EKO-CUP S3 125 – 600 kW Centrometal Heating Techniq Instruction Manual

: August 14, 2024
: Centrometal

Table of Contents

EKO-CUP S3 125 – 600 kW Centrometal Heating Techniq
Product Usage Instructions
FAQ
TECHNICAL INSTRUCTIONS
TECHNICAL DATA
COMPONENT PARTS
BOILER DESCRIPTION
Insulation mounting
CONNECTION TO THE HEATING INSTALLATION
OPERATION AND MAINTENANCE
CONTACT
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EKO-CUP S3 125 – 600 kW Centrometal Heating Techniq

Product Usage Instructions

1. Installation, startup, and maintenance must be carried out by a qualified heating contractor or service organization.
2. Ensure that all electrical installations and fuel-carrying components are handled by a qualified service technician.
1. Do not use the boiler in a flammable or explosive environment.
2. Before performing any work on the boiler, ensure that the electric energy is switched off.
1. Keep the boiler room closed and ensure that combustion air supply openings are not blocked.

FAQ

Q: What should I do if I smell smoke?
A: When you smell smoke, follow these steps:
- Shut off the main gas/oil supply.
- Open windows and doors.
- Do not use open fire, smoke, or a lighter.
- Avoid generating sparks; do not use electrical switches, telephones, plugs, or bells.
- Leave the building immediately and notify the necessary contacts from a safe location.
Q: What can lead to dangerous conditions in the boiler room?
A: Insufficient fresh air for combustion in the boiler room can lead to dangerous conditions. Ensure that air supply openings are not reduced or closed and keep the boiler room protected from rodents and birds.

TECHNICAL INSTRUCTIONS

installation, use, and maintenance of the hot water boiler and installation of the additional equipment

Important

These instructions are an integral part of this product. All rights reserved.
Reproduction of the content of this document and transfer to third parties is not allowed without written approval from the manufacturer.
Make sure the instructions are always with the device, even if it is sold/transferred to another owner, so user or authorized person for maintenance or repairs can consult them.

READ THESE INSTRUCTIONS CAREFULLY BEFORE INSTALLING THE BOILER ! TO HEATING SYSTEM!

Boiler must not be used by children or disabled persons (either physically or mentally) as well as by person without knowledge or experience, unless they are under control or trained by a person responsible for their safety. Children must be supervised in the vicinity of the product.
Boiler must not operate in flammable and explosive environment.
Before any work on the boiler, electric energy must be switched off.
Please note that the installation, startup and maintenance can only be performed by a qualified heating contractor or service organization. Any work on electrical installations and fuel carrying components must be done by a qualified service technician.

Explosive danger due to flammable fumes!
WHAT TO DO WHEN YOU SMELL SMOKE?

Shut off main gas /oil supply!
Open windows and doors!
No open fire! Do not smoke! Do not use a lighter!
Avoid generating sparks! Do not use a electrical switch, telephone, electrical plug or bell!
Notify homeowner, but do not use a door bell or phone!
Leave the building!
Immediately notify the gas or fuel oil supplier from a remote location.
If necessary, notify the police or fire department.
Immediately leave the building, when you hear or see gas leak!

Insufficient amount of fresh air for combustion in the boiler room canlead to dangerous conditions.

Make sure that the openings for combustion air supply are not reduced or closed.
Keep the boiler room closed.
Protect the boiler room and avoid rodents and birds from entering and blocking the air openings.
If above mentioned issues are not solved, the boiler cannot be put into operation.

TECHNICAL DATA

TYPE **EKO-CUP S3| 125| 160| 240| 320| 400| 460| 530| 600
---|---|---|---|---|---|---|---|---
Nominal heat output (kW)| 125| 160| 240| 320.| 400| 460| 530| 600
Heat output range (kW)| 37,5-125| 48-160| 72-240| 96-320| 120-400| 138-460| 168-530| 180-600
Required chimney under pressure (mbar)| 0,05| 0,05| 0,05| 0,05| 0,05| 0,05| 0,05| 0,05
Water amount in the boiler (l)| 225| 290| 390| 465| 615| 735| 865| 970
Exhaust gas temperature at nominal heat output (°C)| 160| 160| 160| 160| 160| 160| 160| 160
Exhaust gas temperature at minimal heat output (°C)| 120| 120| 120| 120| 120| 120| 120| 120
Boiler resistance on the waterside at nominal output (mbar)| see the diagram at page 5
Resistance of the combustion chamber at 80% power output (mbar)| 1,25| 1,60| 1,80| 2,00| 2,50| 3,10| 3,30| 3,75
Resistance of the combustion chamber at 100% power output (mbar)| 1,70| 2,50| 2,60| 2,80| 3,50| 4,00| 4,30| 4,90
Fuel type| fuel oil extra light, FOEL / natural gas (p=20 mbar; p=25 mbar)
Maximum heat input (foel oil FOEL / natural gas) (kW)| 133/133| 170/170| 255/255| 341/339| 425/424| 489/488| 561/562| 636/636
Combustion chamber dimensions (mm)| fi450x870| fi500x870| fi500x1325| fi600x1325| fi650x1300| fi650x1600| fi750x1600| fi750x1850
Combustion chamber volume (l)| 138| 171| 260| 375| 431| 531| 707| 817
Combustion chamber type| overpressure
Gas volume of the boiler (m3 )| 0,18| 0,22| 0,34| 0,48| 0,57| 0,70| 0,88| 1,08
Supply voltage (V)| 230
Frequency (Hz)| 50
Current type| ~
Total mass – 3/6 bar *1 (boiler with casing and accessories ) (kg)| 445 / 460| 563 / 576| 673 / 723| 867/1030| 1080 / 1105| 1184 / 1240| 1418/1635| 1515/1754
Maximal operating overpressure (bar)| *3 / 6 1
Test pressure (bar)| 5,5 / 9 1
Maximal operating temperature (°C)| 90 / 100 / 105 2
Flue gas tube – external diameter (mm)| fi180| fi200| fi200| fi250| fi250| fi250| fi300| fi300
Efficiency on 30% power output (fuel oil extra light LU EL) *3 ** (%)| 94,23| 94,33| 94,57| 94,80| 94,79| 94,78| 94,78| 94,77
Efficiency on 100% power output (fuel oil extra light LU EL) *3 ** (%)| 94,68| 94,57| 94,33| 94,10| 94,17| 94,22| 94,29| 94,35
Efficiency on 30% power output (natural gas) *3 ** (%)| 94,05| 94,05| 94,05| 94,06| 94,06| 94,06| 94,07| 94,07
Efficiency on 100% power output (natural gas) *3 ** (%)| 94,30| 94,33| 94,40| 94,47| 94,45| 94,43| 94,41| 94,40
Exhaust gas flow at 100% power output – OIL / GAS *3 ** (g/s)| 57/60| | | 133/158| | | |
CO2 content at 100% power output – OIL/ GAS *3 ** (%)| 13,12/9,77| | | 12,14/9,43| | | |

If you look carefully, in the table above, you will see some labeled technical data (*n.).
That label means the possibility of ordering boilers with different characteristics.
Table below shows the meaning of labels.

*1

| DESCRIPTION: Boilers EKO-CUP S3 can be ordered with max. operating pressure 3 bar or 6 bar.

If max. operating pressure is 3 bar, test pressure is 5,5 bar. If max. operating pressure is 6 bar, test pressure is 9 bar.

DIFFERENCES: Boiler EKO-CUP S3 with max. operating pressure 6 bar has customized metal sheet thicknesses and layout of stiffeners on boiler body regarding EKO-CUP S3 with max. operating pressure 3 bar.

---|---

*2

|

DESCRIPTION: Boilers EKO-CUP S3 with max. operating pressure 3 and 6 bar can be ordered with three different max. operating temperatures: 90°C, 100°C or 105°C depending on the installed boiler regulation.

*3

| DESCRIPTION: Values, which are given in the table are test-reported values (No. 30-12644/T and No. 30-12643/T issued by SZU s.p., Brno, Czech Republic).

OIL: EKO-CUP S3 125 with burner Giersch R20-ZS-L EKO-CUP S3 320 with burner Giersch M10-Z-L

GAS: EKO-CUP S3 125 with burner Giersch GG20/1-Z-L-N-LN EKO-CUP S3 320 with burner Giersch MG10/1-Z-L-N-LN

The efficiency values were interpolated between the boiler and burner combinations that had been tested.

NOTE: All max. operating pressures can be combined with all max. operating temperatures and vice versa.

Boiler resistance on the waterside at nominal output

COMPONENT PARTS

COMPONENT PARTS OF THE BOILER EKO-CUP S3

IN GENERAL

The boiler EKO-CUP S3 for central heating is assigned for firing with light heating oil and gas. The boiler itself has a modern construction and design regarding to the projected capacity. The boiler is made out of controlled materials of high quality, welded with the most modern technology. EKO-CUP S3 boiler is approved and tested under E-N norms and fulfills all special requests for the connection to the central heating system installation.

BOILER DESCRIPTION

EKO-CUP S3 is a triple flue gas passage steel boiler composed of a stainless steel combustion chamber part, a central combustion chamber with tubes for turbulators. Triple flue gas system with verified turbulator technology and the stainless steel combustion chamber part enables a complete combustion and the reduction of harmful components in the flue gas to a minimum. Stainless steel turbulators in the tube chamber enable a much longer retaining of flue gases and better transmission of thermal energy to the boiler water. Beyond mentioned the turbulators serve for a possible fine regulation of the exit temperature of flue gases depending on the boiler load.

BOILER DELIVERY
The boiler EKO-CUP S3 is delivered together with outer boiler panelling made of elasticated sheet metal and thermal isolation of mineral wool and cleaning tool – cleaning brush.

OBLIGATORY ACCESSORIES (ORDERED ADDITIONALLY):

Basic boiler controller EKO-CUP S3/V3- REG
or
Basic boiler controller CUPREG-Touch

MOUNTING

The boiler EKO-CUP S3 is intendend for mounting in the boiler room, which has to be built according to the thermal rated output of the boiler, normal operation conditions, undisturbed serving and easily accessible boiler, burner and boiler equipment. The boiler must be placed on the 5 to 10 cm high placement above the ground. Edges of the boiler placement must be protected by an iron-made frame (50x50x5 mm). The boiler must be positioned to enable supervision during boiler operation, cleaning and maintenance. Due to easier transport of the boiler into the boiler room, mounting of the thermal isolation have to be done after the boiler is properly placed in the boiler room as is shown on Scheme 1.

Insulation mounting

Scheme 1a: Visual overview of the insulation casing mounting: EKO CUP S3 125-160 kW

PROCESS OF THE CASING MOUNTING ON THE BOILER

Envelope the insulation layer of the mineral wool over the outer cylinder of the boiler and fasten it with metal fasteners.
(VALID only if boiler controller EKO-CUP S3/V3 – REG is installed on the boiler). On the upper front side (2) install the roots (E), which are used for the mounting of the boiler controller (7).
The boiler probe for boiler controller sensors is located between the boiler flow and return lines and set the boiler control (7) to the snaps (E) on the upper front side (2).
- If the boiler control EKO-CUP S3 / V3 – REG is installed on the boiler, it is necessary to push the thermometer sensor, regulation thermostat and boiler controller safety thermostat into the boiler probe.
- If the boiler control CUPREG-Touch is installed to the boiler, it is necessary to push the boiler temperature sensor and the safety thermostat of the boiler regulation into the boiler probe.
Upper front side (2, 3, 4) place on the upper part of the boiler and fasten side (4) to side (2) with screw C (4.2×30).
Place the lower end of the side panels (1) in the grooves on the lower part of the boiler and fasten them to the upper porters with screws (B) (M6x15).
Assemble the last side of the two parts (5a and 5b) with the screws (C) (4.2×30) and fasten it to the sides (1) with the screws (C) (4.2×30) and the upper sides 3 and 4.
Set the spacers with the (4.2 x 30) screws (D) to the marked position and fix the door protection (6) on them.
For the controller electrical connection, it is necessary to open the back lid on the controller, on which the line clamp is positioned.

Scheme 1b: Visual overview of the insulation casing mounting: EKO CUP S3 240-600 kW

PROCESS OF THE CASING MOUNTING ON THE BOILER

Connect covers 1a and 1b with screws A (M5x10) with nuts. Envelope the insulation layer of the mineral wool over the outer cylinder of the boiler and fasten it with metal fasteners.
(VALID only if boiler controller EKO-CUP S3/V3 – REG is installed on the boiler). On the upper front side (2) install the roots (E) which are used for the mounting of the boiler controller (7).
The boiler probe for boiler controller sensors is located between the boiler flow and return lines and set the boiler control (7) to the snaps (E) on the upper front side (2).
- If the boiler control EKO-CUP S3 / V3 – REG is installed on the boiler, it is necessary to push the thermometer sensor, regulation thermostat and boiler controller safety thermostat into the boiler probe.
- If the boiler control CUPREG-Touch is installed on the boiler, it is necessary to push the boiler temperature sensor and the safety thermostat of the boiler regulation into the boiler probe.
Upper front side (2, 3, 4) place on the upper part of the boiler and fasten side (4) to side (2) with screw C (4.2×30).
Place the lower end of the side panels (1) in the grooves on the lower part of the boiler and fasten them to the upper supports with screws (B) (M6x15).
Assemble the last side of the two parts (5a and 5b) with the screws (C) (4.2×30) and fasten it to the sides (1) with the screws (C) (4.2×30) and the upper sides 3 and 4.
Set the spacers with the (4.2 x 30) screws (D) to the marked position and fix the door protection (6) on them.
For the controller electrical connection, it is necessary to open the back lid on the controller, on which the line clamp is positioned.

CHIMNEY

Precisely calculated and performed chimneys is a precondition for a safe boiler operation and economic heating results. The chimney must be well thermal isolated, gas-impermeable and smooth. On the lower part of the chimney, a cleaning door must be installed. The walled chimney must be three- layered with a mineral wool insulation layer in the middle. The thickness of the isolation should be at least 30 mm if the chimney is mounted inside the building and 50 mm thick if it is mounted outside the building walls. The inner diameter of the chimney depends upon the actual chimney height and the boiler power output. The right selection of chimney size must be carried out according to the diagram on Figure 2. The flue gas temperature on the chimney exit has to be at least 30°C higher than the condensation temperature of the combustion flue gases. Please confide the choice and montage of the chimney to a qualified person.

CONNECTION TO THE CHIMNEY

The flue gas tube (flue gas exhaust) between the boiler and the chimney has to be mounted under an inclination between 30 to 45°C (Figure 3). To prevent the entering of condensing fluid from the chimney into the boiler it is necessary and important to mount the flue gas tube 10 mm deeper into the chimney. A flue gas tube longer than 1 m should be thermal isolated with a mineral wool layer, which is 30-50 mm thick. For easier flue gas tube cleaning the tube itself must have an opening (Figure 4). The connections of the flue tube on the boiler and chimney must be properly made and sealed. For easier chimney cleaning we recommend the distance between the boiler and the chimney or wall at least 600 mm.

FRESH AIR OPENING (FRESH AIR SUPPLY)

Every boiler room must have a correct calculated opening for fresh air inlet regarding to the boiler power output. The diameter of the opening for the air inflow is calculated:

A = 6.02 Q

A – surface of the opening in cm
Q – boiler power output in kW

The opening must be protected by a net or grid.

CONNECTION TO THE HEATING INSTALLATION

All installation works must be done by valid national and European standards. Before boiler connection to the heating system installation, it is necessary to clean all tubes in the system from dirt layers. These actions prevent boiler overheating, noise in the heating system, and disturbances on the pump and mixing valve. Connection to the heating system must be performed with lenders to the thread connection with or without a mixing valve to an open or closed system. In a closed heating system, it is obligatory to install a certificated safety valve with an opening overpressure set on 3,0 or 6,0 bar (depending on the configuration shown). Security and expansion lines must not have any stop elements. The boiler water outlet from the safety valve leads directly to the sewerage. During the water filling into the heating system (boiler and radiators), it is necessary to open the mixing valve if it is built and to air-vent the boiler and the heating system. Boiler connection to central heating installation must be preformed in a manner as shown on Scheme 2 and by the norm EN 12828:2012+A1:2014.

WATER QUALITY

In the table below, the maximum permitted concentration of Ca(HCO ) in water for filling or refilling of 3 2 boiler EKO-CUP S3, is given.

Boiler| Concentration of Ca(HCO 3 ) 2 in water for filling or refilling
---|---
EKO-CUP S3 125|

< 2,0 mol / m 3

EKO-CUP S3 160
EKO-CUP S3 240
EKO-CUP S3 320
EKO-CUP S3 400|

< 1,5 mol / m 3

EKO-CUP S3 460
EKO-CUP S3 530
EKO-CUP S3 600

LEGEND

A – Boiler flow
B – Boiler return
C – Circulation pump
D – 3-way therm. motor mixing valve (ESBE CRA111 for boiler
EKO-CUP S3 125, ESBE CRA121 for boilers EKO-CUP S3 160-600)
E – Automatic air vent point
F – Thermal insulation of the security line of the boiler
G – Safety valve max. 3 or 6 bar* (only at the closed heating circuit)
H – Regulation sensor of the 3-way motor mixing valve
I – Tube thermostat (must be adjusted to turn on pump on 60°C)
J – Boiler EKO-CUP S3 with basic boiler controller

Depends on the ordered configuration shown

The hydraulic connection scheme must be performed in a manner as shown on this scheme.
Other parts of the installation, which are not shown in this scheme must be performed according to the norm EN 12828:2012+A1:2014.

BASIC BOILER CONTROLLER (ADDITIONAL EQUIPMENT)

BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG (ADDITIONAL EQUIPMENT)

MAIN SWITCH
The switch with a signal diode for turning the boiler ON and OFF.
BURNER CONTROL SIGNAL LIGHT
If any interference occurs during the boiler operation, this control signal light will light up.
CIRCULATION PUMP SWITCH
The switch for turning the circulation pump ON and OFF.
REGULATION THERMOSTAT FOR THE FIRST BURNER STAGE
Boiler operation temperature setting or changing (10 to 90°C / 35 to 100°C / 65 to 105°C)* is achieved by turning the button.
REGULATION THERMOSTAT FOR THE SECOND BURNER STAGE
Boiler operation temperature etting or changing (10 to 90°C / 35 to 100°C / 65 to 105°C)* is achieved by turning the button.
SAFETY BOILER THERMOSTAT
The safety boiler thermostat stops the burner operation if the boiler water temperature exceeds the maximal permitted temperature thus preventing any major breakdown. When the burner is put into operation again, the following steps must be taken:
- wait until the boiler temperature drops and reaches a value under 70°C
- take the safety lid off (Position (6))
- push the red button
  If there are still frequent interruptions during the boiler operation, it is necessary to contact a qualified person to check it out.
THERMOMETER
The thermometer indicates the boiler water temperature in °C.
POSITION FOR MOUNTING AUTOMATIC CONTROLLER (additional equipment)

BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 90 °C (ADDITIONAL EQUIPMENT)

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 90 °C

BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 100 °C (ADDITIONAL EQUIPMENT)

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 100 °C

BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 105 °C (ADDITIONAL EQUIPMENT)

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 105 °C

BASIC BOILER CONTROLLER (additional equipment): CUPREG-Touch

CONNECTION OF THE BASIC BOILER CONTR. ON EL. INSTALLATION

CONNECTION OF BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 90 °C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 90 °C

CONNECTION OF BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 100 °C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 100 °C

CONNECTION OF BASIC BOILER CONTROLLER – EKO-CUP S3/V3 – REG – 105 °C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller – EKO-CUP S3/V3 – REG – 105 °C

CONNECTION OF BASIC BOILER CONTROLLER. – CUPREG-Touch/90° C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller CUPREG-Touch/90°C

Burner selection

CONNECTION OF BASIC BOILER CONTROLLER – CUPREG-Touch/100° C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller CUPREG-Touch/100°C

CONNECTION OF BASIC BOILER CONTROLLER. – CUPREG-Touch/105° C ON EL. INSTALLATION

see technical instructions delivered with the boiler controller CUPREG-Touch/105°C

BURNER SELECTION

The burner must be suitable for the respective rated output as well as the resistance of the combustion chamber (see Technical data

Burner selection

FUEL	APPROPRIATE BURNER
OIL	Oil burner with fan tested and designated by EN 267 norm.
GAS	Gas burner with fan tested and designated by EN 676 norm.

BURNER ADJUSTMENT

The burner must be adjusted according to the technical instructions for the oil/gas burner.

BURNER MOUNTING

Burner mounting is used if the factory-made opening on the boiler door is too large for the chosen burner. In that case, it is necessary to make a respective opening for the passage of the burner tube and to cut the existing mineral wool isolation layer according to the mentioned opening. If it is necessary, attach holes for the burner.

ATTENTION!

If the factory made the opening on the boiler door it too large for the chosen burner, it is necessary to make an appropriate opening on the blind panel for the passage of the burner tube. The existing isolation mineral wool layer has to be cut to be consistent with that opening. For the burner connection use the existing holes or if it is necessary make new attached holes for the burner. If after the boiler montage, the gap between the burner tube and the mineral wool isolation of the boiler door still exists, it is necessary to fill the gap with pieces of the mineral wool and the braid (which is delivered in the plastic bag with the boiler) so that the gap becomes closed (Figure 5).

BOILER CHECK AND STARTUP

The boiler must not be used in a flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by persons without knowledge or experience, unless they are under control or trained by a responsible person for their safety. Protective gloves are obligatory (Figure 6). Check if the boiler and the whole heating system is filled with water and air-vented. Check if the flue gas tube is properly sealed and if the boiler is connected to the electrical supply. The burner startup must be done by a qualified and authorized service technician.

INSTALLATION CHECK AFTER STARTUP

After startup please check:

if there is no water leakage
if the filling/drainage valve in the system is closed
if the complete installation is air-vented
if the boiler water temperature rises
activate the safety valve and check if it works properly
that during continuous boiler operation, there is no visible chimney condensation

Please repeat the complete check after several days.

OPERATION AND MAINTENANCE

The boiler must not operate in a flammable and explosive environment. It must not be used by children or disabled persons (either physically or mentally), as well as by persons without knowledge or experience, unless they are under control or trained by a responsible person for their safety. Protective gloves are obligatory (Figure 6). During the boiler-heating system take over please check together with the service technician the complete heating system. The service technician must inform you about the general heating system and about its supervision. Beyond this you must be informed about the vital parts of the heating system and their function. After several days of boiler operation please air-vent the heating system once more and fill it with water if necessary. At least once a year (before heating season) it is necessary to check the burner by an authorized service technician. The boiler and the heating system operation will be safe and economic after the previously mentioned actions. In case of operation disturbances, please contact only the authorized service technician.

CLEANING

Protective gloves are obligatory (Figure 6)! It is necessary to clean the boiler at least once a year. Before cleaning switch off the main switch on the boiler control panel, thus preventing a possible burner start. Open the boiler door, pull out the tabulators, clean the boiler tubes and the combustion chamber with the brush. The chimney and the end part of the turbulator tubes can be cleaned through the opening on the back of the boiler. After cleaning return turbulators and the lid of the cleaning opening on the back of the boiler and close the boiler door.

Protective gloves are obligatory!

The company assumes no responsibility for possible inaccuracies in this book originated typographical errors or rewriting, all the pictures and diagrams are principal and it is necessary to adjust each actual situation on the field, in any case, the company reserves the right to enter their own products such modifications as considered necessary.