Termodinamik EKY Series Setup guide

EKY 125-1000
EKY SERIES SOLID FUEL HOT WATER BOILER
WITH MANUAL LOADING
INSTALLATION AND USAGE MANUAL
Digital and mechanical control panel...
H E A T I N G S Y S T E M S

FOREWORD
Dear Customer;
First of all, thank you for choosing our product. We hope you will get
complete satisfaction from DEK Series Electric Combi Boiler.
We would like you to use your device with maximum efficiency, therefore
please read this instruction book carefully before you start using the
product and save it to refer to in the future.
This manual will help you to operate your device safely and efficiently. For
this reason you should pay attention to these:
Please read this instruction book carefully before you install and operate
the product.
Follow the instructions and the rules on safe usage.
The instruction book may apply to other models as well; the differences
between the models are clearly described inside.
H E A T I N G S Y S T E M S

CONTENTS
Foreword
EKY 17-100 Technical Specifications..................................................................1
EKY 125-250 Technical Specifications................................................................3
EKY 125-500 (3 bar) Technical Specifications.....................................................5
EKY 125-1000 (5 bar) Technical Specifications...................................................7
Appliance Information......................................................................................9
Expansion Tank Volumes Suitable for Capacities.............................................11
EKY 17-100, EKY 125-250 Installation Chart................................................12
EKY 125-1000 Installation Chart......................................................................14
EKY 125-1000 Expansion Connection Chart.....................................................15
Common Chimney...........................................................................................16
EKY Digital Control Panel.................................................................................17
Error Codes and Solutions...............................................................................20
EKY Digital Panel Electrical Connection Chart.................................................22
EKY Mechanical Panel Electrical Connection Chart(125-250)......................24
EKY Mechanical Panel Electrical Connections Chart (250-1000)......................25
Use of the Boiler..............................................................................................26
Malfunctions and Troubleshooting.................................................................31
H E A T I N G S Y S T E M S

EKY 17-100 TECHNICAL SPECIFICATIONS
1
H E A T I N G S Y S T E M S
D
C
G
F
E
EKY 17 SIDE VIEW

EKY 17-100 TECHNICAL SPECIFICATIONS
2
H E A T I N G S Y S T E M S
(bar) (bar) kg
Weight
G Flue
Diameter
(mm)
H (Boiler
Input-Output)
J (Safety
Input-Output)
Fuel Loading
Lid Dimensions
(mm)
L (Boiler
Filling-Discharge)
EKY 17
EKY 17
20 183
255 300 420 450 470
560 190x390820 1100 1225 130
49
Capacity
(Coal)
Kw
Water
Volume Operating
Pressure
Test
Pressure
We are reserved the right to make changes in dimensions and appearance.

EKY 125 - 250 TECHNICAL SPECIFICATIONS
3
H E A T I N G S Y S T E M S
338 mm
365 mm

EKY 125 - 250 TECHNICAL SPECIFICATIONS
4
H E A T I N G S Y S T E M S
We are reserved the right to make changes in dimensions and appearance.
R 1 1/4?
R 1 1/4? R 1 1/4? R 1 1/4? R 1 1/4?
J (Safety
Input-Output)
256 246 236 290 518
Water
Volume
(L)
3 3 3 3 3
Operating
Pressure
(bar)
4.5 4.5 4.5 4.5 4.5
Test
Pressure
(bar)
930 950
1050 1000 1290
Weight
(kg)
Model
EKY 125
EKY 150 EKY 175 EKY 200 EKY 250
790 790 790 790 942
A
(mm)
1520
1680 1680 1840 1980
B
(mm)
1735 1735 1650 1650 1760
C
(mm)
1380 1220 1220 1060 1570
D
(mm)
370 520 520 680 700
E
(mm)
1520 1520 1605 1605 1630
K
(mm)
R1 1/2?
R1 1/2?
R 2?
R 2?
R 2 1/2?
H (Boiler
Input-Output)
R 3/4? R 3/4? R 3/4? R 3/4? R 3/4?
L (Boiler
Filling
Discharge)
ØM(mm)
Flue
Diameter
250 250 250 250 250
Model
EKY 125 EKY 150 EKY 175 EKY 200 EKY 250
145 174 203
232
291
Capacity
(Coal)
Kw

EKY 125 - 500 (3 BAR) TECHNICAL SPECIFICATIONS
5
H E A T I N G S Y S T E M S

EKY 125 - 500 (3 BAR) TECHNICAL SPECIFICATIONS CHART
6
We are reserved the right to make changes in dimensions and appearance.
H E A T I N G S Y S T E M S
1340 1350
1640 1550
1340 1350
1840 1810
1340 1350
1840 1810
1340 1350
1840 1810
1640 1550
1840 1810
756 378 350
886 443 350
503 350
593 350
544 400
689 400
697 500
757 500
842 500
980 500
1495
1996
2670 10101186
3181 12221684
1315
1826
2490 10101006
3011 12221514
1195
1706
2370 1010
2891 12221394
1065
1690
2240 1010
2875 10811378
1400
2272
2585 10811088
3457 12221960
A
(mm)
B
(mm)
C
(mm)
D
(mm)
G
(mm)
E
(mm)
F
(mm)
H
(mm)
145
349
174
407
203
465
232
523
290
581
Model
EKY 125
EKY 300
EKY 150
EKY 350
EKY 175
EKY 400
EKY 200
EKY 450
EKY 250
EKY 500
Capacity
(Coal)
Kw
2 1/2?
2 1/2?
2 1/2?
2 1/2?
3?
3?
3?
4?
4?
4?
1 1/2?
1 1/2?
1 1/2?
1 1/2?
1 1/2?
1 1/2?
1 1/2?
2?
2?
2?
3/4?
3/4?
3/4?
3/4?
3/4?
3/4?
3/4?
3/4?
3/4?
3/4?
3
3
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
4.5
3
3
3
3
3
3
3
3
CH
Input-Output
Boiler
Expansion
Tank
Output
Boiler
DischargeOperating
Pressure
(bar)
Pressure
(bar)
Test
1220
2470
1420
3150
1660
3950
1530
3430
2120
4220
Weight
(kg)
Model
EKY 125
EKY 300
EKY 150
EKY 350
EKY 175
EKY 400
EKY 200
EKY 450
EKY 250
EKY 500

EKY 125 - 1000 (5 BAR) TECHNICAL SPECIFICATIONS CHART
7
H E A T I N G S Y S T E M S

EKY 125 - 1000 (5 BAR) TECHNICAL SPECIFICATIONS CHART
8
We are reserved the right to make changes in dimensions and appearance.
H E A T I N G S Y S T E M S

APPLIANCE INFORMATION
ASSEMBLY INSTRUCTIONS
EKYseriesboilersaredesignedtoburn differenttypesoffuelssuchaswood,walnutcoal,quince
coal and low-calorie brown coal in ranging capacities. As it is known, the shaft gasses which
occur as a result of burning wood and coal, and condensation of water vapors shall take place.
Makesurenottooperatetheboilerbelow45°C.Incaseofoperationbelow45°C,thetemperature
of the shaft will be low and this will cause the shaft draft to be insufficient and result in
condensation.Therefore,the life spanofthe boiler shallbe shorter dueto corrosion inshorttime.
The circulation pump in EKY Model boilers stops operating when the boiler water temperature
decreases below 32°C. This is designed to prevent the substantial decrease in the boiler output
watertemperature andaciddrop (sulfuricacid) resulting fromcondensation by meansof cooling
thefirebox.
The fan allowing for burning air stops operating when the boiler water temperature falls under
28°Cand the “fuelout”light on thepanelindicator is on.Thisisdesigned to preventthefan from
cooling more the shaft gasses in case the boiler fuel decreases. When the shaft gas cools down,
condensationoccursintheshaft.Suchcondensedwatercontainsacid.
9
The boiler should be leveled and installed at least at a distance of 20 cm from ground in boiler
roomsonadurablesurface.
Theboilerroomshouldberegularlyventilatedaccordingtoregulationsandrule.
WhenassemblingEKYseriesboilers,itisrequiredtouseopenexpansiontank.Theexpansion
tankshouldbelocated atthetopoftheinstallationand thesafetypipesshould beconnectedtothe
inputs and outputs of the boiler in the shortest route possible. There should never be any flow
control units (valve, check valve, etc.) over the safety pipes. Make sure that the open expansion
tank is always full. The expansion tank volumes suitable for each boiler are given in the table (at
thepage11).
The pump should be installed in such way to avoid boiler and expansion tank flow and return
pipes should not create an air pocket. On points where there is possibility for air to be
accumulated,airtubesorventsystemsshallbeprovidedtopurgetheair.
H E A T I N G S Y S T E M S
CORRECT WRONG CORRECT
WRONG

In order to provide for the safety of the boiler and the assembly in case of power outages,
theinstallationshouldhaveaby-passline.
Make sure to use a suitable check valve for all solid-fuel boilers and the pressure of the
check valve should be equal to the maximum operating pressure of the boiler. On boilers
operating with 3 bar working pressure 3-bar safety valves should be used. (For cylindrical
boilers(25-100)andprismatic(125and250)boilersoperatingwith3-bar).
Inregionspronetoriskoffreezing,expansiontankandinsulationshouldbeused.
Thediameterof theshaftshouldnotbesmallerthantheoutputdiameteroftheboilershaft
andtheinstructionsontheshaftassemblyspecifiedinthismanualshouldbefollowed.
Expansion tank flow and return pipes should be installed with continuous upward
inclinationfromtheboilertothetankwithoutanydownwardbending.
10
Theboiler should be connectedto the chimney of
the building without narrowing the diameter at the
flue outlet and through pipes having minimum the
same or larger diameter at the flue outlet and
through pipes having minimum the same or larger
diameterastheboilerflueoutlet.
For installation of the boiler warning points indicated in the user manual must be
taken into consideration. The supplier will not take any responsibility for wrong
installationoftheboilerandchimney.
H E A T I N G S Y S T E M S
During the installation of the appliance, make sure to leave some space around the
appliance depending on the properties of the appliance enough for the technical service to
handletheappliance.
Make sure the location where the appliance and the waste gas disposal line are situated is
notalivingspace.
Inordertominimizetheheatloss,theinstallationpipesshouldbeheat-insulated.
When selecting mono-phase pump, connect the power cable with an open end sticking
outofthepanelontheboilerintotheelectricterminalofthepump.If3-phase pump is being
used,getaseparatepanelforthepump.
Connectorsandvalvesshouldbeplacedoninletandoutletlines.
WRONG
CORRECT WRONG

Boiler Capacity
(Kcal/h)
If Cast Sectional
Heating Radiators
are used
If Panel Radiators
are used
25.000
40.000
60.000
80.000
100.000
120.000
150.000
175.000
200.000
250.000
300.000
350.000
400.000
450.000
500.000
550.000
600.000
650.000
700.000
750.000
800.000
900.000
1.000.000
65 L
100 L
150 L
200 L
250 L
292 L
333 L
417 L
500 L
625 L
750 L
857 L
1000 L
1125 L
1250 L
1375 L
1500 L
1625 L
1750 L
1875 L
2000 L
2250 L
2500 L
42 L
67 L
100 L
135 L
167 L
200 L
250 L
292 L
333 L
417 L
500 L
583 L
667 L
750 L
833 L
917 L
1000 L
1083 L
1167 L
1250 L
1333 L
1500 L
1667 L
EXPANSION TANK VOLUMES SUITABLE FOR BOILER CAPACITIES
The values given above are intended for nominal conditions. The contractor company shall
perform the precise evaluation and calculations depending on the location and operation
conditionsoftheboiler.
11
H E A T I N G S Y S T E M S
45 L17.000 26 L

EKY 25-100, EKY 125-250 INSTALLATION CHART
12
H E A T I N G S Y S T E M S
A. Input to the Radiators
B. Output from the Radiators
C. Open Expansion Tank
D. Input to the Expansion Tank
E. Output from the Expansion Tank
F. Messenger Line
G. Radiators
H. Air-Purge Valve
I. By-Pass Line Valve
J. Main Valve Pump
K. Main Valve
L. Filling Valve
C
H
A
B
E
F
I
K
JJ
L
G G
D
PUMP ON OUTLET

C
H
B
F
GG
D
PUMP ON INLET
E
A
L
K
J J
I
EKY 25-100, EKY 125-250 INSTALLATION CHART
H E A T I N G S Y S T E M S
A. Input to the Radiators
B. Output from the Radiators
C. Open Expansion Tank
D. Input to the Expansion Tank
E. Output from the Expansion Tank
F. Messenger Line
G. Radiators
H. Air-Purge Valve
I. By-Pass Line Valve
J. Main Valve Pump
K. Main Valve
L. Filling Valve
13

EKY 125-1000 INSTALLATION CHART
(EXCEPT FOR PRISMATIC 125-250 SERIES)
O
14
ATO RADIATORS
BFROM RADIATORS
COPEN EXPANSION TANK
DEXPANSION LINE
EFROM EXPANSION TANK
FMESSENGER LINE
GRADIATORS
HAIR PURGE VALVE
IBY-PASS LINE VALVE
JMAIN PUMP VALVE
KMAIN PUMP
LFILLING VALVE
MSECONDARY PUMP VALVE
NSECONDARY PUMP
OSAFETY VALVE
Air Vent
H E A T I N G S Y S T E M S

In places where the weather is very cold or there is risk of freezing, the expansion tank,
expansioninputandoutputpipesshouldbeinsulated.
The input pipes connecting to the expansion tank should be assembled without turning
downwardsandshouldsteadilylevelupwhengoingfromtheboilertotheexpansiontank.
Ahydrometer should be installed to the assembly in order to control the water level of the
system.
Make sure not to install units like valves, filters, check valve, etc. over the safety pipes
betweentheexpansiontankandtheboiler.
When water comes out of the messenger pipe, it means that the expansion tank is full and
the boiler has reached a specific pressure level. This should be checked at times when water
ispumpedtotheboilerfromthemainwatersupply.
EKY 17-1000 EXPANSION CONNECTION CHART
POSTURE OF THE SHAFT ON THE ROOF
15
These are containers open to
atmosphere and they should be
installed a distance from the top of the
pipe system for hot water systems or at
a distance from the radiator level at the
top.
For the manual feeding boiler, do not
useopenexpansion.
AIR VENT
MESSENGER
PIPE
OUTPUT
FROM
EXPANSION
INPUT TO
EXPANSION
The shaft opening should be at a distance from
the roof ridge for slant tiled roofs.
The shaft opening at a distance from the roof
ridge (only tiled roofs).
The shaft opening should be at a distance
from of at least 80 cm from the roof ridge
for slant roofs.
Roofs with little slant.
H E A T I N G S Y S T E M S

Shaft pipes should be connected to the
shaft in a way having the same diameter
with the boiler shaft output as much as
possible.
In order to intensify the shaft draft, do
not install shaft extractor hoods, fans, etc.
totheoutputoftheshaft.
Make sure not to use bendy pipes at the
distance where the pipes shall be installed
to the shaft from the shaft output of the
boiler.
Boiler Shaft Pipe Diameter
SHAFT ASSEMBLY (FOR ALL MODELS)
Shaftisone ofthemostimportantunitsofthesystem.Whentheshaftis
not high-quality, the burning is not sufficient and no efficiency is
obtained.Andthisresultsinsmokingandsoot.
16
Connecting two solid fuel boilers to the same chimney is not recommended. Where this is
not achievable and if calculations based to chimney cross section and height also allow
usingofothersolid fuelboilers,thenitispossibleto connectmultipleboilersintoacommon
fluesystem.Insuchcasestheconfigurationindicatedinthefigureshouldbeconsidered.
Another point to be observed is that, the
angle of the flue connection with
horizontal axis of the second boiler to be
connectedshouldbelessthanthefirstone.
The second boiler’s flue connection to
main flue connection should be in “swept
connection”asshowninthepicture.
COMMON CHIMNEY
Keep easily flammable materials away from boiler flue connections and hot areas,
whichmayoccuraroundtheboiler.
Minimum 50 cm
Fireproofmetarialmustbeusedforfluepipeandchimneyshouldhave
enough resistance to restrain the fire outside the chimney into the other
partsofthebuildingthroughthechimneyforcertaintime.
Do not install an aluminium folding pipe between boiler’s and
building’sflue.
Do not install any apparatus such as windrose/weathercock at outlet of
chimney.
H E A T I N G S Y S T E M S

EKY DIGITAL CONTROL PANEL
KEYS
1.ENTER
Used for confirming the values
enteredintheappliance.
2.ESC
Used for canceling the operation of the
new value entered in the appliance and
returning to the previous value in the
memory.
3.UP/DOWN KEYS
Used to enter new values in
theappliance.
4.TEMPERATURE SETTINGS
Usedfor setting theboiler temperature
setting.
ELECTRICAL CONNECTION
1 2
3
45
6
7
17
Iftheshaftismadeofironsheetmaterial,insulatethesurroundingoftheshaftandprevent
theheatloss.
Theshaftshouldnothaveasectionalnarrownessatanyspot.
Makesurenottoinstallanotherapplianceormorethanoneboilertothesameshaft.
The boiler should not be installed to the shaft at a reverse angle preventing draught (see
page16).
The shaft should be periodically cleaned not allowing for the formation of tarry soot
insidewhichmakesitimpossibletocleantheshaft.
Thefluepipe(chimney)mustn’tbemountedwithlevelwhichpreventthedroughtofit.
Endofthechimneymustbe40cmhigherthantipoftheroof.
Chimney should be well insulated and heat losses should be reduced. When the chimney
cools down the draught also decreases and in the cooled chimney the formed acids
combined with the effect of condensation can lead corrosion on the inner surfaces of the
chimneyordowninsidetheboiler,thereforechimneysshouldalsobeinsulated.
The electrical connections should be performed by the technical service. The connections
shouldbeperformedas shown in the pages 22, 24 and 25. Incaseofdamages resulting from
different connection or the arbitrary change of the thermostats, the manufacturer cannot be
heldliable.
H E A T I N G S Y S T E M S