Eco Engineering Easypell User manual

Installation
Manual
Easypell
16 - 32 kW
ENGLISH
www.easypell.com
200014EN

Title:
Article number:
Installation Manual Easypell 16 - 32 kW
200014EN 2.0
Version valid from:
Approved:
07/2022
Christian Wohlinger
Author
Eco Engineering 2050 GmbH
A-4133 Niederkappel, Gewerbepark 1
E-Mail: o[email protected]
www.easypell.com
© by Eco Engineering 2050 GmbH
Subject to modifcations

Contents
1 Dear Customer 4
2 Intended use 5
3 Types of safety warning sign 7
4 Prerequisites for installing a pellet boiler 8
4.1 Guidelines and standards for installing a pellet boiler 8
4.2 Central heating room 9
4.3 Flue gas system 10
4.4 Safety systems 11
4.5 Operation of a pellet boiler with an existing boiler 11
5 Warnings and safety instructions 12
5.1 Basic safety instructions 12
5.2 Warning signs 12
5.3 What to do in an emergency 14
6 The Easypell 15
7 Bringing the pellet boiler into the central heating room 17
7.1 Transport 17
7.2 Notes on bringing the unit into the building 17
7.3 Casing parts 19
7.4 Removing the casing, the hopper and the burner 20
7.4.1 Dismantling the burner casing and burner 21
7.4.2 Dismantling the boiler door 22
7.4.3 Dismantling the boiler casing 23
7.5 Change position of flue gas fan 24
8 Performance adjustment 25
8.1 Installing the turbulators and closure plugs 25
9 Connecting up the hydraulics 27
10 Fuses - boiler controller 29
10.1 Plugs on the boiler control unit 30
10.2 Cable routing 31
10.3 Wiring diagrams 32
11 Starting up for the first time 35
12 Starting the pellet boiler 36
13 Controller for heating circuits and DHW 39
13.1 Code level 39
13.2 Version A 40
13.2.1 Commissioning controller version A 43
13.3 Version B 49
13.3.1 Commissioning controller version B 51
13.4 Version C 58
13.4.1 Commissioning controller version C 60
13.5 Version D 69
13.5.1 Commissioning controller version D 71
13.6 Version E 81
13.6.1 Commissioning controller version E 83
13.7 Setting the time program 92
13.8 Setting the time 92
14 Default values and settings 93
15 Spare parts 94
16 Technical data 96
Contents

1 Dear Customer
•This manual is intended to help you operate the product safely, properly and eco-
nomically.
•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.
4 1 Dear Customer
Installation Manual

2 Intended use
The pellet heating system is designed to heat water for central or other indirect heat-
ing systems and hot water supply for buildings. It is not permissible to use the pellet
heating system for any other purpose. Reasonable foreseeable inadvertent uses for
the heating system are not known.
The Easypell complies with all directives, regulations and standards relevant for this
type of equipment within the scope of the declaration of conformity of the CE
marking.
EU Directives Description
2006/42/EC Basic safety and health requirements for the design and con-
struction of machinery
2006/95/EC Directive concerning electrical equipment for use within certain
voltage limits
2001/95/EC Product Safety Guideline
2004/108/EC Directive on the approximation of laws on electromagnetic com-
patibility and repealing Directive 89/336/EC
The following harmonized standards were applied:
Standards Description
EN 303–5 Heating boilers Part 5, Heating boilers for solid fuels, manually
and automatically fed firing systems, nominal heat output up to
300kW
EN ISO 17225–2 Solid biofuels - Fuel specification and classes Part 2: Wood pel-
lets for non-industrial use
The following National Standards, Guidelines and Specifications have been applied:
Standards Description
TRVB H 118 Technical Guideline Preventive Fire Protection, Automatic Wood
Combustion Plants
2 Intended use 5
Installation Manual

6 2 Intended use
Installation Manual

3 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
DANGER
Danger - indicates a situation that could lead to death or lifethreatening injury.
▶Observe the instructions for eliminating this hazard!
WARNING
Warning - indicates a situation that could lead life-threatening or serious injury.
CAUTION
Caution - indicates a situation that could lead to injury.
NOTICE
▶indicates a situation that could lead to property damage.
3 Types of safety warning sign 7
Installation Manual

4 Prerequisites for installing a pellet boiler
You must fulfill the following conditions before operating a fully automatic pellet
boiler.
4.1 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 authori-
ties 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 system. 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 combustion air line from outside and the connect-
ing piece to the chimney are part of the fireplace.
Sound insulation DIN 4109 Please note the building-unique demands on sound
insulation.
8 4 Prerequisites for installing a pellet boiler
Installation Manual

4.2 Central heating room
The pellet boiler is installed in the central heating room.
1.Safety instructions for the heating room
DANGER
Risk of fire
Do not store flammable materials or liquids in the vicinity 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 200cm2). Legislation 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 com-
pletely closed.
Contaminated combustion air can cause damage to the pellet boiler. Never store
of use cleaning detergents 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 humidity 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 over any openings.
6.Flooding
If there is a risk of flooding, switch o the pellet boiler in good time and discon-
nect 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.
NOTICE
Oxidation of chimney
Do not use metal brushes to clean chimneys made of stainless steel.
▶Legislation in your country must be observed.
4 Prerequisites for installing a pellet boiler 9
Installation Manual

4.3 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 design of the chimney is very important. The chimney must ensure safe exhaust
of the flue gases in all operating conditions of the boiler. The flue system must be
designed in accordance with local regulations or ÖNORM EN 13384-1. The flue pipe
must be insulated and must rise to the chimney and be as short as possible.
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
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 eect 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 boiler performance
must be reduced if the chimney does not possess the necessary cross-section. This
may only be performend by authorised personnel.
10 4 Prerequisites for installing a pellet boiler
Installation Manual

4.4 Safety systems
The following safety measures are the prerequisite for safe operation of your sys-
tem.
Emergency stop switch
Every heating system must be able to be switched o 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
pellet boiler. If the boiler temperature exceeds 95°C then the heating system switches
o.
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 dimensions of the hydraulic system.
NOTICE
Starting up
Starting up for the first time has to be performed only by an authorized service tech-
nician.
4.5 Operation of a pellet boiler with an existing boiler
There are dierent regulations in the dierent European countries. Please mind the
prescription of your country.
4 Prerequisites for installing a pellet boiler 11
Installation Manual

5 Warnings and safety instructions
Observing safety instructions ensures that the heating system is operated safely.
5.1 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.
5.2 Warning signs
DANGER
Risk of poisoning
Make sure that the pellet boiler is supplied with sucient combustion air. The open-
ings in the combustion air inlet must never bepartially or completely closed. Ventila-
tion systems, central vacuum cleaning systems,extractor fans, air conditioning sys-
tems, flue gas blowers, 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 con-
nected tight to the chimney using 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
suciently supplied with air and ventilated. Before entering the storage room it must
be ventilated with sucient air and the heating system switched o.
DANGER
Risk of electric shock
Switch o the system before performing work on the boiler.
DANGER
Risk of explosion
Never burn petrol, diesel, engine oil or other explosive materials. Never use liquids or
chemicals to ignite the pellets.
DANGER
Risk of fire
Do not store any flammable materials in the central heating room. Do not hang out
any washing in the central heating room. Always close the boiler door.
12 5 Warnings and safety instructions
Installation Manual

WARNING
Risk of burns
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.
CAUTION
Risk of cut injuries due to sharp edges.
Use gloves for performing all work on the boiler.
NOTICE
Damage to property
Heat the pellet heating system using pellets that comply with EN ISO 17225–2 class A1
only.
NOTICE
Damage to property
Do not use the heating system if it, or any of its components, come into contact with
water. If water damage occurs, have the heating system checked by an service techni-
cian and have any damaged parts replaced.
5 Warnings and safety instructions 13
Installation Manual

5.3 What to do in an emergency
What to do in the event of a fire
•Switch o the heating system.
•Call the fire brigade
•Use approved fire extinguishers (fire protection class ABC).
What to do if you smell smoke
•Switch o the heating system.
•Close the doors leading to living areas.
•Ventilate the central heating room.
NOTICE
EMERGENCY STOP SWITCH
In both cases, the emergency stop switch must be operated outside the boiler room.
14 5 Warnings and safety instructions
Installation Manual

6 The Easypell
Easypell types and power ratings
Eco Engineering oers the Easypell with the following power ratings: 16, 20, 25 and
32kW.
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
2
1
4
3
1 Boiler (heat exchanger) 3 Boiler controller
2 Burner 4 Pellet hopper
6 The Easypell 15
Installation Manual

1 Burner plate 7 Suction fan
2 Flame tube 8 Anti-blowback system
3 Heat exchanger 9 Burner auger
4 Boiler water 10 Electronic ignition
5 Boiler insulation 11 Combustion chamber sensor
6 Combustion chamber cover 12 Ash box
16 6 The Easypell
Installation Manual

7 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
7.1 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 boiler controller and the pellet hopper. This will reduce the
weight of the unit and make it easier to carry.
Tighten the hydraulic connections firmly on site and carry out a density test.
NOTICE
Contamination and corrosion
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.
7.2 Notes on bringing the unit into the building
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.
Minimum door width — max. unit dimension
Easypell 16 / 20 16 – 20 kW 677 mm
Easypell 25 / 32 25 – 32 kW 724 mm
7 Bringing the pellet boiler into the central heating room 17
Installation Manual

Boiler dimensions
E
T
C
90 mm
B
H
F
DA
Dimensions in mm Easypell 16 Easypell 20 Easypell 25 Easypell 32
A: flow & return 1120 1310
B: overall width of pellet boiler 1145 1145
C: Width of boiler casing 665 703
D: Hight flue gas tube 1155 1350
E: Diameter flue gas tube 130 150
H: Height of boiler casing 1092 1294
F: Height hopper 1425 1525
T: Depth of boiler casing 720 770
Boiler Weight
Dimensions in kg Easypell 16 Easypell 20 Easypell 25 Easypell 32
Weight of boiler with casing,
hopper and burner 345 420
Minimum clearance dimensions required
To install the heating system properly and ensure economical operation, you need to
make sure that minimum 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 clearanceof the flue gas tube.
18 7 Bringing the pellet boiler into the central heating room
Installation Manual

a
b
d
c
e
aMin. clearance of flue gas connection from wall or part of
building 150 mm
bMin. clearance of side of boiler from wall or part of build-
ing 300 mm
cMin. clearance of front of boiler from wall or part of build-
ing 700 mm
dMin. clearance of side of burner from wall or part of build-
ing 150 mm
e Min. room height 2050 mm
Legislation in your country must be observed!
The indicated values must not fall below by piping or other.
7.3 Casing parts
Die Verkleidungsteile umgeben den Kessel. Sie verhindern den Kontakt zu heißen,
beweglichen und stromführenden Bauteilen. Sie geben dem Pelletkessel Easypell das
unverwechselbare Aussehen.
7 Bringing the pellet boiler into the central heating room 19
Installation Manual

7
3
2
6.1
5
4
6
1
1 Pellet hopper casing cover 5 Boiler door
2 Boiler casing cover 6 Pellet hopper casing
3 Boiler side panel 6.1 Cover pellet hopper casing
4 Front of boiler 7 Boiler rear panel
7.4 Removing the casing, the hopper 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 follow-
ing sections:
1.Dismantling the burner casing and the burner
2.Dismantling the boiler door
3.Dismantling the boiler casing
20 7 Bringing the pellet boiler into the central heating room
Installation Manual