CTC Union ecoflex, Installation And Maintenance Manual

Page 1: ...162 105 01 4 2015 11 05 Providing sustainable energy solutions worldwide Installation and maintenance manual CTC EcoFlex Wood pellet boiler IMPORTANT READ CAREFULLY BEFORE USE KEEP FOR FUTURE REFERENCE ...

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Page 3: ...Installation and maintenance manual CTC EcoFlex Wood pellet boiler 162 105 01 4 2015 11 05 42 15 03 ...

Page 4: ...____________________ 22 3 9 Menu Block________________________________ 22 3 10 Menu Installer ______________________________ 23 3 11 Menu Settings______________________________ 23 3 12 Menu Setting House Parameters Heating ______ 25 3 13 Menu Setting pellet__________________________ 26 3 14 Menu Inst tank______________________________ 27 3 15 Menu Service_______________________________ 27 3 16 Men...

Page 5: ...been developed to meet the high reliability convenience and safety requirements that we set CTC EcoFlex is a modern and very efficient pellet boiler Optimal combustion and good insulation allow a high level of efficiency to be achieved while maintaining releases which can harm the environment at a very low level The boiler is equipped with automatic ignition but can always be lit manually if requi...

Page 6: ...deration when handling installing and using the boiler Installation must be done according to applicable local standards and regulation Shut off the operation switch before carrying out any service or maintenance on boiler or peripheral equipment The casing over the pellet burner is an important part of the boiler s safety equipment and must always be fitted and secured when the boiler is in opera...

Page 7: ...The use of lower quality pellet can cause operation disruptions for example due to sintering of ashes or blockages in the external feed system Significantly larger volumes of ash will in addition be produced The Pellet boiler is from factory pre set for operation with pellet with a diameter of 8 mm By utilization of pellet with a diameter of 6 mm see section First start in order to perform the req...

Page 8: ...y high level of efficiency and therefore low flue gas temperatures Flue gas temperature can be increased by adjusting the flue gas damper if the boiler is connected to a chimney which requires high flue gas temperatures to avoid condensation Ash bin Ash is collected in the large ash bin which is simple to remove and empty Pellet burner See the section Design Pellet burner Tracks The pellet burner ...

Page 9: ...Driving motor concealed Rotary valve inside the housing Connection plug sensor Level monitor transmitter behind top connection Top connection Level monitor receiver Fan Flame detector Connection plug high voltage power Burner auger pipe Flame detector pipe Ignition element inside primary air pipe Hearth Primary ring Bend gear wheel dosage screw Gear wheel lock Primary air pipe Design pellet burner...

Page 10: ...t on the display In addition the light diode on the room sensor flashes The boiler has a unique design in which safety is a part of the function of the system Safety is therefore not provided by an add on safety system Safety is secured by the path of fuel in the burner auger pipe in practice being broken within the boiler itself There is therefore no continuous line of fuel outside the boiler whi...

Page 11: ...erence between different properties is determined by radiator surface area the number of radiators and how well insulated the house is Adjustment of heating curve basic values The heating curve for your property is set using two values in the product control system This is set in the menu Installer Settings Setting Heating Inclination and Adjustment Arriving at the correct heating curve can take s...

Page 12: ...pecific outdoor temperature Adjustment 0 means 20 C primary flow when the outside temperature is 20 C Adjustment 5 means 20 C primary flow when the outside temperature is 15 C For example Inclination 50 means that the temperature of the water supplied to the radiators will be 50 C when the outdoor temperature is 15 C if adjustment is set to 0 If the adjustment is set to 5 the temperature will be 5...

Page 13: ...em older house nclination 50 High temperature system older house small radiators poorly insulated Inclination 60 Adjustment if the outdoor temperature is lower than 0 degrees At to cold indoors Increase the value at Inclination a couple of degrees Wait one day before the next adjustment At to warm indoors Decrease the value at Inclination a couple of degrees Wait one day before the next adjustment...

Page 14: ...lections will provide you with all the information you need 1 Pellet burner switch The pellet burner is started shut down using this switch For more information see the section Start stop the pellet burner 2 Safety limit thermostat Safety limit thermostat is triggered when the temperature in the boiler becomes too high Reset by pressing the centre button under the cover casing 3 Fuse 10 A The fuse...

Page 15: ...w these rows The arrow disappears when there are no more rows 4 More rows indicator The arrow shows that there are rows above which are not visible in the display Scroll the cursor upwards to view more rows The arrow disappears when there are no more rows 5 Information area All information temperatures values etc are displayed here B Button step backwards or undo Use this button to step backwards ...

Page 16: ...kProgram Installer Settings Service Operation data Outdoor C 5 Indoor C 20 20 Boiler C 70 FlueGas C 160 Primfl C 45 45 Operation data Current A 12 20 Pellet startphase 1K Mixingvalve close Program ID xxxxxxx Program date xx xx xx Operation data Heatingcirc pump On Elpower 3 0 With indoor sensor Without indoor sensor With indoor sensor Without indoor sensor EcoFlex Thurs 8 03 Indoor C 20 0 20 0 Ind...

Page 17: ...r burner 0 El ignition Off Funct test other ElRelay 1 5 3 kW 0 ElRelay 3 6 kW 0 Pellet Off Heatingcirpump Off MixingValve Close DHW pump Off Diode sensor Off Alarm stored Last alarm xxxxx Stored alarm xxxxx xxxxx xxxxx xxxxx Setting Heating Max Primfl C 55 Min Primfl C Off Heating off 16 Heat curve Inclination 50 Adjustment 0 Setting pellet Level sensor 0 50 Flame detector 99 50 Burner type kW 15 ...

Page 18: ...erature The set temperature is displayed in brackets Select this row to change set temperature Can be set in the range 0 0 35 0 C Indoor temp NR If an indoor sensor has not been fitted temperature is adjusted using the outdoor temperature Select this row to adjust the temperature supplied to radiators see the Indoor temperature menu below If NR is displayed night reduction is in progress Boiler C ...

Page 19: ...0 El Boiler C 50 El boiler max kW 6 0 Max fuse A 20 External control NR Setting house Param Setting pellet Holiday off Set tank Setting DHW Save setting Load setting Load factory setting Service Functiontest pellets Funktionstest other Alarm info Time setting Day Thursday Time 18 03 Stored oper data Total operation h 8768 El heat kWh 1234 Pellet h 3456 Max prim C 62 Cold starts 14 Warm starts 354 ...

Page 20: ... value in brackets Boiler C 80 Displays the boiler temperature FlueGas C 160 Displays current flue gas temperature Primfl C 35 35 Displays the temperature of the primary flow to the house s heating system and the temperature which the system aims to achieve This value will vary during operation depending on set parameters and current outdoor temperatures Heatingcir pump On Displays the heating cir...

Page 21: ...R Setting house Param Setting pellet Holiday off Set tank Setting DHW Save setting Load setting Load factory setting Service Functiontest pellets Funktionstest other Alarm info Stored oper data Total operation h 8768 El heat kWh 1234 Pellet h 3456 Max prim C 62 Cold starts 14 Warm starts 354 Night reduction Activated No Yes Type WeekProg Indoor temp red C 2 Prim red C 5 WeekProgram Installer Setti...

Page 22: ...the temperature is raised to normal temp at the times specified after the arrow the temperature is lowered the number of degrees specified at the time specified after the arrow Ex 1 Mon 06 22 On Monday morning at 6 00 am the temperature is raised to normal and remains normal throughout the day until 10 00 pm when the temperature is lowered Ex 2 Mon 06 12 16 22 At 6 00 am the temp is raised to norm...

Page 23: ...ower full auger 68 Power full fan 40 Power part auger 41 Power part fan 20 Power min auger 0 Power min fan 0 Holding min 60 Auger Feeder s 30 Sequenz code 0 Set tank Charge tank Yes Temp tank C 70 Diff C 5 Tank prio No 3 11 Menu Settings Installer Settings In the menu Settings the installer and user make the adjustments to the requirements and demands U settings made by the user I settings made by...

Page 24: ...ou to a sub menu for pellet burner settings see menu Set pellet burner Holiday Off U Where you require constant night time lowering of temperatures for example when on holiday the number of days holiday can be set here Up to 250 days can be set Off not activated Set tank I U This option takes you to a submenu for tank settings see Tank Setting Menu Indoor temp red C 2 U If the holiday function is ...

Page 25: ...et here Other sections of the house should be shut off using thermostat valves or shut off valves Heating off C 16 Outdoor temperature at which the house no longer requires heating The radiator pump stops and the mixing valve valve remains closed The radiator pump is exercised daily for a short period so that it does not jam The system starts automatically when heating is required Heat curve Colle...

Page 26: ...ween the flame detector transmitter and the level monitor receiver i e no pellets in the top connection Value 99 means that the beam between the level monitor transmitter and receiver is fully interrupted i e there are pellets in the top connection Flame detector 99 50 The value is measured light strength in the flame detector The value in brackets is the limit at which the control system interpre...

Page 27: ...nction test Pellet The components in the pellet burner can be function tested in this sub menu Intended for fault tracing the product Function test other The components of the boiler can be function tested in this sub menu Intended for fault tracing the product Alarm info Information on the last alarm tirgged is provided in this menu Functiontest pellet Auger Feeder Off Fan 0 Auger burner 0 El ign...

Page 28: ...ower full fan 40 Power part auger 41 Power part fan 20 Power min auger 0 Power min fan 0 Holding min 60 Auger Feeder s 30 Sequenz code 0 Set tank Charge tank Yes Temp tank C 70 Diff C 5 Tank prio No 3 17 Menu Function test other Installer Service Function test This menu is used to test the product component function It is therefore used by qualified service personnel All product functions stop whe...

Page 29: ... here The indoor s sensor red diode comes on and lights continuously when activated The panel s alarm diode also comes on Functiontest pellet Auger Feeder Off Fan 0 Auger burner 0 El ignition Off Funct test other ElRelay 1 5 3 kW 0 ElRelay 3 6 kW 0 Pellet Off Heatingcirpump Off MixingValve Close DHW pump Off Diode sensor Off Alarm stored Last alarm xxxxx Stored alarm xxxxx xxxxx xxxxx xxxxx Sequen...

Page 30: ... located if the signals sent to the control system are to be correct Always adjust the system with all radiator thermostats fully open After a few days the thermostats can be adjusted individually in the other rooms If you do not manage to set room temperature check That the radiator system is correctly adjusted and is functioning normally That radiator thermostats are open and that the radiators ...

Page 31: ...house does not become cold Alarm is displayed in the display screen If a fault occurs on an indoor sensor EcoFlex automatically switches to graph based operation Alarm is displayed in the display screen If you do not have radiator thermostats on upper floors you may need to fit these Summer basement heating Background heating in basements recreation room bathrooms is often required in the summer m...

Page 32: ...e correct temperature irrespective of season Safety valve for boiler and heating system for closed system Check regularly that the valve works by manually turning lifting the regulation device Check that water runs from the drain pipe The outlet from the drain pipe must always be open Water can drip from the safety valve Drainage The boiler should be disconnected from the power source when drained...

Page 33: ...h The fan and ignition element start after approximately 3 minutes When the fuel reaches the ignition element s hot air outlet the feed rate falls and the pellet fuel ignites after around 6 7 minutes The burner s flame detector indicates when the fuel has been ignited and shuts off the ignition element The fan speed then falls to the reduced rate The fuel feed stops completely for 3 minutes so tha...

Page 34: ...rner using the switch on the control panel well in advance of cleaning so that the burner has time to cool The following should be carried out when cleaning NB Shut of the power supply to the boiler before the casing is removed Open the cleaning door on the top of the boiler NB The cleaning door can be hot Lift off the flue gas damper picture 1 Clean the round tubes with the long soot brush suppli...

Page 35: ...side of components Clean the slots in the primary ring carefully Fit the components Check for wear of the dosage wheel s pins toothed gear and back lock Adjust and replace where required Where required lubricate the drive chain with a little thin oil Sintering Each time a delivery of pellets is received the hearth should be checked so that any sintering continuous ash crust or stone and gravel lik...

Page 36: ...or outside range Alarm High flue gastemp xxx C Clean the boiler Fault Flue gas temperature exceed the value set in the menu Alarm flue gas C Action Clean the boiler as specified in the maintenance section Note This alarm does not stop the pellet burner This can be used as a reminder that it is time to clean the boiler where a suitable alarm level is set 7 Alarm and fault tracing measures The boile...

Page 37: ...e feed auger angle is not too steep or flow has stopped due to bridging in the external fuel storage Action Set the feed auger at a shallower angle and turn it forwards and backwards a few times to loosen bridges The inlet opening should be in the middle of the external fuel storage applies to smaller weekly storage Check That the external feed auger drive motor is functioning and that the motor s...

Page 38: ...indicated a flame for a period of time during hot starts Fuel has been supplied to the burner Check Action Check the flame detector Check that the pellets fed to the hearth consists of whole pellets and not just shavings If the fuel consists of shavings a bed of embers cannot be maintained In the event of frequent stops call in a service technician to check rotary valve tightness If the lock is no...

Page 39: ...hat the feed auger rotary valve and burner auger rotate and are not jammed by for example foreign objects Where the back stop is incorrectly set the gear can be exposed to high levels of wear or the dosage wheel and the gear can be so close together that in some cases they can come into contact which can result in the rotating components being jammed Rectify any faults Do not forget to set the bac...

Page 40: ... supplier control is active Power supplier control uses equipment which an electricity power supplier can install to disconnect high power demanding electricity equipment by district for shorter periods of time The immersion heater is shut off by active power supplier control Only Swedish version Operation data High electric power demand Reduced electrical power A The house s main fuses are overlo...

Page 41: ... is not at the centre of gravity The boiler will lean to one side Removal of packaging The packaging can be removed when the boiler is alongside the installation point Check that the product has not been damaged in transport Report any transport damage to the shipping agent Also check that the below items are included in the delivery Standard delivery Pellet boiler CTC EcoFlex Indoor sensor Primar...

Page 42: ...o the chimney with the shortest feasible flue duct at an angle of 30 40 The flue duct must not be fully inserted through the chimney wall If flue ducts with a cross sectional dimension which deviate from the dimension of the flue gas outlet would be used the connection must be cone shaped Cone angle of maximum 7 5 By the construction of the flue duct between boiler and chimney must feasible action...

Page 43: ... the flue gas chamber roof This setting should ensure that the flue gas temperature is suffinciently high to prevent under normal operation conditions condensation forming Connection to external feed auger and pellet storage The pellet tube can by the connection of a 2 metres feed auger be fitted either to the right left or from above on the right side of the upper panel The pellet tube outlet can...

Page 44: ...ning and plumbing of the system shall be accomplished according to the measurements in the section Technical data The heating system can be carried out according to the hydraulic installation diagram on the following page Refer to other headings in this section for the connection of required components Safety valve boiler In a closed system an approved safety valve according to existing regulation...

Page 45: ... The installation must correspond to existing building regulations Recommended to connect on the upper expansion and rear return flow of the boiler DHW charging pump By the connecton of a DHW storage tank a DHW charging pump must be mounted on the left right expansion primary flow DHW storage tank connection of the boiler The pump is being supplied with electric current from the boiler see Electri...

Page 46: ...nt and systems can look different for example one or two pipe systems The completed installation can therefore differ from what is shown here Legend 01 CTC EcoFlex Pellet boiler 02 Heating circuit mixing valve 03 Heating circuit pump 04 Heating circuit system 05 DHW storage tank 06 DHW charging pump 07 Expansion vessel 08 Safety valve 09 Drain valve in delivery 10 Primary flow sensor in delivery 1...

Page 47: ...l The boiler is then connected as shown in the picture of the connection block This ensures that the phase current is continuously monitored and compared with the set value on the load monitor on the boiler If the current is higher than this value the control unit disconnects a power step A further step is disconnected if this stillis too high etc When the current falls below the set value the ste...

Page 48: ...he grid 230 V 1N 2 Communication only used for systems with heat pump see separate instruction Only Swedish version 3 Reverse valve only used for systems with heat pump see separate instruction Only Swedish version 4 Connection of heating circuit pump 230 V 1 N 5 Mixing valve motor 6 DHW charging pump 7 Primary flow sensor 8 Outdoor sensor 9 Indoor sensor 10 Additional input for remote control nig...

Page 49: ...ndoor sensor and to the boiler Important The wires must be correctly connected for the sensor to function Markings 1 2 and 4 on the heat pump match the markings on the sensor Connection primary flow sensor Fit the sensor to the primary flow pipe ideally after the heating circuit pump The sensor probe is in the sensor front section see diagram Fasten the sensor in place using the enclosed tensionin...

Page 50: ...rature Night time temperature reduction can be activated by a closed function on the Power supplier control input on the connection block The function can be remote controlled using for example Minicall Night time temperature reduction is activated when the input is short circuited irrespective of other night time temperature reduction settings When the short circuit ceases the product returns to ...

Page 51: ...t other Step down to Diode sensor and press OK Check that teh room sensor diode lights if not check cables and connections Select Off using the button decrease button and press If the OK diode goes out the check is ready Return to normal display by pressing the step backwards undo button Check of connected sensors Text will appear in the display if any sensor is incorrectly connected For example A...

Page 52: ...burner is factory set to power Full 15 kW Part 9 kW First start set pellet size diameter Installer Settings Setting pellet The pellet burner is from factory pre set for operation of pellet sizes with a diameter of 8 mm By the operation of pellet with a diameter of 6 mm perform the necessary settings according to the chart below The settings are made according to the description in the section Menu...

Page 53: ...53 CTC EcoFlex Installation 13 Electric diagram 230V 1N ...

Page 54: ...54 CTC EcoFlex Installation 14 Electric diagram 400V 3N ...

Page 55: ...SANALYS M10 3 3 EXPANSION FRAML LADDN BEREDARE Rp 1 INV 2 RETUR RADIATOR G 1 UTV 1 FRAMLEDNING RADIATOR G 1 UTV 6 AVTAPPNING Rp1 2 INV 5 RÖKRÖRSANSLUTNING 150 UTV 4 RETUR LADDN BEREDARE Rp 1 INV Kontr av Ändr av Ändrad från Datum Nr Ändr meddel Ämnes nr E art nr Ersätter art nr Ersättes av Tol system Skala Distr till Antal Ytjämnhet RA Den får ej användas till skada för företagets intressen rf nic...

Page 56: ...56 CTC EcoFlex Installation Declaration of Conformity ...

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Page 60: ...Enertech AB P O Box 309 SE 341 26 Ljungby Sweden www ctc se www ctc heating com ...