Kospel EKCO.T-30 User manual

KOSPEL S.A. UL. OLCHOWA 1 75-136 KOSZALIN
Please read and follow the installation and operating instructions carefully to ensure safe and trouble free
unit operation.
Kospel S.A. may make minor changes if necessary in the unit that will not be shown in the operating instruction
as long as the main features of the unit remain the same.
Used product can't be treated as general communal waste. Disassembled appliance has to be delivered
to the collection point of electrical and electronic equipment for recycling. Appropriate utilisation of used
product prevents potential negative environmental influences that may occur as a result of inappropriate
handling of waste.
In order to get more detailed information about recycling this product you should contact the local govern-
ment unit, waste management service or the shop where this product has been purchased.

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ENG-030B/p.392
Contents
Introduction 4
Installer instruction manual
Technical data 5
Construction 6
Installation 7
Connection of external appliances 9
Start-up 10
Advanced settings 11
User instruction manual
Using a boiler 12
Failures 15
Storing 16
Boiler kit 16

4
In order to install and operate the boiler properly, study this manual thoroughly. A long life and faultless per-
formance of this unit depends mainly on its proper installation and operation.
EKCO.T boilers are intended for central heating system that use the treated water or antifreeze solution as the
medium carrying heat.
The EKCO.T is a low temperature boiler intended for closed or opened central heating systems with forced
circulation (protected according to legally binding norms). The boiler features automatic work control and low
maintenance requirements.
The boiler is equipped with following safety devices:
- a system of flow control,
- an inner temperature controller,
- a safety temperature limiter,
- a safety valve
The boiler also features the following accessories: a circulation pump, a manometer, an automatic vent valve.
A boiler and the necessary
installations should be carried
out by professional.
Introduction

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ENG-030B/p.392
Technical data
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ENG-030B/p.392
Installer instruction manual
Max. pressure MPa 0,3
Min. pressure MPa 0,05
Outflowing water temp. °C 40 ÷ 85
Max. water temp. °C 100
Overall dimensions mm 815 x 503 x 197
Weight kg ~29
Water connection G1"
Safety class IP 21
Boiler type
EKCO.T
30 36 42 48
Rated power consumption kW 30 36 42 48
Rated voltage 400V~
Rated current A 3 x 43,3 3 x 52,0 3 x 60,6 3 x 69,3
Fuse rated current A 50 63 80
Min. connecting wires section mm25 x 10 5 x 16
Max. connecting wires section mm2
phase conductors 2x16 each, neutral and earth conductors 1x 16
The maximum allowed network impedance Ω0,14 0,09 0,035 0,03

6
1
Construction
6
Installer instruction manual
Fig.1 EKCO.T construction
[1] - water inlet
[2] - water outlet
[3] - heating box
[4] - power board
[5] - ZIO board
[6] - safety temperature limiter
[7] - automatic vent valve
[8] - flow sensor
[9] - safety valve
[10] - outlet temperature sensor
[11] - inlet temperature sensor
[12] - circulating pump
[13] - manometer
[14] - control board
[15] - electrical connector
PF - phase conductors connection point
WP - electric cable-bush
M - holes for boiler mounting
EKCO.T consists of the following
main parts:
- a heating box [3] to heat the
circulating medium,
- a control board [14],
- a circulating pump [12] to
force water to flow.
There are safety devices to protect
the boiler from failures and destruc-
tion:
- a safety temperature limiter [6],
cuts off power supply if water
reach temp. of 1000C, as a
result of it the boiler will shut
down (contact an authorised
service),
- a flow sensor [8], starts the
boiler if the correct flow is
reached,
- a safety valve [9] activates
if the pressure in the central
heating system goes over the
pressure limit (3 bar).

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ENG-030B/p.392
(e.g. valves) on the outlet of the safety valve [9] (fig.1),
- unit can’t be installed in a humid place or in a place exposed to the danger of explosion.
- unit must be protected by filter with magnetic insert ( included in the boiler kit).
Conditions of Installation
- appropriate power supplies;
- an efficient electrical installation
which has been completed in ac-
cordance with the binding norms
of electric installation,
- a wet central heating system
made in accordance to binding
norms,
- a wet central heating system
equipped with appropriate ex-
pansion vessel in accordance
with the binding norms,
- a wet central heating system
must be flushed out before boiler
installation,
- do not install any barrier fittings
All installation work should
be carried out with water and
power supply shut off.
Fig.2 Central heating installation
scheme
PI - manometer
ZK - cut-off valve
F - filter with magnetic insert
RW - expansion pipe
NW - expansion vessel
ZT - thermostatic radiator valve
ZP - passage valve
G - heater
RP - room programmed thermostat
EKCO.T boiler (version equipped with heat
exchanger)
ZTD - three-way valve
ZAS - coil cylinder
TZ - cylinder temp. sensor or cylinder
thermostat contacts
2
Installation
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ENG-030B/p.392
Installer instruction manual
Its recommended for electric
installation with thermostatic
radiator valves to apply the dif-
ferential pressure relief valve. It
allows the system to keep mini-
mal flow of medium through
the boiler and reduce noises in
installation during the thermo-
static valves closing. The valve
must be installed in by- pass
conduit (before the boiler)
according to manufacturer’s
instruction.
A filter must be installed on return pipe-work of central heating installation (before
boiler inlet). The filter must be installed in horizontal position accordingly to the arrow
that shows a flow direction.

8
Fig.3 Installation of the boiler on
the wall 3
Installation
1. Hang the boiler up in a vertical
position on fixing screws with
inlet and outlet pipes to the bot-
tom, maintaining clearances from
the walls and the ceiling (fig.3).
2. Connect the boiler to a central
heating system equipped with
cut-off valves (fig.2).
3. Fill the central heating system
with treated water, which sub-
stantially extends the life of the
heating coils.
4. Vent the wet central heating
system.
5. Connect the boiler to the electri-
8
Installer instruction manual
4
cal system (fig.1, 4).
6. Fix the room thermostat, in accordance with manufacturer’s instruction.
7. Connect the room thermostat using two wires for instance 2 x 0,35 mm2 to the RP terminals (fig.5a)
8. Once you have finished the above procedures, you can start the boiler according to “start-up” section (page
10).
Electric installation
should be equipped with resid-
ual current protective devices
and other solutions which will
ensure disconnecting the heater
from the source of power (in-
tervals between all their poles
should not be less than 3 mm).
Do not connect any volt-
age into RP, NA, Tzas inlets! This
can result in connector damage.

!
Fig.4 Connection to electric
mains

!
Inlet Outlet
While applying thermostat
make sure there is no voltage
on its entry!

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ENG-030B/p.392
Room thermostat (RP entry) -
when the voltage free contact gets
opened the boiler will stop heating.
The entry is responsible for boiler
control depending on the room tem-
perature. It’s described in section
INSTALLATION.
Master appliance (NA entry) – you
can limit the electricity consumption,
i.e. the boiler can be switched off
while another appliance consumes
electricity. To do it, an electrician
should install in line an extra open
contact in to the NA entry (voltage
free entry), so that when a master
appliance gets on, the contact will
be opened the boiler switched off.
When the NA contact gets opened,
heating will get off and the pump
stopped. The EKCO boiler may also
work as the second boiler. If it is so,
the master boiler by opening the
NA entry will stop heating of EKCO.
However, the mode of the three-way
valve control stays on so the cylinder
is fed by the heat from the master
boiler.
Connection of
external appliances
5
Fig.5 ZIO board
A - room thermostat
B - master appliance
RP - room thermostat connection point
NA - master appliance connection point
RP, NA – free-voltage entry. Do not connect any voltage!
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ENG-030B/p.392
Installer instruction manual
black
brown
blue

10
1. Open the NA contacts (fig.5)
2. Set up the pump on manual mode (see section „ Advanced settings”)
3. Switch the boiler on ( button).
4. Make sure that a correct flow through the boiler is reached (the "B" in-
dicator is on with a constant light – fig.8). If the installation is filled up
with antifreeze solution, see the „ Special startup procedure” hereunder.
The pump should get vented itself after a short working time, however, if
necessary vent the pump in the following way:
• close the cut-off valve on the outlet
• set the pump on the highest gear (fig.6)
• undo carefully the vent plug (fig.7) on the pump
• after 15-30 s. do the vent plug up
• open the cut off plug
A direct vent pump is allowed even during special start-up procedure.
5. Switch the boiler off (hold button for 3 seconds)
6. Set up the pump on automatic mode (see section „Advanced settings”)
7. Close the NA contacts and connect a room thermostat (fig.5) – this is re-
quired only when you haven’t done it before to begin the special start-up
procedure.
Follow the above recommen-
dations, otherwise we may not
honour your warranty rights.
6
7
Fig.6 Gear pump controller.
Fig.7 Pump venting
Start-up
Special start-up procedure
A flow rate reading error may occur if you start-up the unit at low ambient temperature. This error may occur
because the physical properties of antifreeze solution. If the B indicator flickers (fig.8) and the cut-off valves are
opened you have to close NA and RP contacts (fig.5) which will automatically start the special start-up proce-
dure. As a result, the medium will be warmed up to temperature that enabled you to read the flow rate correctly.
The duration of procedure depends on both the installation capacity and the temperature inside the installation.
When a control panel display (fig.8) shows any parameters alternately and “_“,”_ _“ it means that the procedure
is started. The procedure will close automatically and the unit will start normal operation once the minimal flow
rate is reached.
8. Switch the boiler on ( botton)
9. Set up the temperature of the medium at required temp. (see section „Using the boiler”)

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ENG-030B/p.392
Advanced settings To set the advanced settings of the unit: set up the stand-by mode (press and hold for 3 seconds) then hold
and briefly press .
You can select parameters by pressing button. To change the parameters value press or – in sequence:
- pump working mode –PA (automatic), Pr (manual – the pump works continuously),
- maximum quantity of activated heating elements (no option to change),
- operating characteristics of the unit:
• (no) temperature settings range between 40-850C
• (Po) temperature settings range between 20-600C (co-operation with a hot water cylinder is not available)
- the way of display the outlet temperature of medium when the unit works in winter mode.
• (to) – displaying the outlet temperature from the unit and from left and right heating box ,
- operation in cascade connection:
• (r0) single unit work, the master controller doesn’t recognize the unit,
• (r1) cascade operation
- number of unit that works in cascade. The parameter can only be changed when the unit is set up to work in
cascade.
• (Ax) , x – number of unit in cascade,
- temperature of medium which feed a hot water cylinder (starting the central heating mode). The central heat-
ing mode can be activated by setting the temperature of medium in the range between 50-850C. Setting at 0
C will switch off the central heating mode.
- power of heating box (I indicator is on, fig.8),
- maximum unit power during the cylinder feeding (A, I indicators are on, fig.8).
To exit and save the settings push and hold .
The unit is preset by factory to
co-operate with a central heat-
ing system. For co-operation
with a domestic hot water cyl-
inder the advanced unit settings
must be adjusted.

12
Fig.8 Control panel
A - hot water cylinder indicator
B - pump and flow indicator
C - heating on and room thermostat indi-
cator
D - inlet temperature indicator
E - outlet temperature indicator
F - medium temperature setting indicator
G, H, I - physical units indicators
J - digital display
K - medium temperature setting indicator
(for hot water cylinder)
L - push-buttons
Recommendations
We recommend the following routine maintenance to assure faultless
unit operation:
1. Do not drain the central heating system after the heating season
2. Get rid of any effluent from the central heating system and boiler
connection points.
3. Leave the controller in stand-by mode and do not cut off power supply
between the heating seasons.
4. Contact with authorised serviceman for an inspection before every
heating season.
8
Using the boiler
Control panel operation
The control panel consists of two working areas: the signalling area (elements: A-K) and control area (L). The
user can select three operating modes: stand-by, winter (central heating or central heating + hot water cylinder
heating), summer (cylinder heating).
Stand-by mode
To set the stand-by mode press . and hold for 2 seconds. Note: Do not cut power supply off between heat-
ing season. When the control panel is switched to „stand-by” mode all indicators are off. In this mode the boiler
is off but the pump is activated every day for 15 minutes (this protects the boiler and the whole central heating
installation from being blocked and silted up). The pump will run every day at the same time, it will be the time
of the day when you switch it to the ”stand-by” mode e.g., if you set the pump on a „stand-by” mode at 6p.m.
the timer will activate the pump everyday for 15 minutes starting at around 6p.m.
Winter mode (central heating or central heating + hot water cylinder heating)
To set the winter mode (C.H or C.H + H.W.C.H mode) press , (when you set from „stand-by” to „winter”
mode). The digital display shows the medium temperature. Indicator F flickers when the controller is in the temp.
setting mode. To set the temp. press or
The temp. can be set between 40 – 850C. To ensure smooth and economic boiler operation, the temperature of
the medium (for central heating) has to be set in accordance with current weather conditions (outdoor tempera-
ture), taking into account the building parameters (e.g. compactness, insulation, windowing etc.). An exemplary
The boiler is pre-set by factory
to co-operate with a central
heating installation. For co-
operation with a domestic hot
water cylinder adjust the service
menu settings.

13
ENG-030B/p.392 User instructions
characteristics are shown on fig.9. Optimum settings of the medium tem-
perature can reduce the boiler operating costs.
When the unit works in winter mode (C.H + H.W.C.H) the three way
valve directs the heating medium to either central heating circuit or feed
cylinder circuit.
The priority is to heat the hot water cylinder, at the same time the central
heating circuit is off. When the unit heats the hot water cylinder the unit
power is limited to 1/3 of its nominal power. To change maximum unit
power when the unit heats the hot water cylinder an advanced unit settings
must be adjusted.
If the WE-008 sensor for cylinder water temperature control is applied
(connected to the Tzas entry on the ZIO board) you can switch the controller
to set cylinder water temp.(indicator „K” is active) using button. The dig-
ital display (J) will show the cylinder temp. setting. To set the temp. press
9
or If the thermostat for cylinder temperature control is applied (connected to the Tzas entry on the ZIO board),
the temperature setting on front panel is not available. You can set the temp. directly on the cylinder thermostat.
You can check out the following working parameters by pressing the button.
A display shows (in sequence):
1) Next pressing of inlet temp. (G,D,F indicators are on),
2) Next pressing of outlet temp. (G.E,F indicators are on),
3) Next pressing of medium flow rate through the boiler (H indicator is on),
4) Next pressing of approximate power with which the boiler currently heats (I indicator is on)
5) Next pressing of switch – returns to the “standard” state, where you can change the setting of the tem-
perature of medium (water) in the central heating system.
“A” „B” and „C” indicators:
• boiler co-operates with the hot water cylinder – A indicator is “on”
• pump is working , correct rate of flow through the boiler – B indicator is “on”
• no flow, not sufficient rate of flow (boiler is in failure condition, heating elements are not active) – B indicator
flickers
• room thermostat sends a heating on signal, the required medium temp. has been reached –C indicator is
“on” (green light)
• heating activation- C indicator is “on” (red light)
• the required room temperature has been reached, room thermostat sends heating off signal - C indicator is “off “
Fig.9 Relationship between
medium temperature and
outdoor temperature (at
20°C room temperature)

14
Summer mode
To switch to summer mode press (when you are in main view of winter mode). This mode is available only
if the boiler is enabled to co-operate with cylinder. A heating medium is directed to cylinder’s coil. In this mode
the three-way valve directs the water (medium) to the coil inside the hot water cylinder only. The “summer”
mode should be used after the heating season. A water temp. in cylinder is shown only if the WE-008 sensor is
applied (connected to the Tzas entry on the ZIO board). To set the temp. of water in cylinder press or .
When a cylinder thermostat is applied (connected to the WZ entry on the ZIO board), the temp. settings on
panel control is not available. A digital display shows ‘ - - ‘. The temp. can be set by cylinder thermostat. The inlet
and outlet temp view ,flow rate view, power value view, and button is unactive. To set winter mode press .

15
ENG-030B/p.392
symptom reason action
The indicators on con-
trol panel are off lack of boiler power supply check parameters of the power network and fuses
contact an authorised service
The “K’ indicator
flickering
check parameters of the power mains and fuses
contact an authorised service
B indicator flickers
pump is blocked unblock the pump by unscrew the screw on pump hous-
ing and move the pump rotor manually
medium doesn’t circulate through the boiler
- boiler is blocked
an air-bound central heating system, installation, the
pump and the boiler vent the installation, pump and
boiler
check patency of central heating system clean the filter
a failure of pump’s power supply contact an authorised service
a failure of pump or flow sensor contact an authorised service
C indicator is off , room
thermostat sends heat
on signal
a failure of installation that connect a room
thermostat check installation
a failure of electronic module contact an authorised service
D indicator flickers a failure of inlet temp. sensor, boiler in failure
condition contact an authorised service
E indicator flickers a failure of outlet temp. sensor, heating is
blocked contact an authorised service
C indicator flickers
when The master appli-
ance doesn’t work
a failure of installation that connects the master
appliance check installation
a failure of electronic module contact an authorised service
Boiler doesn’t heat a
cylinder
a failure of cylinder temp. sensor or thermostat contact an authorised service, replace cylinder temp.
sensor or thermostat
a failure of three-way valve actuator replace the actuator
a failure of electronic module contact an authorised service
J panel display shows
“_“,”_ _“, B indicator
flickers
medium temperature in the circuit is too low,
medium flow rate reading error wait until the start-up procedure is finished
Failures
In case, the boiler does not
work properly after the above
checks and none of the failures
is present, contact an authorised
serviceman.
User instructions

16
Keep the boiler in a dry place with a temperature between 5 - 350C.
EKCO.T boiler 1 piece
Fixing screws 2 pieces
Magnetic filter for central heating installation F-MAG 1’’ 1 piece
Storing
Boiler kit
This appliance is not intended
for use by persons (including
children) with reduced physical,
sensory or mental capabilities or
lack of experience and knowl-
edge, 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.