Ecotec A4 Installation guide

1
MANUAL FOR A4 MODEL WITH MAX. OUTPUT 20 kW
Operation and
maintenance
A4 Pellet burner
1-14-3009E
2005-03

2
Store this manual somewhere easily
accessiblefor future use.
Please read through the manual carefully
before starting up your EcoTec pellet system.
The output of your pellet burner is calcu-
lated according to the maximum quantity of
pellets that can be fed in and burned in the
burning cup in 1 hour, (refers to firing using
normal wood pellets as an average of our
fuel specification).
For larger output requirements (between 25-
300 kW), contact Sahlins EcoTec AB.
IMPORTANT!
The burner’s green protective cap and the lid of the control unit
must not be removed unless the voltage (main power) to the
system has been switched off.
The guarantee is valid provided that the product is installed by an
authorised EcoTec dealer.
FOLLOW THE INSTRUCTIONS IN THE MANUAL CAREFULLY AND CARRY
OUT THE RECOMMENDED CARE AND MAINTENANCE.

3
CONTENTS
OVERVIEW OF THE BURNER
OVERVIEW OF THE CONTROL PANEL
FUNCTIONAL DESCRIPTION
EASY TO MANAGE
SAFETY CHECKS/ALARMS
CONTROL SYSTEM / OPERATION
INSTALLATION
CONNECTION TABLE
TROUBLESHOOTING
MAINTENANCE
ADVICE ON FUEL PELLETS
GUARANTEE AND COMPLAINTS
OPERATION LOG
PAGE 4
PAGE 5
PAGE 6
PAGE 8
PAGE 9
PAGE 10
PAGE 16
PAGE 18
PAGE 20
PAGE 22
PAGE 23
PAGE 24
PAGE 25
CONTENTS

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1Burning cup
2Rotary arm
3Gear ring
4Primary ring
5Stop screws, burning cup
6Primary air pipe
7Secondary air pipe
8Hot-air ignition
9Optical sensor
10 Combustion fan
11 Release gate
12 Internal fuel store
13 Drive motor
14 Level sensor (receiver), black
15 Level sensor (transmitter), white
16 Connector
17 Feeder screw
18 Thermal contact
19 Microswitch
20 Quick-release bracket
21 Swivel arm bracket
1
2
3
3
5
5
6
6
7
8
8
9
10
11
11
12
13
13
14
15
16
17
18
19
20
21
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OVERVIEW OF THE BURNER

5
1Start
2Stop
3Display
4Control buttons for display manipulation
5Input operational thermostat cable
6Input Max. thermostat cable
7Input Lambda probe (optional)
8Input/Output multi-unit cable for the
burner
9Input voltage 230/240 VAC
10 Output external feed
11 Cover, terminal block
11
10
9
678
12 3
4
5
OVERVIEW OF THE CONTROL SYSTEM
Control box 3006

6
PELLET FIRING
Pellet firing with EcoTec’s pellet burners is
extremely similar to oil firing. A pellet
burner requires only slightly more main-
tenance than an oil burner. We recom-
mend maintenance measures such as
prudent sweeping of the boiler.
EcoTec pellet burners are supplied as
standard with automatic ignition, but
can always be lit manually.
FULLY AUTOMATIC
Operation of the burner and associated
feedersystems is fully automated and is
controlled via an in-built thermostat.
Complete combustion takes place in a
cost-effective and environment-friendly
way by means of preset oxygenation
using primary and secondary air.
The burner can be adjusted for fuel with
varying energy content.
See fuel specification, page 23.
The burner’s control unit is preprogram-
med and has default settings. The instal-
lation engineer can fine-tune the control
function to optimise combustion in the
boiler with regard to the fuel being used.
Fuel feed of pellets from the external fuel
store to the burner is fully automatic; it
employs a feedersystem that is adjusted
and controlled via the burner’s control
unit.
The burner can also be supplemented
with O2-regulation (lambda probe - this
requires a fully sealed boiler). The burner
then adjusts automatically to maintain
optimum combustion in relation to fuel
quality and actual energy consumption.
See separate manual.
FUNCTIONAL DESCRIPTION

7
PELLET
STORE
THE FEEDER SYSTEM
The feeder system is based on the safety
principle of interrupting the flow of fuel
by free fall (in the hose) between the
external feed and the burner.
NB ALWAYS EXERCISE CAUTION
WHEN HANDLING ASHES, AS
THEY MAY BE HOT.
NB AN ECOTEC BURNER MUST
NOT BE COMBINED WITH ANY
FEEDER SYSTEM OTHER THAN AN
ECOTECORIGINAL FEEDER
SYSTEM.
ASH REMOVAL
All combustion of solid fuel, even if it
takes place in the automated system
employed by EcoTec pellet burners,
requires maintenance and servicing. The
majority of the maintenance relates to
the fuel and its quality; see comparison
below. Good pellets contain no more
than 0.5% ash, meaning that ash only
needs to be removed every 3-4 weeks,
depending on boiler type. Pellets with
2% ash produce enough ash to require
weekly ash removal under the same
conditions.
Switch off the burner using the STOP
button; wait until firing has died down and
the burner has stopped. Wait a further
30 mins to allow the burner to cool.
NB Do not switch off the main power
switch until maintenance is ready to
commence.
The following measures and checks
should be performed each time ash is
removed to ensure safe, trouble-free
operation, or at least once a month until
you have the necessary experience to
judge required maintenance intervals.
A plastic ash collector that can be con-
nected to an ordinary vacuum cleaner is
available as an optional accessory.
A sheet-metal version is also available with
built-in suction fan.
FUNCTIONAL DESCRIPTION

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EASY TO MANAGE
Pellet burners from EcoTec are designed
in line with the main principles we are
accustomed to for oil-fired heating. The
benefit of these main principles is con-
venient handling, where the location of
the fuel store is not being restricted by
the design of the boiler room. In terms
of safety, separation of the burner and
fuel store, in combination with a non-
continuous fuel feed between them
provides increased protection against the
spread of fire in the event of backburn-
ing.
Damage resulting from incorrect hand-
ling, or poor function or installation will
be limited to the burner’s internal fuel
store.
In short, the internal store is only refilled
with a limited quantity of fuel via the
external feeder system at each filling.
Fuel is fed through a tight-fitting outfeed
that is synchronised with the external
feed process.
A thermal contact, located just outside
the boiler on the fuel feed pipe, detects
any heat spreading back into the fuel
feed pipe towards the internal store.
Should this occur, fuel already present in
the fuel feed pipe will be fed into the
boiler immediately, and refilling of the
internal store will cease.
The burner’s control unit is linked to the
boiler’s maximum thermostat.
In the event of an error on the opera-
tional thermostat, the maximum thermo-
stat will step in and prevent the boiler
from overheating.
The burner is also designed to revert to
normal operating mode following opera-
tional disruptions such as a power cut,
fuel interruptions, etc. If this process
fails, this is indicated in the display and
the burner switches off.
EASY TO MANAGE

9
1The main power switch must always
be on.
2Connections between burner and
external feeder system must be prop-
erly mounted and tight.
ALARMS
If a breakdown occurs, this is indicated by text in the display.
There are eight different alarm messages. To remove alarm texts:
3The release gate’s wings must not be
damaged or discoloured and it must
form a tight seal against the walls of
the feed chamber.
Alarm text Description
The burner has stopped because the max. thermostat has been
triggered.
The burner can be restarted using START once the max. thermostat
has been reset.
NB This function interlocks (in the hardware) all motor
operations and ignition.
The burner has stopped because the burner and boiler have
separated. The burner can be restarted using START once the system
has been correctly refitted.
The burner has stopped because the thermal contact on
the feed pipe has been tripped. The internal motor runs continuously
for 15 min. The burner can be restarted using START once the thermal
contact is reset.
The burner has stopped because the boiler temperature has
fallen below the set minimum value.
The burner is restarted using START
The burner has stopped because the set number of ignition attempts
have failed.
The burner can be restarted using START once the fault has been
dealt with.
The burner has stopped because the fire has gone out.
The burner is restarted using START
The burner has stopped because the external feed has run for too
long without any fuel having been fed.
The burner can be restarted using START once the fuel is refilled and
fed into the burner.
NB Option!
The burner has stopped because the external unit (e.g. smoke detec-
tor) has been tripped.
The burner can be restarted using START once the fault has been
dealt with.
Max. thermostat
Burner NOT in place
Back heat
Min. Temp. Stop
Ignition error
No Flame
Fault Ext. Feed
External Alarm
SAFETY CHECKS / ALARM
THE FOLLOWING MUST ALWAYS BE CONSIDERED AND CHECKED

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Important information
NB To avoid hazardous situations, the feed current must always be switched
off before you touch any part of the equipment. Only authorised persons may
carry out changes or repair the equipment.
The manual is intended for authorised persons. It describes adjustments to many basic
functions in the burner. If these adjustments are used incorrectly, serious operating
problems and hazardous situations may arise.
NB When the control system is started, the processor part is always discon-
nected for around 180 seconds to allow any O2sensor to heat up before it can
be used. If you want to bypass the countdown, press STOP once.
Parameter changes
in the control system
are made using the
built-in menu sys-
tem.
Button Description
Used to start the burner
Used to stop the burner
Used to move up through a menu and to change a parameter
to a higher value. Removes information texts, e.g. alarm.
Used to move downwards through a menu and to change a
parameter to a lower value.
Used to select a submenu, select a parameter and
confirm a changed value
Used to return to a previous menu. Used when changing a param-
eter to return without changing the value.
CONTROL SYSTEM / OPERATION

11
In the menus, the cursor is used to highlight the command line that can be changed.
When a parameter is changeable, the cursor changes from to .
The control system may be in one of the following modes: Start, Operation, Standby
or Stopped.
When O2is activated, XXX% (modulation) is shown in the top line of the display.
When O2is inactive MAN is shown.
Menu structure
Condition: Operation 85%
Temperature 60°C
O2(Optional) 9.0%
Act. Run Time 7 s
Act. Stop time 3 s
Required O2(Optional) 8.5%
Setting
Main Menu
Ignition
Start
Operation
Standby
O2(Optional)
Reset all No
Ignition menu
Optical sensor 1
Start menu
Run Time Int. 6 s
Stop Time Int 4 s
Operation menu
Operating temp. 65°C
Run Time Int. 7 s
Stop Time Int. 3 s
Cleaning time 6 h
Min. temp 20°C
Time before stop 10 m
Standby below 20%
Time below 10 m
Run Time Ext. 30 s
Start External No
Manual time 1 m
Pause menu
Run Time Int. 0 s
Stop Time Int 999 s
Delayed action 60 s
O2menu (Optional)
O2control NO
O28%
Calibrate O2NO
CONTROL SYSTEM / OPERATION

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IGNITION SETTINGS
Use the arrow keys to access the Ignition
menu as per the structure tree on page 11.
Optical sensor: Signal level when optical
sensor indicates flame• For O2control an
alternative flame indication may be acti-
vated: This means that at O2regulation,
the O2-signal is used initially to indicate
flames.
START MODE
Press the START button to start the burner.
The system’s start-up sequence is acti-
vated.
If the START button is held down, the
input feed screw is activated for 15 sec.
and fuel is fed into the burning cup.
The burner can be ignited manually or
automatically. If no flame is registered at
start-up, the automatic ignition sequence
begins and ignites the burner.
Once a flame has been registered, the
burner switches from Ignition Mode to
Start Mode and then to Operating Mode.
Use the arrow keys to access the Start
menu as per the structure tree on page 11.
Run Time Int: Indicates the run time of
the internal screw during the start se-
quence.
Stop Time Int: Indicates the stop time of
the internal screw during the start se-
quence.
STOP MODE
Pressing the STOP button once stops the
burner and the combustion fan continues
for a set time. Factory setting is 1 min. If
you press the STOP button twice, the fan
also stops. The display indicates that the
system is in stopped mode.
OPERATING MODE
When the O2-regulation is activated, the
burner’s combustion fan and input feed
screw are controlled in order to achieve set
values for system temperature and percent-
age O2-content. The current stop time and
run time of the internal screw can be read
from the main menu. If the O2-regulation is
not activated, the burner goes into standby
mode once the set system temperature of
+6°C has been reached.
Use the arrow keys to access the Operation
menu as per the structure tree on page 11.
Operating temp: The required system
temperature is specified here.
Run Time Int: Indicates the run time of the
internal screw. With the O2-regulation acti-
vated, the maximum run time is limited to
twice the value indicated here.
Stop Time Int: Indicates the stop time of
the internal screw.
Cleaning time: Indicates at what interval
the burner fan will operate at 100% for 30
sec.
Min temp: For manual operation without
O2-regulation, the system’s min temperature
is indicated here. If the system temperature
falls below this level, the burner will stop.
The burner will also stop if the optical sensor
cannot indicate the flame or, with O2-regula-
tion, if the O2-content exceeds 18% for
more than 5 min.
Time before stop: Indicates the time the
optical sensor must be without light for the
burner to stop and an alarm to sound. It is
also the time the system temperature must
be below the Min temp for the burner to
stop and an alarm to sound.
CONTROL SYSTEM / OPERATION

13
Standby below: Indicates modulation in %
the burner must fall below in order to switch
to standby mode. It is also the level that
must be exceeded for the burner to switch
back to operating mode. Only used when
the O2-regulation is activated and can be set
between 5 and 50%.
Time below: Indicates the length of time
the modulation must fall below Standby
below for standby mode to be activated.
Run Time Ext: Indicates the run time of the
external screw. The external screw starts
when the level sensor is activated and stops
when the time has expired. NB During the
run time the external screw is synchro-
nised with the run times of the internal
screw.
STANDBY MODE
Once the system reaches the set temperature
+ 6°C or the percentage modulation is less
than the set value the burner switches to
standby mode. In standby mode the pilot
light is activated.
Once the temperature has dropped 2°C
below the set value or the percentage modu-
lation has risen over the set value, the burner
switches back to operating mode.
Use the arrow keys to access the Standby
menu as per the structure tree on page 11.
Run Time Int: Indicates the run time of the
internal screw. If the set operating tempera-
ture is exceeded by 8°C, this time is reduced
to one third of the set value. If the value is
“zero” this means that the pilot light func-
tion is switched off.
Stop Time Int: Indicates the standby time of
the internal screw.
Delayed action: Indicates how long the
burner fan will run after the run time of the
internal screw. When the burner switches
from operating mode to standby, the burner
fan will also run for the time set here.
O2-SETTINGS
If O2-regulation is activated, certain pa-
rameters for this function can be adjusted
by the user. The current O2-content can
be read from the main menu.
Use the arrow keys to access the Standby
menu as per the structure tree on page
11.
O2control: Use this to select whether O2-
regulation should be activated (YES) or
not (NO).
O2:Here the required O2-percentage
content for 100% combustion air is set.
TM3006 recalculates the required O2-
content in relation to the combustion air,
which means that the O2-content rises
when the combustion air reduces.
Calib. O2sen: By selecting YES, the O2-
sensor is calibrated. In order to do this,
the O2-sensor must be in circulating air
(21% oxygen) and the control system
must have been switched on for at least
three minutes, so that the sensor can
reach the correct temperature. Once
calibration is complete the text shows O2
Calibration OK. If the O2-sensor does not
produce a fixed signal on calibration,
control box 3006 judges that the sensor
is wrong and continues using the old
stored values. If this happens, the O2-
regulation must be disconnected and the
old sensor replaced with a new one be-
fore this function is used again.
For further instructions regarding the use
of O2-regulation, see the separate manual
RESET
Use the arrow keys to access Reset as per
the structure tree on page 11.
If YES is selected, all parameters in the
burner’s control system will be reset to
their factory settings.
CONTROL SYSTEM / OPERATION

14
FILL EXTERNAL SCREW WITH FUEL
First fill the external screw. Remove the
downward hose from the burner. It may
be useful to put a bucket under the
hose.
Set the estimated number of minutes
using the parameter Manual time and
start the external screw. The screw will
operate for the set number of minutes. If
you want to stop it early, press STOP.
Reattach the downward hose to the
burner.
STARTING THE BURNER
Press START. The burner makes 3 ignition
attempts with 2 min fuel feed before
each attempt. After that there will be an
alarm Ignition error. Remove the alarm
text with and start again. This
sequence should be repeated until the
burner feed pipe is full and there is fuel
in the cup.
At this point the burner will ignite auto-
matically.
During the ignition sequence, the display
indicates which phase the burner is in.
DESCRIPTION OF THE BURNER’S
NORMAL IGNITION, OPERATING AND
SHUT DOWN SEQUENCE
Factory setting
A non- running burner is indicated by
the text STOPPED in the display
•START button, Fan for 20 s. to check
if there is a flame.
•If flame=> Start mode, the burner
runs at 60% for 2 min.
•If no flame=>Ignition mode
•Ignition mode=The fan stops, the
ignition element starts, material is fed
in for three minutes. When the feed/
dosing is complete, the fan starts at
low speed and increases to maxi-
mum. The ignition element and fan
run for 6 min. If there is no flame, the
ignition sequence is repeated a maxi-
mum of 3 times. If there is still no
flame indicated in the system Ignition
error The ignition sequence is indi-
cated with the text Ignition attempt X
•When a flame is indicated, the igni-
tion sequence stops and the start
sequence commences. Indicated with
text Start.
• Start mode, the burner runs at 60%
for 2 min.
•When heating is complete, the
burner transfers to the set operating
mode. Indication with text Operation.
•In operating mode the normal dis-
played is MAN. This indicates that
feed times are fixed.
When O2-regulation is activated, a %-
figure is shown instead, indicating the
current percentage modulation sup-
plied by the burner.
CONTROL SYSTEM / OPERATION

15
• The burner fan has a delayed running
time of 60 s.
• At rest, no pilot light. Indicated with text
Standby
• When the temperature falls and the
system calls for heat = normal start
• In manual mode (NO O2-regulation) the
burner works the temperature up to 6°C
over the set value. Once the temperature
has fallen 2°C below the set value, the
burner starts again.
• For O2-regulation, the burner works to
maintain continuous combustion. The
burner’s output power adapts to the
current energy consumption. So-called
adaptive regulation.
For further instructions regarding the use of
O2-regulation, see the separate manual.
EXTERNAL FEED
The external motor is controlled by the
level sensor, the set run time coincides
with the internal motor
RESTART
If the burner was in operating mode (=
started) before the power cut, it restarts
automatically when the power resumes.
INPUT POWER
The burner is pre-installed with a maxi-
mum output of around 14.7 kW. The
dealer can, if necessary, customise the
maximum output between 12 and 20
kW. The input quantity of fuel may be
easily adjusted to compensate for varying
fuel quality.
The recommended values are tested
using 8 mm pellets. NB! The pellet qual-
ity has a significant effect on the result.
Fan Output Feed Note
100% 20 kW 60/1
90% 18 kW 9/1
80% 16 kW 8/2
70% 14 kW 7/3 Factory setting
65% 12 kW 6/4
CONTROL SYSTEM / OPERATION

16
ENCLOSURE AND ASSEMBLY
The enclosure consists of a plastic box
with a separate connection section.
The top lid must NOT be opened. It
provides mechanical and electrical
(static electricity) protection for
the printed circuit card.
If this part is opened without the
approval of EcoTec, ALL guarantees
will cease to be valid.
The unit is fitted on a vertical wall using
three screws. For the upper fixing point
there is a recess for the screw head on the
rear of the box. Recesses for the two other
fixing points are under the lower lid of the
box (connection part).
The unit contains no parts (except a
fuse) that can be replaced by non-
professionals.
A defective unit must always be returned
to the manufacturer.
Max. ambient temperature is 40°C.
CONNECTION INSTRUCTIONS
The control system is connected to the
home’s distribution box using a permanent
installation.
Feed current: 230 VAC
Max. fuse: 10 A
The box contains screw-type connection
terminal boxes.
TRANSIENT PROTECTION
In order to protect the control system
against disturbances, additional compo-
nents (the relay, solenoid valves etc.)
should be transient-protected. (The DC
relay and solenoid valves with a diode and
the AC relay and solenoid valves with an
RC filter.)
MAIN SWITCH
The system must be equipped with a
main switch.
IMPORTANT
• Connect the box with phase and zero in
the right place. This does not affect the
functions, but as the zero runs unbroken
to the motors, there is a risk that there
will be full voltage at the motors when
you think it is switched off.
•Check that the load on the outputs
never exceeds the system’s total maxi-
mum load for the outputs (2000 W).
Max. load per output is 1000 W.
Max. load (resistive) on the alarm output
(potential-free relay output):
1 A, 230 VAC, 30 VDC
HUVUDBRYTARE
(Pelletsbrännare)
FÅR ENDAST
BRYTAS VID
SERVICE
INSTALLATION

17
THE MAIN SWITCH MUST
ONLY BE SWITCHED OFF IN CONNECTION
WITH SERVICING AND MAINTENANCE.
REMEMBER TO SWITCH
ON THE MAIN SWITCH WHEN
SERVICING IS FINISHED.
Max. thermostat
The max. thermostat cable is prein-
stalled on connection terminal board 4
and 14 in the control system.
Connected to the system’s max. ther-
mostat.
The max. thermostat must be equipped
with a manual reset.
Operational thermostat
The operational thermostat consists of
a separate temperature sensor and
cable. For installation on connection
terminal board 5 and 15 in the control
system. The cable can be extended, if
necessary, but should not be short-
ened.
The temperature is measured ana-
loguely.
The sensor should be fitted to the
plunge pipe to ensure correct tempera-
ture measurement.
Connecting an alarm unit
A buzzer or light is connected to the
potential-free contact, connection termi-
nal board K1 and K2.
The standard units are adapted for a
drive voltage between 12 and 24 VDC.
A cable is connected from connection
terminal board 13 (+VDC) to K1. (Con-
nection terminal board 13 can also be
used in connection with the feed to the
external alarm unit, such as a flue detec-
tor.)
The alarm unit is connected between
connection terminal board K2 and 18
(–VDC). (Connection terminal board 18 is
also used to connect the O2-sensor.)
See connection table page 18-19.
Burner wiring
The multiconductor for the burner is
preinstalled in the control system. The
switch is connected to the left side of the
burner.
Microswitch
The burner’s assembly on the boiler is
monitored using a microswitch.
INSTALLATION

18
CONNECTION TABLE FOR CONTROL BOX 3006
CONNECTION TABLE
Control cabinet
Max. thermostat
Operating temperature
Lambda probe
Incoming feed
External screw
Multi-unit cable

19
CONNECTION TABLE
Burner fan
Level sen.trans
Level sen.rec.
Optical sensor
Internal motor
Thermo gauge
Ignition element
Limit position
*) M:x = Multiconductor for burner
T:x = Thermostat cable for max. thermostat S:x = Operating temperature
Black -
Black
Burner
Red +
Brown
Brown
Blue
Blue
White
White
Orange
Orange
Green/yellow
Black
Red +
Black -
Red
Red

20
TROUBLESHOOTING
The majority of all faults that may arise
are a direct result of defects in the pellet
quality, and its handling or storage.
Therefore, check your supply carefully.
Preferably before you receive it.
Remember it is for your safety that we
preprogrammed the burner to stop and
emit an alarm if it cannot rectify the fault
itself.
FAULT: No text in the display
CHECK: That the main switch is on and
that the current (F1=250 mA) in the
burner’s control unit is complete.
ACTION: Turn on the main switch or
replace the broken fuse in the control
unit. NB Switch off the main switch
when replacing the fuse. Contact an
installation engineer.
The alarm text: * Back heat *
CHECK: Check if the resettable thermal
contact has been tripped.
ACTION: Press the button on the top of
the thermal contact. Switch off the main
power.
ACTION: Change the release gate’s
wings if they are discoloured or mis-
shapen.
ACTION: Check that the flue damper is
not fully open and that the boiler’s flues
are free from fly ash.
Fit backdraft damper.
The alarm text: * Max thermostat *
CHECK: If the boiler’s maximum thermo-
stat has been tripped.
ACTION: Reset the button on the boiler’s
maximum thermostat and restart. Com-
mon causes are wood burning in com-
bination with pellet burning. If the cause
of overheating cannot be established,
the operating temperature sensor must
be checked.
The alarm text: * No Flame *
The burner has received an order to stop
because the optical sensor indicated that
it cannot see light in the combustion
chamber during operation.
CHECK: That the combustion chamber is
not full of ash.
ACTION: Remove the ash.
CHECK: That the optical sensor or opti-
cal sensor pipe is not sooty and thus
cannot detect light.
ACTION: Wipe the optical sensor. If
correctly installed, the optical sensor
should not become sooty between nor-
mal inspections. Air leakage or the
burner being too close to a cooled com-
bustion chamber surface causes soot to
collect, as does poor air supply to the
boiler room. Deal with this as soon as
possible. If incorrectly installed, the
optical sensor may also overheat and
stop detecting light. Contact an installa-
tion engineer if you suspect incorrect
installation.
TROUBLESHOOTING