INSTALLATION AND OPERATING INSTRUCTIONS EKOHEAT 900/1500/2500/4000

Transcription

1 INSTALLATION AND OPERATING INSTRUCTIONS EKOHEAT 900/1500/2500/4000

2 Thank you for choosing an EKOPOWER wood pellet boiler. You have chosen from a range of EKOPOWER products designed to provide efficient and sustainable heating for the ideal level of comfort for your home. This manual forms an essential part of the product and it must be given to the end user. We recommend you read the warnings and recommendations in the manual carefully, as they contain important information on the safety, use and maintenance of the installation. This boiler must be installed, commissioned and annually serviced only by authorised Ekopower personal in accordance with the local legislation and following the manufacturer s instructions. Incorrect installation of these boilers could result in damage to people, animals or property, and the manufacturer will hold no liability in such cases. Ekopower is an innovative new company specialising in producing Danish designed wood pellet boilers. We have developed a new technology to burn wood pellets, creating a range of boilers with the highest performances amongst European manufacturers (up to 95.5%), and the highest classification thanks to their low emissions of CO and NO_ contaminating gases (class A according to standard EN303-5). The innovative Ekoheat range, the result of several years of research, is designed to combine the highest performance in the use and maintenance of this type of device, with a purchase and installation cost that is much more accessible to the end user than any other of the options currently on the market. In other words, Ekopower adheres to a philosophy of innovation with common sense, and sets out with this range to bring consumers who are committed to renewable energies, an alternative that is much closer to the highest levels of biomass technology at a reasonable price for a more sustainable environment.

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4 CONTENTS Page 0 LIST OF COMPONENTS CONTROL COMPONENTS INSTALLATION INSTRUCTIONS LOCATION HYDRAULIC INSTALLATION FUEL INSTALLING THE HOPPER ELECTRICAL CONNECTION EXAMPLE OF A RADIATOR HEATING INSTALLATION EXAMPLE OF A HEATING INSTALLATION WITH RADIATORS AND A DHW STORAGE TANK EXAMPLE OF A ZONED HEATING INSTALLATION EXAMPLE OF AN INSTALLATION WITH A BUFFER TANK FOR 2 UNDERFLOOR HEATING CIRCUITS AND A DHW TANK EXAMPLE OF INSTALLATION WITH THE MS HYDRAULIC KIT EXAMPLE OF INSTALLATION WITH THE DMS HYDRAULIC KIT EXAMPLE OF A HEATING INSTALLATION WITH RADIATORS AND BACK-UP FOR A SOLAR INSTALLATION FOR DHW PRODUCTION FLUE INSTALLATION FLUE DIAGRAM FLUE STRUCTURE CLEANING & MAINTAINCE FLUE TERMINATION NON LOAD BEARING COMPONENTS STARTING UP THE BOILER PRIOR WARNINGS FILLING THE INSTALLATION ELECTRICAL CONNECTION START-UP INSTALLATION DELIVERY DIGITAL DISPLAY: "INFO" DISPLAY CONFIGURATION MENU PROGRAM MAP USER MENU BOILER TEMPERATURE FUEL CLEANING SETTINGS SUMMER MODE DHW PRIORITY Minium pump temperature AUGER CALIBRATION & DATE & TIME SERVICE MENU FUEL FOR IGNITION ASH PLATE MOVEMENT & FAN FUNCTIONING MINIUM POWER EXTRA EQUIPMENT ON/OFF MODE RESTORE FACTORY SETTINGS NEW SOFTWARE CHANGE HOPPER CONTENT CLEAN NOW LANGUAGE SELF TEST MODEL SELECTION TEST NOW BOILER SENSOR READINGS TESTING BOILER COMPONENTS SAFETY PRECAUTIONS CARBON MONOXIDE VENTILATION CLEANING THE ASH DRAWER SAFFETY CUT-OUTS BURNER CUT-OUTS NO FLAME CUT-OUTS TEMPRATURE SAFTETY CUT-OUT SHUTTING DOWN THE BOILER BOILER MAINTENCE BOILER AND FLUE MAINTENANCE CLEANING THE BURNER DRAINING THE CONDENSATION WATER

5 18.4 BOILER WATER CHARACTERISTICS CLEANING THE HEAT EXCHANGER TECHNICAL CHARACTERISTICS DIAGRAMS AND MEASUREMENTS ELECTRICAL DIAGRAM BOILER ELECTRICAL DIAGRAM BURNER ELECTRICAL DIAGRAM CIRCULATING PUMP FLOW CURVES SENSOR SETTINGS ALARM CODES GUARANTEE CONDITIONS WARRENTY CARD NOTES LIST OF COMPONENTS Feed auger. 2. Heat exchanger. 3. Vent cleaning device. 4. Fan. 5. Burner. 6. Ash drawer. 2

6 1 CONTROL COMPONENTS 1. Menu: Touch this symbol to access Main Menu. In this is the boiler functioning display, where all the operating information, settings and values appear. This is used to access the appliance s configuration and technical settings. 2. INFO touch button: Touch this symbol to access boiler information. 3. Lux display: This shows when there is ignition 4. Fan display: This shows what percentage the fan is running at. 5. Burning: This shows what percentage fuel is being used. 6. Auger display: This shows when the feed auger is on/off. 9. Temperature display: This shows the temperature of the water leaving the boiler. 10. Fuel: This displays the weight in Kilograms of wood pellets left in the hopper. 11. START touch button: Touch this symbol to start up or switch off boiler functioning 3

7 2 INSTALLATION INSTRUCTIONS The boiler must be installed by personnel authorised by the relevant national authorities, in compliance with the applicable laws and regulations. This boiler is suitable for heating water to a temperature below boiling point at atmospheric pressure. It must be connected to a heating installation and/or a domestic hot water distribution network, which must always be compatible with its performance and power. This appliance must only be used for the purpose for which it has been expressly designed. Any other use is considered unsuitable and therefore hazardous. The manufacturer shall not be considered liable under any circumstances for damage caused by unsuitable, erroneous or irrational use. Remove all the packaging and check the contents are complete. In case of doubt, do not use the boiler. Contact your supplier. Keep the packaging elements out of reach of children, as they can be dangerous. When you no longer wish to use the boiler, disable the parts that could be a potential source of hazard. 2.1 Location The boiler must be installed in a sufficiently ventilated site, away from humidity. It must be located so that the air grilles on the premises are not obstructed and normal boiler maintenance is possible even if it is placed between items of furniture. One metre of free space must be left above the boiler for this purpose. The appliance should be located in a part of the installation where it cannot be struck by a vehicle. 2.2 Hydraulic installation The hydraulic installation must be made by qualified personnel. The applicable installation legislation is to be complied with, and the following recommendations should also be taken into account: - It is obligatory and essential to install an anti-condensation valve (shunt valve/load valve) with the boiler, to prevent any water condensation in the heat exchanger. If this requirement is not complied with, EKOPOWER s guarantee of the appliance will automatically be null and void. Make sure it is installed in the correct location and diverting the water in the correct direction. - The inside of the installation piping should be thoroughly cleaned (flushed) before switching on the boiler. A magnetic filter should also be fitted. - We recommend inserting cut-off valves between the installation piping and the boiler to simplify maintenance tasks. - Leave adequate free space around the boiler for carrying out any maintenance and repair operations. - Drain valves and suitable devices for correctly bleeding the air from the circuit during the boiler filling stage should be fitted. - Install all the necessary safety elements (expansion vessel/tank, safety valve, etc.) to comply with the applicable regulations for the installation. Make sure there is adequate expansion area in open vented systems tank. - If the boiler is installed at a lower height than the heating installation, it is recommendable to create a siphon at the boiler outlet, to prevent the installation from heating up due to natural convection when heating is not required. -Circulation pump is in the correct location and circulating the water in the correct direction. 4

8 2.3 Fuel The EkoHeat boilers must be fuelled by EN PLUS certified wood pellet. The EN PLUS certificate assures that the fuel s humidity levels and calorific value are ideal for optimum boiler functioning. If this requirement is not complied with EKOPOWER s guarantee of the appliance will automatically be null and void. The following points should be taken into account for correct fuel storage: - The stored pellets should be kept dry all year round. - The applicable legislation in each country for correct fuel storage must be complied with. Wood pellets are made from wood shavings and sawdust and are used in highly efficient and convenient automatic wood boilers. Because they have a low moisture and ash content wood pellets burn very efficiently. What s more they are compact and easy to store. Typically pellets come in bags (ideal for stoves or smaller boiler systems) or are delivered in bulk by truck (ideal for boiler systems with bulk stores). Wood pellets can be ordered from local fuel merchants. Pellets facts (Typical) Dry matter content 90-92% Ash content 0.5% Diameter 6-8mm Length 4 diameter, Density 650 kg/m3, Volume 1.54m3/tonne pellet, Energy 4.7 kwh/kg pellet Benefit 1kg wood pellet replaces 0.41kg of light fuel oil Wood pellets are upgraded or refined wood fuels which have been produced from sawdust, grinding dust, shavings, bark or cutter chips by drying and pressing. No additives are needed to produce them. Lignin released in the pressing process binds the wood material. They are compact and easy to store and use for fully automatic burning in wood pellet boilers or stoves. Good quality wood pellets with a moisture content of 8% will have a calorific value of approximately 4,700 kwh/tonne. 5

9 2.4 Installing the Hopper EKOPOWER supplies a reserve tank for storing the pellets with the boiler. The tank is reversible and can be mounted on either the left or right side of the boiler. There are 2 sizes, 320kg & 160kg. IMPORTANT: Ensure the height of the elliptical holes on the sides of the boiler and on the reserve tank coincide, for correct insertion of the feed auger. To do this, make the necessary adjustments for height and depth. 6

10 2.5 Electrical Connection The EkoHeat boiler is equipped to work on 230 V~ 50 Hz electrical supply. The boiler must be protected by 5 amp fuse unit with RCD or RCBO line protection. The electrical installation must be installed by a qualified electrician. This appliance MUST be earthed. The terminal strip J2 includes terminals for connecting a sensor for the optional DHW circuit. This sensor must be supplied by EKOPOWER. For correct connection of the burner, the burner connections should be made to terminal strips J3 and J4 (see "Electrical Diagram" page 54). IMPORTANT: Before carrying out any work on the boiler s electrical installation, always ensure it is disconnected from the mains. 2.6 Example of a radiator heating installation The EkoHeat boiler is equipped with an electronic control that can govern a radiator heating circuit, with an external circulation kit to prevent condensation in the heat exchanger. The external circulation kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. - Boiler blow-off valve. The figure below shows an example of a hydraulic diagram of a radiator heating installation: EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain-off valve. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. 7

11 2.6 Example of a heating installation with radiators and a DHW storage tank. The EkoHeat boiler is equipped with an electronic control that can govern a radiator heating circuit, an external circulation kit to prevent condensation in the heat exchanger and, optionally, a DHW storage tank loading circuit. The external hydraulic kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. - Boiler blow-off valve. To control a DHW circuit, connect a DHW sensor from the hot water tank to the boiler (optionally supplied by EKOPOWER) and a 3-way diverter valve (see "Electrical Diagram page 54). The figure below shows an example of a hydraulic diagram for a heating installation with radiators and a DHW tank: EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain-off valve. 3WV: 3-way diverter valve. HS: Hot water tank sensor. NV: Non-return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. IMPORTANT: Before any servicing, disconnect the boiler from the mains. 8 IMPORTANT: The 3-way DHW valve should be fitted to enable the flow to the heating circuit when it is not activated.

12 2.7 Example of a zoned heating installation Apart from the examples described in the previous sections, the EkoHeat boiler can be fitted in an installation with several separate heating zones, by installing the suitable control devices for each zone, e.g. zone valves controlled by ambient thermostats fitted in each of the zones to be controlled. Two or more radiator zones can be controlled with any of the previous installation diagrams. The figure below shows an example of a hydraulic diagram for a heating installation with two radiator zones and a DHW tank: EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain-off valve. 3WV: 3-way diverter valve. HS: Hot water tank sensor. NV: Non return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. ZV: Zone valve with auxiliary switch. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. IMPORTANT: Before any servicing, disconnect the boiler from the mains. IMPORTANT: The 3-way DHW valve should be fitted to enable the flow to the heating circuit when it is not activated. 9

13 2.8 Example of an installation with a buffer tank for 2 under floor heating circuits and a DHW tank. The EkoHeat boiler is equipped with an electronic control that can govern a radiator heating circuit, an external circulation kit to prevent condensation in the heat exchanger and, optionally, a DHW storage tank loading circuit. In an installation with a buffer tank, the components installed after the buffer tank are not controlled by the boiler control panel. Suitable control devices for each installation need to be installed for them to function correctly. The external hydraulic kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. - Boiler blow-off valve. The figure below shows an example of an installation with a buffer tank for 2 under floor heating circuits and a DHW tank. EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain-off valve. NV: Non-return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. DP: DHW tank feed pump. IP: Under floor heating circuit impeller pump. MV: Under floor heating mixing valve. 10 IMPORTANT: Before any servicing, disconnect the boiler from the mains. IMPORTANT: The components installed after the buffer tank are not controlled by the boiler control panel.

14 2.9 Example of installation with the MS Hydraulic Kit The EkoHeat boiler is equipped with an electronic control able to govern a heating circuit via an external circulation kit to prevent condensation, for installation and control of an under floor heating circuit and a DHW storage circuit. The MS hydraulic kit includes a central electronic adjustment unit, to manage the functioning of the kit componyents independently from the boiler control panel. The external hydraulic kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. The figure below shows an example of installation with an MS hydraulic kit: EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain-off valve. NV: Non-return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. MSK: MS hydraulic kit. HS: MS hydraulic kit hot water tank sensor. ES: External sensor. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. IMPORTANT: Before any servicing, disconnect the boiler from the mains. 11

15 2.10 Example of installation with the DMS Hydraulic Kit The EkoHeat boiler is equipped with an electronic control able to govern a heating circuit via an external circulation kit to prevent condensation, and, optionally, a DMS hydraulic kit supplied by plumbing wholesaler may also be acquired and installed, to install and control a radiator heating circuit and a DHW storage circuit. The external hydraulic kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. - Boiler blow-off valve. The figure below shows an example of installation with a DMS hydraulic kit: EkoHeat + External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain valve. NV: Non-return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. DMSK: DMS hydraulic kit. HS: MS hydraulic kit hot water tank sensor. ES: External sensor. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. IMPORTANT: Before any servicing, disconnect the boiler from the mains. 12

16 2.11 Example of a heating installation with radiators and back-up for a solar installation for DHW production. The EkoHeat boiler is equipped with an electronic control that can govern a radiator heating circuit, an external circulation kit to prevent condensation in the heat exchanger and, optionally, a back-up circuit for a solar installation for DHW production by storage. The solar circuit must be controlled by a specific device, separate from the boiler. The external hydraulic kit consists of: - Circulating pump. - 55ºC 3-way anti-condensation valve. - Safety valve, calibrated to 3 bar. - Boiler blow-off valve. To control the back-up circuit for the solar DHW circuit, connect a DHW sensor from the hot water tank to the boiler (optionally supplied by EKOPOWER) and a 3-way diverter valve (see "Electrical Diagram page 54). The figure below shows an example of a hydraulic diagram of a heating installation with radiators and a solar circuit back-up system: EkoHeat +External Kit SF: 3 Bar pressure relief valve. CP: Circulating pump. RV: Anti-condensation return valve. EV: Expansion vessel. DV: Air release valve. BV: Drain valve. NV: Non-return valve. DSV: DHW safety valve. DEV: DHW expansion vessel. 3WV: 3-way diverter valve. HS: Hot water tank sensor. SK: Solar circuit hydraulic kit. IMPORTANT: Fit drain valves and devices for correctly bleeding the air from the heating circuit. IMPORTANT: The 3-way DHW valve should be fitted to enable the flow to the heating circuit when it is not activated 13

17 3 FLUE INSTALLATION The EkoHeat boiler is a biomass boiler and it is essential for it to be connected to a flue, i.e. a smoke duct able to create a pressure drop, which in this case should be between Pascal s (Pa)or mbar, in compliance with the applicable laws to this regard. The com must be installed by qualified personnel and must comply with the regulations in force. The following recommendations should be taken into account: - It should have 25mm insulation. - It should be insulated from flue terminal of the boiler to the cowl. - It should have a draft stabilizer fitted. - It should be independently located, with a separate flue for each boiler. - It should be vertical, avoiding any angles greater than 45º. - It should always have the same diameter. It is recommendable for it to be circular, and never any narrower than the boiler outlet. - It is above the eaves line by about 1 metre or 600mm if coming out near the roof apex. - It should have a storm cowl fitted. IMPORTANT: It is obligatory to install a fume inspection plate with condensation collection, to remove the condensation generated in the flue. Otherwise, the condensation may reach the inside of the boiler and cause irreparable damage, which would not be covered by EKOPOWER s guarantee. The condensation pipe should lead to a drain outlet, as a large amount of water may be generated. This connection must be made in compliance with the regulations for draining off condensation water to the drain network. IMPORTANT: It is recommended to install a draught stabiliser to prevent any pressure drop variations in the flue due to atmospheric conditions, which could affect correct boiler combustion. This draught stabiliser must be installed below the fume inspection plate to prevent any leakage of combustion gases. IMPORTANT: It is recommended to install a storm cowl on the Flue. IMPORTANT: If the draft is below 10 Pascal s (Pa), some of the tabulators must be taken out or a 10mm hole drilled on the cap of the tabulator or both. This would be dependent the on flue gas temperature. 14

18 3.1 Flue Diagram From July 1st 2013 it will be mandatory for manufacturers to apply CE Marking to any of their products that are covered by a harmonised European Standard. Each Harmonised European Standard defines requirements for CE marking of that product and has two main components: * Initial Type Testing * Factory Production Control Both must be obtained to achieve CE Marking. 15

19 3.2 Flue structure The design having almost no thermal bridging between the chimney liner and body ensures a quick stabilization of flue gas temperatures and the existence of a strong draught. This enhances the performance of the appliance. It must be constructed from concentric cylinders commonly referred to as the chimney liner and body. The body is made from 304 grade stainless steel which carries the structural load. It has a bright polished finish and is completely weather proof due to its high quality continuously seam welded finish. The liner of the flue is made from 316 grade stainless steel and is designed to automatically cope with the thermal elongation due to changes in temperature. It also must offer excellent resistance against corrosion; this would be to its molybdenum alloy content structure. The chimney is insulated with a densely packed insulation (25mm) which results in a low heat conductivity to the walls of the chimney. All components have specially developed male and female formed ends. Together with a developed locking band system both strengthen the joints and ensure the excellent gas tight properties of the chimney. As stated there must be a minimum distance of 80mm from the outer body of the chimney to any combustible material. However if the chimney passes through a joist or slab then clearance at floor and ceiling joist must be established by the use of a Fire-stop arrangement. No combustible material should protrude beyond the 80mm safety lugs attached. If the chimney passes through a cupboard, attic or separate compartment area to the boiler it should be adequately protected by a non-combustible casing material which must be spaced from the chimney to satisfy the minimum distance stated. This is to ensure that accidental contact of any combustible material or human contact to the surface of the chimney will not occur. Protection in the attic can also be provided by a rigid mesh structure positioned at the relevant distance to the chimney. IMPORTANT: No joints in the chimney sections should be made in the joist area or where there is no access. The connection to the flue pipe or appliance must be sealed using an adaptor. This can be sealed with fire cement or suitable alternative, and this connection should be made in the same room as the appliance itself. The weight of the chimney should be adequately supported using the correct brackets. Where the building is to support the lateral and vertical load it should be inspected to ensure it is capable of supporting the extra load. If the chimney is installed internally it should be supported with the use of wall brackets and fire stops determined by the route chosen. Where a chimney protrudes 1.5M beyond its last support a guy wire bracket support system should be used. On completion of installation a chimney plate must be completed and positioned in an area close to the chimney base for future reference. 16

20 3.2 Cleaning / Maintenance The chimney should be inspected regularly and cleaned at least once a year. This should be carried out with the use of a brush which should not be made from black steel. The chimney should be maintained to ensure that the construction remains in good condition. Any components showing signs of deterioration which may affect performance should be replaced under professional advice, any evidence of leakage identified by smoke staining should be rectified immediately. For chimney information refer to the chimney plate. 3.3 Flue termination As a chimney protrudes through a roof structure it must be sealed with a lead flashing to suit the specific roof pitch. The lead flashing base should be worked into the roof structure to ensure rain water run off situation is achieved. The lead flashing up-stand section should then be trimmed back with a small amount of clearance to ensure the flue diameter being used passes through it snugly. The top of the lead flashing connected to the chimney body should be carefully sealed with a flashband mastic or denso tape. A storm collar should then be fitted to the flue body directly over the top of the flashing unit. To fit the storm collar place it around the flue body and tighten the nut and bolt arrangement. It is recommended that a small amount of flash band mastic or high temperature silicone is used to seal the immediate area around the top of the storm collar. The cowl is the last component to be fitted to the flue installation. For full detail of chimney termination heights see Part J of the building regulations. 3.4 Non load bearing components Wall Bracket: 1.5M intervals or centrally between base/intermediate wall supports for all diameters Guy wire bracket: 1.5 meter intervals beyond last support for all diameters. Roof centring Plate: Attached to chimney to centralise \ stabilise before passing through pitch roof for all diameters. On long external chimney runs a base wall support should be installed to support the tee piece to a total installed height of 3.5meters. An additional intermediate wall support must be used every 3.5meters beyond this point with a wall bracket situated centrally between both load bearing members. If an offset in a chimney run is necessary i.e. to avoid fascia and soffet, an additional wall bracket must be installed directly above the offset to provide extra lateral support. See installation drawings. 17

21 4 STARTING UP THE BOILER 4.0 Prior warnings Repair and maintenance of the boiler must be carried out by a qualified professional, authorised by EKOPOWER. For optimum functioning and conservation of the boiler, it should be serviced annually. Carefully read this instruction manual and keep it in a safe, easily-accessible place. EKOPOWER will not be liable for any damages caused by failure to follow these instructions. Before any servicing, disconnect the boiler from the mains. 4.1 Filling the installation The hydraulic installation must include a fill valve, a manometer, drain valves and the necessary hydraulic components for correctly filling the installation. To fill the installation, open the fill valve until the installation manometer shows a pressure of bars. The installation must be filled slowly, bleeding the air from the water circuit using the drain valves provided on the same. Close the fill valve after filling. IMPORTANT: Switching on the boiler with no water inside could result in serious damage. 4.2 Electrical Connection The EkoHeat boiler must be protected by 5 amp fuse unit and RCD or RCBO device be fitted on electrical supply. There is a 4 amp fuse located on main circuit board. It is important to disconnect electrical supply when doing any maintenance on the boiler. The appliance MUST be earthed. 4.3 Start-up In order for the guarantee to be valid, the boiler must be started up by personnel authorised by EKOPOWER. Before beginning start-up, the following must be complied with: - The boiler must have an electrical supply. - The installation must be filled with water (the pressure must be between 1 and 1.5 bar). - The hopper must be filled with fuel. The start-up sequence is as follows: - Check the flue is correctly installed using a draft gauge. - Check the external hydraulic anti-condensation kit is correctly installed. - Check the reserve tank and the feed auger are correctly installed. The feed auger must be calibrated for correct boiler functioning (See Feed Auger Calibration page 27). Check the right type of fuel is being used (it must be EN PLUS). - If the installation has flow and return valves, check they are open. 4.4 Installation delivery After the initial start-up, the Technical installer will explain to the user how the boiler functions, making any observations they consider relevant. The installer is responsible for clearly explaining to the user the functioning of any control or regulation device forming part of the installation but not supplied with the boiler. 18

22 5 DIGITAL DISPLAY: The EkoHeat boiler is equipped with a digital touch display for viewing and adjustment of the different boiler settings. The different settings shown on the initial display and the touch buttons for browsing and/or adjusting the different set-points are shown below: The different settings shown on the initial display are shown in the table below: 1 Touch button for accessing the Configuration menu display. 2 Touch button for accessing the Info display. 3 Flame level detected in the burner. 4 Percentage fan functioning. 5 Percentage boiler modulation. 6 Feed auger functioning. 7 DHW functioning. (Only with the DHW tank installed and enabled). 8 Circulating pump functioning. 9 Water outlet temperature 10 Amount of pellets in hopper (measurement in kg) 11 Touch button for Starting/Stopping boiler functioning. 19

23 6 "INFO" DISPLAY The "Info" display shows a numbered series of information settings for the particular features of the boiler supplied. This data can be very useful for identifying the boiler. These settings are described in the table below: Settings Operating hours Number of ignitions Software version Controller ID Boiler Type Description Counter showing the hours the boiler has been operating. Counter showing the number of times boiler ignition has taken place. Identification number for the software version the electronic control is working with. Identification serial number of the electronic control. Selected boiler model. 20

24 7 CONFIGURATION MENU This menu is used to adjust the settings connected with boiler functioning. It is the recommended menu for both the installer & boiler user. The table below shows the settings on the "Configuration" menu. Settings User setting Service settings Change hopper content Clean now Language Self-test Exit Description Enter User settings Enter Service settings Enter weight (kg) currently in hopper Chose the number of cleanings Select desired language Run self-tests on components Return to main display 21

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26 8 USER MENU The following sections describe the functioning of each of the menu options in detail. This menu is used to adjust the settings connected with boiler functioning. It is the recommended menu for the boiler user. The table below shows the settings on the "User" menu. Setting Boiler temp (40-80) degrees Celsius Fuel ( kg) Cleaning Summer mode DHW priority Pump Stop (0-80ºC) Auger calibration Date and time Description Maximum boiler temperature. Fuel consumed at full power, in kilograms. Functioning options for the burner and fan cleaning devices. Time clock/summer mode settings. DHW temperature settings. The circulating pump will start up when the boiler temperature exceeds this value. Procedure for calibrating the feed auger. This calibration is required for the boiler to function correctly. Date and time adjustment. The following sections describe the functioning of each of the menu options in detail. 8.1 Boiler Temperature (40-80ºC) This is the set point temperature the boiler will reach. The boilers default setting is 60º. To change this figures, select the desired temperature. 23

27 8.2 Fuel ( kg) This setting is used to adjust the amount of pellets, in kilograms, consumed by the boiler at full power in one hour. This setting is connected with the boiler model (power) and the calorific power of the pellet used. The table below shows the default values for each boiler model: EkoHeat Fuel (Kg.) Cleaning settings All the operating settings for the different automatic boiler cleaning devices can be adjusted from this display. The table below provides a description of these settings, the boiler components controlled by each one and their defect values: Setting Air clean interval (0-120 min.) Air clean time (0-60 sec.) Description Minutes elapsing between each fan cycle for cleaning the boiler fumes. Time in seconds during which the fan is started up for fume cleaning. Default value Ash plate interval ( Kg.) Kilograms of fuel burned before the burner cleaning device & heat exchanger cleaning device start up IMPORTANT: Incorrect modification of these settings can cause boiler malfunctioning. Ensure the setting to be changed has been set to the correct value before changing it. 24

28 7.4 Summer mode/time-clock The EkoHeat has a daily time programmer to control the times at which the boiler switches on and off. 5 different periods during the day can be enabled. The steps for configuring the programmer are as follows: - Enable the time programmer operating mode by selecting YES for the Time programmer (Yes/No) setting. The boiler will start up and stop according to the times programmed. No time periods are programmed and the boiler will function continuously throughout the day. - Select the hour and minutes for the start of the period and the hour and minutes for the end of this period (there must be a minimum of 01:30 hours between boiler start-up and switch-off). - Adjust the periods required, to a maximum of five periods (it is recommended 2 periods to be sufficient as this will increase the life of the ignition element in the boiler). - Touch the Save and restart button to complete the operation. - Touch the "Reset" button to set all the periods to zero and disable the time programmer operating mode. When the time programmer mode is enabled, the symbol " " will appear at the top right of the initial display to indicate the boiler is functioning in this mode. With the boiler in this operating mode, touch the "Start/Stop" button to disable the time programmer. IMPORTANT: Each of the boiler switch-on/switch-off periods must last at least 01:30 hours. 25

29 7.5 DHW Priority The EkoHeat boiler can control a DHW circuit, using a 3-way diverter valve and a DHW sensor. After making the hydraulic installation required, the following settings should be adjusted on the DHW circuit display: Setting DHW circuit activation (Yes/No) DHW differential (0-20 C) Description Setting for enabling the 3-way DHW diverter valve. To correctly install a DHW tank, carefully follow the detailed instructions given in the section "Installing a hot water tank". The lowest temperature gradient with respect to the DHW setpoint temperature at which the hot water tank requires heating again. Default value No 10 Installing a Divert valve (Optional) The hydraulic installation for the 3-way DHW diverter valve should be made so that the heating circuit can flow through the valve when it is in rest position (not energised): HEATING NA / NO BOILER V3V NC D.H.W. For correct hydraulic installation of the hot water tank, carefully follow the assembly and connection instructions enclosed with the same. 7.6 Pump Stop (0-85ºC) The circulating pump installed in the heating circuit is controlled by this setting. The circulating pump is wired to the main controller. The circulating pump will stop if the boiler temperature drops below the value selected for this setting. This temperature is set to 45ºC by default. To prevent any condensation from reaching the heat exchanger which would cause irreparable damage, a load valve is fitted. 26

30 7.7 Auger calibration This display is used to calibrate the fuel feed auger required for correct boiler functioning. It is essential for the boiler feed auger to be calibrated on start-up and whenever the fuel supplier is changed (not all suppliers provide granules of the same density and size). Calibrating the boiler feed auger adjusts the optimum amount of pellets required to supply the burner and produce the correct power and combustion. If the fuel in the hopper runs out, fill the feed auger with pellets again. To do this, follow the calibration instructions up to point 8. In this case it will not be necessary to calibrate the feed auger again, unless you change your pellet supplier. A weighing scales and a suitable pellet collection container are required for this calibration procedure. The steps for correctly calibrating the feed auger are as follows: 27

31 This process must be carried out twice to ensure the correct amount of pellets have been added. IMPORTANT: Calibrate the feed auger before starting up the boiler for the first time. IMPORTANT: Calibrate it again whenever you change your fuel supplier. 28

32 8.8 Date and time This display is used to change the date and time shown on the boiler. To use this function simple press on the digit you wish to change and enter the digit. When time & date is entered, then press exit. IMPORTANT: These settings need to be entered if you wish to use the time programmer. 29

33 9 SERVICE MENU This menu is used to adjust the technical settings for boiler functioning. As the settings on this menu are technical and can affect boiler safety, we highly recommend that they are only adjusted by sufficiently technically qualified personnel. The table below shows the settings on the "Service" menu. Setting Start-up Fuel (0-200 gr.) Ash plate movement ( sec) Fan Performance Minimum performance Extra equipment On/Off mode Restore factory settings New Software Description Amount of fuel required for boiler ignition, in grams. Time required for the burner cleaning device to close, in seconds. Percentage fan functioning for each of the boiler modulation percentages. Minimum performance required for burner functioning. This setting is to add extra equipment. Performance settings of the boiler in this mode. For resetting the boiler s default settings. For updating the electronic control software version. The following sections provide a detailed description of the functioning of each of the menu options. IMPORTANT: We recommend that only authorised technical personnel access this menu. Unsuitable modification of these settings can cause malfunctioning and even damage to the boiler. 9.1 Fuel for ignition (0-200 grams.) This setting is used to specify the amount of pellets required for correct burner ignition. The table below shows the default values for each boiler model: EkoHeat Fuel for ignition (gr.)

34 9.2 Ash plate movement (0-100 sec.) This setting adjusts the time required by the burner cleaning device, in seconds, to return to its closed position after having been in open position. Warning: Never exceed the recommend manufactures time, as this will result in damage to spindle block, which could result in the boiler breakdown. 31

35 IMPORTANT: After carrying out any repair or maintenance operations on the boiler, ensure the burner cleaning device is correctly positioned to its standard default value when it is in closed position. Also put aluminium grease on the shaft for lubrication. 32

36 9.3 Fan functioning This display is used to adjust the fan speed percentages, to ensure correct combustion values at each boiler power modulation percentage. For example, for the EkoHeat 1500 boiler, it is established that for a power percentage of 100% the fan must run at 96% for ideal combustion. The settings can be adjusted separately or the General panel can be used to change all of them at once. If this setting is changed from 100 to 120, all the fan values will increase by 20%. The same operation can be used to reduce all the fan values by 120%, by changing the value to 90 on the General panel. It is recommended to modify the General" panel to adjust the fan values, only if required. 9.4 Minimum power (%) This setting is used to select the minimum boiler operating power, expressed as a percentage of its nominal power. This is pre-set as 10%. 9.5 Extra Equipment 33 This setting is used to select and switch on different external sensors. Simply connect the sensor into the main control board and select the sensor required by selecting the Yes key. The extra equipment that can be added are: Oxygen sensor, Communication box, Smoke temperature sensor, Return temperature sensor, Flow-sensor, DHW temperature sensor, Outdoor temperature sensor, Indoor temperature sensor & Logger.

37 9.6 On/Off mode Boiler set point settings and boiler performance settings. Set-point temperature can be selected (60ºC- 80ºC). Max performance settings can also be adjusted here (50%-100%). When set to Yes Summer-mode/Time-clock will be disabled. 9.7 Restore factory settings Touch the Reset default values button to reset the electronic control to default values. Attention: This should only be done as a last resort. The main feed auger will have to be recalibrated if the controller is reset. Depending on the variation of software an Ekopower technician will have to reload the latest edition of software, which the customer will be liable to pay a call-out charge. 9.8 New software The electronic control software version can be updated using a USB storage device. This setting is to be used by authorised personnel only. 10 CHANGE HOPPER CONTENT This is used for display purposes only and does not affect any other component in the boiler. An example of how it works: If the hopper is empty and you put ten 10KG bags of pellets into it, you would have 100KGs of pellets in the hopper. You would then press CHANGE HOPPER CONTENT on the configuration menu, then enter 100 and accept. You would then see 100KG displayed on the main front display screen (see no.10 on page 19). As the boiler consumes the fuel the hopper content weight would reduce and so would the figure on the display screen. 11 CLEAN NOW This display is used to manually enable a number of ash cleaning device & cleaning springs in the heat exchanger functioning cycles. 1 5 cycles can be set from this display. 12 LANGUAGE In this menu you can select the desired languages. Simply select on the screen which language you require and exit menu. 34

38 13 SELF-TEST 13.1 Model selection This display is used to select the boiler model. The boiler model should only be changed when the boiler s original electronic control is replaced during a repair operation. In the INFO display you can see what the selected boiler is. WARNING: Never select different boilers software as this will lead to the boiler running poorly or the boiler could break down Test now This option is used to view the values for all the electronic control inputs being read at any time, and to manually enable each of the boiler powering systems. This facilitates the various maintenance operations, and error detection. Before accessing the test now, stop the boiler functioning and/or disable the time programmer operating mode, if it is enabled. Test now should only be accessed by qualified technical personnel authorised by EKOPOWER, as incorrect manual activation of the boiler powering systems can cause personal injury and damage to the boiler. You can change the PID & Combustion values. We recommend NOT changing these settings. IMPORTANT: The Test now can only be run when the boiler is switched off and the time programmer disabled Boiler sensor readings This option provides information from the following sensors: Lux sensor, End-stop ash plate, Thermal switch, Boiler temperature, Indoor temperature, Outdoor temperature, Boiling, Hopper, Flow sensor, Smoke temperature, DHW temperature & Return water temperature Testing Boiler components This option is useful in fault finding because it lets you send power to an individual component to see of it is functioning. You can test the following: Internal feeder, Ignition, Ash plate opening, Ash plate closing, Fan, Cleaning springs, External feeder, Circulating pump & DHW pump. 35

39 14 SAFETY PRECAUTIONS 14.1 Carbon monoxide detector Many people are killed each year, and many more suffer ill health from carbon monoxide (CO) poisoning. CO is an invisible, odourless, tasteless and extremely toxic gas. It is produced by appliances and vehicles burning fuels, such as coal, oil, natural gas, wood, etc. CO is absorbed by red blood cells in the lungs in preference to oxygen this result in rapid damage to the heart and brain from oxygen starvation. High levels of CO in a house can be caused by: * Incorrectly or poorly installed fuel-burning appliances * Blocked or cracked chimneys/flues * No ventilation, blocked vents or draught-proofing which makes areas with fuel burning appliances airtight. Suitable locations: * A carbon monoxide detector should be located in the room with the boiler * It should be installed on the ceiling 300mm from walls or light fittings. * Between 1M to 3M horizontally from appliance * If it is mounted on a wall, it should be located at a height greater than the height of any door or window but still be at least 150mm from the ceiling. * If there is a partition in the room, the CO alarm should be located on the same side of the partition as the boiler. * In rooms with sloped ceilings, the CO alarms should be located at the high side of the room. Unsuitable locations: * Next to a door, window, air vent or anywhere that it would be affected by draughts. * Next to a extractor fan * Over heat sources such as radiators or hot air vents. * Where dirt or dust could block the sensor * Near paint, thinners, solvent fumes or air fresheners. * Do not fit alarm until all building work is complete to avoid contamination This information is only precaution information; it does not state that CO emissions will leak from an EKOPOWER boiler. EKOPOWER does not take any responsibility from damages caused from poor installation due to an installer. Good ventilation is extremely important. NEVER IGNORE THE ALARM. Attention: It is recommended that the installer preform a 10 minute CO room test with their analyser when installation is complete and working. 36

40 14.2 Ventilation Part J of the Second Schedule to the Building Regulations, 1997, provides as follows: A heat producing appliance shall be so installed that there is an adequate supply of air to it for combustion and for the efficient working of any flue pipe or chimney. If an air extract fan is fitted in a building containing the boiler (other than a room-sealed appliance), the appliance and flue should be able to operate effectively when the fan is running. A permanent air entry or opening with a total free area of at least 550 mm2 per kw of rated output above 5 kw shall be provided but in no case less than 6500 mm2. Where a flue draught stabiliser is used the total free area should be increased by 300 mm2 for each kw of rated output. Attention: If the boiler is installed in an air tightness premises, ventilation should be piped into the room from outside to where the boiler is installed. If there are other oxygen consuming appliances in the room with the boiler, provisional air should be taken into account. If one vent is inadequate to service the needs of all the appliances place a second vent at a lower level behind the boiler. All air vents should be piped direct from the boiler room to outside air source, not from room to room (internal air). Make adequate provision that air vents cannot be blocked both inside and outside the building. Place necessary warning signage. Warning: Inadequate ventilation can result in carbon monoxide being produced which in return could result in health damage or loss of life. 37

41 15 CLEANING THE ASH DRAWER The EkoHeat boiler is equipped with an ash drawer, where the solid residues from the burnt fuel are collected on cleaning the burner and heat exchanger. This drawer must be regularly cleaned to prevent ash from accumulating and obstructing the bottom of the heat exchanger, which would cause the boiler to switch off. It is recommended to regularly check the drawer and remove the ash that has accumulated. EKOPOWER supplies an optional ash compacting system for incorporation to the boiler, so that the ash does not need to be removed as frequently. Safety warnings: For safe handling of the ash drawer, you should take the necessary safety precautions and wear suitable clothing to protect against possible injury. The following advice should be particularly taken into account: - Switch off the boiler before taking out the ash drawer. If you take out the ash drawer with the boiler on pause, make sure you have replaced it before switching on the boiler again. It is recommended to wait before taking out the ash drawer until no flame is detected in the burner. - It is recommended to wear insulating thermal gloves to protect your hands from any burns from hot parts of the drawer. - It is recommended you wear a protective mask to avoid breathing in any ash particles, particularly in the case of people with allergies or any type of respiratory trouble, who should always wear a mask when carrying out ash removal. - As the ash to be removed from the drawer may be burning or glowing, special precautions should be taken with regard to the type of container it is emptied into. A metal container is recommended, or the ash should be totally put out on handling, using water or another extinguishing agent. EKOPOWER shall not be liable for any damage caused to people, animals or property as a result of incorrect handling of the ash drawer or the ash itself. IMPORTANT: The ash drawer must only be cleaned when the boiler is switched off or on pause. 38

42 16 SAFETY CUT-OUTS The boiler s electronic control system may activate the following safety cut-outs to stop the boiler functioning. When any of these cut-outs occur, the boiler will switch off and a description of the cut-out will appear on the display. IMPORTANT: If any of the safety cut-outs described below should occur repeatedly, switch off the boiler and call your nearest official Technical Assistance Service Burner cut-out When this cut-out occurs, the message "E05: Burner error" will appear on the digital display. The burner and its fuel supply will be cut off. This occurs due to burner anomaly or excessive temperature in the burner fuel supply circuit. To unblock it, press the OK button No flame cut-out When this cut-out occurs, the message "E06: Flame defect" will appear on the digital display. The burner and its fuel supply will be cut off. This occurs when an insufficient flame lux level is detected by the photocell during a certain time lapse. To unblock it, press the OK button Temperature safety cut-out When this cut-out occurs, the boiler digital display will switch off and the electrical supply to the electronic control will be cut off. All the boiler devices will switch off. This occurs whenever the water in the boiler reaches a temperature of 110 ºC. To unblock it, wait until the boiler temperature drops to below 90ºC and press the reset button on the safety thermostat located on the underside of the electrical panel (see Control components page 5). 39

43 17 SHUTTING DOWN THE BOILER To shut down the boiler, touch the Start/Stop button (see "Digital display functioning" page 5). In shutdown mode, the boiler will switch off. To shut down boiler functioning completely, Disconnect it from the mains before carrying out any maintenance. 18 BOILER MAINTENANCE Various maintenance operations should be carried out at different intervals to keep the boiler in perfect working order. The yearly maintenance operations should be carried out by personnel authorised by EKOPOWER Boiler and flue maintenance frequencies The most important aspects to be checked are as follows: Nº Operation of the boiler Frequency 1. Check the pellet storage. weekly 2. Clean the ash in the ash drawer. (Dependant on usage) Monthly 3. Check the boiler visually. weekly 4. Lubricate the burner cleaning device. (Dependant on usage) yearly 5. Check the feed auger is correctly calibrated. quarterly 6. Check and clean the boiler fume circuit and combustion chamber quarterly 7. Check and clean the flue. The flue must be free of any obstacles and have no leaks. yearly 8. Clean the burner. (Dependant on usage) quarterly 9. Check the expansion vessel. It must be full, according to its reference plate. yearly 10. Check the seal between the burner and the boiler. yearly 11. Vacuum the dust out from around the auger in the hopper when emptied quarterly 12. Check the water pressure in the heating installation. In cool mode, it should be between 1 and 1.5 bar. (if a sealed system) quarterly 40

44 18.2 Cleaning the burner. The following procedure is recommended for correctly cleaning the burner: 41

45 IMPORTANT: Always make sure the burner is switch off for a period of time and disconnected from the electrical supply before carrying any maintenance on the burner or boiler. IMPORTANT: The burner cleaning device can only be lubricated when the boiler is switched off, system cooled and the time programmer disabled. IMPORTANT: The burner cleaning device should be lubricated if an unpleasant noise is heard. It should be done each year on the annual overhaul, at the least Draining the condensation water Draining of condensation water from the flue should not be altered in any way and it must be kept free of obstructions. It should be flushed out regular to prevent deposit build up Boiler water characteristics In areas with water hardness of over 25-30ºfH, treated water or inhibitor must be used in the heating installation to avoid any scale deposits on the boiler. It should be noted that even a few millimetres of scale will greatly reduce the boiler s heat conductivity, causing a major drop in performance. Treated water or inhibitor must be used in the heating circuit in the following cases: - Very large circuits (containing a large amount of water). - Frequent filling of the installation. If repeated partial or total draining of the installation is necessary, we recommend filling it with treated water. 42

46 18.5 Cleaning the Heat exchanger The following procedure is recommended for correctly cleaning the heat exchanger: Place cover correctly when reassembling 43