Mareli Systems ECOSTAR AUTO 50 User manual

Mareli Systems
ECOSTAR AUTO 50 KW
Pellet BOILER
Assembly and exploitation manual

2
Mareli Systems
Observing the prescriptions of the present manual is in the user’s favour and is one of
the warranty conditions. Compliance with this instruction is in the interest of the con-
sumer and one of the warranty terms.
• is appliance is not intended for use by people (including children) with limited physical, sen-
sory or mental abilities or lack of experience and knowledge. e installation must be performed
by a qualied expert in the eld of heating installations or authorized by “Marelli Systems’ service.
e place and way of connecting the boiler should be selected carefully in accord with the safety
instructions. Install away from ammable objects!
• Before starting any operation, the user must read and fully understand the contents of this instruc-
tion manual. Incorrect setup may cause hazardous conditions and / or incorrect function of the boil;
• Do not wash the boiler with water. Water can get inside the replace and damage the electronics
and cause an electric shock;
• Do not put clothes to dry on the boiler. Any clothes hangers and other objects must be located
within a reasonable distance from the replace. Fire hazard;
• e user is fully responsible for the proper use of the product which exempts the company from
liability of any users errors or misbehaviour or omissions;
• Any intervention or replacement that is made by unauthorized people or using non original spare
parts for the product can be risky for the user and release the company from all liability;
• Most surfaces of the boiler are extremely hot (the door handle, glass, ue pipe, etc.). Avoid contact
with these parts before assuring yourself that you us temperature resistant gloves as well as suitable
temperature resistant instruments;
• Under no circumstances should the re be ignited with the door open or broken glass;
• e product must be electrically connected to a system equipped with an eective earth conduc-
tor. (Must be grounded);
• Turn o the boiler in case of failure or malfunction;
• All unburned pellets in the burner aer each unsuccessful attempt ignition must be removed
before a new ignition;
• When installing the product all re safety requirements must be respected
If there is a re in the ue pipe, extinguish the boiler, disconnect the power cord and never open the
door. Call competent authorized service technicians;
• Do not light the boiler with ammable materials if the ignition system failed;
• Periodically check and clean the smoke outlet ducts of the boiler (connection to the ue pipe);
• Pellet boiler is not a cooker;
• Always keep the cover closed;
SAFE DISTANCES:
When installing the product a safe distance of at least 600 mm must be respected. is
distance applies to the product located near materials of B or C ammability level. e
safe distance is doubled if the product is close to materials of C3 combustion level.
INSTRUCTIONS FOR SECURITY:

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Mareli Systems
1. PURPOSE
e boiler is purposed to heat domestic and public premises by the means of pellets.
e boiler is equipped with a steel water jacket designed for heating systems with water
temperature up to 90º C at a maximum super pressure up to 0,15 Mpa. Tests are run at
pressure of 0,3 Mpa.
e boiler is designed and manufactured to work with A-class pellets only
( DIN plus 51731 ) with the following characteristics:
What are the pellets.
e pellets are produced by compressed wood-
en waste le from the production of various
furniture, sawmills and others. is type of
fuel is environmentally friendly because in
the production process no agglutinate agents
(glues, resins and others) are added. Actual-
ly, the integrity of the pellets is guaranteed by
the lignite – a natural ingredient contained in
the wood itself. While the wood has a calorie
capacity of 4.4 kW/kg (15% humidity at 18
months drying), the pellets have 5.2 kW/kg.
• Material 100% pure conifer or broad-leaf
wood;
• Diameter Ф6/8 mm;
• Length 20-30mm;
• Calorie capacity 5.2 kW/kg;
• Ash content < 8%;
e use of pellets with characteristics dierent from the recommended may result in
power decrease, unstable and inconsistent work of the boiler.
Info: To ensure the proper work of the boiler the pellets must be stored in a dry place!
Recharging of pellets can be done during work, with the following sequence:
1. Open the bunker (located at the top of the product);
2. Fill the hopper, using non-combustible container;
3. Close the lid of the bunker;
Attention!!! Use gloves! Beware of hot surfaces!

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Mareli Systems
1615
808 861
808
861
100,00
220
318
G 1"-1/4
G 1"-1/4
G 1"-1/4
167
1053
448
168
298

5
Mareli Systems
1615
808 861
808
861
100,00
220
318
G 1"-1/4
G 1"-1/4
G 1"-1/4
167
1053
448
168
298

6
Mareli Systems
Automatic cleaning
mechanism for the
turbulators
(OPTIONAL)
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
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8
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m


Display
Manual cleaning
mechanism for the
turbulators
Combustion
Chamber
Igniter
Automatic cleaning
Mechanism for the
brazier
Ashtray
Pellet Bunker

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Mareli Systems
3. ASSEMBLY
3.1 General conditions.
All national, regional and European requirements for safe operation of the appliance
must be respected during installation and operation.
Prior to installation, load capacity of the place where the boiler will be intended must
be ensured. e weight of the boiler is specied in the technical data table.
To ensure the correct and safe operation of the boiler, the following conditions must
be met:
e installation of the boiler and its accessories must be carried out by authorized per-
sons.
e oor where the boiler is installed should be at and horizontal, made of re-resist-
ant materials at least 1500 mm in front of the replace and not less than 400 mm on
both sides and at the back of the wall.
Minimum distances from the wall to the boiler should be at least 400 mm. e mini-
mum space in front of the replace should be 1500 mm. e minimal distance of the
boiler from combustion materials should be no less than 1500 mm.
e door of the replace should be closed tightly during the work process. Opening it
during work is absolutely forbidden.
When installing the boiler, the connections between the individual pipes and the chim-
ney rooop must be dense.
When the re is rst ignited, a smell occurs as a result of the paint being heated.
e replace is painted with heat-resistant paint, which achieves its ultimate resist-
ance aer repeated use of the boiler. THEREFORE KEEP OUTSIDE INTERACTIONS
WITH THE COATING TO A MINIMUM in order not to damage it.
A. A neighboring wall.
B. e rear wall.
C. Sidewall.
D. Floor protection.
E. Ignitable element.
1 = 400 (mm)
2 = 600 (mm)
3 = 400 (mm)
4 = 300 (mm)
5 = 1500 (mm)
6 = 120 (mm)
7 = 800 (mm)
A
B
C
D
E
1
2
3
4
5
67
D

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Mareli Systems
CHECK ITEMS
BEFORE INSTALLATION
Chimney exit
Chimney
Connection to
chimney
Connection to
the boiler
Security
distances
e oor
Inlet air
e chimney
revision door

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Mareli Systems
3.2 Basic rules and prescriptions.
e boiler with water jacket operates on water heating boiler principle.
e advantage of this type of heating system is the maximum utilization of the heat that is pro-
duced during the combustion process. With this method the heat from the combustion chamber
is taken to remote and hard to reach for a normal heat exchange premises in order to maintain an
even temperature and warmth comfort.
• Ensure that every branch and element of the installation is airtight at every single moment of its ex-
ploitation.
• All elements of the installation must be protected from freezing, especially if the enlarging pot or
other parts are situated in non-heated premises.
• e circulation pump can be chosen by the capacity required by using the following formula:
G=0,043. P , (m³/h), in which:
P, kW is the heat output of the water jacket. e circulation pump can be turned on and o by
the means of a thermostat in combination with an electric switch.
• e rst service cleaning of the pump’s lter must be done immediately aer testing the installation.
• If an old installation is going to be used it must be washed several times to ensure the removal of any
accumulated dirt on the surfaces of the water jacket.
• Do not drain the circulating water of the installation during the non-heated season.
• Chemical treatment of the circulating water is not recommended.
Chart 1 is a basic combined chart for heating with solid fuel boiler, electrical boiler equipped
with water serpentine and a solar panel. For economy and eciency of the system and a constant
availability of cheap hot water a qualied assembly of the automatic shier controlling the ther-
mal ows to and out of the solar panel and the boiler is required.
Chart 2 shows a one storey heating with a compulsory circulation. e advantage of this chart is
that the water-conducting elements can be hidden.
e enlarging pot must have a direct atmosphere connection which means that it must be placed
on the highest spot in the system. Its capacity can be determined as 0,1 part of the total capacity
of the system.
e lling or unloading of the system is done via a hose through a facet mounted in the lowest
area. Mounting a membrane enlarging pot is permitted when constructing a closed type system.
During the initial 3-4 start-ups a condensation on the surfaces of the water jacket may occur
which depending on the fuel’s humidity and the temperature of the incoming water may reach
0,3 litr on a single start-up. e accumulating char reduces the temperature dierence and the
condensation.
• “Mareli Systems” provides a warranty and out of warranty service and replacement of the
water jackets.
• e warranty is not valid in case of a boiler with a swollen water jacket which is a result of
pressure increase in the system and improper connecting.
• e water jackets are tested under pressure of 400 kPa (4 bar).
It is recommended that the assembly is performed by an authorized specialist.
Radiator
Deaerator
Expansion vessel
Return Valve
Lyra
Boiler
Stove
Pump
RadiatorRadiatorRadiator

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Mareli Systems
Example scheme for installation of an anti-condensation valve. It is recommended
that the valve be at least 50 C. At the discretion of the installer, a valve with a higher
return water temperature may be installed.
3.3 Assembly of the duct components.
Duct components and pipes
For the assembly of the duct pipes the use of non-ammable materials, resistant to the ammable
products and condensation is obligatory. e assembly must be performed in such a manner so
it guarantees the airtight sealing and prevents condensation. If possible, avoid adding horizontal
sections. Direction shi is done by using knee joints with a max angle of 45˚.
For heating devices equipped with a smoke ventilator, i.e all of the “MARELI” boilers, the follow-
ing instructions must be observed:
• Horizontal sections must have a minimum incline
of 3° upwards;
• e length of the horizontal sections must be as
short as possible, but without exceeding 3 m;
• More than four direction shis are forbidden,
including the cases where a T-shaped element is
used;
• e duct components must be airtight and to be
insulated if extending outside the premises in
which the replace is installed;
• e duct components must allow a soot cleaning;
• e duct components must have a constant sec-
tion. A section change is allowed only in the
chimney joint;
CHIMNEY EXITS (ANTI-WIND)

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Mareli Systems
Chimney
e chimney or the duct component must conform with the
following requirements: to be airtight, waterproof and prop-
erly insulated, to be constructed with materials resistant to
the normal mechanical wear and to the heat coming from the
combustion products and condensation.
• To be kept away from ammable materials.
e recommended chimney dra at work - from 12-20 Pa.
45
5 m (MAX)
(MAX)
Attention!!! In case of a re hazard turn o the product from the display. is will stop the oxygen
ow to the product.
Roof incline ≥ 10 °
Height above the roof = 40 cm
90°
Distance measured at 90 ° from
roof area = 1.3 m

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Mareli Systems
3.4 Types of connection to the chimney
Chimney exit
Moisture channel
Chimney
ermal insulation
External wall
Connection to chimney
Flue gas connection
“T”
connection
e chimney
revision door
Heat generator

13
Mareli Systems
3.5 Air intake
Suction pipe or air intake is placed in the back and has a circular section with a diameter of 48 mm.
e combustion air can be aspirated:
• From the camera, as long as it is near an air intake communicating with the outside wall hav-
ing a minimum area of 100 cm2, properly positioned and protected by a grid.
• Or by connecting directly outside with a suitable tubing having an inner diameter of 48 mm
and a maximum length of 1.5 M.2
4. Cleaning
Cleaning the replace should be done only when cold. e cleaning of the combustion chamber
must be carried out daily.
For this purpose, make sure the replace has ceased operation and is completely cold. Pull up the
combustion pot and remove it from the boiler and then clean it from soot.
When removed fuel pot at the bottom of the combustion chamber opens a hole designed for the
accumulated ash. Collect ashes in the ashtray and return fuel pot in place and then close the door.
e replace is ready for operation.
Cleaning of ues and chimneys are conducted once every 1.5 tons of fuel used
Combustion
Chamber
Manual cleaning
mechanism for the
turbulators
Automatic cleaning
mechanism for the
turbulators
(OPTIONAL)

14
Mareli Systems
CLEANING THE PELLET TANK
ECOSTAR AUTO

15
Mareli Systems
Le inspection door
Right inspection door
ECOSTAR AUTO
ECOSTAR AUTO

16
Mareli Systems
230V/50HZ
PUMP 2
PUMP COLD
WATER
HOT WATER
OUTLET
SAFETY
VALVE
EXHAUST
FAN

17
Mareli Systems
IT IS MANDATORY THAT AT EACH EMPTYING OF THE ASH CONTAIN
ERS, THE COMBUSTION BOX IS ALSO CLEANED.
1
ECOSTAR AUTO

18
Mareli Systems
EMPTY THE FIRST ASH CONTAINER
2
ECOSTAR AUTO

19
Mareli Systems
REMOVE THE 2 OTHER ASH CONTAINERS FROM THE SIDES.
3
ECOSTAR AUTO

20
Mareli Systems
EMPTY THE 2 SIDE ASH CONTAINERS
ECOSTAR AUTO