1. EnsightBioenrgy Woodpecker Boiler Training Workshop Charlottetown, PEI 24th January, 2011

3. Introduction

4. About Bioscan Tech

5. About Woodpecker Energy

6. Product Range

7. What’s New

8. Domestic Range

9. Boiler Construction

10. Pellet Burner

11. Self Cleaning Systems

12. Controller Capabilities

13. Commissioning

14. Pre-Commissioning Checks

15. Start Up

16. Draft / Underpressure Adjustment

17. Flue Gas Analysis

18. Servicing

19. Troubleshooting

20. Flues / Venting

21. Buffer Tanks

22. Commercial Range

23. Explore the Thermon 150 / 300

24. Feeding Systems

25. Remote Monitoring

26. Fillomatic Pellet Transport System

27. Fillomatic or Transvac ?

28. Auger Options

29. Controller Capabilities

30. Q&A

32. Declan Crosse Research & Development Director Woodpecker Energy

33. Woodpecker Product Range Woodpecker Self Cleaning / De-Ashing

34. Woodpecker Product Range Woodpecker Self Cleaning / De-Ashing 25kW / 45 kW with Fillomatic

35. Woodpecker Product Range Thermon 150 / 300kW

36. What New Thermon Commercial Boiler 150/300kW Reference Site – 2012 London Olympic Atheletes Village Fillomatic Pellet Transport System Control System Functions Buffer Management Remote Access and Monitoring

37. Domestic Range

38. Boiler Construction LCD controller 110 Kg Hopper Combustion Chamber Automatic Cleaning 5 Stage Modulating Burner

39. Boiler Construction 94% Efficient

40. Burner Construction

41. Burner Construction Ignitor holding cone and holder Ignitor Hole

42. Self Cleaning - Boiler

43. Self Cleaning - Burner Air Compressor Air Cleaning Pipe

44. Self Cleaning - Burner

45. Self Cleaning - Burner

46. Self Cleaning - Burner

47. Controller Capabilities

48. Controller Capabilities Combustion Control Auto Ignition Standby Mode Cleaning Control Diagnostics Remote Control Remote Access Pump Management UPS

50. Start up check

52. Flue installation – The flue must always run vertically with no 90 degree bends. Check the end of the flue for an anti-downdraught cowl if lower than the roof apex. Twin walled insulated flue pipe only.

53. Plumbing at the boiler – The pump is recommended to be on the return side. The expansion must be sized correctly – Min. 20 litres and 1 litre for every 1kW thereafter. Additional expansion will be required if using a buffer tank or a high volume circuit.

54. Unlock the controller – Unlocking code can be advised by Woodpecker Energy.

55. Boiler system test – Run a test on the auger, combustions fan, exhaust fan, pump, element, Belimo valve, boiler cleaning, burner cleaning (if applicable) and de-ash system. SYSTEM MENU > OUTPUTS TEST > AUGER ……………..

56. Check the alignment of the element – See section on the ignition element in the appendix.

58. Monitor draft - Adjust at each stage of ignition (20Pa min.)

59. Ensure all functions are operating correctly – Make sure that the water, flue gas temp and photocell are giving correct readings. This can be viewed in the SYSTEM MONITOR of the USER MENU.

60. Monitor photocell and flue gas temperature reading during start up – At the end of Variable ignition and Stabilisation the light level (L01 – THERMOSTATS MENU – factory set at 30) should be over 30%and the flue gas temperature (S18 – THERMOSTATS MENU – factory set at 10C) should be over 10C.

61. Monitor the transition from start up to running mode – Once draught adjustments have been set for ignition monitor the light reading near the end of stabilisation and transition into run mode. If the light level reads < 30% see section on Er12/Er13 in the Errors section of this manual.Draft Sampling Point

62. Commissioning Check Up Variable Ignition Pre-Heat Pre-Load Stabilisation Run Mode 35 sec (t08) 40 sec (t00) 40 sec (t38) 4 min (t01) 90 sec (t02) TIMERS 100 LIGHT 30% 30% 0 Draught 20 Pa min. 20 Pa min. 20 Pa min. Light may dip slightly at this point At this stage : Light > 30% F.G.T > 10C At this stage : Light > 30% F.G.T > 10C Correct Level of Pellets

64. Set boiler to manually adjusted power levels – in ENABLES MENU set P45 to 0. This will allow you to set the boiler to run at a particular Power Level. This Power Level can be adjusted in the USER MENU > Power. To start with set this to 5.

65. Check draught. – Wait until the water temperature has reached 55C then check the draught at the draught sampling point. Adjust the speed of the exhaust fan (SYSTEM MENU > EXHAUST FAN > (Select code for the relevant power level) until min. 20Pa is reached ( any value draught value between 20Pa and 40Pa is o.k.). Let each power level settle for 2-3 minutes before dropping to the next and repeating the process. Once power level 1 is reached let the system settle for 5-10 minutes.

66. Carry out flue gas analysis. - Adjust combustion fan (SYETM MENU > COMBUSTION FAN > (Select code for relevant the relevant power level) to achieve CO2 reading of approx 12% and CO of less than 100 ppm. Let each power level settle for 5-10 minutes before increasing to the next power level. Repeat the process for power levels 2,3,4 and 5. At the lower power level if CO2 of 12% is difficult to achieve adjust the combustion fan to keep the CO (ppm) under 100.

67. Return the boiler to automatically adjusted power levels. – Always return the value P45 in the ENABLES MENU to 1 once the flue gas analysis and draught setting has been completed. This will allow the power levels to be managed automatically.

70. Set boiler to manually adjusted power levels – in ENABLES MENU set P45 to 0. This will allow you to set the boiler to run at a particular Power Level. This Power Level can be adjusted in the USER MENU > Power. To start with set this to 5.

71. Check draught. – Wait until the water temperature has reached 55C then check the draught at the draught sampling point. Adjust the speed of the exhaust fan (SYSTEM MENU > EXHAUST FAN > (Select code for the relevant power level) until min. 20Pa is reached ( any value draught value between 20Pa and 40Pa is o.k.). Let each power level settle for 2-3 minutes before dropping to the next and repeating the process. Once power level 1 is reached let the system settle for 5-10 minutes.

72. Carry out flue gas analysis. - Adjust combustion fan (SYETM MENU > COMBUSTION FAN > (Select code for relevant the relevant power level) to achieve CO2 reading of approx 12% and CO of less than 100 ppm. Let each power level settle for 5-10 minutes before increasing to the next power level. Repeat the process for power levels 2,3,4 and 5. At the lower power level if CO2 of 12% is difficult to achieve adjust the combustion fan to keep the CO (ppm) under 100.

73. Return the boiler to automatically adjusted power levels. – Always return the value P45 in the ENABLES MENU to 1 once the flue gas analysis and draught setting has been completed. This will allow the power levels to be managed automatically.

75. Burner Servicing

77. Burner Servicing Pellet Feed Pipe Separate Inner and Outer Tubes Photocell Clean cresote deposits from plates

78. Burner Servicing Change Igniter

79. Hopper / Auger Cleaning Pellet Level Sensor Auger Bearing Larger slot in plate to allow motor to move before full load is exerted.

80. Troubleshooting

81. Venting / Buffer Tanks Venting – Direct Vent / Conventional Chimney - Discussion Buffer Tank - Size is important. - Discussion

82. Fillomatic

83. Fillomatic Auger Options Standard Auger

84. Fillomatic Auger Options Floor Track System

85. FillomaticController Diagnostics Night time refill External Alarm

86. Q&A Questions Please !

87. Thank You