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Komplett

Effecta Komplett Installation & Service Manual

Rev. JG.012-01-02
INSTALLING MAINTENANCE SERVICE ASSEMBLY
EFFECTA KOMPLETT
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We at Effecta would like to thank you for putting your trust in us when choosing your new boiler. The ”Effecta Komplett” has been developed to give you maximum performance, comfort and quality. In order to get the best results from your boiler, we suggest that you follow the recommendations in this installation guide.
Checking your delivery
Check that the boiler has not been damaged during transportation. If the boiler has been damaged, you must report this to the transportation company immediately.
Your safety
If you discover any faults or defects in our products, it is important that you report them as quickly as possible to your installation engineer, so that the fault can be rectified. Make sure that there are no flammable materials close to the boiler, to help prevent risk of fire. You must use your own judgement when operating the pellet boiler. Remember that the hatches and some surfaces can get hot. You must take caution to avoid being burnt.
The user
It is the user´s responsibility to operate the boiler according to our instructions. If you do not operate and maintain your boiler correctly, the environmental impact of the boiler will be greater, it´s efficency will be reduced and the service life of some components will be shorter. If there is anything that you are not sure about, please contact your installation engineer or Effecta for advice.
Warranty
The warranty takes effect from the date on which the boiler is installed. The supplied installation form must be completed and returned to Effecta. You can find the other guarantee terms on (page 3).
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Scope of delivery
Please check all components delivered. The standard delivery as follows:
- Effecta Komplett boiler
- Cleaning handle with brush
- Rake with scraper
- Fluetube with draught stabiliser
- Turbulators, 8pcs.
- Drain cock
- Shunt valve (mounted)*
- Electrical heater 3-9 kW (mounted)
- Valve combination
- Room thermostat
- Flow sensor
- Flue gas sensor
- Boiler temp sensor
* not delivered with Effecta without coil
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Introduction
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System data:
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Warranty
Installer:
Date:
Electrical installer:
Effecta products are guaranteed to be free of defects in materials and workmanship for two years from the installation date. This applies to wear parts, such as seals, the main body of the boiler and electrical components. This guarantee also covers original spare parts. Any faulty products will be replaced or repaired at the discrimination of the retailer or Effecta. If a faulty product is replaced, Effecta is entitled to replace it with a new or reconditioned product of the same or a similar type. Effecta is liable for the costs of any servicing or repairs. Effecta gives a 5 year guarantee on the remaining components. See the attached guarantee document.
If you have a complaint, you must contact Effecta before starting any servicing work.You must submit your complaint without delay. You must always state the type of product, the date of purchase and the serial number.
Otherwise the heating and plumbing industry's current regulations apply in the case of complaints.
Guarantee terms:
The guarantee is valid on condition that:
- The boiler and the heating system have been installed in accordance with the installation instructions and in a professional manner.
- The location where the product is installed is suitable for the purpose.
The guarantee does not cover:
- The overall functioning of the heating system, costs incurred as a result of the heating system
- being out of operation or the cost of the temporary replacement of products.
- Damage or injury caused by negligence during the installation or by operating the boiler in a way which conflicts with the installation and user instructions.
- Damage caused by abnormal wear, incorrect operation and maintenance.
- Damage caused by the boiler being positioned in an unsuitable location.
- Damage caused by vermin.
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Contents
2 Introduction
2 Scope of delivery
3 Warranty
3 Terms of warranty
3 System data
4 Contents
5 In general
5 Symbols in this document
6 To the installer
7 The components
7 Exploded view, burner
8 Safety and function
9 The safety systems
10 Placement of components
11 The fuel
11 The chimney
12 Cleaning system boiler
13 Cleaning system burner
14 The mothterboard
15 1,2 or 3 Phase connection
16 Electrical connection
17 The menu system
18 The menu system
19 The menu system
20 The menu system
21 The menu system
21 Alarms at disruption
21 Ignition phase of the burner
22 First start
22 Tuning the boiler
23 Tuning the burner
24 Hot water
24 Valve combination
25 Shunt control
26 Adjustment of heating curves
27 Examples of curves
28 Mounting the auger
28 Mounting and adjusting of the draft stabilasor
29 Replacing the combustion fan
30 Servicing the flame detector
30 Overheated droptube
31 Charging the igniter
32 Cleaning the air box and outer tube
32 Mounting and adjusting of the draft stabilasor
33 Service and cleaning
34 Trouble shooting
34 The sensors
35 Documentation of settings
36 Dimensions
37 Hyudralic scheme
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The Boiler
Effecta Complete is a boiler which is to be fueled with wood pellets. No other kind of fuel is allowed to be used. Not logs or oil.
Disassembly and disposal
It will be many years before your Effecta boiler is worn out, but it is important that you follow the regulations in force at the time concerning disassembly and disposal of your boiler.
The fuel
The boiler should normally burn 6/8 mm fuel pellets which come either in 16 kg sacks or are supplied by bulk truck. If you have built a bulk storage container, you should follow the current recommendations to ensure that the quality of the pellets does not deteriorate. Never use pellets which do not meet European pellet standards, as this may result in problems in operating the burner.
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In general
Information
This symbol is shown with info to the installer which can be important to know and understand. Neglecting these informations can be harmful to the prestanda in the product.
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Symbols in this document
Warning
This symbol is shown when the installer or user must be careful in the handling of the product. Neglecting these warnings can result in damage to the product or personal injury.
Dangerous electricity
This symbol means that extra caution should be taken. Otherwise serious personal injury might occur. When maintaining the product where this symbol is present the power must be disonnected. All electrical wiring must be done by a proffesional.
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To the installer
It is time to install the Effecta Komplett pellet boiler. Please follow the examples we provide for a safe installation. After installation, be sure to instruct the customer on how the heating system and the boiler work, in order to avoid unnecessary complications in the future.
Set up
The boiler is positioned so that the surface temperature of flammable building material does not exceed 80°C. The boiler should be positioned at least 15 cm (1) from the wall. The distance from the smoke valve to a flammable wall with ignition protective covering must be at least 30 cm (4). In order to clean the boiler, a minimum clear space of 1 metre (2) is required in front of the boiler and on the side at the convection section and at any inspection panel in the chimney. A passage with a minimum width of 0.5 (3) m is required along one of the long sides of the boiler. The pellet hopper aint alowed to stand closer than 120 cm from the boiler.
The boiler room
The boiler must be installed in a boiler room or boiler house. The ceilings and walls must be fitted with ignition protective covering and the floor must be made of non-combustible material. Minimum ceiling height at the boiler is 2 metres. The boiler room or boiler house must be equipped with a fresh air intake with the minimum dimensions 150 x 150 (5.) mm or with a sufficiently large free sectional area to avoid low pressure in the boiler room. It must be impossible to close the air intake.
Chimney
The chimney should have a diameter of at least 120 mm. If your chimney is smaller, Effecta should be consulted before installation. The draught in the chimney should be about 15 pa at low temperatures. It is important that the chimney is tested and approved by a certified chimney sweep before a new boiler is installed. If the chimney has a strong draught, a draught controller (see page 32) may need to be installed for good boiler operation. If you have a tall chimney and an outgoing flue gas temperature below 170°C, there is a risk of condensation in the chimney, which can damage the chimney in the long term. A suitable temperature is 70-80°C one metre down into the chimney. Ask your local chimney sweep for help to measure the temperature. If the chimney is tall and has a large area, a draught that is too strong may mean high levels of flue gas and overignition in the firebox. If this is the case, a draft stabiliser must be installed.
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The shunt valve
The shunt valve controls the heat supply from the boiler to the radiator circuit. Effecta Complete is fitted with motorised shunt control. The room temperature can be adjusted on a scale on the thermostat. An automatic system will significantly reduce fuel consumption and provide a more comfortable environment.
The valve combination
The mixing valve is used to ensure that the temperature of the hot water in your shower and elsewhere in the house is comfortable. Set the system to the temperature you want by turning the thermostat between +/-.
The burner
The burner is mounted on the left or right side. The burner heats the water in the boiler which provides heat to the domestic and hot water.
The turbulators
In the tubes in the convective part hangs the turbulators. The turbulator`s function is to reduce the heat in the flue gases on behalf of the temperature in the boiler. They must always be fitted in the boiler. If the flue gas temperature should be to low, the turbulators can be cut off. Always contact the installer before doing this.
The sealings
The seals on the hatches must be checked every year. If the hatches do not seal properly, the efficiency and the combustion process of the boiler will deteriorate.
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The components
1. Combustion fan 9. Feeding tube
2. Fan seal 10. Overheating protection
3. Electrical console 11. Seal feeding tube
4. Flame detector 12. Pellet retarder
5. Rear housing 13. Inner tube
6. Rear housing seal 14. Outer tube
7. Cover overheating protection 15. Stop plate
8. Ignition console
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Exploded view, burner
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Safety and function
Before using the product, the owner and/or other user must read and understand the content in this manual. The directions must be followed. This is to make sure that the product is functioning correctly and accidents and injuries are avoided. Incorrect use or incorrectly tuning can result in damages to property and personal injury or lacking function in the product. The boiler room where the product is installed, the chimney and other components must be approved according to current legislations.
The commisioning of the product must be made by a proffesional, according to Effectas directions and current legislations. Controls and tuning of the product should be made by a proffesional. A chimney sweeper should also be contacted when commisioning the product. The electrical connections must be done by a professional, according to Effectas instructions in this manual.
The casing outside of the burner must always be fitted on the boiler when the boiler is connected to the electrical power. Before cleaning and maintenance of the product, make sure it is disconnected from the power line.
It is strictly forbidden to open any doors when the burner is igniting. If any door or hatch is opened when the burner is running, great caution must be taken. Any kind of interferance or using of other than original spare parts can result in damage to the product or person. It also removes Effecta from any liability.
This manual should be kept during the whole life span of the product. Any updates will be reported on the Effecta web page: www.effecta.se.
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The flexi pipe between burner and auger
The flexi pipe prevents any fire coming in to the hopper. It is made from a heat sensitive material which melts if it gets to hot. If replaced, a new must be ordered from Effecta.
The overheating protection on the feeding tube
It stops the feeding if the fan temperatures gets to high. Reset is made manually.The cover must always be in place when connected to main power.
Flame sensor
The flame sensor monitors the fire in the burner. If light is missing for a set time during fire the burner stops and goes into cooling phase.
Overheating protection on the boiler
There is an overheating protection on the boiler which cuts the power to both the boiler and the burner if the temperature in the boiler exceeds 95°C.
Compressed air cleaning system
In this cleaning system there are three different safety devices.
1. The motherboard controls the time the compressor can run.
2. There is a pressure switch that stops the compressor at a preset pressure.
3. A safety valve wich releases air if pressure exceeds 9bars.
Power outage
After a power outage the control system remembers where in the sequence the burner was. If it was in the ”Run” mode, the fan blows for four minutes to burn out any pellet rests. Then it goes into normal mode.
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The safety systems
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Placement of the components
Front Back Topp
1 Adjustable feet 1 Drain tap 1/2” 1 Hole for measuring instruments
2 Soot door 2 Return hot water circuit 1” 2 Sootdoor flue pipe
3 Handle soot door 3 Flow hot water circuit 1” 3 Sootdoor 3 pc.
4 Cover plate electricity 4 Hoses electrical wiring 4 Flue pipe
5 Over heat protection (behind front) 5 Shunt valve
6 Display 6 Hose for sensor
7 Feeding tube pelletburner 7 Connector feedmotor/auger
8 Protective cover 8 Mixing valve
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Wood pellet is made by sawdust, a byproduct from from handling woods. Wood contains lignin that makes the pellet hard without any glue or other binder used.
On the market there are several different kinds of pellet. The quality and energy can be different between them. The diameter is 6 or 8mm, the normal length is between 5 and 30mm. Pellet with high quality has a density of 600-750 kg/m3. The moist content is 5-9% in weight. Oil has an energy content of 9,9kW/kg and wood logs about 4,0kW/kg. Wood pellet has 4,7­5,0kW/kg in energy content. To maintain a good combustion the pellet should be stored in a dry place and be protected from dirt. Pellet is delivered in sacks with 16kg content or in bulk by truck.
Effecta Complete can handle most of the different types of wood pellet that is 6-8mm. The quality should meet european standards. Good pellet with small amount of dust and an even quality helps to reach good combustion, less maintenance of the product and also less environmentally harmful emissions.
The worse quality of the fuel, the more cleaning and maintenance of the product.
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The fuel
The amount of pellet fed into the burner should be controlled every time the pellet brand or quality is chan­ged. If the deviation is more than 0,5kg/hour compared to the numbers in the ”Warranty and Installation” paper, the burner should be tuned.
Inspection
We recommend that the local chimney sweeper inspect and give advices and guidances regar­ding any necessary steps needed to be taken regarding the chimney and the boilers connection to it. Some issues needed to be considered:
Dimensions
Suitable dimensions are from about ca Ø120 to Ø160 mm for a steel construction and about 140x140 mm for a bricked. The length of the chimney should be so that a draft of 15-20 Pa is reached during operation. A much larger/smaller flue might be needed to be adjusted to receive a proper draft. If a new installation of the flue is done, the chimney manufacturer can give advice regarding the dimen­sioning. Generally speaking, a flue used for burning oil works for firing pellet in the same power range. The draft stabiliser attached to the flue tube should always be used if nothing else is stated from Effecta.
The flue gas temperature should be checked.
The temperature in the flue directly after the boiler in the flue should be about 160 - 200ºC. With a tall and big chimney there is a risk of condensation which can lead to corrosion and/or frost damages. To control this you can check the temperature 1 meter down from the top of the chimney. The temperature should be at least 80ºC in the end of a burning session. Suggestions for actions to be taken if needed is e.g. insulate the chimney or mount a steel pipe inside the chimney. This will increase the temperature in the flues without effecting the efficeny of the boiler. Other actions are increasing the power output of the burner or removing/cutting off turbulators. This will however decrease the burners efficency some. The draft stabiliser helps keeping the chimney free from condensation by ventilating it.
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The chimney
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The solenoid
The solenoid is mounted on the right side of the soot hatch on the top of the boiler. The solenoid flips the turbulators up and down to keep the tubes clean.
1 Solenoid
2 Lifting shaft
3 Flipper
4 Suspension
5 Turbulator
The turbulators
The turbulators in the tube helps reducing the flue gas temperature and also cleaning the tubes when pulled up and down.
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Cleaning system boiler
Function and service
Cut the power to the boiler before servicing. The solenoid is mounted on the boiler to keep the convective part clean. It is controlled from the menu ”Cleaning” on the control panel. It can be set to work/not work in different times during the day.
Suspension
On every suspension there are two turbulators that is removed when cleaning the tubes with a brush.
Lifting shaft
The shaft is pulled up by the magnet making the turbulators also being pulled up.
Flipper
Flips when the solenoid activates.
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