ALLAN'S Ecomax Auto-Stoker Installation And Operating Manual Download Page 1

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Auto-Stoker Coal Boiler

Ecomax

Installation and Operating Manual

Manufactured by:

Location

Postal

1 Thomas Burns Street
Dunedin 9016, New Zealand
PO Box 49, Dunedin 9054

Phone
Fax

+64 3 477-7909
+64 3 477-7908

www.allans.co.nz

Engineering / Sheetmetal / Long Run Roofing / Scaffolding / Christie Glasshouse and Garden Sheds / Ecomax Boilers

Summary of Contents for Ecomax Auto-Stoker

Page 1: ...ual Manufactured by Location Postal 1 Thomas Burns Street Dunedin 9016 New Zealand PO Box 49 Dunedin 9054 Phone Fax 64 3 477 7909 64 3 477 7908 www allans co nz Engineering Sheetmetal Long Run Roofing...

Page 2: ...F C E ECOMAX COAL BOILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 2 of 36...

Page 3: ...abilities 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 Children should be supervi...

Page 4: ...r the First Time Priming 20 General Operation 20 Notes on Fuel Selection 21 Optimising Boiler Operation 22 Maintenance 23 Daily Maintenance 23 Monthly Maintenance 24 Yearly Maintenance 25 Dislodging a...

Page 5: ...n quality to produce up to 26kW of energy The running costs can be less than one eighth of the price of electricity and can be cheaper depending on regional coal prices The fire is mechanically fed wi...

Page 6: ...ding external pipework 34 litres Water Connections 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...

Page 7: ...F C E ECOMAX COAL BOILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 7 of 36 Product Overview Product Dimensions...

Page 8: ...OILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 8 of 36 Product Description Combustion Chamber Door Ash Pan Scrubber Coils Spanner Flue Spigot Boiler Hopper Coal Feed Screw Gearbox Mo...

Page 9: ...Manual Rev 6 doc Page 9 of 36 Scrubber Coils Flue Spigot Combustion Chamber Insulating Board Burn Pot Blower Smoke Back Tube Heat Exchanger Tubes Coal Feed Screw timer Top dial ON minutes Bottom dial...

Page 10: ...500 kg or 1 000 kg for trailer loads and 2 000 kg for truck loads The hoppers have sloping sides at angles of no less than 50 so that they will empty fully The large hoppers have self supporting legs...

Page 11: ...of ashes according to local regulations Flue A stainless steel 150mm nominal diameter flue is recommended Insulation 25mm fiberglass hot water cylinder insulation is used Smoke Back Tube A smoke back...

Page 12: ...n area of 18 000 mm2 or the equivalent to 150mm or a rectangle 180mm x 100mm is required If the area under doorways is not sufficient then ducts or louvres must be installed to maintain ventilation Ne...

Page 13: ...n 300mm in front of the Ash Pan The floor protector must not be any less wide than the appliance and extend at least 200mm from the side of the Ash Pan unless it comes into direct contact with a wall...

Page 14: ...nsions are greater to allow for better access during installation and servicing In particular ensure there is sufficient room to remove the Coal Feed Screw Clearances above the appliance can be any si...

Page 15: ...r own specific rule on the height of the flue but most follow Rule 4 5 6 b and Schedule 6 and Section 4 9 1 of AS NZS 2918 2001 Minimum clearances to combustible materials outlined in these and any lo...

Page 16: ...F C E ECOMAX COAL BOILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 16 of 36 Ecomax flue kit schematic...

Page 17: ...l that has an oxygen barrier must be used as internal corrosion of the Coal Boiler could otherwise occur A rust inhibitor must be used to treat the water and prevent internal corrosion A draining valv...

Page 18: ...ot be able to heat the water sufficiently and the warranty on the appliance may be voided A mixing valve may also be used to maintain the water temperature in the water jacket During the process of fi...

Page 19: ...hecked Floor protector fitted if required Appliance securely fastened to support Water system sealed pressurised properly bled and leak tested Flue installed to AS NZS 2918 2001 and or any other local...

Page 20: ...to local body regulations Operating for the First Time Priming With suitable stone free pea sized coal in the hopper turn the Coal Feed Screw switch on and feed fuel right through from the hopper unti...

Page 21: ...d at least once a day with the Scrubber Coils moved up and down in the Heat Exchanger Tubes the Burn Pot checked for stones or blockages and the general operation checked Notes on Fuel Selection It is...

Page 22: ...ash pan it is running too rich Reduce the fuel input by either decreasing the Coal Feed Screw ON time or increasing the Coal Feed Screw OFF time Open up the plate on the Blower to allow more air into...

Page 23: ...If this is not carried out permanent damage may occur Carrying out these tasks twice a day is recommended Attach the Scrubber Coil Spanner and swing it up and down repeatedly to make the Scrubber Coi...

Page 24: ...ones Make sure all the air ports are completely clear to ensure efficient combustion Empty the Ash Pan or after 20 hours burning Ensure the Ash Pan seals with the bottom of the Combustion Chamber when...

Page 25: ...ot be excessively warped and it should slide easily into place It must seal well against the bottom of the Combustion Chamber Replace if necessary Check the Burn Pot for signs of deformation and wear...

Page 26: ...e Ash Pan and cleaning the flue If soot is left in the appliance condensation can form which could produce acid and corrode the appliance Unbolt the Scrubber Coils and thoroughly scrape the inside sur...

Page 27: ...e the Ash Valve is fully closed Check that the Scrubber Coils are all moving freely If any of them are jammed or are difficult to move they MUST be freed or replaced Check the condition of the gearbox...

Page 28: ...to get coal to drop onto the Coal Feed Screw When the Hopper is empty scrape the sides to make sure they are smooth Remove build up of fines at the bottom of the Hopper Paint with non stick surface p...

Page 29: ...rs are fully and completely closed and the seals are effective Safety switch on coal pipe has tripped This is due to excessive heat in coal pipe possibly fuel burning in coal pipe This switch requires...

Page 30: ...replaced Smoke observed at cowl or issuing from Boiler or Hopper Smoke Back Tube blocked Remove Smoke Back Tube and check entire length for blockages Check connection point on top of Coal Feed Screw...

Page 31: ...the Combustion Chamber are fully and completely closed and the seals are effective Door seal failure Replace any missing or damaged seals Buildup of clinker in Burn Pot Boiler running cold If the wat...

Page 32: ...ension pins regularly breaking Seam of coal with too many stones Stones can be present in the fuel from the supplier or be picked up during transport Coal Feed Screw worn Remove coal screw and check f...

Page 33: ...F C E ECOMAX COAL BOILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 33 of 36 Wiring Diagram...

Page 34: ...s due to causes beyond the control of the manufacturer or its franchised dealers Replacement or sealing except where due to faulty manufacture or assembly Flues cleaning of flues removing of carbon bu...

Page 35: ...F C E ECOMAX COAL BOILER Instructions and Manuals Coal Boiler Manual Rev 6 doc Page 35 of 36 Owner Details Serial Number Installation Date Installer...

Page 36: ...c Page 36 of 36 Manufactured by Location Postal 1 Thomas Burns Street Dunedin 9016 New Zealand PO Box 49 Dunedin 9054 Phone Fax 64 3 477 7909 64 3 477 7908 www allans co nz Engineering Sheetmetal Long...

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ALLAN'S Ecomax Auto-Stoker, Installation And Operating Manual

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