Effecta Komplett III Manual

Rev. EA. 015-08-24
INSTALLING
MAINTENANCE
SERVICE
ASSEMBLY
EFFECTA KOMPLETT III
20-25-35 kW

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
2
We at Effecta would like to thank you for putting your trust in us when choosing your new
boiler. The ”Effecta Komplett III” has been developed to give you maximum performance,
comfort and quality. In order to get the best results from your boiler, we suggest that you
follow the recommendations in this installation guide.
Checking your delivery
Check that the boiler has not been damaged during transportation. If the boiler has been
damaged, you must report this to the transportation company immediately.
Your safety
If you discover any faults or defects in our products, it is important that you report them as
quickly as possible to your installation engineer, so that the fault can be rectified. Make sure
that there are no flammable materials close to the boiler, to help prevent risk of fire. You must
use your own judgement when operating the pellet boiler. Remember that the hatches and
some surfaces can get hot. You must take care to avoid being burnt.
The user
It is the user´s responsibility to operate the boiler according to our instructions. If you do
not operate and maintain your boiler correctly, the environmental impact of the boiler will be
greater, its efficency will be reduced and the service life of some components will be shorter.
If there is anything that you are not sure about, please contact your installation engineer or
Effecta for advice.
Warranty
The warranty takes effect from the date on which the boiler is installed. The supplied
installation form must be completed and returned to Effecta. You can find the other guarantee
terms on (page 3).
▀ Scope of delivery
Please check all components delivered.
The standard delivery as follows:
- Effecta Komplett III boiler
- Cleaning handle with brush
- Rake with scraper
- Flue attachment
- Draft stabiliser
- Turbulators, 8pcs.(mounted)
- Drain cock
- Shunt valve + motorized shunt control, not in ”Light” version
- Electrical heater 3-9 kW (mounted), not in ”Light” version
- Thermostatic mixer valve, not in ”Light” version
- Room thermostat, optional in ”Light” version
- Outdoor sensor, optional in ”Light” version
▀ Introduction

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
3
Effecta products are guaranteed to be free of defects in materials. The main body has a 5 year
warranty against leakage of water and all other parts have a 2 year warranty.
The warranty also covers original spare parts. Any faulty products will be replaced or repaired at
the discretion of the retailer or Effecta. If a faulty product is detected, Effecta is entitled to
replace it with a new or reconditioned product of the same or a similar type.
If you have a complaint, you must contact your retailer before starting any servicing work.You
must submit your complaint without delay. You must always state the type of product, the date of
purchase and the serial number.
Otherwise the heating and plumbing industry’s current regulations apply in case of complaints.
Guarantee terms:
The guarantee is valid on condition that:
- The boiler and the heating system have been installed in accordance with the installation
instructions and in a professional manner.
- The location where the product is installed is suitable for purpose.
The guarantee does not cover:
- The overall function of the heating system, costs incurred as a result of the heating
system being out of operation, or the cost of the temporary replacement of products.
- Damage or injury caused by negligence during the installation or by operating the boiler in
a way which conflicts with the installation and user instructions.
- Damage caused by abnormal wear, incorrect operation and maintenance.
- Damage caused by the use of non-original spare parts.
- Damage caused by the boiler being positioned in an unsuitable location.
- Damage caused by vermin.
The terms may be different from country to country. Check with your installer.
▀ System data:
▀ Warranty
Installer:
Date:
Electrical installer:

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
4
▀ Contents
2 Introduction 43 Cleaning
2 Scope of delivery 44 Cleaning and service
3 Warranty 45 Service
3 Warranty terms 46 Service
3 System data 47 Adjusting door to ash compartment
4 Contents 48 Troubleshooting
5 In general 49 Documentation of settings
5 Symbols in this document 49 Technical data
6 Your safety 50 Technical specification K3 external feeding
7 Safety components 51 Technical specification K3 internal storage
8 Components 52 Technical specification K3 suction system
9 Fuel 53 Connection suggestions internal hotwater and radiators
10 Boiler room 54 Connection suggestions radiators and heaters
11 Placement of components K3 external feeder 55 Connection suggestions accumulator tank with solar heating
12 Placement of components K3 internal storage 56 Connection suggestions several heating cicuits
13 Placement of components K3 vacuum system 57 Component placement K3
14 Placement of components K3 vacuum system 58 Component placement K3
15 Placement of components K3 internal storage 59 CE
15 Placement of components K3 electrical system
16 Placement of components K3 burner
17 Cleaning system burner
18 Cleaning system boiler
19 Disassembly for move
20 Function suction system
21 Suction system and storage
22 Installation of suction nozzles
22 Installation of hoses
23 Electrical connection
24 Outlets of the circuit board
25 Outlets of the circuit board
26 Electrical Schematic
27 Electrical Schematic
28 The menu system
29 The menu system
30 The menu system
31 The menu system
32 The menu system
32 Alarms
32 Update software
33 Tuning the boiler
34 Tuning the boiler
35 Hot water
35 Valve combination
36 Shunt control
37 Tuning the boiler
38 Examples of curves
39 Mounting draft regulator
40 Overheated fallshaft
40 Replacing the combustion fan
41 Replacing the igniter
42 The chimney
42 Flue attachment

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
5
The boiler
Effecta Komplett III is a boiler which is to be fueled with wood pellets. No other kind of fuel is
allowed, not logs or oil.
Disassembly and disposal
It will be many years before your Effecta boiler is worn out, but it is important that you follow
the regulations in force at the time concerning disassembly and disposal of your boiler.
The fuel
The boiler should burn 6 mm ø pellets which come either in sacks or are supplied by bulk truck.
If you have built a bulk storage, you should follow the current recommendations to ensure that
the quality of the pellets does not deteriorate. Never use pellets which do not meet European
pellet standards DIN+, as this may result in problems in operating the burner.
▀ In general
▀ Symbols in this document
Information
This symbol is shown with to indicate important information the installer should know and
understand. Neglecting this information can affect the performance of the product.
Dangerous electricity
This symbol means that extra caution should be taken otherwise serious personal injury
might occur. When maintaining the product where this symbol is present the power must
be disconnected. All electrical wiring must be done by a Professional and comply with
current building regulations.
The product manual is a document that gets updated. You always find the latest version
on our webpage www.effecta.se
Hot surfaces
This symbol is shown when there is a risk of burns to people. Always wait for the boiler to
cool down before you do any service.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
6
▀ Your safety
Before using the product, the owner and/or other user must read and understand the content
in this manual. The directions must be followed. This is to make sure that the product is
functioning correctly so accidents and injuries are avoided. Incorrect use or burner adjustment
can result in damage to property and personal injury or poorer performance of the product.
The boiler room where the product is installed, the chimney and other components must be
approved according to current legislation.
The commisioning of the product must be made by a professional, according to Effectas
directions and current legislations. Controls and tuning of the product should be made by a
professional. A chimney sweeper should also be contacted when commisioning the product.
The electrical connections must be done by a qualified electrician, according to Effectas
instructions in this manual.
The casing outside of the burner must always be fitted on the boiler when the boiler is
connected to the electrical power. Before cleaning and maintenance of the product, make sure
it is disconnected from the main power.
It is strictly forbidden to open any doors when the burner is igniting. If any door or hatch is
opened when the burner is running, great caution must be taken. Any kind of interference or
use of anything other than original spare parts can result in damage to the product or person. It
also removes Effecta from any liability.
It is strictly forbidden to make any changes or alterations to the boiler without prior approval
from Effecta. If any changes are made, the safety functions, or any other function, might not
work as it is supposed to, and all warranties and liabilites from Effecta are cancelled.
This manual should be kept during the whole life span of the product. Any updates will be
reported on the Effecta web page: www.effecta.se.
Remember to always disconnect the power before working with the boiler.
Wait until the boiler has cooled down before starting work.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
7
Drop tube
Between the storage and the feeder there is a meltable plastic tube which is
destroyed when it is overheated.
The overheat protection on the fall shaft
This stops the feeding and the fire damper if the fan temperatures gets
too high. Reset is made manually.The cover must always be in place when
connected to main power. It only cuts the power to the auger and fire damper.
Safety lock
If the boiler is equiped with a suction system there is a fire damper mounted.
This is closed during filling, overheating or loss of power.
Flame sensor
The flame sensor monitors the flame in the burner. If a valid value is lost for
more than 120sec the feeder stops. The burner is cooled down with maximum
rpm of the fan for (X) minutes before stopping. The pellets suction is not
allowed to start if the flame sensor detects light
Overheat protection on the boiler
There is overheat protection on the boiler which cuts the power to both the
boiler and the burner if the temperature in the boiler exceeds 95°C.
Compressed air cleaning
On the cleaning to the burner there are two safety systems. The controller
limits the the time the compressor is allowed to run, there is also a pressure
switch which closes the compressor when preinstalled pressure is reached.
Flue gas fan
A flue gas fan is mounted on the flue tube. The fan helps to maintain a stable
underpressure in the boiler and prevents back heat but also improves the com-
bustion. More on the fans adjustements are on pg. 33.
Door switch
The door switch stops the auger/feeder and no more pellets are fed into the
burner when the door to the combustion chamber is open.
Automatic fuses
Automatic fuses are installed in the electrical system, which are triggered if
there are any eletrical faults in the boiler. If triggered, an authorized electrician
should be contacted to determine the cause.
▀ Safety components

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
8
The shunt valve
The shunt valve is connected to the boiler or accumulator tank.The shunt valve
controls the heat supply from the boiler to the heating circuits of the house.
Heat regulation
The boiler is equiped with its own heat regulator. In the ”Shunt control” menu you
can choose how to control the heat in the house. More on how to regulate the
heat is found on pg. 36.
The thermostatic mixer valve
The mixing valve is used to ensure that the temperature of the hot water in your
shower and elsewhere in the house is comfortable. Set the system to the tem-
perature you want by turning the thermostat between +/-. If you have a Komplett
Light the mixer valve is mounted on the accumulator tank.
Feeder
The feeder is either internal or external on the boiler. The feeder controls the
amount of pellets fed to the burner.
The burner
The burner is mounted on either the right or left side. The fuel from the feeder is
ignited and combusted, which heats up the water in the boiler.
Turbulators
Within the tubes in the heat exchanger hang the turbulators. The turbulators function
is to transfer heat from the flue gas to boiler water. They must always be placed in
the boiler. If the flue gas temperature in the chimney is too low, the turbulators can
be cut off to increase the temperature.
Draft stabiliser
The draft stabiliser gives the boiler stabile draft conditions, this improves
combustion and efficiency.
Hot water coil
Within the boiler is a hot water coil that heats up the water for the house. The
water you can drain from the boiler depends on the boiler temperature, the mount
of flow you through and which effect the boiler is set to. We recommend a flow
of 12-42l/min in the taps. In the Light model there is no coil, here you heat your
water in a external water heater.
The sealings
The seals on the hatches must be checked every year. If the hatches do not seal
properly, the efficiency and the combustion process of the boiler will deteriorate.
Dust and ash can also leak out during cleaning.
▀ Components

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
9
Wood pellets are made of sawdust, a byproduct from handling wood. Wood contains lignin that
makes the pellet hard without any glue or other binder being used.
There are several different kinds of pellet on the market. The quality and energy can vary
between them. The diameter is 6-8mm, the normal length is between 5 and 30mm.
High quality pellets have a density of 600-750 kg/m3. The moisture content is 5-9% in weight.
Oil has an energy content of 9,9kWhr/kg and wood logs about 4,0kWhr/kg. Wood pellets have
a energy content of 4,7-5,0kWhr/kg. To maintain good combustion the pellets should be stored
in a dry place and be protected from dirt. Pellets are delivered in sacks with 10-15kg content or
in bulk by truck.
The Effecta Komplett III can handle most of the different types of wood pellets that are between
6-8mm, but in UK only 6mm should be used. The quality should meet DIN+ standards. Good
pellets with a small amount of dust and that are uniform helps achieve good combustion, less
maintenance of the product and also less environmentally harmful emissions.
The worse the quality of fuel is, the more cleaning and maintenance of the product will be
required.
▀ The fuel
The amount of pellets fed into the burner should be controlled every time the pellet
brand or quality is changed. If the deviation is more than 0,5kg/hour compared to the
numbers in the ”Warranty and Installation” paper, the burner should be tuned.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
10
▀ Boiler room
It is time to install the Effecta Komplett III pellet boiler. Please follow the examples we provide
for a safe installation. After installation, be sure to instruct the customer on how the heating
system and the boiler works, in order to avoid unnecessary complications in the future.
Set up
The boiler is positioned so that the
surface temperature of flammable
building material does not exceed
80°C. The boiler should be positioned
at least 10 cm (1) from the wall. If the
distance between the flue tube and
flammable wall is less than 30 cm
an ignition protective covering
must be used (4). In order to
clean the boiler, a minimum
clear space of 1 metre (2)
is required in front of the
boiler. A passage with a
minimum width of 0.5m (3)
is required along one of
the long sides of the boiler.
Check the regulations of your
country in order to place the
pellet hopper an approved
distance from the boiler.
Boiler room
The boiler must be installed in a boiler room or boiler house. The ceilings and walls must
be fitted with ignition protective covering and the floor must be made of non-combustible
material. Minimum ceiling height in the boiler room is 2 metres. The boiler room or boiler house
must be equipped with a fresh air intake with the minimum dimensions 150 x 150 mm(5.) or
with a sufficiently large free sectional area to avoid low pressure in the boiler room. It must be
impossible to close the air intake.
Chimney
The chimney should have enough area to manage the effect from the boiler. At standstill the draft
should be between 5-10pa. It is important that the chimney is tested and approved by a HETAS
approved installer before a new boiler is installed. If the chimney is tall and has a lot of mass to
heat up there is a risk of condensation. Measure the temperature 1m down from the top when the
burner is running, the temperature should be 70°C.
Read more about the chimney on pg 42.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
11
Front Back Top
1 Adjustable feet 1 Drain cock 1 Flue gas measuring point
2 Ash door 2 Return hot water circuit 2 Boiler fan
3 Door switch 3 Flow hot water circuit 3 Cleaning access
4 Front cover 4 Hoses electrical wiring 4 Flue connection
5 Handle Front cover 5 Shunt valve* 5 Draft stabiliser
6 Display 6 Conduit for sensor
7 Fall shaft pellet burner 7 Connector feed motor/auger
8 Protective cover 8 Mixing valve * for hot water
▀ Placement of components K3 external feeder
* Not on Light

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
12
Front Back Top
1 Adjustable feet 1 Drain cock 1 Flue gas measuring point
2 Ash door 2 Return hot water circuit 2 Boiler fan
3 Handle ash door 3 Flow hot water circuit 3 Cleaning access
4 Front cover 4 Hoses electrical wiring 4 Flue connection
5 Handle Front cover 5 Shunt valve* 5 Handle storage lid
6 Display 6 Conduit for sensor
7 Gas damper 7 Connector feed motor/auger
8 Internal storage 8 Mixing valve * for hot water
▀ Placement of components K3 internal storage
* Not on Light

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
13
Front Back Top
1 Adjustable feet 1 Drain cock 1 Flue gas measuring point
2 Ash door 2 Return hot water circuit 2 Boiler fan
3 Handle ash door 3 Flow hot water circuit 3 Cleaning access
4 Front cover 4 Hoses electrical wiring 4 Flue connection
5 Handle Front cover 5 Shunt valve* 5 Draft stabiliser
6 Display 6 Conduit for sensor
7 Insulated cover plate 7 Connector feed motor/auger
8 Lower cover plate 8 Mixing valve * for hot water
▀ Placement of components K3 vacuum system
* Not on Light

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
14
▀ Placement of components K3 vacuum system
Side Front Top
1 Meltable plastic tube 1 Fallshaft 1 Vacuum fan
2 Safety ball valve 2 Safety lock 2 Connection hose suction nozzle
3 Internal feeder 3 Capacitive sensor
4 Internal feed motor 4 Connection for filling pellets

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
15
▀ Placement of components K3 electrical system
1 Motherboard
2 Card electrical heater
3 Terminal block N and PE
4 Power supply boiler 20A fuse
5 USB connection for updating software
6 Capacitor underpressure fan
7 Expansion board
8 Lambda board
9 Mechanical overheat protection
VARNINGLIVSFARLIG SPÄNNING
ACHTUNGGEFÄHRLICHE SPANNUNG
AVERTISSEMENTTENSION DANGEREUSE
WARNINGDANGEROUS VOLTAGE
VARNINGLIVSFARLIG SPÄNNING
ACHTUNGGEFÄHRLICHE SPANNUNG
AVERTISSEMENTTENSION DANGEREUSE
WARNINGDANGEROUS VOLTAGE
VARNINGLIVSFARLIG SPÄNNING
ACHTUNGGEFÄHRLICHE SPANNUNG
AVERTISSEMENTTENSION DANGEREUSE
WARNINGDANGEROUS VOLTAGE
▀ Placement of components K3 internal storage
1 Hose clamp 2pcs
2 Meltable plastic tube
3 Handle storage lid
4 Gas damper
5 Internal storage
6 Internal feeder
7 Internal feed motor

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
16
▀ Placement of components K3 burner
Side Front Top
1 Outer tube 1 Combustion tube 1 Connection compressed air
2 Fallshaft 2 Fallout pellets 2 Connection flame sensor
3 Overheat protection fall shaft 3 Flame sensor hole 3 Power to the burner
4 Combustion fan 4 Hole for ignition element
5 Flame sensor 5 Hole for compressed air
6 Ignition console
7 Blowpipe to the compressor

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
17
▀ Cleaning system burner
Function
On the side of the burner there is a compressor with a compressed air hose mounted which
cleans the burner. Compressed air is blown into the burner. When the cleaning starts the com-
pressor builds up a pressure in the hose which then is released with a pressure shock and the
ashes are removed from the burner. You can set how often, how long and during which times
cleaning is allowed in the ”SERVICE”menu.
Compressor
The compressor builds up a pressure in the air hose.
The compressor has a life span of about 2500h, and
can then drop in pressure head or leak air. Then there
is a renovation set to renovate the compressor.
Compressed air hose
The hose is only used to store air before it is
released into the burner.
Pressure gauge
Shows the pressure in the hose. It is also an
indicator when or if you need to adjust the pressure
for optimisation.
Pressure switch
Stops the compressor when targeted pressure
is reached, there is a adjustment screw which is
preset on 7 bar.
1 Compressor
2 Capacitor
3 Pressure switch
4 Pressure gauge
5 Solenoid valve
6 Compressed air hose
Remember to always cut the power to the boiler before starting any work on it.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
18
Magnet
The magnet is mounted on the right side of the boi-
ler. The magnet lifts the turbulators in the tubes.
Lifting shaft
Rotating the lift shaft lifts the turbulators and clean
the tubes.
Turbulators
The turbulators in the tube help by reducing the flue
gas temperature and also cleaning the tubes when
pulled up and down.
Suspension
On every suspension there are two turbulators
that are removed when cleaning the tubes with
a brush.
Flipper
Flips when the magnet motor activates.
1 Magnet
2 Lifting shaft
3 Flipper
4 Susoension
5 Turbulator
▀ Cleaning system boiler
Function
On the boiler there is an magnet motor which does the maintenance and ash cleaning of the con-
vection section. The magnet is controlled from the ”Cleaning” menu, there you can set the times
it allowed to clean. The magnet is relatively quiet, and if it doesn´t disturb it should be allowed to
clean around the clock.
Remember to always cut the power to the boiler before starting any
work on it.

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
19
▀ Disassembly for move
The boiler is fully mounted when delivered. If the boilers width exceed the door you can
disassemble it to a smaller size
Remove the cover of the suc-
tion system. If the boiler has
an internal storage remove
the screws which holds the
top part.
Then remove the 4 plastic
covers which conceals the
screws for the cover plates.
They hold the coverplates to
the internal storage.
Loosen the 4 screws and
remove the cover plates.
Loosen the bolts to the lid.
Remember to disconnect all
the cables to the suction sys-
tem before you remove the lid
If the boiler has a suction sys-
tem disconnect the safety ball
valve. Loosen the hose clamp
on the fall shaft. Loosen the
2 nuts which holds the safety
ball valve to the storage and
remove it all.
If there is an internal storage
just remove the hose.
Unscrew the 3 bolts holding
the storage and remove it.
Disconnect all the cables to
the burner. Then unscrew the
4 bolts which holds the burner
plate to the boiler. Remove
the burner straight out.
Make sure when you reassemble the storage that all
hose clamps and other sealings are tight. Leakage will
cause disruptions due to there being no underpressure.
1 Magnet
2 Lifting shaft
3 Flipper
4 Susoension
5 Turbulator

Effecta AB - Västra Rågdalsvägen 21 - 434 99 Kungsbacka - 0300 - 22320 - [email protected]
20
▀ Function suction system
If the boiler is equipped with a suction
system the menu on the right is shown.
In the ”INSTALLATION” menu you need to
change settings in order to customize the
system for your energy needs.
Function
The suction system includes a number of
important components. On the storage
there is a suction motor which builds up a
underpressure in the hose connected to the
filling outlet of the storage. The proximity
sensor senses the need for filling pellets,
when set time between fillings is reached,
the safety ball valve closes and the suction
system is allowed to start, with a delay of
60sec. The suction motor tries to fill the storage by running for 15min - resting for 15min - running
for 15min and so on. If the storage hasn´t been filled after 80mins the boiler alarms ”Suction
time”. A filling normally takes 15-20min suction time.
Time between fillings
How often your system chooses to fill is down to your settings in the menu. We recommend you
set it as far a part you can, but with a margin so that the storage never is empty. A full storage
contains roughly 200kWh of energy. If your house consumes 8kWh, the storage last for about
24hours.
Night blocking
If the boiler is placed so you can hear it, you can block refilling of pellets certain times of the day.
In the ”SERVICE” menu you can set when refilling is allowed(On) and when its not allowed(Off).
Then refilling isn´t allowed between these hours, unless there is a risk of downtime of the burner,
in which case the filling cycle runs even though you have turned it off.
Fill storage
If you activate ”Fill Storage”, the storage will be filled regardless of settings. This function is
used when you first start the system or if the storage is empty. Note that if the storage has been
emptied, the feeder must be filled again. In the ”Installation” menu you find the function ”Fill
feeder”. The boiler must be in mode ”Off” for this function.
Proximity sensor
The proximity sensor is mounted from the factory. When the
light is on there are pellets near the top of the storage. If the
sensor needs to be adjusted it should be done when the storage is
full. Find the setting for On/Off on the screw. Adjust it so that the
light is lit.
Filling interval
Night blockage
Fill storage
8 h
Yes
No
Consumption
kW/h kW/day Time filling, h
5 120 30
10 240 15
15 360 10
20 480 8
25 600 6
In-
stal-
lation