Kospel GB-030AB User manual

ELECTRIC CENTRAL HEATING FLOW
BOILER
EKCO.T

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 inuences
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 government unit, waste
management service or the shop where this product has been purchased.

3
GB-030AB_
Safety instructions
1. Read and strictly follow this installation and operating instructions to ensure a
long life and reliable boiler operation.
2. An efcient electrical installation which has been completed in accordance with
the binding norms of electric installation.
3. A wet central heating system equipped with appropriate expansion vessel made
according to binding norms of hydraulic installation.
4. A wet central heating system must be ushed before boiler installation.
5. Do not install any barrier ttings (e.g. valves) on the outlet of the safety valve.
6. Boiler must not be installed in a humid place or in a place exposed to the danger
of explosion.
7. Boiler installation and all electrical and hydraulic work must be performed by a
qualied professional installer.
8. All installation work must be performed when the power and water supply is
turned off.
9. Electric installation should be equipped with residual current protective devices
and other solutions which will ensure disconnecting the heater from the source
of power (intervals between all their poles should not be less than 3 mm).
10. Boiler is pre-set by the manufacturer to work with the central heating system.
Change the factory settings („Extended Menu”) to setup the boiler to work with
DHW Cylinder.
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.

4
Installation work
1. Hang the boiler up in a vertical position on
xing screws with inlet and outlet pipes to
the bottom, maintaining clearances from the
walls and the ceiling.
2. Connect the boiler to a central heating system
equipped with cut-off valves.
3. Fill the central heating system with a treated
water, that extends the life of the heating
elements.
4. Vent the central heating system.
5. Connect a boiler to the electrical system.
6. Fix the room thermostat, in accordance with
manual instruction.
7. Connect the room thermostat (by using two
wires 2 x 0,35 mm2) to the terminal of control
panel (RP entry).
8. Once you have nished the above pro-
cedures, you can start the boiler. See the
„Start-up” section.
Return Inlet Flow Outlet
Boiler connection to the central heating system
A magnetic lter must be installed on return pipe of central heating
installation system (before boiler inlet). The lter must be installed in
horizontal position, accordingly to ow direction (see arrow on the lter
body), with the magnetic insert chamber to the bottom.
PI - manometer
ZK - cut-off valve
RW - expansion pipe
NW - expansion vessel
ZT - thermostatic valve
ZP - passage valve
G - radiator
RP - room thermostat
boiler with cylinder
ZTD - three-way valve
ZAS - DHW Cylinder with a coil
TZ - cylinder temperature sensor
or cylinder thermostat point of
contact

5
GB-030AB_
Room thermostat (RP input) –
when the voltage free contact gets
opened the boiler will stop heating.
The input is responsible for boiler
control depending on the room
temperature.
Master appliance (NA input) – you
can limit the power used, 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 to the NA connector
(voltage free input), 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 second boiler. If it is so, the master boiler
by opening the NA input will stop heating of EKCO. However, the mode of the three-way
valve control stays on so a DHW cylinder is charged by the heat from the master boiler.
black
brown
blue
Connection of external appliances
ZTD - three-way valve with a servo-motor
ZAS - connection point of three-way valve
Tzas - connection point of water temp. sensor (in cylinder)
WE - 008 - KOSPEL water temp. sensor (in cylinder)
C - cylinder thermostat
A - Auraton 2005 room thermostate
B - master appliance
WZ - connection point of cylinder thermostat
RP - room thermostat connection point
NA - master appliance connection point
MR - radio module connection point

!
While applying other thermostat than Auraton 2005 make sure there is
no voltage on its output!
Do not connect any voltage into RP, NA input! This can result in perma nent
ZIO module damage.
CYLINDER
PUMP
room thermostate
Auraton 2005
back

6
Advanced settings
For advanced settings switch the control panel to standby mode (press and hold
button for 3 seconds) then press and hold , button, and press shortly.
To select parameter press , or buttons enable you to change the value:
- working mode of pump – PA (automatic), Pr (manual – continuous duty of pump),
- max. number of active heating elements (settings is blocked)
- Operating characteristic of boiler:
• (no) temperature control between 40 – 85oC,
• (Po) temperature control between 20 – 60oC (co-operation with DHW Cylinder
is not available),
- the way of display the outlet temperature of medium when the boiler works in
winter mode.
• (to) – displaying the outlet temperature from the boiler only
• (t.o.) – displaying the outlet temperature from the boiler and from left and right
heating box ,
- operation in cascade connection:
• (r0) independent boiler operation, the boiler is not recognised by master sensor,
• (r1) cascade operation,
- number of boiler that works in cascade. This parameter can only be changed
when the boiler is set up to work in cascade.
• (Ax) , x – number of boiler in cascade,
- temperature of medium which feed a DHW Cylinder (starting the DHW mode).
This mode can be activated by setting the temperature of medium in the range
between 50-85oC. Setting at 0oC will switch off the DHW mode..
- power of heating box (I indicator is on),
- maximum boiler power during the cylinder feeding (A, I indicators are on)
Press and hold button to exit and save the settings..
Special start-up procedure (when the system is lled with an
antifreeze solution)
A ow rate reading error may occur if you start-up the boiler at low ambient temperature.
This error may occur because the physical properties of antifreeze solution. If the B in-
dicator ickers and the cut-off valves are opened you have to close NA and RP contacts
which will automatically start the special start-up procedure. As a result, the medium will
be warmed up to temperature that enable you to read the ow rate correctly. The duration
of procedure depends on both the installation capacity and the temperature inside the
installation. When a control panel display (J) shows selected parameters alternately and
marks („-”, „--”) it means that the procedure is started. The procedure will close automati-
cally and the boiler will start normal operation once the minimal ow rate is reached.

7
GB-030AB_
Start up
LED
1 2 3 4 5
LED
1. Disconnect the NA contacts.
2. Set the pump on manual mode, see
the „Advanced settings” section.
3. Switch the boiler on (press button).
4. Check pump mode is set to the rec-
ommended factory setting (see Table
Below). To do this press button for
no more than 2 seconds. The LED’s
should illuminate the current operat-
ing mode (see image).
5. In case the LED’s are signaling a
different operating mode from the
recommended table below, set the
appropriate mode according to the
following instructions: press but-
ton for longer than 2 seconds, but
less than 10 seconds, the pump then
enters programming mode. LEDs glow
to indicate the current settings. To go to the other settings of the pump, in accordance
with the table, you can enter the correct combination of glowing LEDs by pressing
if the LED combination is correct, by not pressing the button for 10 seconds the
pump will remember this setting and will exit from programming mode.
Note: holding button for more than 10 seconds will lock the programming
mode on the pump so no changes can be made. To re-enable programming
of the pump settings hold button again for more than 10 seconds.
6. Make sure that a proper ow through the boiler is reached (the „B” indicator is
on with a constant light). The pump should self vent after a short time of running
however, if necessary, vent the pump in the following way:
• close the isolating valve on the outlet,
• leave boiler running for 15-30 s.
• open the isolating valve,
7. Switch the boiler off (hold button for 2 seconds).
8. Connect NA contact.
9. Set the pump on automatic mode, see „Advanced settings” section.
10. Switch the boiler on (press button).
11. Set the temperature of the boiler to required temperature, see the „Operating” section.
In the case of blocking the pump impeller due to a long layover out of heating
season and simultaneous non-compliance with the recommendation to leave
the driver in this period in a parking mode, please restore proper movement of
the impeller. To do this, please use PH2 screwdriver, press and turn the screw
left, located in the middle of the front panel of the pump (picture on page number
7). The pump impeller should be unblocked then.

8
Control panel
A - DHW cylinder indicator
B - pump and ow indicator
C - heating on and room thermostat indicator
D - inlet temperature indicator
E - outlet temperature indicator
F - medium temperature setting indicator (for CH
system)
G, H, I - physical units indicators
J - digital display
K - medium temperature setting indicator (for DHW)
L - push-buttons
The control panel consists of two working
areas: the signalling area (elements: A-K)
and control area (L). The user can select
the following working modes:
Rated power
[kW]
Pump lifting
height [m]
LED 1
red
LED 2
yellow
LED 3
yellow
LED 4
yellow
LED 5
yellow
4 ● ●
5 ● ● ●
6 ● ● ● ●
30 - 48 7 ● ● ●
- stand-by,
- winter (CH or CH + DHW heating),
- summer (DHW heating),
Stand-by mode
To set the stand-by mode press and keep button for 2 seconds. Important: Do not
cut power supply off between heating season. When the control panel is switched to
„Stand-by” mode the control panel is off. In this mode the pump is activated every day
for 15 minutes (what 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 6 p.m. the timer will activate the pump everyday for 15 minutes
starting at around 6 p.m.
Winter mode (CH or CH + DHW heating)
To set the winter mode press , (when you switch from „stand-by” to „winter” mode).
The digital display shows the CH medium temperature. Indicator F is on when the
controller is in the CH medium temp. setting mode. To set the temp. of CH medium
value press or . The temp. can be set between 40 – 85oC. To ensure smooth
and economic boiler operation, the temperature of the medium has to be set in ac-

9
GB-030AB_
cordance with current weather conditions (outdoor temperature), taking into account
the building parameters (e.g. compactness, insulation, windowing etc.). Optimum
settings of the medium temperature can reduce the boiler operating costs.
When the boiler works in winter mode (C.H + DHW heating) the three way valve directs
the heating medium to either central heating or feed cylinder circuit.
The priority is to heat the DHW Cylinder, at the same time the central heating circuit
is off. When the boiler heats the DHW Cylinder the boiler power is limited to 1/3 of its
nominal power. To change maximum boiler power (when the boiler heats the DHW
Cylinder) an advanced unit settings must be adjusted. If the WE-008 sensor for cyl-
inder water temperature control is applied (connected to the Tzas input on the ZIO
board) you can change the water temperature setting in cylinder by using button.
The digital display (J) will show the cylinder temp. setting. To set the temp. press
or If the thermostat for cylinder temperature control is applied (connected to the
WZ input 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 read the following
working parameters by pressing button.
A display shows (in sequence): inlet temp. (G,D,F indicators are on), outlet temp. (G,E,F
indicators are on), medium ow rate through the boiler (H indicator is on), estimated
power with which the boiler currently heats (I indicator is on). Pressing button again
allows you to set the the temperature of CH medium. Pressing button (when you
are in the parameters view mode) let you get back to the CH temperature setting mode.
Regardless of current work mode (setting, view) the “A” „B” and „C” indicator shows:
• A indicator is “on” - boiler works in DHW mode
• B indicator is “on” - pump is on, proper rate of medium ow through the boiler
B indicator ickers when there is no ow or the rate of ow is too low (boiler is in
emergency mode, heating elements are off)
• C indicator is “on” (green) - room thermostat sends a heating on signal, the
required medium temp. has been reached
• C indicator is “on” (red light) - heating activation
• C indicator is “off “ - room thermostat sends heating off signal, the required room
temp. has been reached
Summer mode
To set the summer mode press , (when you switch from „Winter mode” to „Sum-
mer mode”).
This mode is available if the boiler is enabled to co-operate with the DHW Cylinder. A
heating medium is directed by three way valve to cylinder’s coil only.
This mode should be used in time between the heating season. A water temp. in
cylinder is shown only if the WE-008 sensor is applied (connected to the Tzas input
on the ZIO board). You can change the water temperature setting in cylinder by us-
ing or button When a cylinder thermostat is applied (connected to the WZ
input on the ZIO board), the temp. settings on panel control is not available and the
digital display shows ‘ - - ‘. The temp. can be set by cylinder thermostat. The view of
inlet and outlet temp, ,ow rate,power value and button is unactive. To switch to
winter mode press shortly.

10
Failures
symptom reason action
Control panel indica-
tors are off lack of boiler power supply
check parameters of the power network
and fuses
contact the seller
B indicator ickers
pump is blocked
Unblock the rotor of the pump by insert-
ing a screwdriver into slot that is placed
in front of the pump (as shown in the
gure on page no.7). Push the screw-
driver and turn in a random direction.
medium doesn’t circulate through
the boiler - boiler is blocked
an air-bound of central heating system,
vent the installation, pump and boiler
check patency of central heating system,
clean the lter
a failure of pump’s power supply contact the seller
a failure of pump or ow sensor contact the seller
C indicator is off,
room thermostat
sends heat on signal
a failure of installation that con-
nect a room thermostat check installation
a failure of electronic module contact the seller
D indicator ickers
D indicator ickers a failure of inlet
temp. sensor, boiler in emergency
mode
contact the seller
E indicator ickers a failure of outlet temp. sensor,
heating is blocked contact the seller
C indicator ickers
when the master
appli ance doesn’t
work
a failure of installation that con-
nects the master appliance check installation
a failure of electronic module contact the seller
Boiler doesn’t heat a
cylinder
a failure of cylinder temp. sensor
or thermostat
contact the seller, replace cylinder temp.
sensor or thermostat
a failure of three-way valve
actuator replace the actuator
a failure of electronic module contact the seller
J panel display
shows “_“,”_ _“, B
indicator ickers
medium temperature in the circuit
is too low, medium ow rate
reading error
wait until the start-up procedure is
nished

Technical data
Max. pressure MPa 0,3
Min. pressure MPa 0,05
Outowing 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
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
5 x 50
The maximum allowed network impedance Ω 0,14 0,09 0,035 0,03
Rated power consumption kW 30 36 42 48
Rated voltage 380V~
Rated current A 3 x 45,6 3 x 54,7 3 x 63,8 3 x 72,9
Fuse rated current A 50 63 80
Min. connecting wires section mm25 x 10 5 x 16
Max. connecting wires section mm2
5 x 50
The maximum allowed network impedance Ω 0,14 0,09 0,035 0,03

KOSPEL S.A.
ul. Olchowa 1
75-136 Koszalin
tel. [phone]
[email protected]
www.kospel.pl