommended principal hydraulic scheme for the hot water
electric boiler of series “ELTHERM”...........................................................18
4.3. Procedure for connecting the hot water electric boiler of series
“ELTHERM” of the electrical power circuit. ..............................................20
5. System starting procedures. .......................................................................... 22
5.1. Basic requirements...................................................................................22
5.2. Starting up the hot water electric boiler of series “ELTHERM”........22
5.2.1. Interface control board of hot water electric boiler of series
“ELTHERM”...................................................................................................23
5.2.2. System very first start .......................................................................24
5.2.3. Operating of the hot water boiler of series “ELTHERM”............24

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5.2.4. Operating of the hot water electric boiler of series “ELTHERM”
in direct heating systems.................................................................................25
5.2.5. Operating of the hot water electric boiler of series “ELTHERM”
in accumulating heating systems....................................................................26
5.2.6. Operating of the hot water electric boiler of series “ELTHERM”
in mixed heating systems ................................................................................26
5.3. Operating parameters of the boiler.....................................................26
5.3.1. Operating parameters for adjustment of the hot water electric
boiler of series “ELTHERM”.........................................................................27
5.3.2. Nominal operating mode of the boiler.............................................27
5.4. Control of the thermal capacity of the heating system.........................28
5.4.1. Decreasing the thermal capacity of the boiler:...............................28
5.4.2. Increasing the thermal capacity of the boiler:................................28
5.4.3. Controlling thermal capacity of the heating system’s elements: ..28
5.5. Stopping the operation of the system......................................................28
5.6. Turning OFF the boiler............................................................................28
 Emergency stop of the system. ................................................................28
5.7. Showing and teaching the end user about the maintenance and
adjustment procedures.......................................................................................29
5.8. Safety and unexpected risks ....................................................................30
5.9. Operation faults and their repairing......................................................30
5.10. Hot water electric boiler of series “ELTHERM” warranty form
completion........................................................................................................32
5.11. Actions, after the hot water electric boiler of series “ELTHERM” is
not in exploitation anymore...............................................................................32
6. Electrical scheme of hot water electric boiler of series “ELTHERM”..... 33
QUALITY CERTIFICATE ................................................................................. 35
WARRANTY SERVICE PROCEDURES LIST............................................... 37

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1. Hot water electric boiler of series “ELTHERM” – general description and
advantages
The hot-water electric boiler of series “ELTHERM” is a modern, ecological
source of heat, designed for floor and central heating of small and middle-size
housing and industrial buildings. The electric hot water boiler of series
“ELTHERM” is designed for vertical wall mounting only. The boiler heats the
circulating fluid directly, thus making the heating system dynamic. It is
manufactured in the following modifications:
“ELTHERM” - with relay- contactor power supply commutating control system;
“ELTHERM M” - with electronic power supply commutating control system;
“ELTHERM MM” - with electronic commutating power supply control system
and integrated closed expansion vessel;
The kit of the hot water electric boiler of series “ELTHERM” consists
of:
•Main module – according to the model – 1 sp.;
•User manual – 1sp.;
•Wall mounting hanger – 2sp.;
•Room thermostat – 1sp.;
•Circulating water filter – 1sp.;
The electric boilers of series “ELTHERM” are economic, environment friendly,
high efficiency and compact units, allowing installation in narrow spaces. The
electric hot water boilers can be used in every system of central or local heating in
direct, hybrid or accumulating systems. It can be integrated in existing heating
systems, parallel to any type of hot water boiler (i.e. gas, oil or solid fuel hot water
boilers). For the security of the operation, it is recommended to install the electric
boilers in systems, working with circulating pumps, providing forced circulation of
the circulating fluid (which in most of the cases is circulating water). The boilers
minimal pressure safety switch prevents operation at low pressure (of absence) of
circulating water in the heat exchanger. The operating temperatures, as well as the
pressure of the circulating water are indicated by the mounted thermo-manometer.
The electric boilers are made with thermal capacity in the following range: 4, 6, 8,
10, 12, 14, 16 and 18 kW. In order to connect the hot water electrical boiler of
series “ELTHERM” to the power supply electric mains, a permission/authorization
for such connection by the local power supply electric company is required,
following the local legislation and country norms.

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The unit is equipped with
•adjustable thermal capacity operating module, which controls the
functions of the unit and is adjustable to the specific needs of a heating system;
•electric heaters, which work in parallel. The number of the attached
electric heaters is determined by the thermal capacity of the boiler;
•manual thermal capacity switching, which allows optimal operation;
•interface panel, equipped with control and light indicators;
•three speeds circulating pump, which makes forced circulation of the
fluid;
•closed expansion vessel – option, only for “ELTHERM MM”;
Advantages of the hot water electric boiler
•the electric hot water boiler can operate in any type of heating system of
central or local heating, i.e. in direct, hybrid or accumulating type;
•the boiler can be attached in parallel of any type of hot water boiler (i.e. gas,
oil or solid fuel boiler) and can be used as back-up heating unit in case of
malfunctioning of the primary hot water boiler;
•the boiler transforms the electrical energy into heat energy, with practically
no loses, no local pollutant emissions;
•the boiler is installed in order to apply the so called “fuel switch process” for
appliances, utilizing other energy sources – diesel, natural gas, LPG, coal, or
could be installed as back-up heat source;
•the boiler’s design allows easy installation. The heating system and the
boiler/equipment however need minor redesign and reconstruction in order
to allow such process;
•the boiler operates automatically and achieves operation comfort, delivered
by operating of other energy sources, it also permits remote control by
programmable room thermostat;
•the design of the boiler is quite compact, which allows installation in narrow
rooms and high flexibility at installation and operation;
•automatic operation of the boiler allows variable thermal load adjustment
and economic operation of the heating system, which guarantees optimal
thermal comfort and reduced energy consumption;
•simplified installation procedure and initial adjustment, which guarantees
faster assembly and unified approach;
•high efficiency;
•high safety operation due to installed sensors for faulty regimes;
•no local pollutant emissions;
•simplified maintenance and service;

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2. Hot water electric boiler of series “ELTHERM ” – technical data
2.1. General information for the type of the electric hot water boiler of
series “ELTHERM” are given in Table 2.1;
2.2. Thermal and technical data of hot water electric boiler of series
“ELTHERM” of thermal capacity range 4 – 10kW are given in Table
2.2;
2.3. Thermal and technical data of hot water electric boiler of series
“ELTHERM” of thermal capacity range 12 – 18kW are given in Table
2.3;
Model of the boiler Type of control Closed expansion vessel
ELTHERM Contactor External, not supplied
ELTHERM M Circuit board External, not supplied
ELTHERM MM Circuit board Built-in
Table 2.1. General information for the type of the electric hot water boiler of series
“ELTHERM”;

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Parameter Dimension Value
Model of hot water electric
boiler model “ELTHERM” - 4, 4M,
4MM 6, 6M, 6MM 8, 8M, 8MM 10, 10M, 10MM
Thermal capacity of the boiler kW 4 6 8 10
first stage 4 4 6 6
Thermal stages , kW second stage - 2 2 4
Electric capacity kVA 4 6 8 10
Operating current A 6 9 12 15
Cross section of the power
supply cable mm23 x 2.5 + 1.5 3 x 4.0 +
2,5
Nominal current of the main
automatic fuse A 10 16 20
Power supply - L1, N, PE, 50Hz; 3x230V/400V
Efficiency % 99.1
Weight of the boiler kg 40
Boiler’s water jacket capacity dm³ 9.5
W-width 515
D-depth 245
Overall
dimension of
the system:
(WxDxH) H-height mm
630
Operating overpressure of the
circulating water MPa 0.25 in one-boiler operation;
0.18 in parallel operation with solid
fuel boiler
Heating system expansion
vessel type - Opened or closed (upto 0.25MPa)
Factory tested overpressure MPa 0.4
Recommended circulating
water temperature in the boiler ºC 85oC in opened systems; 95oC in closed systems
Minimal recommended return
water temperature in the boiler ºC 60
Supply flow 1”
Connections Return flow G 1”
Electric protection - IP40
Table 2.2. Thermal and technical data of hot water electric boiler of series
“ELTHERM” of thermal capacity range 4 – 10kW;

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Parameter Dimension Value
Model of hot water electric
boiler model “ELTHERM” - 12, 12M,
12MM 14, 14M, 14MM 16, 16M, 16MM 18, 18M, 18MM
Thermal capacity of the boiler kW 12 14 16 18
first stage 6 6 6 6
second stage 6 6 6 6
Thermal stages , kW third stage - 2 4 6
Electric capacity kVA 12 14 16 18
Operating current A 18 21 24 27
Cross section of the power
supply cable mm23 x 4.0 + 2.5 3 x 6.0 + 4.0
Nominal current of the main
automatic fuse A 20 25 32
Power supply - L1, N, PE, 50Hz; 3x230V/400V
Efficiency % 99.1
Weight of the boiler kg 45
Boiler’s water jacket capacity dm³ 7,8 / 10.8 dm3
W-width 676
D-depth 179
Overall
dimension of
the system:
(WxDxH) H-height mm
938
Operating overpressure of the
circulating water MPa 0.25 in one-boiler operation;
0.18 in parallel operation with solid fuel
boiler
Heating system expansion
vessel type - Opened or closed (upto 0.25MPa)
Factory tested overpressure MPa 0.4
Recommended circulating
water temperature in the boiler ºC 85oC in opened systems; 95oC in closed systems
Minimal recommended return
water temperature in the boiler ºC 60
Supply flow 1”
Connections Return flow G 1”
Electric protection - IP40
Table 2.3. Thermal and technical data of hot water electric boiler of series
“ELTHERM” of thermal capacity range 12 – 18kW;

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3. Description of the construction of hot water electric boiler of series
“ELTHERM”
3.1. Main properties
The hot water electric boiler of series “ELTHERM” consists of the following
elements/modules:
•heat exchanger, which has number of electric heaters, allowing easy
maintenance and operation;
•control module, which allows manual adjustment of the thermal capacity
and operating mode of the boiler;
•circulating pump, which makes forced movement of the heat transport
media (the circulating water). The pump has serially connected mechanical
filter, in order to prevent clogging and blockage of the pump’s rotor;
•closed expansion vessel – only for model “ELTHERM MM”;
Figure 3.1. View of the of the electric hot water boiler of series “ELTHERM”
without expansion vessel;

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Figure 3.2. View of the of the electric hot water boiler of series “ELTHERM” with
expansion vessel;

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Figure 3.3. View of the main modules of the electric hot water boiler of series
“ELTHERM” (the unit show is particularly with installed expansion vessel);
NOTE : the supplied circulating water filter should be installed onsite at the
installation process of the boiler. Please refer the filter’s producer requirements
for proper installation, maintenance and service procedures;
Closed expansion vessel
Boiler’s structural frame
Control panel of the
b
oile
r
Electric heaters
Electric boiler heat
exchanger
Circulating pump
Pressure safety valve
Inflow pipe G1” Outflow pipe G1”
Automatic air release
vent

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Figure 3.4. Front view of the of the electric hot water boiler of series
“ELTHERM” with expansion vessel with overall dimensions;
Figure 3.5. Side view (left figure) and top view (right figure)of the of the electric
hot water boiler of series “ELTHERM” with expansion vessel with overall
dimensions;

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3.2. Detailed description of the hot water electric boilers of series
“ELTHERM”
The electric boiler consists of a boiler body, control panel, a circulating
pump, filter and control-measuring element (additionally the model “ELTHERM
MM” includes closed expansion vessel). They are installed in sheet metal casing.
The hot water boiler of series “ELTHERM” is designed to be vertically wall
mounted. The boiler’s heat exchanger is produced of welded steel vessel with
thermal isolation. The heat exchanger has from one to three integrated electrical
heaters, depending on the thermal capacity of the electrical hot water boiler, which
can be manually step-wise switched by the end user. The casing is made of painted
sheet metal, attached to a carrying metal frame by screws. The control panel is
closed by metal cover with screws. According to the model, the control module
differs: relay-contactor or fully electronic (i.e. circuit board). In the circuit board
version, the fuse of the operation power supply circuit is on the board. In the relay -
contactor system these operational power supply circuits fuse is installed beside the
control panel.
The flow of the circulating water in the heat exchanger of the boiler, as well as in
the heating system, is provided by a thee-step circulating pump. The attached
operating thermostat controls the operation mode of the boiler until the set-point of
the set-point value of the temperature is reached. The hot water electrical boiler has
also safety thermostat, which switches off the unit in case of emergency
overheating. The boiler also has low pressure limit pressure switch, which breaks
off the power supply at low pressure of the circulating water in the heating system
(in most cases due to leaks of the circulating water, or absence of circulating fluid
in the system).
The control board of the boiler is equipped with thermo-manometer, which
indicates the operating temperature and pressure of the circulating water in the
boiler’s heat exchanger.
The producer reserves the right to make changes of the design of the hot water
electric boiler of series “ELTHERM” without noticing the end user;

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4. Installation of hot water electric boiler of series “ELTHERM”
Requirements and recommendations.
4.1. Some basic requirements for correct installation of electric hot water
boiler of series “ELTHERM” are :
•The boiler should be positioned in order to guarantee comfort maintenance
and easy access for maintenance and service procedures;
•In case of low noise requirements, it is not recommended to install the boiler
of model “ELTHERM”, as at operation certain noise could be heard. The
circuit board version does not generate the above mentioned noise;
•The installation process of the boiler, its attachment and connection of the
heating system should be performed by authorized personal only, following
the approved heating system’s project;
•Connect the boiler to the heating system by appropriate fittings – see the
technical data table for more information;
•Installation and maintenance of the boiler is performed by specialized trained
personal of authorized companies;
•Connection of the boiler to the power supply and the external control
modules should be performed by authorized technician only;
•The power supply cable cross-section should follow the requirements,
specified in the technical data of the boiler;
•Connect the control module of the boiler with the room thermostat or weekly
programmable thermostat, if available;
•Before starting the boiler, the heating system should be thoroughly checked
for leaks in order to guarantee safe operation of the system;
•The maintenance of the boiler should be performed by adult person, who is
familiar with the safety procedures and the user manual of the appliance;
•The hot water electric boiler of series “ELTHERM” should be connected to
heating system, supplied with OPENED or CLOSED expansion vessel. In
case of closed expansion vessel, the heating system must be supplied with
alarm pressure valve, which opens at pressure above the operating pressure
of the boilers (0.25MPa) and should have certificate according to PED
97/23;
•Both the entire heating system and the hot water electric boiler should be
totally filled with circulating fluid (water) and air-free before operating the
boiler;

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4.2. Basic requirements for the properties of the circulating water of the
heating system:
The circulating water must comply with the following requirements:
Parameter Limit value Dimension
oxygen contents < 50 μg/kg
general hardness < 50 μgeq/kg
dispersed substances < 5 μg/kg
pH 8- 9,5 -
free carbon dioxide not permitted -
Table 4.1. Properties of circulating water of a heating system, with connected hot
water electric boiler of series “ELTHERM”.
NOTES: In principle heating systems, which are hydraulically opened to the
atmosphere allow direct contact between the circulating fluid (in most cases it is
water) and the air. During the heating season the water content in the expansion
vessel absorbs oxygen from the atmosphere though the free surface. The increased
oxygen content in the water threatens the metal of the unit, as well the pipes.
Through the free surface of the expansion vessel water evaporation is observed as
well. Considering these, appropriate water should be added through the expansion
vessel – it must cover the requirements of norm BDS 15207-81.
During the heating season regular checking of circulating water level in the
expansion vessel should be performed by the end user. The water content in the
circulating system should be kept constant. If additional water is required, then
precautions should be taken, not to add air in the heating system as well. The water,
utilized for filling purposes of the heating system should be decontaminated and
air-free, and is not dedicated for any other purposes, but as a circulating fluid only.
Any heating system drainage is inadmissible, except when repairing
modules/sections of the system. Practical experience shows that water level
checkup should be performed regularly in a period of 14 days in order to sustain
quasi-constant water content.
In case that additional water is required, the filling process should be
performed carefully, when the hot water boiler is cooled to the ambient
temperature. This precautions are induced due to prevent rising of thermal stress of
the steel boiler’s body and its damage (leakage).
In case that the boiler as well as the heating installation will not be in
exploitation for a long period, then in order to prevent local water freezing and
damages, it is advisable to perform total drainage of the circulating water. Please
take into account that the presence of liquid in the heating system, as well in the

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boiler will prevent oxidation process of the metal surfaces, corrosion and system
failures.
4.3. Installation of the hot water electric boiler
The installation process of the hot water electric boiler of series
“ELTHERM” should be based on authorized project, which governs the
requirements of acting norms and recommendations.
•To the power supply - EN 60335-1/1997 - “Household and similar electrical
appliances – safety. Part 1. General requirements”;
•Fire safety requirements;
•Requirements for local heating systems;
4.1.1. Installation of the hot water electric boiler of series “ELTHERM”,
considering it’s easy maintenance and servicing:
oThe minimal space in front of the boiler for maintenance, etc, should
be 1000 mm;
oThe minimal distance from the boiler’s left side and a wall should be
100 mm for models “ELTHERM” and “ELTHERM M”, in order to
allow easy maintenance and servicing procedures, for model
“ELTHERM MM” the minimal distance on the left is 800 mm in
order to allow access for maintenance and easy replacement of the
electric heaters if the boiler;
oThe minimal distance between the top side of the boiler and a wall
(ceiling) should be 100 mm, in order to ensure easy access for the
maintenance procedures of the boiler’s modules;
oThe minimal distance between the bottom side of the boiler and a
wall (ceiling) should be 800 mm for models “ELTHERM” and
“ELTHERM M”, in order to ensure easy access for the maintenance
procedures of the boiler’s modules, for model “ELTHERM MM” the
minimal distance is 200 mm;
othe supplied circulating water filter should be installed onsite at the
installation process of the boiler. Please refer the filter’s producer
requirements for proper installation, maintenance and service
procedures;
4.1.2. Boiler’s positioning according to the requirements for attachment
to the electric power supply circuit
The boiler should be positioned and should allow easy access for operation and
maintenance;

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4.2. Procedure for installation of the hot water electric boiler of series
“ELTHERM” of the heating system
After the hot water electric boiler of series “ELTHERM” has been positioned, it
should be connected to the heating system, considering the appropriate
requirements. In order to ensure safe and reliable operation of the boiler, it should
be horizontally leveled, which will allow easy air relieving of the circulating water.
4.2.1. Connecting to the heating system
The electric boiler of series “ELTHERM” should be connected to the heating
system by appropriate fittings and other control elements – it should be performed
following the prepared project.
After the boiler has been positioned and attached to the heating system, a hydraulic
test should be made – fill the heating system with circulating water, following the
requirements. Check and repair the connections for leakages prior any following
procedures. De-air the boiler and any other modules of the heating system in order
to allow nominal circulation of the fluid and safe operation of the heating unit;
ATTENTION : if the electric boiler is not air-free, then there is high risk of
damaging the electric heaters due to lack of active cooling agent in the heat
exchanger of the boiler;
4.2.2. Recommended principal hydraulic scheme for the hot water electric
boiler of series “ELTHERM”
Recommended principal hydraulic scheme for connecting the hot water electric
boiler of series “ELTHERM” to a heating system, equipped with expansion vessel
is shown on the following figure.

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1
2
3
4
Figure 4.1. Recommended principal hydraulic scheme for connecting the hot
water electric boiler of series “ELTHERM” to a local heating system.
1
2
3
5
Figure 4.2. Recommended principal hydraulic scheme for connecting the hot
water electric boiler of series “ELTHERM” to a local gravity driven heating
system.
Description of the modules:
1- electric hot water boiler;
2- filter;
3- stop valve;
4- air purge valve;
5- solid fuel boiler;
6- heat accumulating tanks;
7- mixing valve;
8- circulating pump;
9- return flow thermostat;

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Figure 4.3. Recommended principal hydraulic scheme for connecting the hot
water electric boiler of series “ELTHERM” to a heating system and heat
accumulator tanks.
ATTENTION: The finalization of the system installation and performing the
commissioning tests should be filled in the appropriate documents of the boiler,
where the required data fields should be filled in (this is obligatory).
4.3. Procedure for connecting the hot water electric boiler of series
“ELTHERM” of the electrical power circuit.
NOTE : the electric hot water boiler of series “ELTHERM ” should be connected
to the electrical power supply only after successful connection to the heating
system has been performed, no circulating water leakages has been found and the
heating system is totally free of air (make sure to open all the control valves and
other control modules in order to allow the air to get out of the heating system).
Check the condition of the circulating pump’s rotor by unscrewing its protective
cap and observing the movement of the rotor at power supply of the pump. Do not
operate the boiler if the pump’s rotor is blocked as this will result in boilers
overheating;
Figure 4.4. View of the circulating pump – use screw-driver to mount the tap of
the pump.