Maktek 25 MKK-S Quick start guide

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CONTENT
1.!GENERAL!WARNINGS!BEFORE!OPERATING!THE!UNIT..............................4!
2.!FEATURES!OF!THE!BOILER.......................................................................5!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!
3.!SECTIONS!OF!THE!BOILER.......................................................................6!
4.!INSTALLATION........................................................................................7!
4.1!INSTALLATION!AND!WATER!FLOOD....................................................9!
BOILER!INSTALLATION!SCHEMA..............................................................10!
4.2!AIR!CONNECTION..............................................................................11!
4.3!CHIMNEY...........................................................................................11!
CHIMNEY!CONNECTION!SCHEMA............................................................12!
!!5.!TECHICAL!FEATURES.............................................................................…13!
6.!CONTROL!PANEL.....................................................................................14!
7.!FIRST!OPEATION!AND!USE.......................................................................15!
7.1!FIRST!BURNING..................................................................................15!
7.2!WARNINGS!FOR!USE.......................................................................….16!
8.!CLEANING!AND!MAINTAINANCE........................................................…....17!
9.!ELECTRICAL!SCHEME!............................................................……………......18!!
!10.!TROUBLE!SHOOTING...............................................................................19!
!11.!CARRIAGE!AND!TRANSPORT....................................................................20!
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PREFACE!
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MAKTEK!is!one!the!leading!institutions!in!Turkey!in!heating!industry!since!its!foundation!in!1976!
.!Inconsideration!of!monitoring!technological!developments!
closely,!MAKTEK!!takes!the!pride!of!presenting!MAKTEK!Solid!Fuel!Boilers!in!Turkey!and!World!
market.!
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Our!company,!which!has!acquired!advanced!technology!and!superior!quality,!stands!on!in!
accordance!with!these!principles.!This!handbook!is!a!helpful!guide!during!operation!and!
maintenance!of!the!user!boiler!assembly.!For!malfunctions!and!maintenance,!please!contact!our!
authorized!service.!
Our!after!sales!service!network!is!always!at!your!service!with!abundant!spare!parts!and!
widespread!service!organization.!
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1.GENERAL!WARNING!BEFORE!OPERATING!THE!UNIT
• Please check the conformity of waste gas , water and electric infrastucture of the area
• to the necessary technical parameters where the boiler will be installed.
• For safe use of electricity , make sure that the grounding of the installation is isolated
and there is no phase.
• Your boiler is under guarantee for 2 years against component and production defects as
long as it is used in line with the suggestions in this manual. Our company cannot be held
liable for any misuse of the product.
• Please do not use the boiler out of its purpose. The boiler is designed to supply hot water
(maximum 90 degrees) to your heating system.
• Clean air must always be provided in the area where the boiler is installed. Due to reasons of
security, the installation of the boiler to closed areas with human presence is strictly
forbidden.
• Please do not operate the boiler without water. Do not feed cold water to hot boiler. If,for
any reason the boiler temprature is over 90 degrees, do not attempt to feed cold water to the
boiler until the boiler temprature drops down to 40 degrees. The best solution for over
heated boiler is to take out burning coal outside of the boiler
• Please do not drain the system water except repairing or during times of frost.
Antifreeze material can be added to sytem water up to 15%
• During operation, the temprature difference between return and flow can be maximum 20
• degrees.
• Water with high calcer rate is extremely dangerous for boiler and installation. In this
case, please use water softeners . Product failures as a result of blocked water passes is
out of scope of factory guarantee
• Each year,before start of heating season,the boiler’s chimney connection and internal parts
• must be checked and cleansed. This will enable efficient operation of the boiler.
• Please do not take hot water out of the boiler for domestic use purposes

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2.!FEATURES!OF!THE!BOILER!
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- Capacity between 25.000 kcal-250.000 kcal/h
- Burns the fuel which is up to 20mm diameter with high energy thanks to automatic fuel feeding.
- Heating with high efiiciency for coal and all solid fuels
- Monitoring of heating water on digital screen
- Electronic control panel
- Safe use with safety thermostat against overheating
- Energy saving thanks to special body design
- Burning air which comes from the hot bulb surface, ensures homogenous burning of the coal.
- Suited to use small coal, prina, nut shell as fuel
- Monitoring and setting feeding and waiting time on the electronic control panel
- Detoriations as a result of burning are minimised thanks to cast iron burning bunker
- Fan with quiet running cycle period and clap ensures maximum efficiency
- Automatic feeding enables ash to fall down in ash drawer.
- Wet rotor, 3 level circulation pump provides the intended circulation flow and energy saving
- When the fuel is totally used up in the fuel feeding tank and system temperature is under 25
degrees, the boiler shuts down automatically and extra running of the fan, pump and feeding
engine stops.
- Thanks to its three pass combustion chamber design, the boiler uses the acquired heat from fuel
at maximum level
- 2 years warranty
- CE Certificate
- Economic life cycle of the boiler is estimated to be 15 year
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3.!SECTIONS!OF!THE!BOILER!
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*See!techic!table!for!dimensions!stated!with!letters!
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SECTIONS OF THE BOILER
1. Control Panel
2. Top (cleaning) cover
3. Fan
4. Fuel Combustion Lid
5. Sifter
6. Stocker
7. Engine with Reductor
8. Stocker Fuel Disposal Lid
9. Circulation Flow
10. Safety Flow
11. Chimney Exhaust Pipe
12. Smoke Case
13. Circulation Return
14. Safety Return
15. Filling and Draining
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4.!INSTALLATION!
* Boiler must be installed evenly and must be placed on 10 cm high place in boiler room
installations.
*Boiler must be connected to a good drawing chimney and minimum number of elbows
should be used between chimney and boiler.
*Boiler must be placed at a location with enough air intake for an efificient burning. It is required
to use open expansion tank for the installation of MAKTEK Automatic Coal Boilers.
* Boiler- expansion tank return pipes must be absolutely isolated in extreme cold regions.
* Warning line should be installed for taking the overflow water from the expansion tank.
*There shouldn't be any valves, check valves on the pipes between boiler expansion tank
*Expansion tank volumes based on capacity are shown below:

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MODEL CAPACITY EXPANSION TANK
25 MKK-S
25.000 kcal/h
50 lt
40 MKK-S
40.000 kcal/h
75 lt
60 MKK-S
60.000 kcal/h
100 lt
80 MKK-S
80.000 kcal/h
200 lt
100 MKK-S
100.000 kcal/h
250 lt
125 MKK-S
125.000 kcal/h
275 lt
150 MKK-S
150.000 kcal/h
300 lt
200 MKK-S
200.000 kcal/h
500 lt
250 MKK-S
250.000 kcal/h
600 lt
* At first operation of the boiler, installation pipes should be cleaned up before the connection.
The most appropriate way is to flood water from one end of the pipes and to drain off at the
other side.
*Circulation pump must be installed on boiler water return pipe.
*During installation, there must be enough working space left for technical service
intervention, boiler control, and fuel feeding
*Valve connection should be made on boiler water flow and return lines.
*Chimney connections should be leakproof, same diameter pipes without any narrowing
sections should be used from the exit of boiler to the chimney hole.
*Grounding connections should be done, electricity connection of circulation pump should be
done correctly. Only technical services are authorized at all electricity related breakdowns.
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4.1!INSTALLATION!AND!WATER!FLOOD
Please use open expansion tank for MAKTEK Solid Fuel Boilers. Closed expansion tank
systems may trigger steaming of the boiler when there is an electric cut out or when the pump is
not functioning.
Please connect open expansion tanks according to standarts.
No valve or similar materials must be installed on safety return or flow line of the open
expansion tank.
In order to increase safety if the pump does not function,a by pass line must be secured between
inlet and outlet spot of circulation pump as show in installation schema. The valve on by pass line
should be kept closed during normal functioning . ıf there is an electricity cut and a risk of
overheating appears, the valve must be open and the evacuation of hot water must be provided by
natural circulation. The diameter of the pipe to be used at by pass line should be the same
diameter size with the pipe used in installation at minimum.
As an extra security measure, an infinite power source may be used for electricty cut.
Please mount 3 bar security valve on the boiler for safety against over pressure in open
expansion systems.
We suggest the mounting of the pump on return line in order to protect from over heating
(steam).
All connections and valve positions must be checked after the installation of the boiler is
complete.
Operations like water flooding or evacuation must be done while the boiler is not working
and cold.
Please flood water to the system until water comes out of warning pipe. Please close the valves
when the filling is complete.
Please purge air in the system where necessary. Avoid any installation that might block air in the
system, if any doubt, please use automatic purger.
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BOILER!INSTALLATION!SCHEMA

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4.2!AIR!CONNECTION!
The!area!where!the!boiler!is!installed!must!always!be!suppplied!with!fresh!air!by!using!a!
window!or!a!duct.!In!order!for!a!boiler!to!burn!safely!and!efficiently,!fresh!air!is!required.!
Otherwise!once!the!burning!starts,!the!oxygen!level!will!drop!causing!the!burning!to!be!
inefficient.!In!turn,!this!will!result!in!formation!of!soot!in!the!boiler!and!chimney!and!will!
require!frequent!cleaning.!
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4.3!CHIMNEY
• The chimney that will be connected to the boiler must be independent. The chimney
must be connected to provide minimum draught. A boiler without chimney connection
should not be operated.
• Chimney connection pipe and pipe systematic should be installed and checked by
authorized people only. May we remind you that the biggest factor in boiler efficiency
is chimney design and draught.
• Proper chimney connection pipe should not smaller than the boilers chimney diameter,
vertical length must not be shorter than 60 cm and longer than 2 meters and pipe must be
connected to the chimney with minimum 10 degree of angle.
• We suggest not to use enamel stove pipes as it creates tar in chimney connection pipe or
chimney system.
• In case of an elbow use in chimney connection, the elbows must be round with a wide
angle. Quantity of an angle must be minimum 2 pieces.
• Chimney connection must be installed to allow demounting from the boiler and avoid
gas leaking.
• Chimney connection pipe must not be extended to the outside and must be connected to a
pipe.
• The contact of chimney connection pipe with flammable material must be avoided.
• Chimney connection pipe must not be pushed inside the chimney.
• The direction of the pipe should not be changed, should there is a need ,it must be
positioned by 60 degrees.
• The chimney must be leak proof and air transperancy from inside and outside must be
avoided.
• No other boiler or device must be connected to same chimney. This would decrease
chimney draught and decrease boiler efficiency.
• Parallel chimneys should have no inter connection.

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• There should be no sectional narrow down in any place of the chimney.
• Main walls of the building should never be used as chimney wall element. The
chimney must be inside the building, if the chimney must pass from outside, the
isolation must be done properly.
• The chimney must be frequently cleaned in order to avoid tar and soot and clogs.
• Please avoid foreign objects, cement or surface flow inside the chimney, as these will
increase the risk of narrow chimney section and will result in decrease on chimney draught.
CHIMNEY!CONNECTION!SCHEMA!
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5.!TECHNICAL!SPECIFICATION
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6.!!BOILER!WITH!STOCKER!CONTROL!PANEL
( Fuel Waiting Period Setting Button )
(Fuel Feeding Period Setting Button)
( Fan Button )
( Termostat Setting Button)
(Fan Led )
(Pump Led)
(Fuel Finshed Led)
(Fuel Squeezed Led)
( Up Burron)
(Down Button)
( 7 part Led Indicator )
(Reductor Button )
(Fan Button)
(Fuel Feeding Button)
(Alarm Button)
(On/ Off Button)
Fuel Feed Button
Feeds the fuel manually when fuel feed button is pushed
Reductor Button
Reductor becomes ON or OFF when Reductor button is pushed.
Fan Button
Fan becomes ON or OFF when Fan button is pushed
On/ Off Button
System becomes ON or OFF ( Button should be pushed 2 seconds for
both position)
Alarm Button
Alarm stops
Increasing Button
Increases the value of the set function
Decreasing Button
Decreases the value of the set function
Lcd Screen
Shows the temperature in normal conditions. In setting condition, setting
value is shown on screen.
Fuel waiting period
setting button
Sets the waiting period after fuel loading (04-255 sec)
Fuel feeding period
setting button
Sets fuel loading period. (04-60 sec)
Fan Setting Button
Sets speed level of fan ( From 1 to 5 )
Thermostat Setting Button
Adjust the intended temperature ( from 35 °C' to to 90 °C)
Fan led
Shows fan activation
Pump led
Shows pump activation
Reductor led
Shows reductor activation.
No Fuel led
Shows lack of fuel
Fuel Congestion Led
Shows reductor is congested
Failure Codes
* ( H1 ) No Fuel
* ( H2 ) Heating sensor is not connected or broken
*( H3 ) Temperature of the boiler water is very high
*( H4 ) Fuel is congested in reductor
ATTENTION !!! Fuel loading and feeding value is in Table 1. Loading and feeding settings belongs to the fuel only
It is necessary to do new settings when the fuel type is changed
SAFETY TERMOSTAT Safety termostat is placed behind the control panel and is active during a possible
breakdown of boiler water setting thermostat to prevent the increase of boiler water temperature. Hence, ensures an
extra safety and protects the boiler. Recommended to be set at 80 °C.
IMPORTANT!!!
Current boiler water temprature is shown on digital screen when adjustment settings is not in use

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7.!FIRST!OPERATION!AND!USE
7.1!INITIAL!BURNING
Before initial burning, system water must be full and system air must be purged.
Fuel loading must be done over the sifter. The sifter prevents the entrance of foreign objects, large
size coal pieces inside the reductor and damage reductor and helezon. Also it enables the passing of
the proper size of coal which will burn easily and efficiently
At initial burning, fan and reductor must be on and boiler water temprature must be previously set.
The reductor must be manually operated and fuel must be loaded to the combustion chamber. For
sufficient fuel loading,burnign pot must be loaded at the maximum level.
Small wood pieces must be ignited with gas and paper for burning the fuel in boiler. Then boiler
lids must be closed and fan must be runned in low speed until the coal is completely combusted. If
fan blows too much air, big slinders occurr because of the cooling effect of burning tank.
Make the fuel feeding and waiting settings according to boiler and fuel type from the Chart 1:
25.000!
kcal/h!
40.000!
kcal/h!
60.000!
kcal/h!
80.000!
kcal/h!
100.000!
kcal/h!
125.000!
kcal/h!
150.000!
kcal/h!
200.000!
kcal/h!
250.000!
kcal/h!
Coal!5000!
kcal/h!
Feeding!
/sec)!
4!
6!
9!
12!
15!
19!
24!
32!
40!
Waiting!
(sec)!
106!
110!
116!
116!
122!
130!
138!
156!
174!
Coal!7000!
kcal/h!
Feeding!
/sec)!
4!
5!
9!
9!
11!
14!
18!
25!
32!
Waiting!
(sec)!
110!
116!
122!
122!
126!
130!
138!
156!
174!
When the ignition is complete, make the reductor button on and operate the boiler with the
settings you did.
Increase the fan speed after ignition and provide the fuel efficiently.
It would be good to set the boiler water temperature at high degree (70°C) from control panel.
Afterwards this temperature can be set to desired degree.

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7.2!WARNINGS!FOR!USE
Circulation pump will start running when the burning continues and boiler water temperature comes
to 35°C. This prevents extra electric cunsumption and heats boiler immediately so prevents
damages from sweat of steam. Prevents water that is not properly heated to the raditaors.
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Boiler water temperature decreases when the fuel is finished and when it is 30°C, circulation
pump stops running. When the boiler water temperature decreases to 25°C all functions stops.
Fan automatically stops running when the boiler water temperature comes to set thermostat
degree. Fan starts running when the boiler water decreases 5°C below set degree.
Running and stopping of circulation pump and fan can be monitored from flashing leds on digital
indicator on control panel.
Circulation pump will run automatically for 3 seconds in every 25 hours unless the boiler is
unplugged. This prevents the failures on pump uring long periods when the boiler is not in use.
CAUTION!!! If the electricity power goes off, the circulation pump will stop working so the
high heat trapped in the boiler and it will increase the boiler water to the boiling point. In this
case you should do as following;
1- Close the air inlet of the fan completely.
2- DO NOT open the lids of the boiler.
3- If there are by-pass valves installed in the system, open them.
4- When the power comes back, return to your previous adjustments. Follow the steps to
start combustion to start burning in the boiler.!
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8.!CLEANING!AND!MAINTAINENCE
Following instructions should be followed in order to keep boiler working safe and efficient for
long time.
Quality of the fuel used, would effect the boiler cleaning time, consumption amount of fuel
and efficiency of boiler.
Small coal is burned in boiler. Do not burn dust and coke coal. Ash drawers should be cleansed
up every day.
High quality high calorie and dry coal should be used in order to get high efficiency.
Smoke pipes inner surface should be cleaned up with a brush and turbulators must be cleaned up
with a tissue or cloth in every 15 days. Air inflow in burning pot air holes must be checked.
Holes which don't have air flow must be unclogged. Air holes must be cleaned up by turning on
the fan for 15 minutes.
Electricity connection must be cut off before the maintainance. Please ventilate the
area before cleaning the boiler.
Electricity, chimney, installation connections should be done before winter time.!
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9.!SUGGESTIONS!!FOR!ECONOMIC!USE
-In!order!to!properly!ventilate!!the!premises,!please!open!the!windows!for!short!period!
of!time!!!while!the!radiator!valves!are!closed!
-! Pay!attention!not!to!heat!up!too!much:!room!temprature!must!be!kept!at!20!degrees.!
Each!degree!makes!a!6%!economy!on!heating!costs!
-!!!!!When!the!weather!is!dark,!please!close!the!shuttters!if!available!
-!!!!!Do!not!cover!your!radiators!with!objects!
-!!!!!Make!use!of!special!setting!of!the!control!panel,!set!the!!using!water!from!control!panel!
-! Consume!hot!water!considerably.!You!will!consume!less!water!and!energy!during!
shower!in!comparison!to!taking!a!long!bath.!
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10.!ELECTRICITY!SCHEMA
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11.!TROUBLE!SHOOTING
Problem
Reason
Solution Offer
Reductor doesn't work
There is H4 warning on
control panel digital screen
Electricity connection might be loose
Check the connection
Tighten the klemens
cables.
Shaft from the reductors can be
congested
Clean up the shaft bearing
helezon entrance hole
check the fuel congestion led.
If it doens't work call service.
Push ON-OFF button 2 seconds.
Motor can be broken
Call service.
Reductor runs but fuel can
not reach to burning cell
Bunker – fuel tank connection can be
blocked
Fuel should be pour from a
siever and dry fuel should be
burned.
Burning efficiency is low
Fuel is not well quality
Use high quality, dry and
proper size fuel.
Boiler settings are not made according
to the fuel type.
Make the proper settings from table
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Chimney draught is weak.
Chimney should be cleaned up.
There is H2 warning
on control panel
digital screen.
Heat sensor or card can be broken.
Call service
Smoke comes from chimney
connections
Air holes which are inside the
boiler, can be blocked.
Clean up holes and smoke pipes
regularly
Boiler Chimney connections can be
loosen
Check the boiler chimney
exit and pipe connections.
Chimney draught is weak.
Clean up the chimney.
Fan doesn't run
Set termostat
temperature is
achieved
Fan stops running when the
boiler water catches up the set
termostat temperature. When
temperature decreases 5
degrees it starts running again.
Fuel can be finished
Make fuel loading.
Fan button can be off.
Open main fan button.
There is H3
warning on control
panel digital screen.
Boiler water temperature is very high
* Check the water in boiler. If it
is inadequate, complement.
* Circulation pump is congested
* Boiler valves can be off
* There is air in system and
there is no circulation. Purge
the air.
H1 warning on
control panel digital
screen
No fuel or fuel might be congested.
*Check the fuel in stocker.
Complete the fuel if it is inadequate
and carry out the procedure in first
use.
* Fuel was wet when poured inside
the stocker, it is now stucked and
can not be loaded. Fuel is pumped
down by applying pressure with an
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12.!CARRYING!AND!TRANSPORT
A)!PLACING!THE!BOILER!ON!VEHICLE!
!*When the boiler is placed placed on vehicle, loading should be with crane.
* Gates of the vehicle should be opened previously.
* Make use of the supporting ring while loading boiler with crane.
* Pass the crane boom hook from the supporting ring.
*Make sure that hook pim is in safety mode.
*Uphold the crane boom and take the space.
*Slowly uphold the boiler that bottom level should be 30-40cm up from the ground.
*Keep away from sudden moves that would cause boiler to shake.
*Move the boiler next to vehicle in this way.
*Lift the boiler from 30-40 cm higher than the vehicle body and take it down on vehicle body
correctly.
*Remove the hook from crane supporting ring.
Attention : Boiler must be carried in vertical position, make use of the supporting ring. When
the boiler is lifted up with crane, there shouldn't any living being under the boiler. Boiler must
be carried with its accessories installed on it.
B)!!CARRYING!BOILER!ON!VEHICLE!
When the boiler is carried with a vehicle, it should be tied to vehicle strictly, supporting stuff
which would prevent slipping, should be put around. Boiler should not be carried with fragile,
smashable and living beings. Top of the vehicle should be covered with canvas after placing
boiler. Driver should keep away from sudden moves that would cause danger.
C)!UNLOADING!THE!BOILER!TO!THE!PLACE!OF!USE!
Boiler!should!not!be!placed!in!work!or!residence!places,!should!be!placed!in!a!seperate!boiler!
room.!
When!unloading!the!boiler!to!boiler!room,!crane!must!be!used!again,!points!that!are!stated!in!
Clause!A,!should!be!considered.!
If!the!place!of!use!is!not!appropriate!for!crane!entrance,!boiler!should!be!unloaded!in!a!proper!
place!and!carry!with!rollers!to!the!place!intended!
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