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Auto-Stoker Coal Boiler
Installation and Operating Manual
Manufactured by:
Engineering / Sheetmetal / Long Run Roofing / Scaffolding / Christie Glasshouse and Garden Sheds / Ecomax Boilers
By
Ecomax
Location
1 Thomas Burns Street
Dunedin 9016, New Zealand
Postal
PO Box 49, Dunedin 9054
Phone
+64 3 477-7909
+64 3 477-7908
Fax
www.allans.co.nz
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Table of Contents
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Summary of Contents for ALLAN'S Ecomax Auto-Stoker
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Page 1: Caution
Auto-Stoker Coal Boiler Ecomax Installation and Operating Manual Manufactured by: Location 1 Thomas Burns Street Phone +64 3 477-7909 Dunedin 9016, New Zealand +64 3 477-7908 Postal PO Box 49, Dunedin 9054 www.allans.co.nz Engineering / Sheetmetal / Long Run Roofing / Scaffolding / Christie Glasshouse and Garden Sheds / Ecomax Boilers... - Page 2 F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 2 of 36...
- Page 3 CAUTION THIS APPLIANCE MUST BE INSTALLED BY APPROVED AND COMPETENT PERSONNEL ONLY. FAILURE TO INSTALL THE APPLIANCE IN ACCORDANCE WITH THESE INSTRUCTIONS LOCAL BUILDING REGULATIONS AND BY-LAWS WILL INVALIDATE THE WARRANTY. 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.
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Page 4: Table Of Contents
CONTENTS CAUTION ....................1 CONTENTS ..................4 Introduction ..................5 Specifications ..................6 Product Overview ................7 Product Dimensions ....................7 Product Description ....................8 Component Description .................... 10 Installation ..................12 Installation Location ....................12 Floor Protector ......................13 Coal Hopper ......................13 Installation Clearances ....................14 Flue ........................... -
Page 5: Introduction
Introduction Dear Customer, Congratulations on choosing an Ecomax appliance to heat your home and hot water. You have also purchased a New Zealand manufactured appliance with after sales service and parts readily available, unlike some imported central heating appliances. The “Ecomax” Auto Stoker is used to supply hot water to central heating systems, which includes underfloor, radiators, fan convectors and domestic/commercial hot water all year round. -
Page 6: Specifications
Specifications Electrical Specification: Single phase 230V 50Hz AC Weight (Empty): 150kg Water Capacity of Appliance (not including external pipework): 34 litres Water Connections: ¾” BSP Female Fuel Type: Pea sized coal only Fuel Input (Max): 7kg/hr Heat Output (Max): 26kW Efficiency: 74% Average Particulate Emission Factor: 1.2g/kg Average Particulate Emission Rate: 57g/MJ... -
Page 7: Product Overview
Product Overview Product Dimensions F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 7 of 36... -
Page 8: Product Description
Product Description Scrubber Coils Spanner Flue Spigot Combustion Ash Pan Ash Valve Lever Chamber Door Boiler Hopper Coal Feed Screw Motor Gearbox F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 8 of 36... - Page 9 Scrubber Coils Flue Spigot Combustion Chamber Insulating Board Smoke Back Tube Heat Exchanger Tubes Burn Pot Blower Coal Feed Screw timer Top dial ON (minutes) Bottom dial OFF (minutes) Boiler fuse Coal Feed Screw ON/OFF Boiler ON/OFF F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 9 of 36...
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Page 10: Component Description
Component Description Burn Pot - The coal is burnt in the burn pot with the air supplied through the air ports and the coal supplied from the coal screw below. The burn pot is made of cast iron and can be removed by cutting the three metal tags that are holding it in place with a cutting disc. - Page 11 Ash Removal – The ash is removed from the ash pan located in the bottom of the boiler. Use leather gloves when handling the ash pan. Always allow ashes to cool properly (a minimum of seven days) in a non-combustible container before disposing of ashes according to local regulations.
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Page 12: Installation
Installation Installation is carried out in the following steps: • Determining the Coal Boiler’s installation location, taking into account flue position, accessibility for coal delivery to the hopper, accessibility for future servicing and availability of electrical connections and suitable locations for water piping and pressure relief •... -
Page 13: Floor Protector
for instance high wind areas may adversely affect the performance of the appliance through high back pressure in the flue. Cooling winds can also prevent the evacuation of fly ash in the flue, leading to restrictions in the flue over time. Floor Protector The New Zealand standard AS/NZS 2918:2001 states that if the appliance is to be installed on or within 500mm of any heat sensitive or combustible materials in the... -
Page 14: Installation Clearances
Installation Clearances It is essential that the Coal Boiler is installed with AT LEAST the minimum clearances to combustibles as illustrated below. If possible, it is recommended that these dimensions are greater, to allow for better access during installation and servicing. -
Page 15: Flue
Flue This appliance is designed to be run with Ø150mm stainless steel flue with Ø250mm galvanised liner. Keep horizontal or inclined flue sections to a minimum, as accumulation of ash will occur in these sections and access for cleaning needs to be provided. - Page 16 Ecomax flue kit schematic: F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 16 of 36...
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Page 17: Water Connection
Water Connection The water system for the Coal Boiler must be a sealed, pressurised system. It must be sized appropriately for the dwelling and the expected heating load it will carry by a suitably qualified person. The expansion vessel should be at least 10% of the total volume of the system. - Page 18 the temperature of the water in the appliance. This ensures the Coal Boiler will get up to an ideal temperature operating range before it starts to circulate the water. If the pump is not connected to the Coal Boiler, the appliance may not be able to heat the water sufficiently and the warranty on the appliance may be voided.
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Page 19: Installation Checklist
Note: Schematic depicted is an example only. It is the responsibility of the installer to design and install a suitable circulation system based on each installation’s unique conditions. Installation Checklist Minimum clearances to combustibles checked Minimum clearance for removal of Coal Feed Screw checked Floor protector fitted (if required) Appliance securely fastened to support Water system sealed, pressurised, properly bled and leak tested... -
Page 20: Operating Your Appliance
Operating Your Appliance General Safety The Coal Boiler is fully sealed, but during normal operation some of the panels may get hot. Do not stack or lean anything against the appliance, and make sure all combustible materials are at least to the minimum clearances stated in the Installation Clearances section. -
Page 21: Notes On Fuel Selection
When the heating system is up to temperature and no more heat is required, the temperature in the water jacket will make the Blower and Coal Feed Screw turn off. The pump will continue running until the temperature in the water jacket has cooled enough. -
Page 22: Optimising Boiler Operation
Optimising Boiler Operation Each batch of coal will have slightly different burning characteristics. Each time a new batch is run through, check the flame in the Burn Pot. It should be a short, bright orange or yellow flame all the way around the outside of the Burn Pot, with darker, unburnt fuel coming up through the middle. -
Page 23: Maintenance
Maintenance Quick Reference Daily Maintenance Daily maintenance at least once a day is critical for the long life of the appliance. If this is not carried out, permanent damage may occur. Carrying out these tasks twice a day is recommended. •... -
Page 24: Monthly Maintenance
• Open and close the Ash Forceful in and Valve by forcefully pushing out movement The Ash Valve Lever in and with blower out. This will allow any fines going and ash and ash under the Burn Pot pan in place to drop into the Ash Pan. -
Page 25: Yearly Maintenance
Yearly Maintenance Yearly maintenance should be carried out before the start of the heating season to allow time to rectify any issues. • Remove the top and clean out all the fly ash in the top of the Combustion Chamber. Remove the plate at the top of the Combustion Chamber so you can see the Burn Pot and scrape all soot build up from the... -
Page 26: If The Appliance Is To Be Shut Down For A Long Period
Dislodging a Stone from the Coal Feed Screw Turn off the boiler and disconnect the tension clip, and with a spanner rock the Coal Feed Screw back and forth until the stone is dislodged. Drive the stone through to the Burn Pot by turning the Coal Feed Screw with the spanner. -
Page 27: Starting The Appliance After It Has Been Shut Down For A Long Period
Starting the Appliance After it has Been Shut Down for a Long Period • Have the flue cleaned by an approved serviceman. • Make sure the power is off to the appliance. • Check for any signs of rust, moisture or condensation in the Hopper, Combustion Chamber, Heat Exchanger Tubes and the area around the Ash Pan. -
Page 28: Troubleshooting
Troubleshooting All corrective action should be taken while the appliance is cold. Observed Fault Possible Cause Solution No coal Refill hopper with fresh fuel. Prime appliance No heat from as per Operating for the First Time/Priming radiators/in section house Damp coal Coal can absorb moisture from the atmosphere if left for too long. -
Page 29: Coal Feed Screw Not Turning
Observed Fault Possible Cause Solution Pump water The pump is factory set to turn on once the temperature set water temperature reaches 65° (unless using a too low mixing valve). This prevents too much cold water surrounding the Combustion Chamber and affecting combustion. -
Page 30: Smoke Observed At Cowl Or Issuing From Boiler Or Hopper
Observed Fault Possible Cause Solution Tension clip Check to see if Coal Feed Screw has jammed broken before replacing. Motor thermal If the Coal Feed Screw is jammed and for overload tripped some reason the tension clip doesn’t break, the resultant load on the motor can cause the thermal overload to trip. -
Page 31: Buildup Of Clinker In Burn Pot
Observed Fault Possible Cause Solution Burn pot has When cold, clean out Burn Pot and Retort of clinker (fused all ash/clinker ash) Burn Pot worn Replace Burn Pot Burn Pot retort Open Ash Valve and clean out all ash inside. blocked Heat Exchanger Use the spanner to lift the Scrubber Coils up... -
Page 32: Tension Pins Regularly Breaking
Observed Fault Possible Cause Solution Seam of coal Stones can be present in the fuel from the Tension pins with too many supplier or be picked up during transport. regularly stones breaking Coal Feed Remove coal screw and check for wear, Screw worn especially the first 100mm at the end of the screw under the Burn Pot. -
Page 33: Wiring Diagram
Wiring Diagram F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 33 of 36... -
Page 34: Warranty
Warranty The following warranty is available to the first owner of each appliance during the period specified below at any Ecomax Ltd franchise dealer authorised to service the appliance. The repair or replacement free of all charges including labour charges of that part if the appliance requiring repair or replacement is a result of defective material or workmanship in manufacture and/or assembly during a period commencing on the date of delivery of the appliance in a new and unused state to the first purchaser and... -
Page 35: Owner Details
Owner Details Serial Number Installation Date Installer F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 35 of 36... - Page 36 Manufactured by: Location 1 Thomas Burns Street Phone +64 3 477-7909 Dunedin 9016, New Zealand +64 3 477-7908 Postal PO Box 49, Dunedin 9054 www.allans.co.nz Engineering / Sheetmetal / Long Run Roofing / Scaffolding / Christie Glasshouse and Garden Sheds / Ecomax Boilers F:\C - E\ECOMAX\COAL BOILER\Instructions and Manuals\Coal Boiler Manual Rev 6.doc Page 36 of 36...
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