E-Compact Slim_Manual_v1 1

E-Compact Slim_Manual_v1 1
Installation & Operation
Manual
E-COMPACT 18 Slim / E-COMPACT 15
Wood Pellet Boiler
woodenergysolutions.co.uk
V.1.0 09/13
ECOMPACT Slim
Contents
Contents
Page 1
1. Introduction
2. Warnings and Guarantee / Warranty Information
2.1
Safety Instructions
2.2
Operating Warnings
2.3
Guarantee / Warranty Information
2.3.1 Limitations
2.3.2 Exclusions
2.4
The Clean Air Act 1993
3. Pre-Installation Considerations
3.1
Pellets
3.2
Considerations for Installation
3.3
Operating Area
3.4
Connection to the Flue
3.5
Operating Problems Caused by Draft Defects in the Flue
3.6
Plumbing Connections
4. Installation and Assembly
4.1
Unpacking
4.2
Preparing the Base
4.3
Electrical Connections
4.4
Control Panel Schematic
4.5
Water Connections
5. Control System
5.1
Error Codes
6. Commissioning
7. Boiler Operation and Maintenance
8. Technical Data
9. Service Log
2
3
3
4
4
5
5
6
7
7
8
9
10
11
12
13
13
14
15
16
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19
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33
Version 1.0 20/09/2013
woodenergysolutions.co.uk
© Wood Energy Solutions
ECOMPACT Slim
Introduction
Page 2
1.
INTRODUCTION
Dear Customer,
We wish to thank you for choosing this ECOMPACT pellet boiler product from Wood Energy
Solutions (WES).
In order to get the best performance from your appliance we recommend that you read this
booklet carefully before lighting the appliance for the first time.
While thanking you again, may we remind you that the appliance MUST NOT be used by children,
and that they must always be kept at a safe distance from it!
Revisions to the publication
In order to improve the product, to keep this publication up to date the manufacturer reserves the
right to make modifications without any advance notice. Any reproduction, even in part, of this
manual without the consent of the manufacturer is prohibited.
Care of the manual and how to consult it
• Take good care of this manual and keep it in a place which can easily and quickly be reached.
• If this manual should be lost or destroyed, or if it is in poor condition, ask for a copy from your
retailer or directly from the manufacturer, providing product identification data.
• Information which is essential or that requires special attention is shown in bold text.
• Italic text is used to call your attention to other paragraphs in the manual or for any additional
clarifications.
ATTENTION
This warning sign indicates that the message to which it
refers should be carefully read and understood, because
failure to comply with what these notices say can cause
serious damage to the boiler and put the user's safety at
risk.
INFORMATION
This symbol is used to highlight information which is
important for proper boiler operation. Failure to comply
with these provisions will compromise use of the boiler
and its operation will not be satisfactory.
OPERATING SEQUENCES:
Indicates a sequence of buttons to be pushed to access
menus or to make adjustments.
MANUAL
Indicates that you should carefully read this manual or the
related instructions.
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Warnings & Guarantee Conditions
ECOMPACT Slim
Page 3
2.
WARNINGS AND GUARANTEE /WARRANTY INFORMATION
2.1. SAFETY INSTRUCTIONS
• Installation of the boiler, making the electrical connections, checking its
operation, and maintenance are all tasks which should be carried out by qualified
and authorised personnel.
• Install the boiler in accordance with the regulations in force in your local
area, region and country.
• For the correct use of the appliance and to prevent accidents, the instructions
given in this booklet must always be followed.
• Use, adjustment and programming must be carried out by adults. Errors or
incorrect settings may cause hazardous conditions and/or poor operation.
• Before beginning any operation, the user, or whoever is preparing to operate on
the appliance, must have read and understood the entire contents of this
instruction booklet.
• All responsibility for improper use is taken entirely by the user and such use
relieves WES of any civil or criminal responsibility.
• Any kind of tampering or unauthorised substitution of non-original spare parts can
be hazardous for the safety of the operator and relieves WES of any civil or criminal
responsibility.
• Most of the surfaces of the appliance are extremely hot (the boiler door, the
handle, smoke discharge pipes, etc.). Avoid coming into contact with these parts,
without adequate protective clothing or suitable implements such as gloves with
thermal protection or implements which keep the hands cool.
• Carefully explain this hazard to elderly people, disabled people and particularly to
all children, keeping them away from the appliance while it is running.
• Under no circumstances should the appliance be run with the door open.
• Do not touch the appliance with wet hands, in view of the fact that it is an
electrical appliance.
• Before carrying out any cleaning or maintenance operation, make sure in advance
that the appliance is isolated from the mains electricity supply, by removing
the mains isolator fuse.
• The appliance must be connected to an electrical system which is equipped with an
earth conductor, as laid down in directives 73/23 EEC and 93/98 EEC.
• The fuse must be of adequate rated capacity for the stated electrical power of
the appliance.
• Incorrect installation or faulty maintenance (not conforming to the requirements
set out in this booklet) can cause harm to people, animals or property. In such
cases WES is absolved from any civil or criminal responsibility.
Adhesives sealants and paints used in the manufacture of the product are cured and
present no known hazards when used in the manner for which they were intended.
The appliance contains no asbestos.
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Warnings & Guarantee Conditions
ECOMPACT Slim
Page 4
2.2. OPERATING WARNINGS
• Shut the appliance down in the event of a breakdown or bad running.
• Pellets must not be fed manually into the burner.
• Accumulated un-burnt pellets in the burner after repeated failed ignitions must be
removed before re-lighting.
• Do not wash the inside of the heat exchanger with water.
• Do not wash the appliance with water. The water could get inside the unit and
damage the electrical insulation and cause electric shocks.
• Do not put any fuel, other than wood pellets, in the hopper .
• Install the appliance in a location which is suitable for fire-fighting, and equipped
with all services such as air and electricity supply and provision for discharging
combustion gases.
• If there is a fire in the flue pipe, extinguish the appliance, disconnect it from the
power supply and never open the door. Then contact the competent authorities.
• If the appliance is in storage, it should be in a place that is free of damp, and it
should not be exposed to extremes of temperature.
• It is inadvisable to base the appliance directly on a floor (if located indoors), and if
the floor is made of flammable material, it must be suitably insulated.
• Do not light the appliance with flammable materials if the ignition system breaks
down.
INFORMATION
• In case of any problems, get in touch with your dealer, or a qualified engineer
authorised by WES, and if a repair is necessary, insist on the use of original spare
parts.
• Use only the fuel recommended by WES (ENplus-A1) may be used with this
appliance.
• Periodically check and clean the smoke outlet ducts (connection to the flue pipe).
• Accumulated un-burnt pellets in the burner after repeated failed ignitions must be
removed before lighting.
• Always keep the cover of the fuel hopper closed.
• Keep this instruction manual carefully because it must stay with the appliance
throughout its working life. If the appliance is sold or transferred to another user,
always make sure that the booklet goes with the product.
• If it gets lost, ask WES or your authorised dealer for another copy.
2.3. GUARANTEE CONDITIONS
WES offers the following warranties on this appliance :
• Leaks in the heat exchanger – 5 years
• Faulty electrical components (motors, fan, controller) – 2 years
• Pump, Ignition Element – 1 year
• External Casing – 2 years – except corrosion due to scratches or damage.
from the date of first ignition of the appliance as proved by a valid Commissioning
Report which gives the name of the Installer / Commissioning Engineer and the
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Warnings & Guarantee Conditions
ECOMPACT Slim
Page 5
date on which the commissioning took place. The guarantee is conditional on the
Commissioning Report being filled in and returned to the Manufacturer within 10
days, and requires that the product be installed and commissioned by an approved
WES installer according to the detailed instructions given in the instruction booklet
supplied with the product.
The term 'guarantee' is to be understood to denote the free of charge replacement
or repair of parts recognised to have been defective at the start by reason of
manufacturing defects.
2.3.1. Limitations
The above guarantee does not cover parts subject to normal wear such as gaskets, fibre board on
doors. Damage to the burner pot, baffles and ash pan is not covered if inserted incorrectly . The
replacement parts will be guaranteed for the remainder of the guarantee period starting from the
date of commissioning of the product.
2.3.2. Exclusions
The warranty excludes all ancillary products associated with the system ( e.g. flue pipes, external
circulation pumps, bulk hoppers and augers, plumbing and electrical system.). The warranty does
not cover Third Party damage to the product or damage caused by the plumbing (an example
would be an inappropriately sized expansion vessel) or electrical system. Warranty does not cover
issues arising from pellets that do not conform to Enplus-A1
Recommendations advised to the Customer to be carried out during commissioning must be
completed and advised to your local Dealer in order to validate the warranty.
The requirements for the flue installation, particularly in relation to draught, is the responsibility
of the system owner. Compliance with Local Building Regulations must be adhered to.
The warranty does not cover misuse of the product or sabotage.
Any consequential loss or damage caused by the failure of a component on this product is not covered.
WES refuses to accept any responsibility for any damage which may be caused, directly or
indirectly, by persons, animals or things in consequence of the failure to observe all the
prescriptions laid down in the instruction booklet, especially those concerning warnings on the
subject of installation, use and maintenance of the appliance.
Damage caused by transport and/or handling is excluded from the guarantee.
The guarantee will be invalidated in the event of damage caused by tampering with the appliance,
atmospheric agents, natural disasters, electrical discharges, fire, defects in the electrical system,
and caused by lack of, or incorrect, maintenance in terms of the manufacturer's instructions.
CLAIMS UNDER THE GUARANTEE
The request for action under the guarantee must be addressed to the
Dealer/Retailer, who will forward the claim to WES's technical assistance service.
WES DECLARES THAT THE APPLIANCE WHICH YOU HAVE PURCHASED COMPLIES
WITH EEC DIRECTIVE 2004/108 EC and 2006/95/EC and SUCCESSIVE
AMENDMENTS
WES refuses to accept any responsibility in the event that the appliance or any
other accessory has been improperly used or modified without authorisation.
For all replacement of parts, only original WES spare parts must be used.
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Warnings & Guarantee Conditions
ECOMPACT Slim
Page 6
“The Clean Air Act 1993 and Smoke Control Areas”
Under the Clean Air Act local authorities may declare the whole or part of the district of the
authority to be a smoke control area. It is an offence to emit smoke from a chimney of a building,
from a furnace or from any fixed boiler if located in a designated smoke control area. It is also an
offence to acquire an "unauthorised fuel" for use within a smoke control area unless it is used in
an "exempt" appliance ("exempted" from the controls which generally apply in the smoke control
area).
The Secretary of State for Environment, Food and Rural Affairs has powers under the Act to
authorise smokeless fuels or exempt appliances for use in smoke control areas in England. In
Scotland and Wales this power rests with Ministers in the devolved administrations for those
countries. Separate legislation, the Clean Air (Northern Ireland) Order 1981, applies in Northern
Ireland. Therefore it is a requirement that fuels burnt or obtained for use in smoke control areas
have been "authorised" in Regulations and that appliances used to burn solid fuel in those areas
(other than "authorised" fuels) have been exempted by an Order made and signed by the
Secretary of State or Minister in the devolved administrations.
Further information on the requirements of the Clean Air Act can be found here :
http://smokecontrol.defra.gov.uk/
Your local authority is responsible for implementing the Clean Air Act 1993 including designation
and supervision
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Pre-Installation Considerations
ECOMPACT Slim
Page 7
3. Pre-Installation Considerations
3.1. Pellets
Wood pellets are manufactured by hot-extruding compressed sawdust
which is produced during the working of natural dried wood. The
compactness of the material comes from the lignin which is contained
in the wood itself, and allows the production of pellets without the use
of glues or binders.
The market offers different types of pellet with characteristics which
vary depending on what mixture of woods is used. The diameter varies
between 6 mm and 8 mm, with a standard length in the range 5 mm to
30 mm. Good quality pellets have a density which varies between 600
kg/m3 and 750 kg/m3, with a moisture content which varies from 5%
to 8% by weight.
Besides being an ecological fuel (exploiting timber residues to the
maximum and achieving cleaner combustion than is possible with fossil
fuels), pellets also have technical advantages. While good-quality
timber has a calorific power of 4.4 kW/kg (with 15% moisture,
therefore after about 18 months' seasoning), the equivalent figure for
pellets is 4,9 kW/kg.
To ensure good combustion, the pellets must be stored in an area that
is free of humidity and protected from dirt. The pellets are usually
supplied in 10 kg. bags, so storing them is very convenient.
Good quality pellets ensure good combustion, thus lowering the
emission of harmful agents into the atmosphere.
The poorer the quality of the fuel, the more
frequently will intervention be necessary for
cleaning the internal parts, such as the grate and
the combustion chamber.
The main certification of quality for pellets in the European market are
Enplus-A1 these ensure respect of:
Calorific power: 4.9 kW/kg
Water content: max 10% of weight
Percentage of ashes: max 0,5% of weight
Diameter: 6mm
Length: max 30mm
Contents: 100% untreated wood, with no added bonding
substances (bark percentage 5% max)
Packaging: in sacks made from ecologically compatible or
biologically decomposing material.
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Pre-Installation Considerations
ECOMPACT Slim
Page 8
WES recommends using certified fuel in its appliances to ENplus-A1.
The use of fuel of inferior quality or not conforming to the specification given
above compromises the running of your appliance and can therefore lead to the
termination of the guarantee and of the manufacturer's responsibility for the
product.
WES domestic pellet appliances run exclusively on pellets with a diameter of 6
mm. It is recommended that the brand of pellets used during commissioning are
used during normal operation. If you change you pellet supplier or brand a recalibration may be necessary and a call-out charge will apply.
The E-Compact 15 has been recommended as suitable for use in smoke control
areas when burning Enplus-A1 wood pellets
3.2. CONSIDERATIONS FOR INSTALLATION
IMPORTANT!
Installation and assembly of the appliance must be carried out by qualified personnel.
The appliance must be installed in a suitable position to allow the normal operations of opening
and ordinary maintenance.
The site must be:
• capable of providing the environmental conditions for operation
• equipped with power supply 230V 50 Hz (EN73-23)
• capable of taking an adequate system for smoke discharge
• provided with external ventilation (if located indoors)
• provided with an earth connection complying with CEI 64-8
The appliance must be connected to a flue pipe or an internal or external vertical duct
conforming to current standards UNI7129 - 7131 9615.
The boiler must be positioned in such a way that the power isolation fuse is accessible.
IMPORTANT!
The boiler must be connected to a flue pipe or a vertical duct which can discharge
the fumes at the highest point of the building.
The fumes are however derived from the combustion of wood products, and if
they come into contact with or close to walls, they can cause smoke staining.
Also take care because the fumes are very hot and almost invisible, and can cause
burns on contact.
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Pre-Installation Considerations
ECOMPACT Slim
Page 9
3.3 OPERATING AREA
For proper functioning, the appliance should be positioned in a
location where it is able to take in the air necessary for combustion of
the pellets (about 40 m3/h must be available), as laid down in the
standard governing the installation and in accordance with local
national standards. All louvres on the external casing of the boiler
must be un-obstructed at all times as these allow air for comubustion
and for cooling to enter the appliance enclosure. Heavy snowfall can
also obstruct the air in-take louvres and cause the appliance to not
burn clean. Smoke emanating from the flue is a symptom of this.
Snow must be cleared from around the appliance at the earliest
opportunity.
Where the appliance is to be installed indoors it is not
permissible to install the appliance where another
heating appliance is installed (fireplace, stove etc.)
which does not have its own independent air intake.
Locating the appliance in a room with an explosive
atmosphere, e.g workshop or tool shed, is prohibited.
The floor of the room where the appliance is to be
installed must be strong enough to take its weight.
If the walls are not flammable, position the appliance with a clearance
to the rear of at least 45 cm.
For flammable walls, keep a minimum distance of 45 cm at the rear,
30 cm on the sides and 150 cm at the front.
If the flooring is made of wood, provide a floor
protection surface in compliance with current
national standards.
300
Service Clearances
The minimum service clearances around the
appliance are as follows :
Rear – 50mm Nominal
Ends – 300mm
Front – 600mm
Concrete plinth should extend 300mm past
front and ends.
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300
300
600
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Pre-Installation Considerations
ECOMPACT Slim
Page 10
3.4. CONNECTION OF THE FLUE
WES recommend that the Therminox range of stainless steel insulated
flue pipe is used with this product. A full range of straight, offset, elbow
and ‘T’ elements is available to overcome any obstruction which the
flue should avoid. The proper draught conditions in the flue is critical
for the efficient working of wood pellet boilers. The flue can exit the
boiler house/garage through the roof or through the wall by using a
bend on the flue. The combustion chamber works in negative pressure.
The smoke duct for the discharge of fumes will also be under negative
when connected to an efficient flue pipe as directed.
All sections of the flue must be capable of inspection
and removable to enable periodic internal cleaning.
Position the appliance bearing in mind all the instructions and
considerations above.
IMPORTANT!
All 90 degree changes of direction in the flue pipe
must be either removable or capable of inspection.
For locating the boiler against a wall ensure adequate
flue support using approved wall brackets.
.
THE FLUE PIPE RUN MUST NOT INCLUDE MORE THAN 2-3 METRES OF
HORIZONTAL PIPE MUST AND NOT MORE THAN THREE 90° ELBOWS
(INCLUDING ‘T’s). IT IS ALSO ADVISABLE NOT TO EXCEED 8 METRES IN
LENGTH WITH THE PIPE Ø 100 mm
WES recommends the use of 100mm Therminox flue for use with this
appliance.
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Pre-Installation Considerations
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Page 11
3.5. HOW THE E-COMPACT OVERCOMES ISSUES CAUSED BY DRAUGHT
DEFECTS IN THE FLUE
Of all the weather and geographical conditions which affect the
operation of a flue pipe (rain, fog, snow, exposure to sunlight, direction
of facing), the wind is unquestionably the most decisive. In fact, along
with thermal depression caused by the difference in temperature
inside and outside of the chimney, there is another type of depression
or over-pressure: dynamic pressure caused by the wind. An updraft
always increases depression and hence draught. A crosswind increases
depression provided the cowl has been installed properly. A downdraft
always decreases depression, at times inverting it.
Considerations for naturally ventilated chimneys
Besides the direction and force of the wind, the position of the flue and
the cowl with respect to the roof of the building and the surrounding
landscape is important.
The E-Compact Air Flow Regulation System is equipped to deal with the
conditions referenced above by regulating the air flow through the
combustion chamber. An air flow sensor mounted on the air intake
duct measures the volume of air drawn pulled through the burner pot
by the exhaust fan. If downdraught conditions are present and air flow
increases, the exhaust fan increases speed to maintain the required air
flow. The opposite reaction occurs in up-draft conditions.
IMPORTANT!
In areas of extreme weather, especially wind, additional
measures may need to be provided for, in consultation
with WES. Flue draft stabilisers will be required where
natural draft of >100pa is present or anti-downdraught
cowls will be required where downdraft of >10Pa exists.
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Pre-Installation Considerations
ECOMPACT Slim
Page 12
3.6 PLUMBING CONNECTIONS
IMPORTANT!
The connection of the boiler to the plumbing system
must be carried out ONLY by specialized personnel who
are capable of carrying out installation properly, in
compliance with current standards in the country of
installation.
If installation of the boiler will involve interaction with
another, pre-existing system complete with heating
equipment (gas boiler, methane boiler, fuel oil boiler,
etc.), it is even more advisable to call in qualified
personnel, who subsequently will be responsible for
conformity of the system with current applicable law.
WES will not be held responsible for damage to persons or things in
the event of failed or incorrect operation if the aforementioned
warnings are not complied with.
For connection of the plumbing system to the appliance, the user
should refer to chapter 4, INSTALLATION AND ASSEMBLY; specifically,
paragraph 4.5, CONNECTION TO PLUMBING SYSTEM.
It is recommended that a suitable anti-freeze
solution is added to the heating system to prevent
the freezing of water within the boiler in the case of
a power outage. The boiler has an anti-freeze
function which activates the pump in the event of
the temperature in the boiler dropping below 5°C.
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ECOMPACT Slim
Installation & Assembly
Page 13
4. INSTALLATION AND ASSEMBLY
4.1. UNPACKING
The ECOMPACT Slim Pellet Boiler will come packaged on a single pallet.
The flue will be packaged separately.
The materials which make up the packaging are 100% recyclable. Their storage or recycling are therefore
the responsibility of the final user, in compliance with
local regulations. Do not store the boiler without it’s
packaging. Remove the nylon strapping, cardboard
packaging and bubble wrap
and recycle in the
appropriate manner.
When unpacking the boiler use the checklist below to ensure that all the
required components to complete the kit have been supplied. In the
unlikely event of an omission you must notify the manufacturer within
48 hrs of delivery. The Manufacturer reserves the right to charge for
items deemed lost after 48hrs.
Unpacking checklist
Item
Location
Received YES/NO
Baffle Set – 2 Pieces
Combustion Chamber
Burner Pot
Combustion Chamber
User Manual Pack *
Combustion Chamber
Stainless flue support brackets x 2 **
Hopper
Outdoor Models Only
Single – twin wall flue adaptor **
Hopper
Outdoor Models Only
Rain cap **
Hopper
Outdoor Models Only
Flue straight lengths 1m x 2 **
Supplied in separate
packaging
Outdoor Models Only
* The User Manual Pack includes a User Manual, Quick Step User Instructions, Commissioning
Report, keys for lockable doors and a heat proof gloves.
** Flue components listed above may vary depending on where the boiler is being installed.
Please check with your installer.
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ECOMPACT Slim
Installation & Assembly
Page 14
4.2. PREPARING THE BASE
Careful planning at an early stage will greatly help the installation process and make sure that all
the required clearances are adhered to for servicing and that any potential issues with the routing
of the flue can be resolved.
The ECOMPACT pellet boiler should be positioned on a concrete plinth at least 50mm high and
should project a min. 300mm beyond the sides and the front of the appliance .The plinth must be
capable of supporting the weight of the appliance when full with fuel and the plumbing system has
been filled with water.
Use the template below for constructing the plinth and for positioning the flow and return
pipework and electrical supply.
Refer to service and access clearances around the appliance on Page 8
300
300
300
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Installation & Assembly
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Page 15
4.3
ELECTRICAL CONNECTIONS
Electrical installations should only be carried out by suitably qualified and
certified electricians. If in doubt on any issue relating to the electrical
connections on the appliance contact WES Technical Support or your Local
Dealer for guidance before carrying out any connections.
The ECOMPACT boiler must be supplied with a 230V 50 Hz electrical supply via a two pole
isolation switch rated for Overvoltage Category III and protected with a 6A circuit breaker. Also,
the unit shall have a 30mA RCD installed into the mains supply. It is recommended that a power
isolation switch is located adjacent to the boiler to isolate the power during servicing and
maintenance but also out of the reach of children and to prevent accidental turning off of the
mains power.
Room thermostats shall be supplied/controlled by safety extra low voltage.
Brown - Permanent Live
Black – Time Clock Control Live
Blue – Neutral
Green / Yellow - Earth
Only authorized WES personnel may open the control panel on the boiler. Any interference
with the wiring in the control panel will invalidate the warranty. The boiler and
complete plumbing system must be adequately earthed and bonded in accordance with local
Building Regulations and Bye- Laws.
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Installation & Assembly
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4.4
BOILER CONTROL PANEL SCHEMATIC
Only authorised WES personnel may open the control board. Any
tampering with the PCB will immediately invalidate the warranty.
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ECOMPACT Slim
Installation & Assembly
Page 17
4.5
WATER CONNECTIONS
The diagram below indicates the plumbing connections at the rear of the boiler. The return
connection is factory fitted with a 25/6 Standard pump.
Incorrectly sized expansion vessel will
invalidate the warranty. A minimum
18 litre vessel is recommended for
the boiler plus additional expansion
for the heating and domestic hot
water system.
Ensure that the pre-charge in the
vessel is equal to the initial system fill
pressure of between 1-1.5 bar.
The boiler can be plumbed into either an open vented system (the maximum static head of water
permissible is 90 ft. (27.44 meters) or a sealed system. If plumbed into a sealed system an
appropriately sized expansion vessel should be used and installed as per manufacturers
instructions. The expansion vessel should be sized based on the water capacity in the boiler and
the water in the entire heating system.
The pump is on the return pipework just before the boiler. It is recommended that a by-pass pipe
between the flow and return is used with a valve to regulate the temperature of the water
returning to the boiler. Also, the system designer should ensure that there is adequate provision in
the system for heat dissipation from the boiler during the shut-down / extinguishing phase..An
automatic air vent and pressure relief valve must be fitted to the flow pipework immediately
outside the boiler. The pressure relief valve should be piped to a drain to prevent injury to the
User or Service Technicians if it is activated. All unused connections should be sealed with
blanking plugs.
A non-return valve should be fitted to prevent back-siphonage
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ECOMPACT Slim
Installation & Assembly
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Once the plumbing has been completed the system should be fully flushed to clear any debris
which may have become lodged in the pipework. The system should generally be filled from the
lowest point on the system to force any air to the highest point where it can be vented. The
flow pipe on the boiler is fitted with a manual air vent for venting air from the boiler.
The system must then be filled and the pump can be run continuously for a few hours to
completely de-aerate the system. Hold the ESC button on the controller for 3 seconds to
activate the pump. Repeat the procedure to turn it off. Only when the system has been fully
vented can the boiler be commissioned.
The installation and the design of the central heating system must be in accordance with BS EN
14336:2004: Heating Systems in Buildings. Installation and commissioning of water based
heating systems. BS EN 12828: 2003; Heating Systems in Buildings. Design of water based
heating systems. BS EN 12831: 2003; Heating Systems in Buildings. Method for calculation of
the design heat load.
Always ensure that all connections are making a watertight seal.
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Control System
ECOMPACT Slim
Page 19
5. CONTROL SYSTEM
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Control System
ECOMPACT Slim
Page 20
ERRORS
DESCRIPTION
DISPLAY
Error activation Safety thermostat High voltage
Er01
Water over-temperature
Er04
Exhaust over-temperature
Er05
Water pressure low
Er09
Water pressure high
Er10
Real Time Clock error
Er11
Ignition Failed
Er12
Accidental Extinguishing for low Exhaust Temperature
Er13
Error activation Pressure switch (Only with the Exhaust fan ON)
Er14
Lack of voltage
Er15
RS485 Communication error (Not applicable on this product)
Er16
Extinguishing for Lack of Pellet
Er18
Lambda Regulator error (Not applicable on this product)
Er22
Vacuum Error below the minimum threshold
Er34
Vaccum Error above the upper threshold
Er35
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Control System
ECOMPACT Slim
Page 21
5.1 ERROR CODES
In the unlikely event that the appliance fails to start or shuts down unexpectedly, then the Error
code show on the display will give an indication as to the potential cause of the problem. Some of
the errors can be cleared by the house holder and they are :
Er01 - Water Safety Thermostat – Press the reset button A and then hold button B for three
seconds to clear the error from the controller.
A
B
Error codes must be notified to the service
personnel in order to diagnose the problem.
Er04 - Water over temperature – Hold button B for three seconds. If the problem persists
contact you service agent.
Er05 – Exhaust over-temperature – Check that baffle is in position and clean inside of combustion
chamber.
Er09 – Low water pressure – Contact your installer.
Er10 – High water pressure – Contact your installer.
Er12 - Failed Ignition– Empty any un-burnt pellets from the burner pot and hold button B for
three seconds to clear the error. Er13 - Accidental Extinguishing for Low Exhaust Temperature –
Empty any un-burnt pellets from
the burner pot and hold button B for three seconds.
Er15 - Loss of Voltage– Usually occurs after a power-cut. Empty any un-burnt pellet from the
burner pot and hold button B for three seconds. Turn off the time clock for 10 seconds before
switching on again.
Er18 – Lack of Pellet – When the pellets reach the pellet sensor in the hopper the system
extinguishes to prevent having to re-prime the auger. Refill the hopper and hold the button B for 3
seconds. Turn off the time clock for 10 seconds before switching on again.
Er34 – Low vacuum pressure – clear the error by holing button B for 3 seconds. Turn off the time
clock for 10 seconds before switching on again.
Er35 – High vacuum pressure - clear the error by holing button B for 3 seconds. Turn off the time
clock for 10 seconds before switching on again.
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ECOMPACT Slim
Commissioning
Page 22
6.
COMMISSIONING
Commissioning of the E-Compact range of boilers can be divided into 3 sections :
Pre-Commissioning Checks
Auger Calibration & Fire-Up
Client Handover
Pre-Commissioning Checks
Pre-Commissioning checks ensure that the installation complies with the guidelines contained in
this manual and that local bye-laws and code requirements have been complied with. Precommissioing checks include :
Boiler room survey to establish if the boiler is on the appropriate base,
air and venting requirements have been complied with,
all plumbing connections are complete and system is filled and that expansion vessels, PRV’s and
air vents are appropriately sized, all pipework has been checked for leaks and is insulated and that
a form of heat leak is present
electrical connections are complete and safe, electrical installation is fully grounded, power
disconnect is in place and appropriately sized fuses are used.
fuel is available to commission the boiler.
It is recommmended that a Pre-Commissioning checklist is completed by the Installed and returned
to the Commissioning Engineer before commissioning is arranged.
It is also advisable to carry out an Outputs Test to ensure proper functionality of all components.
Auger Calibration
One very important part of the commissioning process is to check that the auger is delivering the
correct amount of fuel into the burner grate. Wood pellets are an organic substance and so can
vary in density, durability, calorific value, etc. . A simple check on calculating the fuel feed rate is
illustrated below. For this procedure you will need a simple digital weighing scales capable of
weighing up to 5kgs (11 lbs) and a bowl to collect the fuel.
Digital Scales
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Commissioning
ECOMPACT Slim
Page 23
Before we can carry out the auger calibration we must temporarily disconnect the boiler door
switch as we will have the boiler door open during this procedure. This can be done by turning off
all electrical power to the boiler and removing the cover from the control board. Undo connections
57/58 and a link wire or ‘jumper’ between these connections.
Once the door switch has bee disconnected and the
hopper has been filled with fuel the auger will need
to be primed. This is accessed through the :
User Menu > Load function
When this function is activated the slide plate
mechanism must open first (usually about 30
seconds), before the main feed auger starts to turn.
Wait until pellets can be heard dropping into the
burner then continue to allow pellets to feed into
the burner for a further 30 seconds. Pressing the
ESC key (P1) will stop the Load function. The burner
auger will continue to run for 30 seconds to push
the fuel in the burner onto the grate.
Clear the fuel from the grate and remove the grate
from the burner. The system is now ready to check
the calibration of the auger.
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Commissioning
ECOMPACT Slim
Page 24
Check the Auger ON value for Power 7 in :
System Menu > Auger > C09
This value is the Auger ON time for Power 7 on each cycle. Enter the Auger Capacity menu :
System Menu > Outputs Test > AugerCapacity
This Menu gives the option to run an auger simulation at Power 1 - Power 7. We need to check the
fuel delivery rate at Power 7 first. Set this to 7 and press SET (key (P3). Once the slide plate
mechanism has been opened the counter starts and the system simulates the auger ON/OFF cycle
for power 7.
Fuel being delivered
into burner
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Commissioning
ECOMPACT Slim
Page 25
Allow the counter to run for 360 seconds then press
ESC (key P1) to stop the simulation. Collect all the
fuel into a bowl of a known weight taking care not
to leave any behind.
Weigh the quantity of fuel then run the following
calculation :
If the feed rate is too low or too high at Power 7 then change the auger value C09 accordingly and
repeat the procedure to confirm the correct amount. Repeat the procedure for Power 1 and Power
4. Once these settings have been confirmed we can evenly space out the settings between, e.g.
Power 2, 3 and Power 5 and 6.
Once the auger calibration has been completed replace the burner grate, turn off the power and
reconnect the door switch.
Ensure that the baffles are in place and fitted correctly.
We are now ready to start an ignition cycle for the first time.
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Commissioning
ECOMPACT Slim
Page 26
First Fire-Up
Hold the ON/OFF key (P2) for 3 seconds until ‘Ignition Started’ appears on the display. The system
will go through each stage for the specified time as per the graph below. The various stages can be
observed from the main screen and other infromation is available through the monitor screens.
As the water temperature in the boiler nears its set point the system should start to modulate
down through the power levels. Once the target temperatue has been reached the system will
enter the Extinguishing stage, Final Cleaning and then rest in Standby until the water temperature
drops by 3C.
It is recommended that a flue gas analysis is carried out to obtain a nominal 12% CO2 at Power 7
adn down to 8-10% CO2 at Power 1. This will ensure a consistant level of combustion and any air
adjustments can be made through the Combustion Fan menu by the adjusting the appropriate
power level fan speed.
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Commissioning
ECOMPACT Slim
Page 27
Customer Handover
After every commissioning the Customer must be provided with training by the Commissioning
Engineer. The following is a list of items which should be covered during the product induction
with the Customer :
Provide a general overview of the product and identify the main components and their function,
illustrate how to turn on and off the appliance and adjust water temperature through the User
Menu
demonstrate where and how to fill the appliance with fuel and advise of the correct quality of fuel
to be used,
demonstrate how to clean down the combustion chamber by removing and replacing the baffles,
emptying the ash containers in the main combustion chamber and the lower ash chamber,
explain how to remove the burner grate and clear the air holes to ensure good combustion,
explain the various error codes that may appears and provide instruction on how to manage and
clear errors messages. Provide warning on which error codes are system critical codes and should
not be reset by the Customer,
the Customer must be warned of the safety implications when handling hot ash and that heat
proof gloves should be used.
The product Warranty must be explained to the Customer and they shall sign the commissioning
card confriming that they have received instructions on how to operate the appliance, understand
the risks when handling hot ash and agree to the product warranty.
The warranty card shall be returned to WES by fax, e-mail or post within 14 days from the
commissioning date.
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Boiler Operation & Maintenance
ECOMPACT Slim
Page 28
7
BOILER OPERATION & MAINTAINANCE
The ECOMPACT Slim has been developed to ensure that the User is able to carry out the most
basic functions in a safe and convenient manner. Once the installation has been successfully
carried out the User interaction is quiet simple from a regular inspection on the combustion
chamber to remove ash to filling the hopper with pellets.
Turning ON and OFF the boiler
• It is recommended that your boiler is controller by an external time clock. The time
programs should be set to the times that heat is required at different periods throughout
the day. You should also make allowance for the ignition time of the appliance, i.e. the
time it takes from when the time clock signals the boiler to start until the flame has fully
developed in the appliance (usually approx. 10-20 minutes).
• When choosing your programs on your time clock it is recommended that you program
the clock for long runs instead of short runs. This gives the boiler time to settle and
match the heat demand of the property. It is also when the boiler is most efficient.
• If the boiler is not being controlled by a time clock then it can be turned on and off locally
at the display on the boiler control panel. Hold the ON/OFF button for 3 seconds to start
the boiler. Hold the ON/OFF button for 3 seconds to turn off the boiler.
Emptying the Ash Pan
• The boiler contains two areas where ash needs to be removed at regular intervals.
• The primary ash pan is located in the main combustion chamber. The frequency of
emptying the ash pan is determined by the length of time the boiler has been running
and under what load conditions. Once the ash in the ash pan has reached the top then it
should be emptied. A daily check during the first few days of operation will give an
indication as to when it needs to be emptied.
Always make sure that before you open the main combustion chamber
door that the boiler has been switched off as has been allowed to cool
down sufficiently so as not to cause injury.
Always empty ash into a metal container as ash which may appear cool
could be hot in the centre.
Never use plastic brushes or dust pans to clean ash from the boiler.
Always use heat resistant gloves when handling the ash pan or
cleaning the boiler.
When the combustion chamber door is opened, even with the boiler in
the OFF position, the combustion fan will run at full power
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Boiler Operation & Maintenance
ECOMPACT Slim
Page 29
Always allow boiler to cool down
before opening the combustion
chamber door.
Unscrew the two fixing knobs on the
ash pan.
Carefully remove the ash pan and dispose
of the ash into a metal container.
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Boiler Operation & Maintenance
ECOMPACT Slim
Page 30
If the burner pot contains ash remove
the pot for the holder and scrape the
contents into a container. Also make
sure that the air holes are clear.
Carefully replace the pot ensuring that
it is properly seated.
Failure to replace the pot correctly
can cause damage and invalidate
the warranty. Your installer will
show you how to do this correctly.
Emptying the Ash Pan
• The boiler contains an ash area where ash needs to be removed at regular intervals.
• The ash pan is located in the main combustion chamber. The frequency of emptying the
ash pan is determined by the length of time the boiler has been running and under what
load conditions. Once the ash in the ash pan has reached the top then it should be
emptied. A daily check during the first few days of operation will give an indication as to
when it needs to be emptied.
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Boiler Operation & Maintenance
ECOMPACT Slim
Page 31
Filling With Fuel
• The boiler will indicate when the level of pellets reaches a low level. The system will shut
down and will wait for the hopper to be refilled.
• Open the pellet hopper lid and carefully pour approved pellets into the hopper.
• Never fill the hopper above the guard mesh across the opening of the hopper.
Never allow any foreign material to enter the hopper. This will lead to the
malfunction of the auger system and could cause damage to the appliance
and invalidate your warranty.
Always close the lid to the hopper once it has been filled with pellets.
Never leave the hopper lid open for prolonged periods as rain or moisture
can affect the pellet.
Always supervise children when the hopper lid is open in case foreign
material is placed into the hopper or children climb into the hopper.
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ECOMPACT Slim
Technical Data
Page 32
7. TECHNICAL DATA
Technical Data
Nominal Output
Nominal HeatInput
Efficiency Nominal Output (EN 303-5)
Smoke Temperature at Nominal Power
Smoke Temperature at Reduced Power
Min. Required Draft
Exhaust Gas Mass Flow
CO2 at Reduced and Nominal Power
kW
Kg/hr
%
°C
°C
Pa
g/s
%
ECOMPACT 15 / Slim 18
4.6 –15/ 18
5.0 – 18.2/19.8
89/90.7
120-140
70-90
10
3.3 – 10.6
10.8 – 12.7
°C
Bar/kPa
bar
inch
inch
inch
°C
Class
50 - 85
3 / 269 kPa
1.5
1”
1”
1/2"
105
Class 5
Boiler Electrical Power Requirement
Max. Electrical Consumption (Start-Up)
Avg Electrical Consumption in Normal Running
Current on Start-Up
Current During Normal Operation
Watts
Watts
Amp
Amp
230V 50Hz
448
164
2.5 Amp
1.2 Amp
Width
Height
Length (Excluding Flue)
Fuel Hopper Capacity
Boiler Flue Diameter (I.D)
Boiler Dry Weight
Water Content
mm
mm
mm
kg
mm
kg
litres
480
1100
1150
60
100
160
18
Water Operating Temperature Range
Maximum Operating Pressure
Recommended Operating Pressure
Water Flow Connection
Water Return Connection
Boiler Drain
Boiler Safety Thermostat Setting
Boiler Class
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Boiler Operation & Maintenance
ECOMPACT Slim
Page 33
Flue Height
Determined
on Site
1135mm
1071mm
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495mm
© Wood Energy Solutions
ECOMPACT Slim
Service Log
Page 34
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
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© Wood Energy Solutions
ECOMPACT Slim
Service Log
Page 35
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
Date
Service Provided
Service
Engineer
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© Wood Energy Solutions
Wood Energy Solutions
Donaskeigh, Tipperary, Co. Tipperary, Ireland
Booths Hall, Chelford Rd., Knutsford, England WA16 8GS.
[email protected]
www.woodenergysolutions.co.uk
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