THERMOSTAHL ECW 15, ECOWOOD PLUS, ECOWOOD STANDARD, ECW 20, ECW 30 Installation And User Manual

SOLID FUEL BOILER

ECOWOOD STANDARD/PLUS

INSTALLATION AND USER MANUAL

VERSION:

2.2

UPDATE:

20.08.2017

Contents

1. GENERAL INFORMATION ................................................................................... 3

1.1. Proper use of the appliance ................................................................................ 3

1.2. Safety warnings ................................................................................................ 3

1.3. Data label ........................................................................................................ 3

1.4. Document information ....................................................................................... 3

2. TECHNICAL FEATURES AND DIMENSIONS ......................................................... 4

2.1. Technical features ............................................................................................. 4

2.2. Function principle .............................................................................................. 4

2.3. Dimensions ...................................................................................................... 5

2.4. Fuel ................................................................................................................. 6

3. BOILER MOUNTING ........................................................................................... 7

3.1. Transportation and delivery ................................................................................ 7

3.2. Boiler room ...................................................................................................... 7

3.3. Chimney .......................................................................................................... 8

4. INSTALLATION ................................................................................................ 10

4.1. Hydraulic connections ...................................................................................... 10

4.2. Return temperature protection .......................................................................... 10

4.3. Filling the system ............................................................................................ 10

4.4. Chain thermostat installation (STANDARD VERSION) ........................................... 11

4.5. Connection diagrams ....................................................................................... 12

5. ELECTRICAL CONNECTIONS ............................................................................ 13

5.1. General instructions ......................................................................................... 13

5.2. Control panel functions (PLUS VERSION) ............................................................ 13

5.3. Electrical connections (PLUS VERSION) .............................................................. 15

5.4. Hydraulic function scheme ................................................................................ 16

5.5. Connecting exhaust temperature sensor ............................................................ 17

5.6. Connecting temperature sensors ....................................................................... 17

6. BOILER START-UP ........................................................................................... 18

6.1. Initial lighting checks ....................................................................................... 18

6.2. Start-up ......................................................................................................... 18

6.3. Checks to carry after initial start-up .................................................................. 18

6.4. Fuel loading .................................................................................................... 19

6.5. Operation mode .............................................................................................. 19

6.6. Combustion regulation ..................................................................................... 21

6.7. Supervision mode............................................................................................ 21

6.8. Stop mode ..................................................................................................... 21

6.9. Chimney damper adjustment ............................................................................ 21

7. SERVICE AND MAINTENANCE .......................................................................... 22

7.1. Cleaning the boiler .......................................................................................... 22

7.2. Cleaning the chimney box ................................................................................ 23

7.3. Maintenance intervals ...................................................................................... 23

7.4. Basic service procedures .................................................................................. 24

7.5. Maintenance after long stop .............................................................................. 24

8. TROUBLESHOOTING ........................................................................................ 25

CE DECLARATION OF CONFORMITY ............................................................................... 26

GENERAL INFORMATION

3

1. GENERAL INFORMATION

1.1. Proper use of the appliance

Before you make use of this appliance make sure you have read and fully understood the
instructions included in this manual.

The installation and use of the appliance must be performed according to the instructions
indicated in this manual in combination with the current national safety regulations.

The appliance is designed for use in pumped hot water central heating systems. Any other use
is considered improper and is prohibited. THERMOSTAHL ROMANIA declines any responsibility

for damages or injuries caused by improper use; in this case the risk is completely at the user’s

responsibility.

To ensure an efficient and flawless function of the appliance, it is strongly recommended that
you have performed an annual service by a qualified technician.

1.2. Safety warnings

All installation and maintenance procedures must be carried out by professional and authorized
personnel, in compliance with the indications in the present manual and national regulations.
Any failure to correctly install this appliance could cause damage or injuries!

Do not make modifications to parts of the appliance, unless you have contacted the company
and an authorized service contractor.

Only original accessories and spare parts must be used to ensure correct and safe function.

Make sure you respect the cleaning and maintenance procedures on the corresponding intervals.
Failure to do so can cause malfunction to the appliance and possible damages.

The boiler is design to function on the fuels indicated in the corresponding paragraph. Any other
fuel is prohibited. Do not use explosive or flammable substances! Do not store such substances
inside the boiler room.

The working pressure varies according to the model. Make sure you use the appropriate water
pressure.

Working in a pressure higher than the one indicated in this manual is strictly
prohibited and dangerous!

1.3. Data label

The data label of the appliance is placed on the boiler’s side cover, on the external part. Make
sure that it is properly placed and readable.

On the label it is indicated the serial number and the manufacturing year of the appliance.

1.4. Document information

This document is an integral and indispensable part of the product and must be retained in good
condition by the user. Keep it in a safe place for future reference.

If the appliance is sold or transferred to another person, this manual has to always follow the
appliance and handed to the new user or installer.

TECHNICAL FEATURES AND DIMENSIONS

4

2. TECHNICAL FEATURES AND DIMENSIONS

2.1. Technical features

The ECOWOOD boiler series is designed for function on any type of solid fuel: wood, agricultural
residues, carbon, briquettes, with a minimum diameter of 20mm. The boiler is equipped with
two doors: one upper for fuel loading and a lower door for ash removal. There is also an inner
door for access to the heat exchanger.

ECOWOOD STANDARD is equipped with a thermometer and chain thermostat regulator.
ECOWOOD PLUS version is equipped with a modulating fan and a digital controller. The boiler
can also control the heating pump and the hot water pump, as well as being connected with an
exhaust gas temperature sensor for full fan modulation and maximum fuel savings.

ECOWOOD boiler is designed to operate in economy mode, providing a constant heating of
houses or small industrial premises.

The boiler is made of steel, ideal material for thermal fluctuations, resistant to expansion and
contraction. Monobloc construction, with no other welded structures is an advantage of
ECOWOOD boiler. Also this boiler is protected against thermal shock.

ECOWOOD boiler is designed so that all surfaces that are in contact with the flame are cooled
by water, including the grate where the ash and combustion residues fall. The two roads flue at
the top, the large number of flue pipes, large volume of the furnace and boiler water as well,
and symmetrical construction causes a high yield.

DESCIPTION OF COMPONENTS

 Steel boiler body with cylindrical heat exchanger
 Removable rear smoke box with inspection cleaning door
 Upper door for ignition, fuel loading and cleaning access
 Lower door for ash removal
 Ash box positioned on the lower part of the fire chamber
 Combustion fan positioned on the lower door (PLUS version)
 Chain thermostat regulator and air door positioned on the lower door (STANDARD version)
 Glasswool body insulation of 50 mm thickness
 Electrostatically painted external covers
 Control panel for electromechanical operation (PLUS version)

2.2. Function principle

The function of the ECOWOOD boiler is based on
exhaust gas evacuation through the chimney. The fuel
is positioned on the grate. The combustion takes place
in the fire chamber. During the combustion the flame
comes in contact with the side walls of the fire
chamber, which are surrounded by water. The fire
chamber is of big volume in order to receive big
dimension logs and to ensure a long autonomy.

The combustion air is supplied by the fan and
distributed through an air distributor, positioned below
the fuel grate. The combustion is regulated through the
fan, controlled by the control panel.

The exhaust gases are guided through the heat
exchanger to the smoke box, and afterwards evacuated
to the chimney. The smoke box is equipped with an
inspection and cleaning door, which also actions as an
explosion relief.

The doors have an insulation cord to ensure air-tight
closing. Each door is equipped with a handle, which
must always be well tightened during the combustion.

Fig 2. Boiler function

TECHNICAL FEATURES AND DIMENSIONS

5

2.3. Dimensions

a) PLUS b) STANDARD

Boiler

Type

Feeding

door

H

W

F

L

T1-T2

T3

T4

T5

PLUS

STAN

PLUS

STAN

mm

mm

inch

ECW 15

340x360

1235

1205

540

915

1050

890

1½”

Ø180

¾”

½”

ECW 20

340x360

1235

1205

540

915

1150

990

1½”

Ø180

¾”

½”

ECW 25

340x360

1235

1205

540

915

1250

1090

1½”

Ø180

¾”

½”

ECW 30

340x360

1235

1205

540

915

1350

1190

1½”

Ø180

¾”

½”

ECW 40

345x475

1380

1320

650

1015

1200

1090

2”

Ø220

¾”

½”

ECW 50

345x475

1380

1320

650

1015

1300

1190

2”

Ø220

¾”

½”

ECW 60

345x475

1380

1320

650

1015

1400

1290

2”

Ø220

¾”

½”

*Nominal output is obtained with good quality wood, with 15% humidity.

TECHNICAL DATA

Boiler

Type

Nominal
Output*

T

max

P

max

Effici

ency

Water

contents

Fire

chamber

length

Max.

wood

length

Fire

chamber

volume

Weight

P

S

kW

o

C

bar % lit

mm

mm

m3

kg

ECW 15

15

90

2

83

65

450

400

0,14

200

190

ECW 20

20

83

80

550

500

0,17

225

215

ECW 25

25

83

95

650

600

0,20

245

235

ECW 30

30

83

115

750

700

0,23

270

260

ECW 40

40

83

135

650

600

0,32

330

320

ECW 50

50

83

155

750

700

0,36

355

345

ECW 60

60

83

175

850

800

0,41

400

390

TECHNICAL FEATURES AND DIMENSIONS

6

2.4. Fuel

The ECOWOOD series is designed for use with solid fuel of biogenic or fossil nature. This means
different types of natural wood, solid residues of organic nature coming from trees or agricultural
plants, wood briquettes of various types. Carbon or other similar fossil fuels are allowed, but
only in combination with wood and maximum 20% volume ratio at every load. If you want to
use solely carbon as fuel, please contact the manufacturer.

Good quality wood is oak, ash, beech, maple, olive tree and fruit trees, except cherry. Medium
quality wood is chestnut and birch. Low quality wood is poplar and willow.

The nominal characteristics of the boiler are calculated for use on wood!

Table 1. Calorific power of different types of wood

Every type of wood contains a significant amount of humidity, which highly affects its combustion
behavior and calorific value. Boiler output, efficiency and autonomy will significantly diminish as
the humidity increases. The nominal data presented in this manual are calculated for humidity
content 15%.

For proper and efficient function and a long lifespan, it is strictly recommended that only dry
wood is used, with a humidity content of 15%. Practically, this means at least one year dry
wood. Maximum humidity content allowed is 25%.

As understood, wood is an extremely heterogeneous fuel, due to different essences, different
humidity contents, shapes and dimensions. This is why the combustion behavior highly varies
through time and average data as fuel consumption, autonomy, and output are very difficult to
forecast.

It is prohibited the use of laminated wood, or other chemically treated wood. It

It is prohibited the use of explosive, inflammable materials, plastic, domestic
residues, etc.

0

10

20

30

40

50

60

2,2 2,8 3,4 3,7 4,0 4,3 4,6 4,8 5,1

Humidity [%]

Lower Calorific Power [kWh/kg]

Calorific power in relation to humidity

Fuel

Calorific power

kWh/kg

kcal/kg

Oak

4,2

3.600

Beech

4,0

3.450

Birch

4,3

3.700

Poplar

4,1

3.500

Pine

4,4

3.800

Spruce, Fir

4,5

3.900

Wood briquettes

4,0 – 4,9

3.600 – 4.200

Carbon

Anthracite

5,6 – 6,5

4.800 – 5.600

Coal

4,5 – 6,4

3.900 – 5.500

Brown carbon

2,7 – 4,2

2.300 – 3.600

Lignite

1,6 – 3,8

1.400 – 3.300

BOILER MOUNTING

7

3. BOILER MOUNTING

3.1. Transportation and delivery

The boiler is delivered on wood pallet, well positioned with metal plates. Remove them carefully
by unscrewing the screws holding them in place.
The loading and unloading of the boiler must be performed with a forklift or a crane.

The boiler is very heavy. Do not try to lift by hands or other unsuitable
equipment. Danger of injury! Perform all moves with extreme caution.

Remove the boiler packaging with attention. Keep the packaging material away from
children since it can be dangerous. After having unpacked everything, make sure that the

appliance is intact and undamaged. In case of doubt do not use the appliance and inform the
supplier.
The ECOWOOD boiler is delivered with the following equipment already fitted and mounted:

 Boiler steel body
 Glasswool insulation mounted on the boiler body and tightened with plastic tapes
 Metal covers mounted on the boiler body
 Turbinators positioned inside the fire tubes
 Digital control panel (PLUS version)

The following accessories are positioned inside the boiler body. Remove them carefully by
opening the upper door.

 Cleaning tools
 Chain regulator (STANDARD version)
 Fan and fan cover (PLUS version)

In the documentation folder you will find:

 Technical manual
 Warranty leaflet

3.2. Boiler room

3.2.1. General requirements

The boiler must be installed in a special and separate room. This room must be chosen so that
it offers easy access for fuel transport, air supply and exhaust gas evacuation. The doors of the
boiler room must be metallic, open outwards, and have at least 0,9 m width.

The boiler installation is prohibited in rooms with extensive dust, dangerous
gases, and moist spaces.

For the correct boiler function it is necessary that the boiler room has openings for natural
ventilation and combustion air supply. It is recommended that two different openings are used
for this purpose, positioned on opposite walls and diagonally to ensure good air circulation. The
total surface of the openings must be at least 1/12 of the boiler room surface. Forced ventilation
is prohibited in the boiler room.

The boiler room must be provided with a drainage channel. All safety devices must be connected
to this channel.

The boiler room must have an appropriate fire extinguishing system, according to the regulations
in force. In case that the building is designed with a fire alarm system, a smoke detector must
be positioned on top of every boiler.

The fuel storage is prohibited in the boiler room. If so, the storage must be separated from the
boiler with a non-flammable wall, and proper distanced from the boiler.

BOILER MOUNTING

8

3.2.2. Boiler room dimensions

The boiler must be placed on a horizontal plane, with adequate mechanical resistance to support

the boiler’s weight. The boiler must be positioned in the room in such a way so that it is easily

accessible from all the sides. The following dimensions are recommended (see Fig 2):

The distance between the boiler and the back
wall - is the proper distance that allows easy
access for inspection and maintenance.

The distance between the boiler and side wall ­at least 0,6 m.

The height of the boiler room - at least 2 m.

Access and service spaces of boiler room and hall
doors paths will always be free.

In the boiler room will be displayed operating
instructions, taking into account the specificities
of the boilers mounted. Also, you will see internal
instructions of staff and service duties.

Fig 2. Boiler room dimensions

3.3. Chimney

The chimney installation must supply sufficient draught, air tightness and protection against
condensation.

The appropriate chimney installation is very important for the boiler’s efficient

and safe function!

The chimney must be positioned if possible in the interior of the building. It must be vertical,
with no changes in the direction. The cross-section of the chimney can be round or rectangular.
If the chimney is installed in the exterior, it must be insulated.

The horizontal part connecting the boiler’s chimney pipe with the vertical chimney must have
maximum length 2 m. If this distance is bigger, it is recommended to have a 15-30o inclination
upwards. The connection with the boiler’s chimney pipe must be air-tight.

The chimney must be equipped with a cleaning door at its base. Also cleaning doors are
recommended where there are changes in direction and ash can be accumulated. Tactical
cleaning is recommended (every 3 months) for efficient boiler function.

A chimney terminal must be installed at the end of the chimney for protection against weather
effects and foreign objects entrance. In areas with strong winds a special anti-downdraught
terminal is recommended.

The chimney height must exceed the roofline by at least 1 m. If there are other obstacles
positioned on the roof, the chimney height must exceed them by at least 1 m. If there are
multiple chimneys, minimum distance between them is 0,3m.

BOILER MOUNTING

9

Each boiler should be connected to an independent chimney. Connection of multiple
boilers to the same chimney is not recommended.

Fig 3. Chimney distances

Fig 4. Chimney connection

INSTALLATION

10

4. INSTALLATION

4.1. Hydraulic connections

The boiler is intended for connection with an open expansion vessel network. The boiler can be
connected also with closed expansion vessel, if it is equipped with an overheating serpentine
(optional).

The boiler is intended for maximum working temperature 90oC and maximum pressure 2 bars.
When connected with a closed expansion vessel, its volume must be chosen double to a similar
installation on liquid or gas fuel.

If a connection pipe is not used, it must be sealed before water fill!

4.2. Return temperature protection

For the correct function of the boiler and for protection against corrosion it is very important to
ensure steady temperature at the return of the boiler of at least 55oC.

This can be ensured by installing a recirculation pump between the boiler outlet and return (see
connection diagrams).

An alternative variation is by installing at the return of the boiler a three-way thermostatic valve.

Having a return temperature less than 55oC is very dangerous for the boiler long­life and can cause warranty loss!

4.3. Filling the system

After completing all the hydraulic connections, the circuit may be filled with water. After filling
the system, open the radiators air valves to get rid of the air in the installation.

Verify that the installation pressure is according to the technical feature of the boiler. The
pressure must be verified through the boiler’s manometer. An additional manometer should be
installed on the cold water inlet to verify the cold pressure, at the lowest point of the installation,
at a point close to the boiler.

The whole installation must remain under nominal pressure for at least 10 minutes. During this
period, check that all the connections are tight and there are no water leakages. Make sure that
during this period no pressure drop appears.

After firing the boiler, make sure the network functions properly at working temperature and
pressure.

Legend

T1

Outlet

T2

Return

T3

Chimney pipe

T4

Safety kit connection

T5

Discharge valve connection

INSTALLATION

11

The hardness of the mains water supply affects the boiler’s life span. It is
recommended to use a water softener if water hardness exceeds 15of.

Do not fill the system at the working pressure! When the boiler will be heated,
the water pressure will raise. Filling pressure must be at least 1 bar lower than

working pressure!

4.4. Chain thermostat installation (STANDARD VERSION)

ECOWOOD STANDARD is equipped with an air door on the
lower part and is delivered with chain thermostatic
regulator.

Install the regulator at the connection pipe on the upper
side of the boiler and pass the chain through the hook
provided on the air door.

Choose the desired boiler temperature from the
thermostat head (red scale is valid).

The thermostatic regulator controls the boiler temperature
by controlling the supply of combustion air. The chain
length must be adjusted so that when the set temperature
is reached the air door is in closed position and no air is
supplied.

INSTALLATION

12

4.5. Connection diagrams

4.5.1. Open expansion vessel connection

Legend

1-9.

Separation valves

B

Hot water boiler

10,11.

Radiator valves

VED

Open expansion vessel

12.

Radiators

PCI

Central heating pump

13-15.

Safety valves

PRC

Recirculation pump

16.

Filling valve

RP

Pressure reducer

17.

Drainage valve

F

Filter

18.

Cold water valve

A

Air relief valve

19-24.

One-way valves

FD

Water softener

4.5.2. Closed expansion vessel connection

Legend

1-9.

Separation valves

B

Hot water boiler

10,11.

Radiator valves

VE

Closed expansion vessel

12.

Radiators

PCI

Central heating pump

13-15.

Safety valves

PRC

Recirculation pump

16.

Filling valve

RP

Pressure reducer

17.

Drainage valve

F

Filter

18.

Cold water valve

A

Air relief valve

19-24.

One-way valves

FD

Water softener

ELECTRICAL CONNECTIONS

13

5. ELECTRICAL CONNECTIONS

5.1. General instructions

All electrical connection must be performed by an authorized professional, in conformity with the
local regulations and the indications of this manual. Connections must be done according to
norms EN 60529 and EN 60335-1, and protection norms IP 40 and IP 44.

All wiring must be waterproof insulated. Exposed cables should be protected within plastic
channel. The main electrical supply of the boiler must be connected to an independent safety of
max 16A. The boiler room lighting must be on a separate circuit.

The user is obliged to connect the boiler to an efficient grounding system.

THERMOSTAHL ROMANIA SRL declines any liability for damage caused to
people, animals and goods, due to defects caused by faulty electrical
connections or lack of connecting the boiler to an efficient grounding system.

5.2. Control panel functions (PLUS VERSION)

5.2.1. Description of buttons and display

After turning the regulator on, the START and STOP buttons are used to enable and disable
airflow respectively.

ECOWOOD PLUS version is equipped with a safety thermostat (STB). If the boiler reach a

temperature of 95°C safety thermostat interrupts power fan. Restarting the boiler can only be

done by detecting and removing the cause that produced overheating, or waiting for the boiler
to cool down below 90°C.

Legend

1.

“F” button:

-short press – access the menu

-long press – exit submenu

2.

STOP button, value decrease

4.

START button, value increase

5.

Mains switch

6.

Fuse holder

ELECTRICAL CONNECTIONS

14

5.2.2. Description of the main display screen

Legend:

1. Preset boiler temperature.

2. Measured temperature of boiler.

3. Signal arrow.

4. SUMMER – hot water mode symbol.

5. PRIORITY - hot utility water mode symbol.

6. Boiler regulation mode.

7. Room thermostat - this symbol lights up
when the temperature set at the
thermostat is reached (contacts are
disconnected).

8. Alarm symbol.

9. Signal of increasing the preset boiler
temperature due to hot utility water
heating.

10.

Signal decreasing the preset boiler
temperature due to operation of the
room thermostat.

11. Service menu symbol.

12. Hot utility water temperature sensor.

13. Boiler pump symbol.

14. Hot utility water pump symbol (HUW).

15. Boiler temperature sensor.

16. Exhaust temperature sensor.

17. Airflow power.

18. Fan operation symbol: not visible–
regulation is off; visible-regulation is
on; flashes-the regulator is in the
SUPERVISION mode.

19. Hot utility water tank symbol.

Icons:

Temperature settings

1 – preset boiler temperature

2 – measured boiler temperature

Settings for hot utility water

01- Hot water priority

02- Simultaneous operation of
heating pump an hot water pump

03- SUMMER mode

04- Disable the hot water filling
pump

Blow-off time

Blow-off interval

Maximum fan speed

Boiler regulation mode

01- CLASSIC

02- PID

03- PID-S

Minimum fan speed

Service menu

ELECTRICAL CONNECTIONS

15

5.3. Electrical connections (PLUS VERSION)

Note: Do not use the ecoSTER room panel and room thermostat at the same time!

The regulator is designed to be fed with 230V~, 50Hz voltage. The electrical system should be
three core (with protective wire), and in accordance with applicable regulations. The grounding

cable should be connected to the terminals marked with the symbol .

The connection wires should not have contact with hot surfaces (with temperature exceeding
the nominal temperature of their operation). Terminals L, N and number 1-8 are intended only
for connecting devices with mains supply 230V~. Terminals 9-20 are intended for cooperation
with low voltage devices (below 12 V).

Tips of the connected wires, especially power leads, must be secured against splitting by means
of insulated clamp sleeves, in accordance with the drawing below:

Legend

T1.

Boiler temperature sensor (type CT4)

T2.

Hot utility water temperature sensors (type CT4)

T3.

Emission temperature sensors (type CT2s)

T.

Room thermostat

DZT-1.

Additional thermal safeguard (type DZT-1 85°C or 90°C)

1.

Mains fuse in the regulator

2.

Mains switch in the regulator

3.

Protective terminals PE

4.

Metal enclosure of the regulator

L/N.

Electrical supply

STB.

Safety temperature limiter

ELECTRICAL CONNECTIONS

16

Fig 5. Securing wire tips a) right, b) wrong

5.4. Hydraulic function scheme

The presented hydraulic diagram does not replace the central heating system
design and it can be used for reference purposes only.

Brief description of the system functioning: after firing the boiler up, the central heating pump
is activated after the boiler exceeds the central heating pump activation temperature (service
parameter n0, by default n0=40°C). The hot utility water pump is activated when the tank
temperature (6) drops below the preset value. If at this time the preset boiler temperature is
lower than the preset hot utility water temperature, the regulator increases the preset boiler
temperature in order to fill the hot utility water tank.

After filling the hot utility water tank, the hot utility water pump can continue work for a preset
time, in order to collect heat from the boiler. After the room thermostat (5) operates, the
regulator decreases the preset boiler temperature and/or temporarily disables the central
heating pump (2).

Fitting an emission temperature sensor (8) in the boiler flue enables very fast detection of fuel
depletion and turns the fan off. Moreover, it allows operation in the PID- EMISSION boiler
regulation mode, and preview of the emission temperature.

Legend

1.

Regulator

2.

Central heating pump

3.

Hot utility water pump

4.

Fan

5.

Room thermostat

6.

Hot utility water tank

7.

Central heating system

8.

Chimmey duct

9.

Boiler

T1.

Boiler temperature sensor

T2.

Hot utility water
temperature sensor

T3.

Emission temperature
sensor (optional)

ELECTRICAL CONNECTIONS

17

5.5. Connecting exhaust temperature sensor

.

The emission sensor should be fitted in the boiler flue (3). The gap between the sensor and the
flue should be sealed. The sensor should be installed by a qualified fitter, while observing
regulations applicable for chimney systems. The emission sensor should be connected to the
sensor terminals according to the electrical scheme. The emission sensor lead cannot touch hot
elements of the boiler and the flue, the temperature of which exceeds 350°C. The emission
sensor should be installed in such distance from the boiler at which it is not directly exposed to
flames, and where the emission temperature does not exceed 450°C.

5.6. Connecting temperature sensors

The regulator is compatible only with sensors type CT4 (sensor of boiler and hot utility water)
and CT2s (emission sensor). It is prohibited to use different sensors. Sensor leads can be
extended with wires with section of at least 0,5mm2. Total length of the sensor leads cannot
exceed 15m. The boiler temperature sensor CT4 should be fitted in the boiler bulb pipe. Hot
utility water temperature sensors CT4 - in the thermometric pipe welded into the tank.

The sensors must be secured against coming loose from the measured surfaces.

BOILER START-UP

18

6. BOILER START-UP

6.1. Initial lighting checks

Before you start the boiler, make the following checks:

 Check all the hydraulic connections and make sure they are tight. Make sure there is no

leakage or moisture on the pipes or other equipment.

 Make sure that the connection with the chimney is air-tight and the chimney installation is

properly made.

 Check that the controller bulbs are well inserted and secured in the boiler’s bulb.
 Make sure that the pressure in the network is correct.
 Check that the boiler pump and the central heating pumps function properly.
 Make sure that the connection with the expansion vessel is correct and the expansion volume

is sufficient for the boiler. No valves should be installed between the boiler and the expansion
vessel.

 Make sure the boiler’s separation valves are open.
 Make sure that there is sufficient air supply and natural ventilation in the boiler room.

Do not store inflammable materials or fuel close to the boiler! Before you light
the boiler make sure the boiler room is clear and safe.

6.2. Start-up

To correctly start up the ECOWOOD boiler follow the next steps:

 Make sure the control panel switch is set to STOP and that fan does not function.
 Make sure the chimney damper is positioned in horizontal position (completely open).
 Open the upper door (fire chamber) and introduce a sufficient amount of small and thin

pieces of wood.

 Using sheets of thin paper light the wood placed inside the boiler.
 Close the door of the boiler.
 Wait several minutes until the flame develops and produces some embeds.
 After formation of embeds, load the fire chamber with wood. Position them on top of the

grate.

 Close the door and secure it with the handles.
 Activate the airflow by pushing the START button.

It is prohibited to light the boiler with inflammable or explosive liquids.

6.3. Checks to carry after initial start-up

During the first start-up you need to carefully check the air-tightness of all the connections,
especially the doors and the connection with the chimney.

Check that the thermostats function properly and devices operate accordingly. Wait for the boiler
to reach the preset temperature and make sure the fan stops properly and the flame falls down.

Check the temperature and pressure rise in the network. Make sure it is according to the
indications. Check if there is any water leakage in the network.

After burning of the fuel is completed, check the situation inside the boiler. If the walls are too
black, it means that there is insufficient air supply. If there is condensation forming on the boiler
walls, it means that the pump operation starts at a low temperature or the fuel has too big
humidity content. Make sure you set the pump according to the indications and you install a
return temperature protection system as indicated.

BOILER START-UP

19

6.4. Fuel loading

In order to correct add fuel to the boiler follow the next steps:

 Stop the fan function by pressing the STOP button. Wait 30 seconds for the fume to exit the

boiler.

 Open the upper door slowly to avoid leakage of smoke. Load a sufficient amount of fuel.

Each loading should be regulated according to the boiler output and the heat demand. Never
load too much to fuel to fill all the fire chamber volume! Maximum fuel should be 70-80%
of the fire chamber volume.

 Close the door and secure with the handle.
 Start again the fan function by pressing the START button.

When loading fuel in the boiler do not throw them but position them carefully.

6.5. Operation mode

The regulator features three selectable methods of regulating the combustion process: CLASSIC,
PID, PID-S. In order to choose the operation mode, press the F button in the main window until

the arrow is in the boiler regulation mode position . Use „+” or „-" buttons to set value
according to instructions below.

CLASSIC regulation (regulation mode 1)
The method is based on the T1 boiler indication, and consists in decreasing of the airflow power
from Maximum revolutions to Minimum revolutions while achieving the preset boiler
temperature. Revolutions start to be reduced at 5°C (service parameter n7) before the preset
boiler temperature. After achieving the preset boiler temperature, the SUPERVISION mode is
activated, where blow-offs are performed.

PID regulation (regulation mode 2)
This method is based on boiler temperature indications T1, it consists in constant, smooth
modulation of the fan revolutions in order to stabilize the preset boiler temperature. The
regulator itself selects the airflow power in such a way that the boiler generated minimum
amount of heat necessary to satisfy the heat demand of the building. Transition to the
SUPERVISION mode is rare and it happens during lack of heat demand. This is the preset setting
of the boiler.

PID-S regulation with exhaust temperature sensor (regulation mode 3)
This method is based on emission sensor indications T3. It consists in constant, smooth
modulation of the fan revolutions in order to stabilize the preset emission temperature. As
opposed to the PID, the airflow operation is more stable, without excessive increasing of the
airflow power, which makes that method more economical in respect of fuel saving.

After loading the fuel and pushing the START button, the fan operates with maximum revolutions
As the preset emission temperature is approached, the revolutions are automatically reduced.
When the emission temperature reaches the preset temperature for the first time, a slight
adjustment is made.

Moreover, after equipping the regulator with an emission sensor, it is possible to enable very
fast detection of fuel shortage. This provides additional saving of heat energy resulting from
almost instantaneous deactivation of the fan when the fuel runs out. Also, the fuel needs not be
added quickly, as fast detection of the lack of fuel maintains glow in the boiler furnace for a
longer time.

In order to preset the emission temperature, press the “F” button until the following window
appears:

BOILER START-UP

20

Use the „+” and „-” buttons to respectively increase or decrease the preset emission
temperature; please note that the value in the upper part of the thermometer symbol is x10,

e.g.: 20°C, means 200°C. The preset emission temperature should generally be between 160
and 250°C.

The optimal preset emission temperature depends on the type of fuel and the heat necessity,
and it should be determined experimentally. When burning wood, the flame should be blue­yellow, and when burning coal – yellowish. For example, the optimal temperature for wood is
between 190 and 260°C.

If optimal emission temperature causes excessive heating up of the boiler, it is best to store the
surplus energy in a thermal buffer. If the central heating system does not feature a thermal
buffer, you must find such preset emission temperature at which the temperature of water in
the boiler is at the desired level. If it is too hot in a room, decrease the preset emission
temperature, and increase it in the opposite case. The preset boiler temperature is in this method
of secondary importance, it prevents exceeding undesirable temperature of the boiler. It is

recommended to preset the boiler temperature as 10°C higher than the expected boiler

temperature after the emission temperature settles. After the boiler reaches the preset
temperature, the regulator switches to SUPERVISION mode.

Note: the regulator will automatically switch from regulation mode 3 to mode 1, if the
emission sensor is damaged or if the emission temperature exceeds the emission
sensor measuring capacity. Therefore, it is important to set proper parameters for the
regulator to operate in mode 1, without causing any danger.

Setting emission temperatures lower than 160°C can cause condensing in the
chimney!

If PID-S mode is chosen, it is recommended to use combined with a buffer tank.

High emission temperature, even if the fan rotates slowly, can mean that the
boiler is blocked of ash and need to be cleaned.

If emission temperature reaches higher than 400oC the boiler will stope and
alarm will be activated.

BOILER START-UP

21

6.6. Combustion regulation

After completing the fuel loading procedure and closing the door, set the required temperature.
After the fan is activated, you can adjust the air volume from the control panel.

The flame will have to occupy about two thirds of the fire chamber and quietly lick the cylindrical
heat exchanger. Its shape must be fully developed and with not too many detachments at the
flame end. Its color must be vivid orange-yellow, not too transparent.

GENERAL SUGGESTIONS

 The flame needs to have reasonable dimensions and fill up the fire chamber as told.
 The flame must not be too red (too low air supply).
 The flame must not have big detachments and sparkles (too high air supply).
 The flame must not be too small. If it is slow, easily influenced by air currents and the

chimney draught, it means that the air supply is too low.

 The smoke at the chimney must be clear-grey. Black smoke means lack of air supply.
 If too much ash and big coal pieces fall down to the ash box reduce the air supply.

The flame is too fast, dry, and might make a noise.

6.7. Supervision mode

After the boiler has reached the preset temperature, it will enter in SUPERVISION mode. In the
SUPERVISION mode the fan is enabled cyclically for short periods, in order to prevent the fire
from going out and to remove accumulated combustible gases from the fire chamber.

6.8. Stop mode

Unless the START button is pressed in the main display window (right after turning the regulator
on via the mains switch), the device controls only the pumps.
The central heating pump and the hot utility water pump operate in accordance with their
algorithm. They are activated if appropriate conditions are met. The conditions for pump
activation are described in individual sections of the manual.

6.9. Chimney damper adjustment

The boiler chimney pipe is equipped with a damper. This
can be set in various positions to throttle the exhaust
gases.

At nominal function of the boiler this damper should be
normally open. Also it should always be at open position
at boiler start-up.

If the chimney draught is too big and the gases are
evacuated too fast, set this damper at a side position by
inserting the positioner at a different hole.

Fig 6. Chimney damper

SERVICE AND MAINTENANCE

22

7. SERVICE AND MAINTENANCE

7.1. Cleaning the boiler

Solid fuel boiler require regular cleaning in order to function properly and efficient. Cleaning
must be effected at least once a week. The boiler is equipped with three cleaning tools

appropriate for the cleaning procedure of the boiler, as shown in Fig 7.

The boiler function must be stopped

before cleaning! Make sure all the
devices are stopped, and the boiler has
cooled down. It is strictly prohibited to clean
the boiler while in function!

Fig 7. Boiler cleaning tools

Open the upper door to have access to the heat exchanger. Remove the turbinators from the
tubes, and clean the tubes with the appropriate tool. Afterwards clean the exterior surface of
the cylindrical heat exchanger with the exchanger cleaning tool, as shown in Fig 8. With the
same tool, scrape the ash and any other remains from the side walls of the boiler.

Fig 8. Cleaning of the heat exchanger

Open the lower door of the boiler and remove the
ash box. Empty all the containing ash. With the ash
cleaning tool you can scrape the lower surface of
the boiler for any residues of ash.

The ash must be disposed in an

appropriate container! Do not throw the

ash together with the domestic garbage. Be
careful since ash might contain hot particles,
even long time after stop.

Fig 9. Removing the ash

Legend:

1.

Tubes cleaning tool

2.

Heat exchanger cleaning tool

3.

Ash cleaning tool

SERVICE AND MAINTENANCE

23

7.2. Cleaning the chimney box

To ensure efficient and safe function of the boiler, you must
clean the chimney box from ash residues at least every 3

months.

The ash box is equipped with a cleaning door for this purpose,
as shown in Fig 10. In order to open the door, unscrew the
wing nuts, remove the washers and springs that keep it in
place.

Clean the interior of the chimney box and remove all the ash
and residues.

Put back the door the same way as removed.

The springs must not be omitted! They act as
safety in order of explosion of exhaust gases in

the chimney box.

Fig 10. Cleaning the chimney box

7.3. Maintenance intervals

7.3.1. Daily maintenance

The pressure of the network must be daily verified to be within the allowed limits. Make sure
that all the safety devices and pumps function properly.

7.3.2. Weekly maintenance

The boiler must be cleaned every 3-4 days or at least once a week, depending on the ash quantity
accumulated on the boiler walls and in the heat exchanger. Cleaning procedure must be
performed according to the instruction given in the corresponding paragraph.

Check the quantity of ash accumulated in the ash box. The ash disposal can be performed every
1-2 weeks, depending on the ash quantity formed.

7.3.3. Monthly maintenance

Check the doors and the sealing cord. Make sure the contact with the boiler is air-tight. If ash
has accumulated on the sealing cord, clean it.

Check the fan and make sure it functions properly. Clean from dust and check that the air
passage is clear of obstacles and dust.

Remove the turbinators from the heat exchanger and check their condition.

It is recommended that you clean the chimney box of the boiler and the chimney pipes at least
every 3-4 months, in order to assure efficient and safe function of the boiler.

SERVICE AND MAINTENANCE

24

7.4. Basic service procedures

7.4.1. Service after overheating

If overheating occurs, the safety valves of the boiler must open.

Make sure the boiler pump is working. In case of blackout open all the valves of the system to
let hot water out of the boiler. In any case a blackout protection UPS is recommended to be
installed on the boiler pump.

If the chimney damper is not fully opened, put it in fully open position.

All safety devices must lead to drainage! After overheating, make sure that all the water from
the safety devices has drained, and the system has filled with cold water. Check the pressure
and the temperature of the boiler.

At overheating, the safety thermostat will activate, and cut electrical supply to the fan. In that
case, you need to manually reset the safety thermostat and put the system back in function.
Unscrew the plastic cover of the safety thermostat and press the switch. Put the plastic cover
back.

Verify the causes of the overheating! If it happens again, check the installation
and function of the pumps and safety devices!

7.5. Maintenance after long stop

It is necessary to perform a general maintenance and cleaning of the boiler after the heating
season. Clean thoroughly all the surfaces of the boiler as described in the corresponding
paragraph. Also clean the chimney box, and all the chimney parts where ash might be deposited.
After cleaning all the ash, empty the ash box and leave the boiler clean for the next winter
season.

After long stop of the boiler, before you put in function you need to perform the following checks:

 Check the condition of the electric cables and the sensors. Make sure they are not damaged.

Check that the thermometer indicates the correct temperature and all the thermostats
function properly. Make sure the bulbs are properly positioned in the case.

 Make a general check of the chimney and make sure it is clean and free of obstacles.
 Verify the pressure in the heating network and the boiler.

Do not empty the water of the boiler and the heating installation after the heating
season! It will corrupt all the installation and especially the boiler.

 Check that all the valves are working properly. Replace them if necessary. Pay special

attention so that all the safety equipment of the boiler functions properly!

 Make sure all the ball valves of the boiler and other relative equipment are open.
 Check the function of the pumps. They might be blocked after long stop.
 Check that there have been no modifications to the installation and the boiler room

(ventilation openings, chimney, doors).

 Check the fan and clean from dust. Turn it manually to ensure it is not blocked.

TROUBLESHOOTING

25

8. TROUBLESHOOTING

Problem

Cause

Solution

The lamps of the
control panel do not
light

- no electrical supply to the lamp

- the control panel is not
connected to electricity

- lamp defect

- electric cable defect

- check/replace the lamp

- connect to electricity

- check/replace the cables

The boiler does not
reach set
temperature

- fan blocked

- air passages are blocked

- boiler is not cleaned

- incorrect boiler start-up

- insufficient water in the system

- too big pump debit

- boiler under dimensioned

- bad quality fuel used

- insufficient chimney draught

- check/replace the fan, check the
function of the fan regulator and
thermostat

- clean the air passages

- clean the boiler

- start the boiler correctly

- fill the system

- regulate the pump speed

- change the fuel used

- check/clean the chimney

High temperature in
the boiler, but low
temperature at the
radiators

- too high hydraulic resistance in
the heating network

- thermostatic mixing valve is
connected wrong

- increase the pump speed

- check/replace the mixing valve

Condensation
formation in the fire
chamber

- too big boiler power

- too low return temperature in the
boiler

- fuel with excessive humidity

- load less fuel in the chamber

- install a return protection
system/thermostatic valve

- change the fuel used

Smoke coming out of
the doors

- boiler doors not regulated

- defect sealing cord of the door

- insufficient chimney draught

- too high air supply by the fan

- regulate the doors so that the
sealing cord stays tight

- check/replace the sealing cord

- check/clean the chimney

- reduce the air speed

The fan does not
function or it makes a
lot of noise

- set temperature reached

- disconnected by safety
thermostat

- capacitor/motor defect

- bad electrical connection of the
fan

- correct boiler function

- reset manually

- check/replace the fan

- check the electrical connection of
the fan

26

DECLARAȚIE DE CONFORMITATE EC

CE DECLARATION OF CONFORMITY

(conform cu ANEXA VII din Directiva Europeană 97/23/EC)

(in compliance with the Annex VII of the European Directive 97/23/EC)

Producător / The Manufacturer’s name: THERMOSTAHL ROMANIA SRL
Adresa producătorului / Manufacturer’s address: Str. Drumul Osiei 57-59, sector 6, București, România

PRIN PREZENTA, DECLARĂ

Declares that the equipment

Tip:
Type:

Cazan de apă caldă cu funcționare pe combustibil solid -încărcare manuală
Heating boiler for solid fuel, manually stocked

Obiectul declarației:

Object of the Declaration:

ECOWOOD STANDARD / ECOWOOD PLUS
Seria / Anul:
Serial Number / Year:

ESTE CORESPUNZĂTOR CU CERINȚELE DIRECTIVEI 97/23/EC-ECHIPAMENT SUB PRESIUNE

MEETS THE REQUIREMENTS PROVIDED BY THE 97/23/EC DIRECTIVE-PRESSURE EQUIPMENT

ȘI A URMĂTOARELOR DOCUMENTE:

AND THE REQUIREMENTS OF THE FOLLOWING DOCUMENTS:

Produsul este conform cu următoarele standarde:

The product is in compliance with the following standards:

EN 303-5:2012

Cazane de încălzit.
Partea 5: Cazane speciale care utilizează combustibili solizi, cu încărcare manuală şi automată, cu puterea utilă mai mică sau egală
cu 500 kW. Terminologie, cerinţe, încercare şi marcare

Heating boilers.
Part 5: Heating boilers for solid fuels, hand and automatically stocked, nominal heat output of up to 500 kW
Terminology, requirements,testing and marking

Directive Europene aplicabile echipamentului

European Directives applied to the equipment

97/23/EC

Directiva Echipament sub Presiune (HG 584/2004) / Pressure Equipment Directive (PED)

2014/35/EC

Directiva Echipamente de joasă tensiune / Low Voltage Directive (LVD)

2014/30/EC

Directiva Compatibilitate Electromagnetică / Electromagnetic Compatibility Directive (ECD)

Informații suplimentare / Additional information:

Toate echipamentele care fac obiectul prezentei declarații au fost testate hidraulic la presiunde de proba egală cu 1,5 ori presiune maxima de lucru, conform
cu Anexa I – p. 7.4 a Directivei 97/23/EC.

As provided by the Annex I - p. 7.4. of the 97/23/CE Directive, all the equipment object of the present Declaration have been hydraulic tested to a test pressure equal
to 1,5 times the maximum allowed working pressure.

Director General

General Director

România, București, 15 Octombrie 2015
Matsios Dionysios

THERMOSTAHL ROMANIA

HEATING SYSTEMS S.R.L.

DRUMUL OSIEI 57-59, sector 6

Bucharest 062395, Romania

www.thermostahl.ro