Eco Engineering Easypell 16 User manual

Installation
Manual
Easypell
16 — 32kW
ENGLISH
200014_EN 1.2 ·www.easypell.com

Title: Installation Manual Easypell 16 — 32kW
Article number: 200014_EN 1.2
Version valid
from:
12/2015
Approved: Wohlinger Christian
Author
Eco Engineering 2050 GmbH
A-4132 Lembach, Mühlgasse 9
Tel.: [phone] / 74 50
Fax.: [phone] / 74 50 – 10
E-Mail: [email protected] © by Eco Engineering 2050 GmbH
www.easypell.com Subject to modifcations

Contents
11DDeeaarrCCuussttoommeerr ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .................................. 44
22TTyyppeessooffssaaffeettyywwaarrnniinnggssiiggnn................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 55
33PPrreerreeqquuiissiitteessffoorriinnssttaalllliinnggaappeelllleettbbooiilleerr ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 66
3.1 Guidelines and standards for installing a pellet boiler .................................................................................. 6
3.2 Central heating room ................................................................................................................................... 6
3.3 Flue gas system.............................................................................................................................................7
3.4 Safety systems ............................................................................................................................................. 8
3.5 Operation of a pellet boiler with an existing boiler ...................................................................................... 8
44WWaarrnniinnggssaannddssaaf
feettyyiinnssttrruuccttiioonnss................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 99
4.1 Basic safety instructions ............................................................................................................................... 9
4.2 Warning signs............................................................................................................................................... 9
4.3 What to do in an emergency.......................................................................................................................10
55TThheeEEaassyyppeellll............................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..............................................1111
66BBrriinnggiinnggtthheeppeelllleettbbooiilleerriinnttootthheecceennttrraall hheeaattiinnggrroooomm ................................................................................................................................ .. .. .. .. .. .. .. .. 1133
6.1 Transport...................................................................................................................................................... 13
6.2 Notes on bringing the unit into the building ............................................................................................... 14
6.3 Casing parts ................................................................................................................................................ 16
6.4 Dismantling the burner casing and the burner ........................................................................................... 17
6.4.1 Dismantling the burner casing and burner ............................................................................................... 17
6.4.2 Dismantling the boiler door...................................................................................................................... 19
6.4.3 Dismantling the boiler casing.................................................................................................................. 20
77AAddjjuus
sttiinnggppoowweerrrraattiinngg ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..2211
7.1 Installing the turbulators and closure plugs................................................................................................. 21
88CCoonnnneeccttiinngguupptthheehhyyddrraauulliiccss ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2233
99TThheebbooiilleerrccoonnttrroolllleerr................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .......... 2244
9.1 Plugs on the boiler control unit....................................................................................................................25
9.2 Cable routing.............................................................................................................................................. 26
9.3 Wiring diagrams..........................................................................................................................................27
1100SSttaarrttiinngguuppffoorrtthheeffiirrssttttiimmee ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2
288
1111SSttaarrttiinnggtthheeppeelllleettbbooiilleerr................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 2299
1122CCoonnttrroolllleerrffoorrhheeaattiinnggcciirrccuuiittssaannddDDHHWW ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. 3300
12.1 Version A....................................................................................................................................................30
12.1.1 Commissioning controller version A ........................................................................................................ 33
12.1.2 Selecting the set DHW temperature ....................................................................................................... 34
12.1.3 Setting the time program for DHW heating ........................................................................................... 35
12.1.4 Setting the time....................................................................................................................................... 38
12.1.5 Status display ..........................................................................................................................................40
12.2 Version B ...................................................................................................................................................40
12.2.1 Commissioning controller version B ....................................................................................................... 42
12.2.2 Setting the boiler heating period............................................................................................................ 43
12.2.3 Setting the time ......................................................................................................................................46
12.2.4 Status display ......................................................................................................................................... 48
1133MMaallffuunnccttiioonnss................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ..................................4
499
13.1 Malfunctions - what to do ..........................................................................................................................49
13.2 Fault texts..................................................................................................................................................49
1144AAppppeennddiixx ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ............................................ 5533
14.1 Checklist for checking the heating system................................................................................................ 53
14.2 Retrofit motor cleaning device ................................................................................................................. 55
1155SSppaarreeppaarrttss ................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ...................................... 5588
1166TTeecchhnniiccaall ddaattaa................................................................................................................................ .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. .. ............................6600
Installation Manual Easypell 16 — 32kW

4Dear Customer
11 Dear Customer
• This manual is intended to help you operate the product safely, properly and economically.
• Please read this manual right through and take note of the safety warnings.
• Keep all documentation supplied with this unit in a safe place for future reference.
Please pass on the documentation to the new user if you decide to part with the unit at a later date.
• Please contact your authorised dealer if you have any questions.
200014_EN 1.2

Types of safety warning sign 5
22 Types of safety warning sign
The warning signs use the following symbols and texts.
Types of safety warning sign
1. Risk of injury
2. Consequences of risk
3. Avoiding risk
1. Risk of injury:
Danger - indicates a situation that could lead to death or life-
threatening injury.
Warning - indicates a situation that could lead life-threatening or
serious injury.
Caution - indicates a situation that could lead to injury.
Note - indicates a situation that could lead to property damage.
2. Consequences of risk
Effects and consequences resulting from incorrect operation.
3. Avoiding risk
Observing safety instructions ensures that the heating system is
operated safely
Installation Manual Easypell 16 — 32kW

6Prerequisites for installing a pellet boiler
33 Prerequisites for installing a pellet boiler
You must fulfill the following conditions before operating a fully automatic pellet boiler.
3.1 Guidelines and standards for installing a pellet boiler
Overview of standards and guidelines applying to the installation of a pellet boiler.
Check whether you need to obtain planning permission or approval from the authorities for installing a new
heating system or changing your existing system. Legislation in your country must be observed.
Flue gas system EN 13384–1 Legislation in your country must be observed.
Building and fire pre-
vention regulations
Legislation in your country must be observed.
Type of installation FC 42x Fireplace with a flue gas fan for connection to an air exhaust sys-
tem. The combustion air line from air shaft and the connecting
piece to the chimney are part of the fireplace.
FC 52x Fireplace with a flue gas for connection to a chimney. The com-
bustion air line from outside and the connecting piece to the
chimney are part of the fireplace.
Sound insulation DIN 4109 Please note the building-unique demands on sound insulation.
3.2 Central heating room
The pellet boiler is installed in the central heating room.
1. Safety instructions for the heating room
RRiisskkooffffiirree
Do not store flammable materials or liquids in the vicini-
ty of the pellet boiler.
Do not permit unauthorised persons to enter the central
heating room - children are to be kept out.
Always close the boiler door.
2. Air supply and ventilation of central heating room
The central heating room must be fitted with air supply and ventilation openings (at least 200cm). Legis-
lation in your country must be observed.
3. Combustion air supply
The pellet boiler needs a supply of combustion air.
Never operate the pellet boiler if the air intake openings are partially or completely closed.
Contaminated combustion air can cause damage to the pellet boiler. Never store of use cleaning deter-
gents containing chlorine, nitrobenzene or halogen in the room where the heating system is installed, if
combustion air is drawn directly from the room.
Do not hang out washing in the central heating room.
Prevent dust from collecting at the combustion air intake to the pellet boiler.
4. Damage due to frost and humid air
The central heating room must be frost-proof to ensure trouble-free operation of the heating system. The
temperature of the central heating room must not fall below –3°C and must not exceed +30°C. The air hu-
midity in the central heating room must not exceed 70%.
5. Danger for animals
Make sure that household pets and other small animals cannot enter the central heating room. Fit mesh
200014_EN 1.2

Flue gas system 7
over any openings.
6. Flooding
If there is a risk of flooding, switch off the pellet boiler in good time and disconnect from the power supply
before water enters the central heating room. You must have all components that come into contact with
water replaced, before you start up the pellet boiler again.
7. Cleaning
Clean the flue gas tube and chimney regularly.
OOxxiiddaattiioonnooffcchhiimmnneeyy
Do not use metal brushes to clean chimneys made of
stainless steel.
Legislation in your country must be observed.
3.3 Flue gas system
The flue gas system consists of a chimney and a flue gas tube. The flue gas tube connects the pellet heating
system to the chimney. The chimney leads the flue gas from the pellet heating system out into the open.
1. Design of the chimney
The dimensions and design of the chimney is very important. The chimney must be able to ensure suffici-
ent draft to safely draw away the flue gas regardless of the status of the boiler. Low flue gas temperatures
can cause sooting and moisture damage on chimneys that are not insulated. For this reason moisture-re-
sistant chimneys (stainless steel or ceramic) should be used. Chimneys made of plastic are not permitted.
An existing chimney that is not damp-resistant needs to be rennovated before use.
Boiler size Easypell 16 Easypell 20 Easypell 25 Easypell 32
Flue gas tube diameter
(at boiler) – [mm]
130 150
Chimney diameter as per chimney calculation, EN 13384–1
Chimney design damp-resistant
2. Flue gas temperature
Boiler type Easypell 16 Easypell 20 Easypell 25 Easypell 32
Flue gas temperature
rating
160°C
Flue gas temperature
partial load
100°C
The dewpoint of flue gas with wood pellets (max. 10% water content) is approx. 50°C.
3. Chimney draft
The diameter of the chimney must be selected based on a chimney calculation according to EN 13 384–1.
The suction effect of the chimney draft must extend as far as the chimney connection. The maximum flow
rate that can be drawn through the chimney limits the maximum performance of the pellet boiler. The boi-
ler performance must be reduced if the chimney does not possess the necessary cross-section. This may
only be performend by authorised personnel.
Installation Manual Easypell 16 — 32kW

8Safety systems
3.4 Safety systems
The following safety measures are the prerequisite for safe operation of your system.
Emergency stop switch
Every heating system must be able to be switched off with an Emergency Stop switch.
The Emergency Stop switch must be inside the central heating room.
Safety valve
The hydraulic system must be equipped with a safety valve. This valve opens when the
pressure inside the heating system increases to max. 3 bar. The safety valve must:
–be installed at the highest point of the boiler,
–must not be locked,
–and must be within 1 metre of the boiler.
Safety temperature sensor
The pellet boiler is equipped with a safety temperature sensor. This is located on the pel-
let boiler. If the boiler temperature exceeds 95°C then the heating system switches off.
Expansion tank
All heating systems must be equipped with a pressurised expansion tank. The plumber
or heating system installer must dimension the expansion tanks according to the dimen-
sions of the hydraulic system.
SSttaarrttiinngguupp
Starting up for the first time has to be performed only
by an authorized service technician.
3.5 Operation of a pellet boiler with an existing boiler
There are different regulations in the different European countries. Please mind the prescription of your
country.
200014_EN 1.2

Warnings and safety instructions 9
44 Warnings and safety instructions
Observing safety instructions ensures that the heating system is operated safely.
4.1 Basic safety instructions
• Never get yourself into danger; give own safety the utmost priority.
• Keep children away from the central heating room and storage room.
• Observe all safety warnings on the boiler and in this user manual.
• Observe all instructions relating to maintenance, servicing and cleaning.
• The pellet heating system may only be installed and started up for the first time by an authorised plumber.
Professional installation and start up is the prerequisite for safe and economical operation.
• Never make any changes to the heating system or flue gas system.
• Never close or remove safety valves.
4.2 Warning signs
RRiisskkooffppooiissoonniinngg
Make sure that the pellet boiler is supplied with suffi-
cient combustion air.
The openings in the combustion air inlet must never be
partially or completely closed.
Ventilation systems, central vacuum cleaning systems,
extractor fans, air conditioning systems, flue gas blow-
ers, dryers or similar equipment must never be allowed
to draw air from the central heating room and cause a
drop in pressure.
The boiler must be connected tight to the chimney us-
ing a flue gas tube.
Clean the chimney and the flue gas tube at regular
intervals.
The central heating room and pellet storage room must
be sufficiently supplied with air and ventilated.
Before entering the storage room it must be ventilated
with sufficient air and the heating system switched off.
RRiisskkooffeelleeccttrriiccsshhoocckk
Switch off the system before performing work on the
boiler.
RRiisskkooffeexxpplloossiioonn
Never burn petrol, diesel, engine oil or other explosive
materials.
Never use liquids or chemicals to ignite the pellets.
Switch off the heating system before filling the storage
room.
Installation Manual Easypell 16 — 32kW

10 What to do in an emergency
RRiisskkooffffiirree
Do not store any flammable materials in the central
heating room. Do not hang out any washing in the cen-
tral heating room.
Always close the boiler door.
RRiisskkooffbbuurrnnss
Do not touch the flue spigot or the flue gas tube.
Do not reach into the ash chamber.
Use gloves to empty the ash box.
Do not clean the boiler until it has been allowed to cool
down.
RRiisskkooffccuuttiinnjjuurriieessdduueettoosshhaarrppeeddggeess..
Use gloves for performing all work on the boiler.
DDaammaaggeettoopprrooppeerrttyy
Heat the pellet heating system using pellets that comply
with EN ISO 17225–2 class A1 only.
DDaammaaggeettoopprrooppeerrttyy
Do not use the heating system if it, or any of its compo-
nents, come into contact with water.
If water damage occurs, have the heating system
checked by an service technician and have any dam-
aged parts replaced.
4.3 What to do in an emergency
RRiisskkttoolliiffee
Never get yourself into danger; give own safety the ut-
most priority.
What to do in the event of a fire
• Switch off the heating system.
• Call the fire brigade
• Use approved fire extinguishers (fire protection class ABC).
What to do if you smell smoke
• Switch off the heating system.
• Close the doors leading to living areas.
• Ventilate the central heating room.
200014_EN 1.2

The Easypell 11
55 The Easypell
Easypell types and power ratings
Eco Engineering offers the Easypell with the following power ratings: 16, 20, 25 and 32kW.
Note:
Refer to the data plate for the power rating of your Easypell. The data plate is located on the rear side of
the boiler. Here you find the type designation, manufacturer's serial number and year of build.
Key components of the Easypell
1Boiler (heat exchanger) 3Boiler controller
2 Burner 4 Pellet hopper
Installation Manual Easypell 16 — 32kW

12 The Easypell
1Burner plate 7Suction fan
2Flame tube 8Anti-blowback system
3Heat exchanger 9Burner auger
4Boiler water 10 Electronic ignition
5Boiler insulation 11 Combustion chamber
sensor
6Combustion chamber
cover
12 Ash box
200014_EN 1.2

Bringing the pellet boiler into the central heating room 13
66 Bringing the pellet boiler into the central heating
room
This section describes the prerequisites as well as the working sequence required.
1. Transport
2. Notes on bringing the unit into the building
3. Casing parts
4. Dismantling the casing parts
6.1 Transport
Maine Energy Systems supplies the pellet boiler on a pallet. The pellet boiler is ready to be connected.
The control unit for the boiler controller is integrated into the control panel.
If it is not possible to bring the boiler into the building at ground level, remove the casing, the burner, the boi-
ler controller and the pellet hopper. This will reduce the weight of the unit and make it easier to carry.
CCoonnttaammiinnaattiioonnaannddccoorrrroossiioonn
Make sure that the pellet boiler is located under a roof if
it needs to be stored outside before it is transported/
brought into the building.
Installation Manual Easypell 16 — 32kW

14 Notes on bringing the unit into the building
6.2 Notes on bringing the unit into the building
Before bringing the unit into the building, check the dimensions of all doors to ensure that the boiler has suffi-
cient clearance and can be set up properly.
Minimum door width — max. unit dimension
Easypell 16 / 20 16 — 20 kW 690 mm
Easypell 25 / 32 25 — 32 kW 720
Boiler dimensions
Dimensions in mm Easypell 16 Easypell 20 Easypell 25 Easypell 32
A: flow & return 905 905 1110 1110
B: overall width of pellet
boiler
1210 1210 1227 1227
B1: Width with cleaning lever 1206 1206 1232 1232
C: Width of boiler casing 695 695 728,5 728,5
D: Hight flue gas tube 645 645 844 844
E: Diameter flue gas tube 130 130 150 150
H: Height of boiler casing 1091 1091 1242 1242
F: Height hopper 1267 1267 1517 1517
T: Depth of boiler casing 752 752 796,5 796,5
Boiler Weight
Dimensions in kg Easypell 16 Easypell 20 Easypell 25 Easypell 32
Weight of boiler with casing,
hopper and burner
350 350 430 430
200014_EN 1.2

Notes on bringing the unit into the building 15
Minimum clearance dimensions required
Note:
To install the heating system properly and ensure economical operation, you need to make sure that mini-
mum clearance dimensions indicated below are observed when setting up the boiler.
In addition, make sure that legislation in your country is complied with relating to the minimum clea-
rance of the flue gas tube.
aMin. clearance of flue gas con-
nection from wall or part of
building
450 mm
bMin. clearance of side of boiler
from wall or part of building
200 mm
cMin. clearance of front of boiler
from wall or part of building
700 mm
dMin. clearance of side of burner
from wall or part of building
300 mm
eMin. room height 1950 mm
Note:
Legislation in your country must be observed!
Placement of rubber plates
The pellet heating boiler must be placed on the supplied
rubber plates.
Installation Manual Easypell 16 — 32kW

16 Casing parts
6.3 Casing parts
The boiler is protected by a casing on all sides. The casing parts prevent contact with hot, moving and live
components. They also give Easypell pellet boilers a unique appearance.
1Pellet hopper casing cover 4Boiler door
2Boiler casing cover 6Pellet hopper casing
3Boiler side panel 7Boiler rear panel
200014_EN 1.2

Dismantling the burner casing and the burner 17
6.4 Dismantling the burner casing and the burner
Dismantle the pellet boiler as far as necessary if site conditions require, so that the unit can be brought safely
into the building.
The complete dismantling of all components described here is divided into the following sections:
1. Dismantling the burner casing and the burner
2. Dismantling the boiler door
3. Dismantling the boiler casing
66..44..11DDiissmmaannttlliinnggtthheebbuurrnneerrccaassiinnggaannddbbuurrnneerr
Installation Manual Easypell 16 — 32kW

18 Dismantling the burner casing and burner
200014_EN 1.2

Dismantling the boiler door 19
66..44..22DDiissmmaannttlliinnggtthheebbooiilleerrddoooorr
Installation Manual Easypell 16 — 32kW

20 Dismantling the boiler casing
66..44..33DDiissmmaannttlliinnggtthheebbooiilleerrccaassiinngg
200014_EN 1.2