UIN-UK201505.06
E-COMPACT TWIST ®
25 – 100kW HE
Condensing Pellet Boiler
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
Please read these instructions carefully before installing and/or lighting the appliance for the first time.
Keep this document near the appliance, in a place which can easily be reached.
TABLE OF CONTENTS
0.
INTRODUCTION
1.
GENERAL AND SAFETY INFORMATION
1.1 Symbols used in this manual
1.2 Safety instructions
2.
TECHNICAL FEATURES OF THE E-COMPACT TWIST
BOILERS
2.1 General description of the BCH Boilers
2.2 Description of boiler operation
2.3 Technical data
3.
FUEL
3.1 Fuel considerations
3.2 Fuel consumption
4.
BOILER INSTALLATION
4.1 General warnings
4.2 Unpacking
4.3 Location of the boiler
4.4 Combustion fumes discharge.
4.5 Fuel storage and feeding.
5.
HYDRAULIC INSTALLATION
5.1 Hydraulic connections
5.2 Double temperature set point.
5.3 Hydraulic schemes
10. CLEANING AND MAINTENANCE
10.1 Combustion chamber and heat exchanger
tubes.
10.2 Burner.
6.
ELECTRICAL CONNECTIONS
6.1 Warnings
6.2 Boiler control board diagram
6.3 Wiring
6.4 Room thermostat
6.5 Boilers in cascade
6.6 Lambda probe kit
6.7 Ethernet device kit
11. ASH REMOVAL
7.
7.4 Customization menu (Installer)
8. COMMISIONING
8.1. Water filling
8.2. Boiler parameters setting
8.3. First pellet load
8.4. Turning the boiler ON/OFF. Unlock.
8.5. Manual selection power
8.6. Boiler and Buffer temperature set point.
8.7. Winter-Summer.
8.8. Reset Service
9.
BOILER OPERATION
9.1 Circulation pump control
9.2 Fans control
9.3 Augers
9.4 Fire/smoke dumper actuator
9.5 IGNITION mode
9.6 RUN and STANDBY mode
9.7 EXTINCTION and BLOCK mode
9.8 DHW Production
9.9 Automatic cleanings
12. LIST OF ERRORS. CAUSES AND ACTIONS TO BE
TOKEN.
13. LIST OF CONTROL PARAMETERS
CONTROL PANEL
7.1 Display
7.2 Structure and management of the menu
7.3 Settings menu (User)
2
0. INTRODUCTION
Dear customer,
The pellet dew point is around 45°C, and the
boiler’s efficiency is above 100% then this event
takes place.
The product you have chosen is a biomass boiler
with condensation technology, that is, one of
the most efficient boilers - with least emissions in the market.
The return temperature of a heating circuit
depends on the chosen system:
This boiler can work at seasonal performances
surpassing 103% efficiency, while high class
biomass boilers work up to 95%, and mid class
appliances barely reach 91% efficiency.
Heating systems
Radiators
Low temperature
radiators
Floor heating
Condensation technology
Usual return
temperatures
60˚C
40˚C - 50˚C
30˚C - 35˚C
This return temperature must be between 30ºC
and 40ºC for the flue gas to reach the dew point.
During the combustion process, steam is
released from the moisture contained in pellet.
To do this, condensing boilers have a stainless
steel heat exchanger, with a larger heat
exchange surface, for enabling it to transfer as
much heat as possible from the boiler's
combustion chamber into usable heat. For this
reason, even when working in a non-condensing
temperature range, the boiler performance will
always be higher than a conventional, that is, a
non-condensing boiler, because of its larger
heat-transfer surface.
Condensing boilers exploit the latent heat of
vaporization (change of state heat) condensing
the steam from the flue gas and transferring this
heat to the water circuit of the boiler. That is,
they take advantage of a heat that would
otherwise be lost along with the flue gases
through the chimney.
As a result, flue gas temperature is below 50°C
under condensation conditions, and below 70°C
under non-condensing. In the case of
conventional boilers, flue gas temperature is
usually between 120°C and 200°C.
This boiler complies with current regulations
and has been tested in external laboratories
accredited for certifying this type of product.
Installation of the boiler, checking and
maintenance should be carried out by
authorised personnel.
Condensation happens when flue gas reach a
temperature below the so-called “dew point”.
3
1. GENERAL AND SAFETY INFORMATION
1.1. SYMBOLS USED IN THIS MANUAL
WARNING
Indications identified with this warning sign are essential for a
proper running of the boiler.
DANGER
Indications identified with this danger sign warn of potential
hazards identified for the integrity of people and things.
SUGGESTED USE
Indications identified with this sign show suggestions at installation
and running.
1.2. SAFETY INSTRUCTIONS.
Keep this manual near the appliance throughout its useful life.
Before any operation, read the indications contained in this document.
This manual holds important information regarding use and maintenance of the boiler.
In case of any doubt, contact with your installer, dealer or Service Agent authorised by WES.
Installation and maintenance must be carried out in accordance with the current local regulations
and the instructions contained in this booklet, and should be performed by accredited and qualified
personnel, as required by current regulations.
Improper installation or faulty maintenance can cause harm to people, animals or property. In such
cases, the manufacturer is absolved from any civil or criminal responsibility.
This appliance is only intended for being used in heating systems and indirect production of domestic
hot water. Any other use may cause harm to people, animals or property.
The running of the boiler should be done in accordance with the local and national regulations as
well as European standards.
The appliance should be installed inside technical rooms. It is not designed to work outdoors.
Boiler room must meet the regulations in force.
During installation and running of the appliance, keep children at a safe distance from it.
After a long period of shutdown, check the absence of blocking prior to the ignition.
4
This appliance should not be used as an incinerator. Use only the fuel specified in this booklet.
The Commissioning of this appliance must be carried out by an Authorised Service Agent. This is an
essential condition for the keeping the warranty of this appliance.
In order to improve the product, specifications are subject to change without notice.
This boiler is an electrical appliance. Before carrying out any work inside the boiler, make sure that
it is isolated from the mains electricity supply.
The combustion chamber must always remain closed when the appliance is running. Under no
circumstances should be the door opened when there is a flame inside. Risk of burns and fire.
WES refuses to accept any responsibility in the event that the appliance or any accessory has been
improperly used or modified without authorisation.
For all replacement of parts, only original WES spare parts must be used.
2. TECHNICAL FEATURES OF THE E-COMPACT TWIST BOILERS
2.1. GENERAL DESCRIPTION OF THE BCH BOILERS
E-COMPACT TWIST 25/30/35/45/50/70/100 are
condensing biomass boilers which use as fuel
ENplus-A1 pellets only.
Pellet is fed from an external hopper/silo through
an auger.
The boiler is commanded by a pre-programmed
electronic board that allows a fully automated
performance. The following safety and control
devices are also supplied:
This appliance consists of a boiler body and an
underfed pellet burner. The burner can be fitted
to the right of the boiler or left, upon request.
The boiler body is constructed of sheet steel,
stainless steel and corrosion resistant materials
throughout the flue gas circuit as well as all parts
that may be in contact with condensate.
Combustion chamber is cylindrical and the flue
pipes are arranged concentrically around this
chamber.
-
Combustion chamber temperature probe.
When it reaches 890°C the boiler enters in
blocking mode.
-
Mechanical safety thermostat. When it
reaches 105°C the boiler disconnects auger
feeding.
At the rear of the boiler there are placed
hydraulic connections (flow, return, drain and
water cleaning jets), as well as flue gas pipe and
condensate drain. The condensate discharges
through a drain at the bottom of the boiler,
where a water trap is installed (see section 5.Hydraulic Installation)
-
Water temperature probe. When it reaches
100°C, the boiler enters in blocking mode.
-
Water pressure probe. When preset
low/high pressure is reached, the boiler
enters in blocking mode.
-
Combustion chamber differential pressure
sensor. When preset low/high depression is
reached, the boiler enters in blocking mode.
-
Fire/smoke damper actuator. Spring-return
actuator which tightly closes pellet feeding.
The boiler includes an automatic cleaning system
of the burner plate, which wipes ashes onto a
manually removable ash drawer. It also includes
an automatic water jet system for cleaning the
heat exchanger flue gas pipes.
5
-
-
Snap disc thermostat in pellet feed pipe.
Close the damper actuator if the
temperature of the feed tube pellet reaches
80°C.
Temperature sensor in the smoke box.
Blocks if it reaches 100°C.
-
For safety, provided that the boiler
temperature is greater than 72 ° C, the
output of the boiler which controls the
circulating pump is activated.
2.2. DESCRIPTION OF BOILER OPERATION.
During normal operation, most of the surfaces of the appliance are hot.
Take the appropriate precautions.
Fuel (pellet) enters onto the burn plate from below
through an auger driven by a gear motor. Pellet is
fired by a hot air ignition resistance. The whole
operation is fully automated.
Ash removal, from the burn plate to the ash
drawer, is performed automatically. The ash
drawer must be emptied manually with a cadence
that depends on the boiler working hours.
The flame is born in the burn plate, controlled by a
combustion air fan (blower). This fan provides first
combustion air (primary air) as well as afterburning
air (secondary air), which is injected through a liner
placed in the combustion chamber. Thus, a
thorough combustion is achieved.
The coil-wound heat exchanger is cleaned by water
jets, controlled by a water solenoid valve placed at
the rear of the boiler. This cleaning is performed
automatically whenever the boiler enters in
EXTINCTION or STANDBY mode and the
combustion chamber temperature is low enough.
Combustion gases ascend in the combustion
chamber and descend through the coil-wound heat
exchanger. Flue gases are finally evacuated at the
lower rear of the boiler.
The E-COMPACT boilers operate with a low
temperature set point (heating) and a high
temperature set point (DHW). When there is
demand for DHW, the boiler temperature rises to
meet the demand. Once satisfied, he returns to
work in the heating set point.
For easing the evacuation of combustion gases, as
well as ensuring a minimal depression in the
combustion chamber, an exhaust fan is installed at
the flue gas outlet box.
The operation of the boiler and equipment
incorporated appears further explained in section
9.- Boiler operation.
Condensate is drained by gravity, at the bottom of
the boiler.
6
2.3. TECHNICAL DATA
Dimensions
Type
A
B
C
D1
E1
F1
G1
H1
Water flow/return
connection
Cleaning connection
Water drain
connection
Flue gas pipe
diameter
Ash drawer capacity
Dry weight
mm
mm
mm
mm
mm
mm
mm
mm
BCH-25
695
1.465
850
420
1.365
645
500
250
BCH-30
695
1.465
850
420
1.365
645
500
250
BCH-40
695
1.665
850
420
1.365
645
500
250
BCH-50
695
1.665
850
420
1.365
645
500
250
BCH-60
695
1.665
850
420
1.365
645
500
250
BCH-70
695
1.665
850
420
1.365
645
500
250
BCH-100
840
1.710
1.115
420
1.610
600
525
350
“ GAS/M
1-1/4”
1-1/4”
1-1/2”
1-1/2”
1-1/2”
1-1/2”
2“
“ GAS/M
“ GAS/M
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
3/4”
mm
150
150
200
200
200
200
250
lit.
kg
30
385
30
385
30
415
30
415
30
415
30
415
77
675
7
Technical data
Type
Nominal heat output
Condensing heat output
kW
kW
Range of power output
kW
Efficiency PNOM / PMIN
(70°C/50°C)
Efficiency PNOM / PMIN
(50°C/30°C)
Min. required draft PNOM
/ PMIN
Flue gas temp. PNOM / PMIN
(70°C/50°C)
Flue gas temp. PNOM / PMIN
(50°C/30°C)
Exhaust gas mass flow
PNOM/PMIN (70°C/50°C)
CO
(10%O2)
OGC
(10%O2)
Dust
(10%O2)
NOX
(10%O2)
Water capacity
Water side resistance 10K
Water side resistance 20K
Water operating
temperature range
Min. water temperature
boiler
Max. operating pressure
Test pressure
Electrical consumption
(PNOM / PMIN / Standby)
Class (EN 303-5:2012)
%
%
BCH-25
24,9
25,8
7,5/10/15/
20/24,9
BCH-30
30,0
31,2
9/12/18/
24/30
BCH-40
40,0
41,8
12/16/24/
32/40
BCH-50
50,0
52,4
15/20/30/
40/50
BCH-60
60,0
63,5
18/24/36/
48/60
BCH-70
65,7
69,9
19/26/39/
52/66
BCH-100
100
106
30/40/54/
68/100
94,5 / 93,1
94,5 / 93,0
94,6 / 91,9
95,3 / 93,1
95,3 / 94,1
95,0 / 93,8
99,1 / 98,0
100,6 / 98,5
102,0 / 97,7
102,0 / 97,7
101,7 / 97,7
105,3 / 101,8
101,5 / 100,5 101,5 / 100,5
Pa
8/5
8/5
8/5
8/5
8/5
8/5
8/5
˚C
70 / 61
71 / 60
73 / 59
74 / 58
75 / 59
76 / 59
57 / 47
˚C
50 / 38
48 / 38
46 / 39
44 / 40
44 / 40
45 / 41
39 / 37
g/s
13 / 6
18 / 6
24 / 7
27 / 12
36 / 11
42 / 12
51 / 18
mg/m3
mg/m3
mg/m3
mg/m3
l
mbar
mbar
39
3
39
147
78
331
83
34
2
36
154
78
477
119
25
1
31
166
112
38
10
16
<1
26
179
112
59
15
13
<1
21
143
112
86
21
11
<1
18
123
112
104
26
25
3
18
150
213
238
59
˚C
27 - 80
27 - 80
27 - 80
27 - 80
27 - 80
27 - 80
27-80
˚C
27
27
27
27
27
27
27
bar
bar
3
6
3
6
3
6
3
6
3
6
3
6
5
10
W
104 / 56 / 13 104 / 56 / 13 150 / 73 / 13 150 / 73 / 13 160 / 75 / 13 160 / 75 / 13
5
5
5
8
5
5
5
400 / 230 / 15
5
3. FUEL
3.1. FUEL CONSIDERATIONS
This appliance has been designed for running exclusively on 6 mm diameter wood pellet, quality
ENplus class A1 according to EN 14961-2 standards. “Solid biofuels - Fuel specifications and classes Part 2: Wood pellets for non-industrial use.”
ENplus-A1 pellet can be made of stem wood and/or chemically untreated residues from the wood processing
industry. Its main properties are the following:
Property
Diameter
Length
Moisture content
Ash content
Net Calorific Value
mm
mm
%
%
MJ/kg
kWh /kg
Threshold values ENplus-A1
6 or 8
3,15 ≤ L ≤ 40
≤ 10
≤ 0,7
16,5 ≤ Q ≤ 19
4,58 ≤ Q ≤ 5,28
The fuel supplier must provide certified documentary evidence of its pellet quality.
3.2. FUEL CONSUMPTION
The burner is modulating, with five modulation steps for each output. The boiler chooses automatically the
optimal step for each need. The following charts show outputs and subsequent fuel consumption for each
boiler model at each modulation step:
Modulation step
BCH-25
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-30
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-40
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-50
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-60
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-70
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
BCH-100
Heat output
kW
Pellet consumption (70°C/50°C)
kg/h
Pellet consumption (50°C/30°C )
kg/h
1
2
3
4
5
7,5
1,7
1,6
10
2,3
2,1
15
3,4
3,2
20
4,5
4,2
25
5,6
5,3
9
2,1
1,9
12
2,7
2,5
18
4,1
3,8
24
5,4
5,0
30
6,7
6,3
12
2,7
2,5
16
3,6
3,4
24
5,4
5,0
32
7,1
6,7
40
8,8
8,3
15
3,4
3,2
20
4,5
4,2
30
6,6
6,3
40
8,8
8,3
50
10,9
10,2
18
4,0
3,8
24
5,3
5,1
36
7,9
7,5
48
10,5
9,9
60
13,1
12,3
19
4,4
4,2
26
5,8
5,6
39
8,7
8,3
52
11,6
10,9
66
14,4
13,5
30
6,2
5,7
40
8,2
7,6
54
11,1
10,3
68
14,0
12,9
100
20,6
19,0
Note: regarding fuel with Net CV = 4.8 kWh / kg
9
4. BOILER INSTALLATION
4.1. GENERAL WARNINGS
This appliance is only intended for being used in heating systems and indirect production of
domestic hot water. Any other use may cause harm to people, animals or property.
The appliance should be installed inside technical rooms. It is not designed to work outdoors.
Installation and maintenance must be carried out in accordance with the current local
regulations and the instructions contained in this booklet, and should be performed by
accredited and qualified personnel, as required by current regulations.
During installation and running of the appliance, keep children at a safe distance from it.
Boiler room must meet the regulations in force.
4.2. UNPACKING
Take into account the actual size of the boiler to plan walkways and its connection in the boiler
room.
Observe local regulations on waste and recycling.
Transportation of the boiler should always be done using hand trucks/pallet jacks.
Pay attention to possible imbalances due to uncentered loads on the pallet.
The BCH boiler will come packaged on a single 800 x 1200 pallet. The smoke box and the extraction fan is
supplied disassembled to facilitate passage through doors. The minimum width for the boiler to be carried
without disassembling is 750 mm.
Type
A
B
H
Pallet
[mm]
[mm]
[mm]
[mm]
C
Minimum
passage width
[mm]
BCH-25
BCH-30
BCH-40
BCH-50
BCH-60
BCH-70
1.160
BCH-100
1.300
1.470
760
1.200 x 800
800
1.350 x 900
900
1.670
10
900
1.710
To facilitate the operation of lowering the boiler from the pallet, some useful designed for this purpose can be
supplied on request.
Insert the useful in the holes in the base of the boiler. Actuate both lifting mechanisms gradually and
alternately until the boiler stop supporting the pallet.
Move the lifting mechanisms along the frame to lift the boiler levelled. Hold the boiler manually
to avoid imbalances. Risk of falling boiler in case of unbalanced elevation.
Remove the pallet. Move the boiler to its final location and pose the boiler on the floor.
Remove the mechanisms from the boiler holes.
Slide support for a level
elevation
The mechanisms for lowering the boiler from the pallet must not be used for large
displacements. These displacements should be performed by hand trucks/pallet jacks
11
4.3. LOCATION OF THE BOILER
The boiler room must comply with air venting requirements and regulations applicable in terms
of fire protection, safety in use, etc.
The boiler should be installed in a boiler room frost-protected.
An adequate supply of combustion air and ventilation openings should be ensured by minimum
net free area of 10 cm2 for each kW of nominal heat output, never less than 200 cm 2.
The boiler must have an adequate smoke discharge.
All necessary safety distances to combustible materials must be respected.
Locating the appliance in a room with an explosive/flammable atmosphere is prohibited
The boiler must have around it clearance enough to let servicing be carried out easily. Be aware of complying
minimum distances imposed by local regulations
The minimum distances shown in the diagrams are:
L1
L2
L3
L4
L5
L6
mm
mm
mts
mm
mm
mts
Separation to the wall
Necessary to remove the burner
Required minimum width of the boiler room
Necessary for flue gas evacuation and drainage installation
Necessary to remove the ash pan and door opening.
Required minimum depth of boiler room
4.4. COMBUSTION FUME DISCHARGE.
12
This boiler shall not be connected to a venting system that serves a second appliance fired by other
fuel.
The smoke duct for the discharge of fumes must be installed by carried out complying local regulations
by qualified personnel.
The installation of horizontal sections must have a minimum slope of 3% for letting condensates to
drain down to the smoke box of the boiler, where are discharged to the sewerage.
Smoke duct is composed of a flue pipe and a chimney pipe. Never use a flue pipe smaller in diameter than the
flue connection of the boiler it is being connected to.
Type
Flue gas connection diameter
mm
BCH-25 BCH-30
150
BCH-40
BCH-50 BCH-60
200
BCH-70
BCH-100
250
WES recommends stainless steel insulated chimneys resistant to the aggressive action of temperature and
combustion products.
The calculation of the chimney should be according to EN 13384-1.
The data required for the calculation can be obtained from the technical data in section 2.3.
A ‘T’ element must be installed to overcome any solid or liquid obstruction.
The recommended draft is 5-8 Pa. A flue draft regulator may be required if the draft installation is higher.
4.5. FUEL STORAGE AND FEEDING.
The boiler is fed from a textile silo to the burner through an auger. WES supplies textile silos of different
storage capacities and the correspondent feeding auger kits.
Silo
Reference
Dimension
[mm]
BCSP 201
BCSP 251
BCSP 301
200 x 200 x 250
250 x 250 x 250
300 x 300 x 250
Approx.
capacity
[Ton]
3,0
4,9
6,9
The storage of solid biofuels must comply with current legislation on safety and fire.
The filling of the silo is made through a Storz connector supplied with the silo, by a fuel supplier tanker truck.
The silo Storz must be ground connected for avoiding electrostatic discharges.
Read carefully the instructions supplied with the silo and follow the instructions described therein
before filling it.
13
Auger connection to the burner is done through a flexible pipe,
which must be coupled to the burner inlet, inside the burner
enclosure, securing it with the supplied metal bracket. The
diameter of the feed connection is 60 mm.
Auger electrical supply must be wired on the correspondent
connector at the boiler rear.
5. HYDRAULIC INSTALLATION
5.1. HYDRAULIC CONNECTIONS
This is a condensing boiler. Condensate discharge to the sewage is done through a 40mm water
trap with a height no lesser than 25 cm. The siphon must be filled manually in the first
commissioning of the boiler.
Rear of the boiler
BCH-25 BCH-30 BCH-40 BCH-50 BCH-60 BCH-70
A Water Flow “GAS/M
BCH-100
1-1/4”
1-1/4” 1-1/2” 1-1/2” 1-1/2”
1-1/2”
2”
“GAS/M
1-1/4”
1-1/4” 1-1/2” 1-1/2” 1-1/2”
1-1/2”
2”
“GAS/M
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
D Water drain “GAS/M
1/2”
1/2”
1/2”
1/2”
1/2”
1/2”
3/4”
*
E Condensate “GAS/M
drain trap
1-1/2”
1-1/2”
1-1/2”
B
C
Water
Return
*V2V Heat
exchanger
cleaning
1-1/2” 1-1/2” 1-1/2” 1-1/2”
* These products are supplied with the boiler
The following products must be installed along with the boiler
- Circulation pump. Its volume flow must be adjusted according to the boiler’s nominal heat output
and the temperature rise planned for the installation
BCH-25
BCH-30
-
ΔT
[˚C]
20
15
10
20
15
10
Q
[l/h]
1.082
1.442
2.163
1.298
1.731
2.596
BCH-40
BCH-50
ΔT
[˚C]
20
15
10
20
15
10
Q
[l/h]
1.722
2.297
3.445
2.153
2.871
4.306
BCH-60
BCH-70
ΔT
[˚C]
20
15
10
20
15
10
Q
[l/h]
2.584
3.445
5.167
3.014
4.019
6.029
BCH-100
Safety pressure relief valve, rated at 3 bars and taken to sewage (5 bar to BCH-100).
14
ΔT
[˚C]
20
15
10
Q
[l/h]
4.306
5.742
8.612
-
Expansion vessel. The vessel volume will be calculated based on the volume of the entire
heating system.
Automatic air vent.
Pressure gauges and thermometers.
Mesh Filters.
Check Valves.
Ball Valves.
Energy Meter.
Condensate water trap.
The condensate drain pipe should have a steady incline, with a minimum angle of 3%.
If due to the position of the boiler, the condensate cannot be discharged by gravity, a condensate pump
should be used.
5.2. DOUBLE TEMPERATURE SETPOINT
The boiler can work with two temperature set points.
Low temperature (heating)
High temperature (usually DHW).
When there is no demand for high temperature, the boiler operates at low temperature set point.
When there is demand for high temperature, the boiler automatically switches its set point value of 70°C
(modifiable value Th21-Ih21), so it will increase the temperature of the boiler to this value or until demand
(e.g. DHW) is satisfied. The sensor in charge of this control is the buffer probe temperature.
This feature is only available with if the parameter P35=2 or 3 (see section 5.3.-Hydraulic schemes).
To enable this function, set the parameter A60=1 (SYSTEM MENU → ENABLES).
This functionality allows the maximum efficiency because the boiler only will work temporarily at high
temperature, working most of the time at low temperature.
15
For further information on this feature, see section 9.8.- DHW Production.
5.3. HYDRAULIC SCHEMES
The boiler is able to control the following outputs:
Description
The boiler controls a pump (heating only, without DHW)
The boiler controls a pump and a 3-way valve.
The boiler controls two pumps. One for the low-temperature circuit and another one for
high temperature (usually DHW).
The boiler controls a pump (buffer tank)
Parameter P35
0
2
3
4
The control of these outputs is made by the following sensors:
Boiler temperature probe
DHW/Buffer temperature probe
Room thermostat
(See section 6.4.- Room thermostat)
The choice of the hydraulic schemes is made by assigning the value of parameter P35 according to the
desired scheme (SYSTEM MENU → DEFAULT SETTINGS → PARAMETER P35)
To control more circuits (incl. Thermal Solar) or variation of the flow
temperature by mixing, Woodco Energy Ireland have an external
unit (BC Smart 1) able to perform such controls and functions.
For further information see the manual of the controller BC
SMART-1.
16
17
18
19
20
21
22
6. ELECTRICAL CONNECTIONS
6.1. WARNINGS
It is mandatory to install an all pole disconnection switch with contact aperture of at least 3 mm.
The boiler must be fully grounded.
The electrical installation must be performed by qualified personnel.
This boiler must be supplied with a 230V 50Hz electrical supply.
Before carrying out any work inside the appliance, disconnect it from the mains.
6.2. BOILER CONTROL BOARD DIAGRAM.
Access to the electrical wiring is done by removing the front cover of the boiler, and the metal wiring
protection cover.
23
24
INPUTS
FUNCTION
Line 230V - 50 Hz
Nº
1-2
Safety thermostat
TYPE
230 V
ON/OFF
SF1
SF2
IG
16
V3V
3-way valve
ON/OFF (max 3 A*)
19
VA
(Out 1)
Fire/smoke damper
actuator
ON/OFF (max 3 A*)
22
LI
(Out 2)
Cleaning exchanger
solenoid valve
ON/OFF (max 3 A*)
LP
(Out 3)
B1
SFE
(Out 4)
FAN3
FAN2
FAN1
Burning plate cleaning
linear actuator
Circulation pump
Silo/hopper loading pellet
motor
Exhaust Fan
Combustion Fan 2
Combustion Fan 1
7-8
TTS
31-32
TH
41-42-52
DP
43-44
TS
45-46
TD
47-48
TC
53-54-55
PA
61-62
TTO
Room thermostat
ON/OFF
29-30
75-76-77
SP
Pellet sensor
12 V
65
67
73-74
Combustion chamber
Thermocouple K
temperature
Combustion chamber
differential pressure
12 V
sensor
Safety temperature
NTC 100k
(flue gas box)
DHW/Buffer tank probe
NTC 10k
Boiler probe
NTC 10k
temperature
Water pressure sensor
5V
OUTPUTS
FUNCTION
Burner auger
Ash drawer auger
Ignition element
Nº
3-4
9-10
13
25
27-28
25
TYPE
TRIAC
(max 3 A*)
ON/OFF (max 3 A*)
ON/OFF (max 3 A*)
ON/OFF (max 3 A*)
ON/OFF (max 3 A*)
ON/OFF (max 3 A*)
TRIAC
TRIAC
TRIAC
(max 1,8 A*)
(max 1,8 A*)
(max 1,8 A*)
* All fed outputs are under fuse and the total current must not exceed 6.3 A
6.3.- WIRING.
All sensors and electrical devices included in the boiler are supplied installed and wired.
Only the following devices (depending on the system configuration), might be wired on the connectors
placed at the rear of the boiler:
Description
Cables
TYPE
1
Line
3 x 1,5 mm2
230 V
A
Room thermostat
2 x 1 mm2
ON / OFF
B
DHW/Buffer
temperature
2 x 1 mm2
NTC – 10 k
2
Silo/hopper auger
3 x 1,5 mm2
230 V
3
Pump
3 x 1,5 mm2
230 V
4
3-way valve/ Pump 2
3 x 1,5 mm2
230 V
5
Cleaning exchanger
solenoid valve
Supplied with the boiler
230 V
6
Exhaust fan
Supplied with the boiler
230 V
The buffer probe (NTC 10k) is supplied with the boiler. The length can be extended by a 2x1 mm2 cable.
The electrical connections of the burner are situated on the side of the boiler burner on the drawer.
Nº
Symbol
Designation
Nº
Symbol
Designation
1
Ignitor element
6
Burning plate cleaning
linear actuator
2
Combustion plate
rotation motor
7
Pellet sensor
3
Combustion FAN 1
8
Signal (control)
fire/smoke dumper
actuator
4
Burner auger
9
Signal (control)
combustion fan (FAN 1)
5
Fire/smoke damper
actuator
10
Limit switches linear
actuator
26
11
Combustion FAN 2
(Only BCH-100)
12
Ash drawer auger
The connections in the rear of the boiler and in the burner are plug-in screwless type. The cable fixing is done
by pressing the hole with a screwdriver until you feel that the spring is open. Then insert the cable and remove
the screwdriver. Check correct cable fixing.
Press the spring
Insert the cable
6.4. ROOM THERMOSTAT.
The boiler is supplied with default control heating set point temperature. However has the ability to connect
a room thermostat.
The signal from the room thermostat should be free of potential.
Risk of breakage of the control board.
The operation is set with parameter A07 (System Menu → Enables → Parameter A07)
0
1
2
A07
Assign the behaviour of
the room thermostat
3
4
Room thermostat disabled. The boiler regulates with the set point
temperature. Default parameter.
The thermostat is used to switch the boiler from RUN mode to
STANDBY mode.
The thermostat is used to switch off the circulating pump.
Note: For security reasons, if the boiler temperature exceeds 72°C,
the boiler keeps the pump on.
If the thermostat opens the circuit, the boiler enters mode
EXTINCTION. If the thermostat closes the circuit and the boiler is in
EXTINCTION mode you need to wait until the end of this phase and
the boiler will automatically start the IGNITION cycle.
The thermostat is used to switch the boiler from RUN mode to
MODULATION mode. In MODULATION mode the boiler works
constantly to its minimum power (P1).
6.5. BOILERS IN CASCADE.
The range of E-COMPACT boilers is prepared for multi-boiler systems in parallel (in a cascade).
Commissioning of each boiler is via release ON/OFF (thermostat terminals at the rear of the boiler).
The start-up sequence must be performed by any controller chosen from those available on the market, for an
output on / off potential free.
A
Room Thermostat
27
Wire 2 x 1 mm2
WITHOUT
VOLTAGE
ON / OFF
6.6. LAMBDA PROBE KIT.
As an option, a lambda probe can be installed on any BCH boiler. Its electronic board continuously measures
the quantity of oxygen in the flue gas, thus modifying motors and fans setpoint to achieve the finest
combustion.
The lambda probe kit includes the following
products:
- Lambda probe with connector
- Extension cable with connector
- Lambda Module Electronic card
- Communication cable to boiler main circuit board
- Electrical cable
For further information see the manual supplied with the kit Lambda.
6.7. ETHERNET DEVICE KIT.
As an option, the monitoring and remote control device EasyCheck can be installed on any boiler. This device
(thanks to its web server embedded) allows control and monitoring control of the boiler from the Internet,
either in local or remote network.
The remote monitoring kit includes the following
products:
DIN rail EasyCheck web control unit
Power cables
Communication cable to boiler main circuit
board
With this equipment you can connect remotely to turn on/off/unlock the boiler, display their status, make time
schedules, attendance messaging and recording operating hours and boiler temperatures.
28
For further information, see lambda probe kit and remote monitoring kit manuals.
29
7. CONTROL PANEL
7.1. DISPLAY.
Boiler temperature
Date and time
Chrono
Error code
Combustion power
Setpoint temperature
System state
Selection keys
Lea area
SELECTION KEYS
System ignition if pressed
for 3 seconds. Unlock.
Alarms Reset if pressed
for 3 seconds
DESCRIPTION
(To view, click on the display.
In dark, those that are active)
LED
Ignition resistance ON
Auger ON
SETTINGS menu
CUSTOMIZATION
menu
INFORMATION menu
Pump ON
3-way valve/Pump 2 ON
Fire/smoke damper actuator ON
V2V Exchanger cleaning solenoid valve ON
BROWSING KEYS
Back to Main frame
Burning plate cleaning linear actuator ON
Back to the upper level
Silo/hopper loading pellet motor ON
Up/down scroll
Increase/decrease value
Lack of pellet
Room thermostat contact opened
DHW request
Left/right scroll
Exit from menu saving
data
Exit from menu without
saving data
Press
Winter Mode
Summer Mode
for accessing to the information menu.
Information
Exhaust Press. [Pa]:
Oxygen [%]:
FreqAC [Hz]:
Information
Exhaust T. [°C]:
550
Boiler T. [°C]:
50
Buffer T. [°C]:
50
Safety T. [°C]:
42
WWa
Water Press. [mbar]:
2500
30
15
8
50
Values shown in the Main frame:
→
CHECK UP
→
IGNITION
→
STABILIZATION
→
RUN
→
MODULATION
→
STANDBY
→
EXTINGUISHING
→
OFF
→
BLOCK
System checking
Ignition (includes different phases). See section 9.5 Ignition mode
Flame stabilization
Run mode
Previous phase to Standby
Standby mode
Extinguishing mode
Boiler off
Boiler locked
7.2 STRUCTURE AND MANAGEMENT OF THE MENU
There are two main submenus, SETTINGS menu and CUSTOMIZATION menu. They are accessed by pressing
the icons
and
respectively.
Customization
Keyboard Setting
Display
System Menu
Settings
Thermostats
Summer-Winter
Chrono
Load
Reset Service
7.3. SETTINGS MENU (USER)
USER MENU
1
THERMOSTATS
2
SUMMER-WINTER
3
4
5
CHRONO
DESCRIPTION
Boiler thermostat
Buffer thermostat
Program:
Daily
Weekly
Weekend
LOAD
RESET SERVICE
For setting Boiler Thermostat set point
For setting DHW/Buffer Thermostat set point
For choosing season
Allows scheduling three ON/OFF time lapses for each program.
Burner auger load
Reset counters for the next ash removal
7.3.1. THERMOSTATS
This menu allows setting boiler thermostat and DHW/buffer thermostat set points.
Settings
Thermostats
Summer-Winter
Chrono
Load
Reset Service
Settings
Boiler Th.
Buffer Th.
Settings
Buffer Th.
Settings
Boiler Th.
60
55
55
60
25
35
80
40
80
7.3.2. SUMMER-WINTER
This menu allows choosing Summer / Winter operating mode.
In Winter mode, there is priority for Domestic Hot Water (DHW). When the DHW set point is reached, the
boiler returns to its previous state (RUN or STANDBY).
In Summer mode, when the DHW set point is reached, the boiler will be in STANDBY mode.
31
7.3.3 CHRONO
This menu allows scheduling boiler running hours.
Press
“Enable
CHRONO”
for
enabling/disabling chrono function.
Enabled function
Disabled function
To select the desired CHRONO program, press on one of these options:
- “Enable daily mode”: Individual schedule for each day of the week
- “Enable weekly”: The same schedule from Monday to Sunday
- “Enable week-end”: Two schedules: from Monday to Friday and from Saturday to Sunday
Monday
Tuesday
Wednesday
Thursday
Friday
Saturday
Sunday
From Monday to Sunday
From Monday to Friday
Saturday and Sunday
In each option up to three ON/OFF time lapses can be set. Examples:
Press on the left
right
arrows of the first line to scroll between the three programming options
available: “daily mode”, “weekly”, “week-end”
Press on the left
right
arrows of the second line to scroll days or group of days of the week, according
to the Programming modality selected before.
7.3.4. LOAD
This menu allows loading manually the burner plate from the auger
To enable the auger select ON. To stop the auger, select OFF.
Manual load is allowed only if the system is OFF
32
7.4. CUSTOMIZATION MENU (INSTALLER).
7.4.1. KEYBOARD SETTING.
This menu allows setting time and date, as well as language.
7.4.2.- DISPLAY/KEYBOARD MENU.
This option allows setting the display brightness.
7.4.3. SYSTEM MENU.
This menu allows entering into the Technical Menu. The access is protected by password (default password:
0000). The user must not modify the content of this menu.
Only the installer or a Service Agent are allowed to modify the content of this menu.
WES refuses to accept any responsibility in the event that unauthorized personnel enter in this
menu.
Customization
Auger
Auger 2
Fan 1
Fan 2
Fan 3
Customization
Thermostats
Extinguishing Th
Timer
Default settings
Enables
Customization
Delta
Pressure sensor
Vacuum regulator
Lambda
Counters
33
Customization
Outputs tests
Default parameters
1
2
3
4
5
6
7
8
9
10
11
12
System menu
Auger
Auger 2
Fan 1
Fan 2
Fan 3
Thermostats
Extinguishing Th
Timer
Default Settings
Enables
Delta
Pressure sensor
13
Vacuum Regulator
14
Lambda
15
16
17
Counters
Outputs Test
Default parameters
Description
Allows setting Auger ON seconds from the total Auger Period
Allows setting Auger2 ON seconds from the total Auger2 Period
Allows setting Combustion Fan 1 working values
Allows setting Combustion Fan 2 working values
Allows setting Exhaust Fan working values
Allows setting several thermostats working values
Allows setting Extinguishing thermostat working values
Allows setting working time associated to the different system stages
Allows setting default parameters
Enables/Disables different functions
Allows adjusting delta temperature and several thermostats hysteresis
Allows setting Pressure sensor threshold
Allows setting the parameters needed for adjusting the speed of the
exhaust fan in the presence of a vacuum sensor
Allows setting the parameters for running the boiler under Lambda
Regulator
Allows setting the counters for the system diagnose
Allows a manual test of the different outputs from the touch screen
Resets factory settings
The explanation for each parameter and its default value can be found of section 13.- “CONTROL
PARAMETERS”.
These parameters are factory preset, and can be modified only under manufacturer surveillance.
There are other parameters subject to be modified by the installer, depending on the type of installation. These
are described in the section 8.- “COMMISSIONING”.
MENÚ
15 – COUNTERS. Allows setting the counters for the system diagnose.
This menu shows the following counters:
Submenu
Total time
Functioning time
Run Mode time
Ignitions Nº
Failed Ign. Nº
Errors Nº
Cleaning Nº
Cleaning 2 Nº
Counters reset
Description
Boiler feeding total time
Boiler running total time: time into which at least one fan is working
Boiler actual heating time: time into which heating is effectively produced
(Run/Modulation)
Total number of ignition attempts
Failed number of ignition attempts
Total number of errors
Total number of burning plate cleanings
Total number of heat exchanger cleanings
Reset all counters
34
Error list: shows a list with the most recent errors.
1 – Er09 29/09/2014 09:29
2 – Er16 23/09/2014 13:34
3 – Er16 23/09/2014 09:29
The outputs test menu is detailed in the following chapter 8. COMMISSIONING
8. COMMISIONING.
The Commissioning of this appliance must be carried out by an Authorised Service Agent.
This is an essential condition for the keeping the warranty of this appliance.
Check that all instructions given in the 5.-Hydraulic installation and 6.-Electrical connections
chapters have been followed.
8.1. WATER FILLING.
In locations with hard water (>25ºfH, >250 ppm mg/l, >17.54ºe), the heating water must be softened. It avoids
the formation of limescales which can endanger the correct performance not only of the boiler, but also of the
rest of components (pumps, valves…)
Fill the circuit slowly with cold water, having the air vent opened, until a 1.5 bar pressure is reached.
8.2. BOILER PARAMETERS SETTING.
→ System Menu → Password
9
DEFAULT SETTINGS
Parameter
P35
Plumbing configuration
(Default settings)
P66
RS485 configuration
(Default settings)
(Shaded FACTORY DEFAULTS)
Value
0
2
3
4
Heating
Heating (Pump) + DHW Tank (3W-valve)
Heating (Pump) + DHW Tank (Pump)
Inertial puffer
0
Disabled
1
Enabled. Only if lambda probe is installed.
0
1
A07
Sets room thermostat
(Enables)
(See section 6.4)
2
3
4
A60
Set function double temperature
setpoint
(Enables)
Description
Room thermostat disabled. The boiler regulates with
the flow temperature.
Ambient thermostat is used to switch the boiler from
RUN mode to STANDBY mode then the setpoint is
reached.
Ambient thermostat is used to switch off the
circulation pump when the setpoint is reached.
Ambient thermostat is used to switch off the boiler
when the setpoint is reached.
Ambient thermostat is used to switch the boiler from
RUN mode to MODULATION mode then the setpoint
is reached.
0
Disabled
1
Enabled for plumbing configuration P35=2, P35=3
35
6
THERMOSTATS
Allows the setting of several thermostats
The boiler is supplied with the most usual temperature parameters for the correct operation of the boiler. However,
you can change various parameters such as the maximum and minimum temperatures of the boiler, the maximum
and minimum temperatures of the DHW tank, activation temperature of the anti-ice temperature, etc.
See full listing in section 13. LIST OF CONTROL PARAMETERS → THERMOSTATS.
16
OUTPUTS TEST
Allows a manual test of the different outputs when the boiler is OFF
FAN 1 (%)
FAN 2 (%)
FAN 3 (%)
AUGER 1 (burner, ON/OFF)
AUGER 2 (ashes, ON/OFF)
Igniter (ON/OFF)
Pump (ON/OFF)
3 way-valve (ON/OFF)
Output 1. Fire/smoke damper actuator (ON/OFF)
Output 2. Exchanger cleaning solenoid valve (ON/OFF)
Output 3. Burner plate cleaning actuator (ON/OFF)
Output 4. Hopper/silo auger motor (ON/OFF)
Output test lasts 60 seconds max. After that, the boiler returns to its previous mode.
8.3. FIRST PELLET LOAD.
First, it is necessary that the auger external silo is filled with pellets so that it is ready to supply the boiler. To
do this, perform the OUTPUTS TEST (SYSTEM MENU → OUTPUTS TEST → OUTPUT 4) as many times as
necessary for the auger begins to supply pellets towards the boiler.
After this step, it will be necessary to do the first pellet load, choosing “Load” option from the Settings menu.
This option activates the feeding auger of the boiler. For stopping the pellet load, pres OFF or wait 60 seconds.
Manual load is allowed only if the system is OFF. Repeat manual load until the burner plate has fuel enough.
Keep the manual load until there is enough
pellets in the combustion plate.
Repeat operation if necessary.
36
37
8.4. TURNING THE BOILER ON/OFF. UNLOCK.
The boiler is electrically supplied via a two
pole isolation switch with voltage
indicating light
Hold the
PROGRESS”.
icon for 3 seconds until an acoustic signal is heard. The display will show “IGNITION IN
The boiler will command automatically the performance of all its components, following the current settings.
For turning off the boiler (even in case of emergency stop), hold the
signal is heard. The display will show “EXTINGUISHING IN PROGRESS”.
icon for 3 seconds until an acoustic
In running mode, if the boiler detects an error, it will enter in EXTINGUISHING mode, and once this process
ends, it remains in BLOCK mode.
To unlock, hold the
icon for 3 seconds until an acoustic signal is heard. The display will show OFF.
8.5. MANUAL SELECTION POWER.
Settings
Power
Thermostats
Summer-Winter
Chrono
Load
The boiler is supplied with automatic power modulation operation,
but in the commissioning may be interesting to select the manually
operating power. This is controlled with the parameter A05
(System Menu → Enables).
A05 = 0: Manual selection of power.
A05 = 1: Caldera automatically modulates.
After changing the parameter A05, in the Settings Menu will appear
the option Power, where you can select the chosen power.
8.6. BOILER AND BUFFER TEMPERATURE SETPOINT.
The heating water set point is set as described in 7.3.1. That menu shows how to set both boiler and buffer
thermostats set points.
8.7. WINTER-SUMMER
This menu allows choosing WINTER/SUMMER operating mode.
38
In Winter mode, there is priority for Domestic Hot Water (DHW). When the DHW set point is reached, the
boiler returns to its previous state (RUN or STANDBY)
In Summer mode, when the DHW set point is reached, the boiler will go to STANDBY mode.
8.8. RESET SERVICE
Pressing RESET SERVICE, the ash drawer cleaning interval is reset. This time is defined in the parameter T70.
Once this time is done, the display will show a message to remind the user the need for cleaning the ash drawer.
By default, this parameter is set at 240 hours. The hours counter increases only when the boiler is in RUN mode
and MODULATION mode.
9. BOILER OPERATION
9.1. CIRCULATION PUMP CONTROL
The boiler controls the circulation pump of the following ways:

First start: To increase the speed of heating water in the boiler, the pump starts when the water
temperature of the boiler exceeds 35°C.

Operation safety: Regardless of the setting parameter A07, when the boiler temperature exceeds 72°C,
the boiler keeps the pump on.
9.2. FANS CONTROL
The boiler incorporates a fan to provide combustion air (FAN 1) and an exhaust fan in charge of generating the
necessary depression in the combustion chamber (FAN 3).
Regulation FAN 1 is carried out by the programming introduced in the boiler, in which the mode of functioning
of the fan is determined in the following phases:
Ignition - Stabilization - Power 1 to 5 - Second Ignition - Standby - Extinguishing - Cleaning
The FAN 3 operates automatically to keep the depression set points in the combustion chamber, in the
following phases:
Ignition - Stabilization - Power 1 to 5
This depression set point, is measured by a sensor located in the front of the boiler, behind the metal plate
which protect the electrical circuits.
Combustion
chamber (tube)
When the boiler incorporates the accessory
module LAMBDA, is the lambda probe which
determines the rate of operation of the FAN 1 to
obtain the desired percentage of oxygen in the
flue gas.
Room
(without tube)
39
9.3. AUGERS.
The boiler incorporates an auger driven by a gear motor, to introduce the pellet into the burner.
The auger regulation is managed by the program introduced in the boiler, which determining its time of
actuation in the following phases:
Ignition - Stabilization - Power 1to 5 - Second Ignition - Standby
At the rear of the boiler, the electrical connection of the hopper auger (not supplied with the boiler) it is
provided.
The operation of the external auger is carried out via the pellet detection sensor.
When it detects lack of pellet, the LED
swicht off and sends a signal to the
external auger for transporting pellet
to the boiler.
When the sensor detects the existence
of pellet, the yellow LED lights and the
external auger stops.
WES supplies different models of external augers adapted to the boiler. In the case of installing an auger not
supplied by WES, the parameter T23 should be regulated to prevent error in the boiler due to lack of pellets (
→ System Menu → Password → Times → T23).
-
T23: Delay in stopping the external auger once detected pellet (by default 2 sec.). If the
external auger provides less of pellet than burner auger, T23 has to be increased.
The maximum lack of pellet time until the boiler goes into alarm is 60 sec. (parameter T24).
9.4. FIRE/SMOKE DUMPER ACTUATOR.
The boiler incorporates a dumper actuator with return spring that works as smoke and flame security device.
The boiler governs the opening or closing of the dumper actuator according to the state of the boiler.
 Ignition-Stabilization-Power 1 to 5 - Second Ignition→ OPEN
 Standby - Extinguishing → CLOSED
 Error - Block → CLOSED
Any alarm detected by the boiler, or in case of power failure, the dumper actuator
automatically closes in tight manner the pellet supply duct, thereby preventing
back of fire and flue gas.
9.5. IGNITION MODE
In the IGNITION mode there are the following phases:
Display
CHECK UP
IGNITION
STABILIZATION
RUN
Phase
Open dumper actuator
Check Up
Preheating
Loading
Fix Ignition
Variable Ignition
Stabilization
Run
Description
Open the pellet feed valve.
Check the system
Preheating of the ignition element.
Pellet preload in combustion plate.
(Variable depending on the model)
First phase of the electric ignition.
Second phase of the electric ignition (5 attempts maximum)
Flame stabilization phase
Normal operation. Power modulation.
Time
60 sec.
10 sec.
90 sec.
T03
600 sec.
300 sec.
300 sec.
The Ignition element switch off once it enters in the VARIABLE IGNITION phase and the temperature in the
combustion chamber is above 70°C.
The STABILIZATION phase begins being under VARIABLE IGNITION and the temperature of the combustion
chamber exceeds 85°C.
40
RUN phase begins when the temperature of the combustion chamber exceeds 150°C, regardless of the stage
where you are at that moment.
9.6. RUN and STANDBY MODE.
In RUN mode, the boiler automatically modulates the working power to reach the temperature setpoint. The
modulation range is 5 steps power (P1 to P5), and its operation is determined by the configurable parameter
D08 (System Menu → DELTAS → D08), the default is 12.
When the boiler temperature is lower than (temperature setpoint - D08), the boiler operates at full power (P5).
From then it modulates its power, changing every 3°C (D08/4).
Examples:
Tª setpoint = 50°C
Tª setpoint = 75°C
D08 = 12°C
D08 = 12°C
Boiler Temp.
Power
Boiler Temp.
Power
< 38°C
P5
< 63°C
P5
38°C - 40°C
P4
63°C - 65°C
P4
41°C - 43°C
P3
66°C - 68°C
P3
44°C - 46°C
P2
69°C - 71°C
P2
47°C - 50°C
P1
72°C - 75°C
P1
D8 parameter values must be multiples of 4 (D08 = 4, 8, 12, 16, ...).
The higher the value, the boiler takes longer to reach the setpoint, but instead it will work more regular and
lower consumption because it will work most of the time at different powers of its maximum power.
41
The lower the value, the faster boiler reaches the set temperature, but if the heating system has low inertia,
the boiler can reach excessive temperatures.
When the boiler reaches the setpoint temperature, the boiler goes to MODULATION mode.
When the boiler exceeds 2°C (D10) the temperature setpoint, the boiler is switched to STANDBY mode. In
STANDBY mode the pellet feed valve is closed, so in this mode the boiler does not consume any fuel and the
temperature of the combustion chamber starts to drop.
In STANDBY mode, if the boiler temperature drops below (setpoint-2°C (D10)) (i.e. there is request for heating
or DHW), the boiler out of STANDBY mode and enters in NORMAL mode, modulating their power from the
minimum power (P1).
Run
Modulation
Standby
Power modulation
The boiler setpoint has been reached
The boiler temperature is 2°C over the setpoint
In STANDBY mode, if the temperature of the combustion chamber down below 100°C, the boiler will make the
final cleaning and remain in STANDBY mode. If the heat demand returns, the boiler will start automatically the
full cycle, including the PRELOADING phase.
If the heat demand returns when the temperature of the combustion chamber is above 150°C, the start is
performed omitting the ignition process, so it will enter directly in RUN mode, without performing the
precharge phase.
9.7. EXTINGUISHING and BLOCK MODE.
42
EXTINGUISHING mode is activated when the boiler is turned off manually or by scheduling. In these cases, the
boiler ends in OFF mode.
EXTINGUISHING mode is also activated when the boiler detects an alarm. In these cases, the boiler ends in
BLOCK mode and unlock necessary (see section 8.4).
After starting the EXTINGUISHING mode, the boiler can be automatically out of this state in the following cases:
After a power failure between 1 and 60 minutes, if the boiler was ON.
Manually by pressing the ON/OFF button on the boiler. It starts the IGNITION cycle.
9.8. DHW PRODUCTION
The E-COMPACT TWIST boilers are planned for production of DHW through a DWH Tank (see section 8. Default Settings), parameters P35=2 or 3, and A60 = 1 (System Menu → Enables).
With these parameters, the behaviour of the boiler is as follows:
If there is no demand for DHW, the boiler works with the set point manually entered (e.g.
50°C).
If there is demand for DHW, the boiler automatically changes its set point to 70°C, to satisfy
as quickly as possible the DHW set point manually entered (30-60°C) (See section 8.6.- Boiler
and Buffer temperature set point)
Once satisfied the demand for DHW:
 WINTER MODE: the boiler returns to its previous state (RUN or STANDBY)
 SUMMER MODE: the boiler is switched to STANDBY.
9.9. AUTOMATIC CLEANINGS
The boiler carries out various cleaning automatically:
PERIODIC CLEANING. Combustion plate cleaning by air.
CLEANING 1. Mechanical cleaning of combustion plate.
CLEANING 2. Final cleaning (mechanical for the combustion plate and by water in the exchanger
tubes).
PERIODIC CLEANING consists in putting to the maximum speed the combustion fan for a short period of time
(parameters T07 and T08).
CLEANING 1 consists in putting the cleaning nails into the plate to an intermediate position and simultaneously
the plate begins to rotate. Thus the ashes are swept to the ash drawer. The frequency and duration of the
cleaning is done differently depending on the model of the boiler (T27 and T28 parameters).
CLEANING 2 is performed in these circumstances:
Boiler in EXTINGUISHING mode and temperature of the combustion chamber below 80°C (TH01).
After the cleaning, the boiler is in OFF mode.
Boiler in STANDBY mode and temperature of the combustion chamber below 100°C (TH28). After the
cleaning, the boiler remains in STANDBY mode.
The final cleaning comprises a mechanical cleaning of the combustion plate, similar to the CLEANING 1
described above, but in this case the nails rotate to the end position, so that, they also clean the exit holes of
the primary combustion air.
43
The positioning of the nails is controlled by the
limit switches of the linear actuator located on
the burner.
During CLEANING 2, cleaning exchanger tubes solenoid opens and allows the water flow for a time T54 in
seconds (configurable parameter System Menu →Time → T54). Water flows inside the tubes and it is evacuated
to the drain.
In the case of BCH-100 model, the activation of the solenoid valve is associated to the CLEANING 1.
10. CLEANING AND MAINTENANCE
Read carefully the following instructions in order to avoid unnecessary risks.
The internal cleaning of the boiler must be performed at least once a year by qualified
personnel.
The metallic parts must be mechanically cleaned with a NON METALLIC brush.
Risk of burns. The servicing must be done with the boiler OFF and cold. Warning: even in
these conditions ashes may still be hot.
Risk of electric shock. The servicing must be done with the boiler OFF.
According to the legislation, it is mandatory to keep a servicing logbook.
E-COMPACT boilers are automatic boilers, but for safety, smooth performance and for extending its useful
life, the following maintenance operations, as legislation specifies, are necessary:
TASK
Check the status of pellet storage
Visual inspection of the boiler
Ash cleaning and removal
Review the security elements
Cleaning the burner
Checking and cleaning, if necessary, smoke circuit, boiler flue circuit, flue gas pipe and chimney
Checking tightness seal between burner and boiler
Review the status of thermal insulation
Review automatic control system
Review the expansion vessel
Review of water treatment systems
Review DHW preparation system
Checking for pipes tightness
44
PERIODICITY
weekly
weekly
monthly
monthly
yearly
yearly
yearly
yearly
yearly
yearly
yearly
yearly
yearly
10.1. COMBUSTION CHAMBER AND HEAT EXCHANGER TUBES CLEANING.
Access to the top of the boiler removing
the upper housing and insulation.
Remove the thermocouple and the
boiler cover by releasing the four nuts.
Before cleaning with water, aspires the
ash accumulated on top of the boiler
and inside the combustion chamber.
Check the effectiveness of water
cleaning system by performing an
OUTPUT TEST (Output2) as described in
section 8.2. In case some Injector were
blocked or flow water is diverted,
replace the threaded injector by a new
one.
Remove the cleaning system through
the loose nut. Remember to shut off
the water supply before removing the
toroid.
The flue tubes are cleaned individually introducing inside each tube a 25 mm diameter water hose connected
to the water network. Let the water run for a few seconds inside each tube to flush any solid waste.
Cleaning water with waste are discharged through the condensate drain trap.
10.2. BURNER CLEANING.
Remove the supply hose pellet
and the burner cover to access the
screw of the ignition resistance.
45
-
Remove the heater element to
release the burner grate.
-
Remove the grate by the front
door.
-
Aspire the ash.
-
Clean the burner grate.
To remove the burner inside the boiler proceeds as follows:
Remove the fixing screws and remove the
burner by the lateral door.
Please assemble in reverse order.
46
The heater element must be correctly positioned and fixed with the screw.
Check the correct closure of the connecting piece to the burner of the secondary air nozzle.
11. ASH REMOVAL
The ash volume depends on the number of boiler running hours, as well as the quality of the
used pellet.
Ash removal must be carried out complying local legislation in force.
Pay attention during emptying the ashes, as they may still be hot. In this case you must wait
for them to cool, since there is risk of fire.
Protective equipment: gloves, goggles, mask.
Ashes are a good thermal insulator. It is advisable not completely empty the drawer
The boiler will show the message "CLEANING" in the display to indicate empty signal of the ash box. This
message is displayed after a time T70 programmable according to the boiler output. After emptying the drawer,
enter
User Menu → Reset Service. Thus the counter (see section 8.8) restarts.
The boiler has enough space to store the ash produced for more than a month of normal operation, so that
cleaning and removal of ashes are to be carried out once a month.
The BCH-25 /... / 100 models have an
automatic system that extracts the ashes
from the burner bottom and place them in
an ash box, which can be emptied without
stopping the boiler.
To remove the ash box from its support
base, first enter the bottom lock sheet.
THIS SHEET MUST BE OUT IF THE BOILER IS
RUNNING
During operation of the boiler, the base of the ash box should be filled with ashes to prevent
the exhaust fan can absorb air through the auger. In the commissioning of the boiler, when
47
there are no ashes produced, it is necessary to fill the base of the case with the bag of
vermiculite supplied with the boiler.
48
12. LIST OF ERRORS. CAUSES AND ACTIONS TO BE TOKEN.
Code
Er01
Er03
Er04
Er05
Causes an actions to be taken
Error activation Safety thermostat
The water temperature in the boiler has reached 100 ° C. The boiler enters into EXTINCTION mode.
Let the boiler to cool and make a visual inspection. A manual reset is needed, by pressing until you hear a "click" the switch
located under the cap next to the touch screen. This reset will occur when the boiler temperature has dropped below 90˚C.
Possible causes and actions to be taken:
No water flowing through the boiler circuit. Check manual valves and filters in the circuit. Check the connection and
operation of the pump. Contact your installer.
Boiler temperature probe not connected, badly placed or defective. Check the placement and connection of the probe.
Contact Service Agent.
Existence of air in the boiler circuit. Check the automatic air vent.
Heating circuit without pressure. Contact your installer.
Extinguishing not foreseen for low temperature at the combustion chamber
The boiler moves to EXTINCTION mode because of low temperature at the combustion chamber.
Possible causes and actions to be taken:
Lack of pellets in the auger. Check for fuel. Make a manual auger load (LOAD command in user menu). Contact your
installer.
Pellet feed auger motor stopped. Check the power supply. In case of motor failure, contact your installer or Service
Agent.
Igniter failure. Check resistance (211 Ω / 230 V). In case of failure contact your installer or Service Agent
Reading Error at combustion chamber temperature probe. Verify that flame is placed in the combustion chamber. If so,
combustion chamber temperature probe is not measuring correctly. Stop the boiler and contact your installer or Service
Agent.
Combustion chamber temperature probe no connected, badly placed, or defective. Check the placement and connection
of the probe. Stop de boiler and contact your installer or Service Agent
Water over-temperature
The water temperature in the boiler has reached 95˚C. The boiler enters into EXTINCTION mode.
Let the boiler to cool and make a visual inspection.
Possible causes and actions to be taken:
- No water flowing through the boiler circuit. Check manual valves and filters in the circuit. Check the connection and
operation of the pump. Contact your installer.
- Boiler temperature probe not connected, badly placed or defective. Check the placement and connection of the probe.
Contact Service Agent.
- Existence of air in the boiler circuit. Check the automatic air vent.
Heating circuit without pressure. Contact your installer.
Combustion chamber over-temperature
The combustion chamber has reached 890˚C. The boiler enters into EXTINCTION mode.
Possible causes and actions to be taken:
Faulty performance of auger / incorrect settings. Stop the boiler and contact your installer or Service Agent.
Flue gas over-temperature in chimney
SECURITY message appears on the display. The flue gas sensor exceeds 100°C.
Er09
Er10
Er11
Possible causes and actions to be taken:
The exchanger tubes cleaning system by water is not being effective. Check the valves located upstream of the
solenoid cleaning valve. Stop de boiler and contact your installer or Service Agent
Low water pressure
Water pressure is below 0.5 bar (500 mbar).
Possible causes and actions to be taken:
Water leakage in the heating circuit. When the circuit is cold, re-pressure and purge the circuit. If the pressure drops
again contact your installer.
High water pressure
Water pressure is over 3 bar (3000 mbar).
Possible causes and actions to be taken:
- Safety 3 bar pressure relief valve not installed or defective. Contact your installer.
- Expansion vessel defective or improperly sized. Contact your installer.
Real time clock error
Possible causes and actions to be taken:
- Battery failure of the control board. Contact your installer or Service Agent.
49
50
Er12
Er15
Er16
Er18
Er22
Er34
Er35
Ignition failed
The boiler has not been able to ignite a flame after several programmed attempts.
Possible causes and actions to be taken:
- Igniter failure. Check resistance (211 Ω / 230 V). In case of failure contact your installer or Service Agent
- Absence of pellets in the combustion plate. Make a manual load by selecting LOAD at User menu.
Air obstruction at primary / afterburning air conducts. Clean conducts.
Lack of voltage
The boiler has stopped working because of power failure.
Possible causes and actions to be taken:
Unlock the boiler and return to normal operation.
RS485 lambda probe communication error
The main control board does not communicate with the board of the lambda probe.
Possible causes and actions to be taken:
- Check both boards voltage (LEDs ON). Faulty fuses. Contact your installer or Service Agent.
Check RS485 communication cable. For replacement contact your installer or Service Agent.
Extinguishing for lack of pellet
The sensor pellet detects unavailability of pellet for feeding the boiler.
Possible causes and actions to be taken5
- Fault in auger/vacuum feeding system. Contact your installer or Service Agent.
Sensor pellet faulty. Contact your installer or Service Agent.
Lambda regulator error
Lambda probe regulator has detected an error and blocks the boiler.
Possible causes and actions to be taken:
For disabling lambda regulator error warning modify the parameter P60 = 0 (System Menu → Lambda → Control → P60).
Contact your installer or Service Agent.
Depression below the minimum threshold
Combustion chamber depression has dropped below preset minimum threshold (15 Pa).
Possible causes and actions to be taken:
- Fault in smoke exhaust fan. Contact the Service Agent.
- Pressure sensor defective. Contact the Service Agent.
- Chamber inspection door opened. Close the door.
Pressure sensor or its tubule incorrectly installed. Connect the tubule / place the sensor in the proper position.
Depression above the maximum threshold
Combustion chamber depression has risen over preset maximum threshold (200 Pa).
Possible causes and actions to be taken:
- Pressure sensor defective. Contact the Service Agent.
Excessive draft in the chimney. Place a flue draft regulator. Contact the Service Agent.
NOTE: Errors EL00 to EL08 correspond to boilers equipped with lambda probe. Refer to the manual
provided with the lambda probe.
Other error messages
End Pellet
Prob
Service
Lack of pellet error
The sensor pellet detects unavailability of pellet for feeding the boiler.
Possible causes and actions to be taken:
- The boiler runs out of fuel. Ask for more fuel to your supplier
Fault in feeding pellet to the burner. Check the feeding system (auger or vacuum)
Temperature probe error
When CHECK-UP phase, if one or more probes show 0 °C value, open or short circuit. It does not cause an error; it
is only a display message.
Possible causes and actions to be taken:
Check probes connection. In case of faulty probe, request replacement by contacting the Service Agent
Servicing message
The interval (240 hours in RUN mode) since last emptying of the ash box is fulfilled.
Possible causes and actions to be taken:
Empty the ash box. Restart the counter doing the RESET SERVICE in the user menu.
51
13. LIST OF CONTROL PARAMETERS.
Code
ENABLE
A05
Value
0
1
0
1
A07
2
3
4
Description
Default value
Manual management of the combustion system
Automatic management of the combustion system
External room thermostat input is disabled
External room thermostat is used to switch boiler to STANDBY mode when the set point
is reached.
External room thermostat is used to switch off the circulation pump when the set point
is reached.
External room thermostat is used to switch off the boiler when the set point is reached
External room thermostat is used to switch the boiler to MODULATION mode when the
set point is reached.
1
0
A10
1
From Extinguishing state it’s possible to go directly to CHECK UP
1
A13
1
If boiler temperature is higher than (setpoint+2°C) after time T55, the boiler enters into
STANDBY mode.
1
A14
1
Enable Pressure Sensor Error management
1
A16
1
Enable Power Changing delay
1
A20
0
Water pressure Sensor Configuration Type A
0
A26
0
Exit from STANDBY if there aren’t the conditions
0
A27
1
Extinguishing in STANDBY enable. TH28 and T13 parameters are used.
1
A29
1
Exit from STANDBY if a sanitary water demand occurs enabled.
1
A30
1
Vacuum Regulator on Exhaust Fan Speed Enabled.
1
A60
1
Double temperature set point function enabled for schemes with P35=2, 3.
1
DEFAULT SETTINGS
P02
Maximum number of ignition attempts
5
P03
Number of power steps
5
P04
Number of combustion recipes
P05
Auger 1 period
P09
Pellet level sensor configuration
0
P14
Fan 1 min speed
20
P27
Fan 3 min speed
20
P35
Hydraulic configuration (see section 5.3)
2
P61
OUT1 configuration. Fire/smoke dumper actuator.
1
P62
OUT2 configuration. Cleaning 2 (final cleaning)
13
P63
OUT3 configuration. Cleaning 1 (burner)
4
P64
OUT4 configuration (external auger)
2
P66
P78
1
s/model
0
RS485 communication with lambda module disabled
1
RS485 communication with lambda module enabled
1
Safety function with smoke probe enabled.
0
1
THERMOSTATS (Thermostat hysteresis are shown as IHxx in menu)
TH01
Boiler off
80 (-2)
TH02
Ignition resistance off
70 (+2)
TH03
Pre-Extinguishing for low chamber combustion temperature
100 (-2)
TH06
Move to STABILIZATION Mode
85 (+2)
52
TH07
Move to MODULATION Mode
850 (+20)
TH08
Flue gas Safety
890 (+20)
TH09
Bypass Ignition (move to RUN)
150 (+5)
TH18
Anti-freeze
TH19
Circulation pump ON
35 (+2)
TH20
DHW min temperature
40 (+2)
TH21
DHW max temperature. Automatic set point for high temperature operation.
72 (-2)
TH24
Boiler water temperature
60
TH25
Boiler safety thermostat
95 (+2)
TH26
Boiler min range thermostat
25
TH27
Boiler max range thermostat
80
TH28
Extinguishing exhaust temperature in STANDBY
100 (-5)
TH29
Buffer thermostat
45 (±2)
TH30
Differential thermostat
3 (±1)
TH35
Extinguishing exhaust temperature Power 1
200
TH36
Extinguishing exhaust temperature Power 2
300
TH37
Extinguishing exhaust temperature Power 3
400
TH38
Extinguishing exhaust temperature Power 4
450
TH39
Extinguishing exhaust temperature Power 5
500
TH55
Min. value for buffer thermostat
30
TH56
Max. value for buffer thermostat
60
TH78
Flue gas safety temperature
5 (-0)
100 (+2)
DELTA TEMPERATURE
D01
Delta temperature to exit from STABILIZATION phase (to add to TH06)
50
D08
Delta temperature for power modulation in proportional combustion management
8
D10
Delta temperature for moving from MODULATION to STANDBY
2
TIME
T01
Check-up Cleaning time (air sweeping)
10 s.
T02
Preheating phase
90 s.
T03
Auger preload
s/model
T04
Fixed ignition
600 s.
T05
Variable ignition
300 s.
T06
Stabilization
300 s.
T07
Periodic cleaning repetition (air sweeping)
60 m.
T08
Periodic cleaning duration
15 s.
T09
Safety thermostat delay
60 s
T10
Safety pressure switch delay
60 s.
T11
Exit from STANDBY delay
10 s.
T13
Minimum Extinguishing time at Standby
60 s.
T14
Pre-Extinguishing
900 s.
T15
Safety Extinguishing
60 s.
T16
Final cleaning time
60 s.
T17
Power shifting delay
30 s.
T18
Power shifting delay at IGNITION
30 s.
T22
Entering time delay at STANDBY
10 s.
T23
Pellet tank loading time after minimum level signal
2 s.
T24
Pellet tank loading time for reaching the minimum level
60 s.
53
T25
Delay on closing from pellet sensor signal
0 s.
T26
Delay on opening from pellet sensor signal
0 s.
T27
Cleaning system delay on RUN mode
60 m.
T28
Cleaning system time
20 s.
T50
Fired/smoke dumper actuator open time
60 s.
T54
Cleaning engine 2 ON at the end of Extinguishing
20 s.
T55
Waiting time to go in Standby from Modulation
10 s.
T68
Exit delay from Security function
T70
Cleaning Message Timer
10 s.
240 h.
WATER PRESSURE SENSOR THRESHOLD
S01
Pressure sensor minimum threshold
500 mbar
S08
Pressure sensor maximum threshold
3000 mbar
COMBUSTION CHAMBER DEPRESSION SENSOR
PR 00
IGNITION mode set point
60 Pa
PR 01
STABILIZATION mode set point
PR 02
Power 1 set point
s/model
PR 03
Power 2 set point
s/model
PR 04
Power 3 set point
s/model
PR 05
Power 4 set point
s/model
PR 06
Power 5 set point
s/model
PR 20
IGNITION mode depression delta
3 Pa
PR 21
STABILIZATION mode depression delta
3 Pa
PR 22
Power 1 depression delta
3 Pa
PR 23
Power 2 depression delta
3 Pa
PR 24
Power 3 depression delta
3 Pa
PR 25
Power 4 depression delta
3 Pa
PR 26
Power 5 depression delta
3 Pa
PR 70
Min depression threshold alarm
5 Pa
PR 90
Max depression threshold alarm
200 Pa
30 Pa
T69
Depression sensor. Regulation time
5 s.
T70
Depression sensor. First regulation waiting time
60 s.
T80
Delay after Depression Alarm
60 s.
PARAMETER LIST OF LAMBDA REGULATOR
Parameter
Description
Value
TH50
Lambda ON thermostat set
200°C (± 4)
TH51
Lambda ON thermostat min.
200°C (± 4)
TH52
Lambda ON thermostat max.
850°C (± 20)
P66
Communication RS485 with Lambda module disabled
Communication RS485 with Lambda module enabled
0
1
T62
O2 monitoring interval
10 sec.
T63
Maximum time regulator out of range
10 sec.
T64
Delay for the first regulation
20 sec.
P58
Outputs order management
13
P60
Lambda regulator error management
P67
FAN 1 regulation direction
0/1/2
0
54
P68
FAN 2 regulation direction
0
P69
Auger regulation direction
1
P70
Outputs regulation management
1
UC81
FAN 1 regulation step
1%
US81
FAN 2 regulation step
--
C81
Auger regulation step
0,1 sec.
The parameters that define the behaviour of the auger and fans are:
Ignition
Stabilization
Power 1
Power 2
Power 3
Power 4
Power 5
Second Ignition
Standby
Extinguishing
Periodic Cleaning
Ignition.
Min. speed vacuum regulator
Ignition.
Max. speed vacuum regulator
Burner
Auger
C01
C02
C03
C04
C05
C06
C07
C08
C09
---
Ashes
Auger
C21
C22
C23
C24
C25
C26
C27
C28
C29
C30
--
---
FAN 1
FAN 2
FAN 3
UC01
UC02
UC03
UC04
UC05
UC06
UC07
UC08
UC09
UC10
UC11
US01
US02
US03
US04
US05
US06
US07
US08
US09
US10
US11
UA01
UA02
UA03
UA04
UA05
UA06
UA07
UA08
UA09
UA10
UA11
--
--
--
UA41
--
--
--
UA42
Speed min. / max
% O2
Power
Burner
Auger
FAN 1
FAN 2
Value
TOLERANCE
P1
C43 / C63
UC43 / UC63
US43 / US63
oO3
o23
P2
C44 / C64
UC44 / UC64
US44 / US64
oO4
o24
P3
C45 / C65
UC45 / UC65
US45 / US65
oO5
o25
P4
C46 / C66
UC46 / UC66
US46 / US66
oO6
o26
P5
C47 / C67
UC47 / UC67
US47 / US67
oO7
o27
If the lambda probe kit is installed, please see the manual provided with lambda probe kit.
55
NOTES:
56
Head Office: WoodCo Energy SA,
Rte de Courgenay 38, 2900 Porrentruy, Switzerland.
t: +41 324668008
WoodCo Energy Ireland
Unit D Cahir Business Park, Cahir, Co. Tipperary, Ireland.
t: +353 52 7445330
w: www.woodco-energy.com
e: info@woodco-energy.com
57